Hot Dip Galvanising Specification PDF

RESEARCH DESIGNS AND
STANDARD ORGANISATION
SPECIFICATION
FOR
HOT DIP ZINC GALVANISATION OF STEEL MAST,
(ROLLED & FABRICATED)
TUBES AND FITTINGS USED ON 25KV AC OHE
No. ETI / OHE / 13 (4 / 84)
1
SPECIFICATION NO.ETI/OHE/13(4/84)
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW – 226011.
SPECIFICATION
FOR
HOT DIP ZINC GALVANIZATION OF STEEL
MAST, (ROLLED & FABRICATED)TUBES
AND FITTINGS USED ON 25 KV AC OHE
Printed November, 1984.
ISSUED BY
TRACTION INSTALLATION DIRECTORATE

2
Specifications for equipment that are attached with the bid document.
S.No. Title of Specification Specification No. Page No.
1. Hot dip zinc galvanization of Steel ETI/OHE/13(4/84) with A & 4 - 18

masts (rolled & fabricated) tubes C Slip No.1, 2 & 3 or latest.
and fittings used on 25 kV AC OHE
2. Solid Core Cylinderical Post ETI/OHE/64 (10/88) with 19 - 30

Insulator for 110 kV. A & C Slip No.1 or latest..
3. 25 kV AC single pole & Double ETI/OHE/16(1/94) with A & 31 – 64

pole isolators for Railway C Slip No.1 & 2 or latest..
electrification
4. 110 kV Double Pole Isolator ETI/PSI/122 (3/89) with 65 – 92
A & C Slip No.1 or latest..
5. Solid core porcelain insulators for ETI/OHE/15(9/91) with A & 93 - 155
25 kV AC 50 Hz. Single Phase C Slip No.1, 2, 3, 4 & 5 or
overhead Traction lines. latest..
6. 220 kV or 132 KV or 66 kV or 25 TI/SPC/PSI/PTs/0990 with 156 - 190

Kv Potential transformers. A & C Slip No. 1, 2 & 3 or
latest..
7. 25 kV Drop out fuse switch and ETI/PSI/14(1/86) with A & 191 - 204
operating pole. C Slip No.1 or latest..
8. 25 kV / 240 V, 5 KVA, 10 KVA & ETI/PSI/15(08/2003) or 205 - 238

50 KVA, 50 Hz Single phase, oil latest.
filled Auxilliary transformers.
9. 110 kV Lightning Arrester ETI/PSI/137 (8/89) with 239 – 269
A&C Slip No.1, 2,3,4 & 5
10. Metal Oxide gapless type lightening ETI/PSI/71 Rev.5(1/87) with 270 – 297
arrestor for use on 25 KV side of A&C Slip No.1, 2,3,4 & 5 or
Rlys., traction sub-stations and latest.
switching stations.
11. Current Transformer, 220 kV or 132 ETI / PSI / 117 / (7 / 88) with 298 – 333
kV or 110 kV or 66 kV Correction Slip No.1 to 7 or
latest.
12. 25 KV AC 50 Hz, Single phase, Oil ETI/PSI/90 (6/95) with A&C 334– 367
filled Current transformers with CT Slip No.1 to 4 or latest..
ratio of (i) 1000-500/5A & (ii)
1500-750/5 A
13. 30 MVA, 110/27 KV Single Phase TI/SPC/PSI/30/TRN1050 or 368 - 446
3
Traction Power Transformer. latest.
14. Earthing of power supply ETI/PSI/120(2/91) 447- 461

installation for 25 KV AC, 50 Hz. with A&C Slip No.1 or
Single phase Traction system. latest..
15. Low Maintenance Lead Acid 40 RDSO/PE/SPEC/TL/0040- 462 – 485

AH & 200 AH Cells for Traction 2003 (Rev-0) or latest.
Distribution System.
16. Charger for 110 V, 40 AH & 110V, ETI/PSI/158(08/96) or latest. 486- 503
200 AH Maintenance Free, Sealed,
Lead Acid Battery.
17. Outdoor Circuit Breaker for TI/SPC/PSI/CB/0000 with 504- 569

Railway AC Traction Substations. AC Slip No.1 & 2 or latest..
18. Control and Relay Panel for TI/SPC/PSI/PROTCT/4050 570 - 645

Protection System for 50 Hz AC or latest.
traction substations parallel
operation on 25 kV Side.
Note : Drawings indicated in the specifications are in the CD attached with the bid
documents.
4
Specification No. ETI/OHE/13 (4/84)
Specification for Hot Dip Zinc Galvanization of Steel Mast, (Rolled & Fabricated)
Tubes & Fittings used on 25 kV AC OHE.
1. SCOPE
1.1 This standard specifies the requirement of zinc coating on rolled / fabricated masts,
tubes and fittings applied by hot dip galvanizing and the criteria for sampling and
inspection of such galvanized members.
1.2 This supersedes RDSO Specification No. ETI/OHE/13 (9/82) issued in September
1982 and No. ETI/OHE/13 (11/83) issued provisionally in November, 1983.
2. PREFERENCE SPECIFICATIONS
In preparation of this specification, assistance of the following Indian Standard and

other specifications has been taken.
(i) IS : 4759-1979 : Specification for Hot Dip Zinc Coatings on

Structural Steel and other allied Products.
(ii) IS : 209-1979 : Specification for zinc.
(iii) IS : 2629-1966 : Recommended Practice for Hot Dip

Galvanizing of Iron and Steel.
(iv) IS : 6158-1971 : Recommended Practice for Safe-guarding

against Embrittlement of Hot Dip Galvanized
Iron & Steel Product.
(v) IS : 2633-1972 : Method of Testing Uniformity of Coating on

Zinc Coated Articles.
(vi) IS : 6745-1972 : Method for Determination of weight of Zinc

Coating on Zinc coated iron and steel articles
(with amendment No. 1).
(vii) ASTM A-123 : Spec. for Zinc (Hot Galvanized) Coatings on

(1978) Products Fabricated from Rolled, Pressed
and Forged Steel Shapes, Plates, Bars and
Strips.
5
3. GENERAL REQUIREMENTS
3.1 QUALITY OF ZINC : Zinc conforming to at least grade Zn 99.95 specified in IS :

209-1979 shall be used for the purpose of galvanizing.
3.2 BASE METAL : The steels and castings shall be in accordance with clause 2 of IS :
6158-1971. Where steel is supplied by the fabricator, it is the responsibility of the
fabricator to select suitable steel which will withstand normal galvanizing operation
without embrittlement.
The edges of tightly contacting surfaces should be completely sealed by welding. The
residue of coated electrodes should be removed, prior to pickling, by brushing,
chipping or sand blasting.
3.3 SURFACE PREPARATION : Surface shall be cleaned and prepared as per clause 4
of IS: 2629-1966. Malleable iron castings shall be shot and grit blasted before
galvanizing.
3.4 GALVANISING : The members shall be galvanized in accordance with the practice
contained in the IS : 2629-1966 unless otherwise specified in the succeeding
paragraphs.
4. COATING REQUIREMENTS
4.1 MASS OF ZINC COATING : Minimum average mass of zinc coating on different
kinds of articles shall be as under :-
Class of Material Environment where Minimum average weight

used of zinc coating (g/m2)
Rolled steel masts, angles, Suburban and lightly 610

channels and members polluted area.
fabricated therefrom, steel
forgings.
-do- Marine and chemically 1,000

polluted areas.
Malleable iron castings. Suburban and lightly 610

polluted area.
-do- Marine and chemically 1,000

polluted areas.
Structural tubes all 610
6
Note : Articles galvanized with 1000 g/m2 zinc coatings shall be identified by a band
of green paint by the galvaniser.
4.2 FREEDOM FROM DEFECTS : The zinc coatings shall be uniform, adherent,
reasonably smooth and free from imperfections such as flux ash and dross inclusions,
bare patches, black spots, pimples, lumpiness and runs, rust stains, bulky white
deposits and blisters, etc. These terms have been defined in IS : 2629-1966 which
(duly amended wherever necessary) are given at Appendix ‘A’.
4.3 STEEL EMBRITTLEMENT : The design of the product and the selection of steel,
wherever steel is to be supplied by fabricator, for its suitability to withstand normal
galvanizing operations without embrittlement or the method of fabrication shall be
the responsibility of the fabricator. Recommended precautions to properly design,
fabricate and prepare the material for galvanizing to prevent embrittlement shall be as
per IS : 6158-1971.
5. TESTS.
5.1 TYPE TESTS
(a) Visual Inspection (Clause 7.1)

(b) Adhesion of coating (Clause 7.2)
(c) Uniformity of coating (Clause 7.3)
(d) Mass of zinc coating (Clause 7.4)
Each test shall be conducted on three samples.
5.2 ACCEPTANCE TESTS

(b) Adhesion of coating (Clause 7.2)
(c) Uniformity of coating (Clause 7.3)
(d) Mass of zinc coating (Clause 7.4)
5.3 ROUTINE TESTS
6. SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY.
6.1 LOT : All the materials of the same type and the same steel, whose coating
characteristics are intended to be uniform, shall be grouped together to constitute a
lot. A lot shall not consist of more than one shift’s production or 100 nos. whichever
is lower.
7
Samples shall be taken from each bath for test. Where the galvanizing is done without
the presence of Purchaser, the manufacturer may prepare lots consisting of the articles
of the same type and material and galvanized in the same bath. If there are more than
one bath, separate lots shall be prepared for each bath.
6.2 SCALE OF SAMPLING : Samples in accordance with TABLE 1 shall be taken, at

random, from each lot for tests.
TABLE 1
Scale of Sampling.
---------------------------------------------------------------------------------------------------
Lot size Sample size Permissible no. of defective
Units
---------------------------------------------------------------------------------------------------
Up to 25 3 0
26 – 50 5 0
51 – 100 8 0
---------------------------------------------------------------------------------------------------
6.2.1 For materials of inconvenient lengths such as OHE masts and from which it is not
possible to cut a specimen for coating characteristic tests, two test pieces of same
cross section and not less than 90 cms length shall be galvanized in the same bath
along with the masts for each lot upto 100 masts. In such case, the visual test shall be
conducted on the main piece and the tests for the adhesion, uniformity and thickness
of coating shall be conducted on the test piece.
6.3 The samples selected in accordance with Table 1 above shall be subjected to the
visual inspection (clause 7.1).
If any sample fails to conform to the requirement, the lot shall be rejected. The
galvaniser, however, may segregate the good pieces of the lot and submit them once
again for inspection.
6.4 If the lot inspected for visual inspection, passes the test, 3 samples for coating
characteristics (Clause 6.5) shall be taken from the samples, which were subjected to
the visual tests. In case of masts and other long articles, these tests would be
conducted on test specimen cut from 90 cm long test pieces galvanized in accordance
with Clause 6.2.1.
6.5 Each of the 3 samples will be subjected to test for adhesion, uniformity, mass of zinc
coating. Should any sample fail in any test, six more samples shall be taken from the
lot and all the 3 tests repeated. Should any sample fail in the retest, the lot shall be
rejected. If it is not possible to take six samples for the test, the lot shall be rejected.
6.6 The material in a lot which has been rejected may be stripped and re-galvanized and
submitted for inspection and tests.
8
7. TEST METHODS
7.1 VISUAL INSPECTION : The material shall be inspected visually to observe that it is
smooth, reasonably bright, continuous and free from such imperfections as
flux/ash/dross inclusions, bare patches, black spots, pimples, lumpiness runs, rust
stains, bulky white deposits and blisters. The stains of flux, usually white in colour,
shall not be regarded as flux intrusions (See Appendix ‘A’).
7.2 ADHESION OF GALVANISED COATING :
7.2.1 Coating shall withstand the knife tests as prescribed in IS : 2629-1966. When cut or
pried into, such as with a stout knife applied with considerable pressure, in a manner
tending to remove a portion of the coating, it shall only be possible to remove small
particles of the coating; and it shall not be possible to peel any portion of the coating
so as to expose iron or steel underneath.
7.2.2 On articles fabricated from angles, channels, beams and rolled sections of 8 mm or
more thickness, the adhesion may, alternatively, be tested by pivoted hammer tests as
per IS : 2629-1966. This test is not suitable for curved and round surfaces.
7.3 UNIFORMITY OF GALVANISED COATING :
7.3.1 On small articles, which can be conveniently handled the uniformity of the coating
shall be determined by Preece Test in accordance with IS : 2633-1966 by dipping the
whole article in the copper sulphate solution. For sheets, strips and other fabricated
articles a 10 cm x 10 cm specimen may be cut for tests. For tubes, 100 mm long piece
shall be cut from each end of the product, after discarding 300 mm length from the
end. The article shall withstand 5 dips of one minute each.
7.3.2 For long articles, such as masts, etc., measurement of coating thickness at a number
of places by magnetic method (Clause 7.4.4) shall be taken as a uniformity test.
Note : The Preece Test is primarily meant for articles where surface is mechanically
scrapped or wiped after dip in the galvanizing baths, such as tubes, wires, etc.
7.4 MASS OF GALVANISED COATING :
7.4.1 The average mass of galvanized coating shall be determined by any one of the
following methods as agreed between the purchaser and the galvaniser before the
tests.
7.4.2 Mass before and after galvanizing : The mass of coating may be determined by
weighing the article before and after galvanizing, subtracting the first mass from the
second and dividing the result by the coated surface area. The first mass shall be
9
determined after pickling, rinsing and drying; and the second after cooling to the
ambient temperature.
7.4.3 Stripping method : In case of materials galvanized without purchasers’ inspection,

average mass of coating shall be determined by stripping the entire article in
accordance with IS : 6745-1972 (See Appendix ‘B’). If the surface area of the entire
article cannot be measured easily or if the article is inconveniently large, a specimen
of 100 sq. cm. area may be cut from each of the three samples ( 90 cm long test-
piece in case of masts) and stripped.
7.4.4 Magnetic thickness gauge method :
7.4.4.1 For large products such as poles, towers, structural shapes and castings the average
weight of the coating shall be determined by a magnetic thickness gauge.
7.4.4.2 Before making the measurement the gauge shall be calibrated by measuring the
thickness of zinc coating on a test panel and comparing the measured value with the
value obtained by stripping method on the same piece.
7.4.4.3 In case of masts etc. readings shall be taken along the length at 100 mm interval and
in approximate centre of the flange and then averaged to give a single figure for
thickness of coating. For castings etc. at least 5 readings may be taken at convenient
locations nearly in the centre. Thickness, in micro-meters, when multiplied by 7.047
would give the average mass of zinc coating (g/m2). Three articles in each lot of upto
100 shall be tested in this manner. Thickness shall not be less than the minimum
value specified in Clause 4.1.
8. RECTIFICATION OF DAMAGE
8.1 Normally all fabrication work in the case of galvanized articles shall be completed
prior to galvanizing. If, for any reason, fabrication such as cutting, drilling or welding
has to be undertaken after galvanizing, protection of metal exposed as a result of
fabrication and rectification of damaged galvanized areas shall be done in accordance
with either the following methods or any other method approved by the Purchaser.
8.2 USE OF ZINC BASED SOLDERS : The surface to be protected, or the surface
where galvanizing has been damaged, shall be cleaned and any oxides removed with
a weak acid solution and a wire brush. The surface shall be thoroughly washed with
water to make it free from any traces of acid. The cleaned area shall be heated with a
welding torch and rubbed with white salammoniac. A piece of zinc stick or rod 5-10
mm diameter of high purity shall be melted on this area and spread out with a heated
piece of salammoniac. The areas shall then be washed down by water and lightly wire
brushed. The workmanship shall be such that the finished surface is smooth and non-
porous.
10
8.3 USE OF ZINC RICH PAINTS : The damaged surface after cleaning, as mentioned in
para 7.2 shall be painted with two or more coats of zinc rich primer followed by a
finishing coat of a zinc rich paint as per the painting schedule recommended by the
manufacturers. It is to be ensured that the dry film thickness of zinc rich primer shall
not be less than the average thickness of the galvanized coating. The complete
painting system i.e. zinc rich primer with the finishing zinc rich paint for this purpose
shall be produced from a source of repute and approved by the Purchaser.
11
APPENDIX “A” (Cl. 4.2)
DEFECTS, THEIR CAUSES AND REMEDIAL MEASURES
Defects Causes Recommended actions Ground for rejection

Paint grease or oil residues Check cleaning practices
Bare spots Scale or rust residues Check pickling practices

Residual welding slag Blast-clean wells; avoid
coated rods
Breakdown of preflux Check preflux and drying
Yes, if bare spots
coating conditions
are bigger than 8
mm dia. or 8 mm
Aluminium content of bath Regulate aluminium
diagonal.
too high additions
Rolling defects in basic steel Check steel supply
Article in contact during Keep articles separated.
galvanizing.
Analysis or original surface Check steel supply.
General condition of steel.
roughness Over-pickling Reduce pickling use No
inhibitor
High galvanizing
temperature or long Adjust galvanizing
immersion time or both conditions.
Pimples Entrapped dross particles Avoid agitation of dross No, unless dross
layer; check carry over of contamination is
pickle salt. heavy
Withdrawal speed too high Remove work slowly

Cold galvanizing bath. Increase temperature.
Lumpiness and Delayed run-off from Remove work slowly.
runs (uneven seams, joints, bolt holes, etc. No.
drainage) Article in contact during
withdrawal.
Stale flux burnt on during Refresh or renew flux

dipping. blanket.
Flux inclusions Surface residues on steel. Check steel preparation. Yes.
Flux picked up from top of Skim before withdrawal.
bath.
Ash burnt on during Skim bath before dipping.
dipping.
Yes, if in gross
Ash inclusion Ash picked up from top of Skim before withdrawal.
lumps.
bath.
12
Black spots Includes flux particles from Confine fluxing to top of Yes.
flux ‘dusting’. bath.
Dirt smuts, splash marks. Check storage conditions. No.
Dull grey Steel composition (high sili- Check steel supply for No.
coating (all con, phosphorous or carbon) composition order to adjust
alloy, no free severe cold work. for galvanizing.
zinc). Slow cooling after galvani- Avoid hot stacking quench.
sing.
Release of absorbed hydro- Avoid over pickling; use
gen during solidification of inhibitor.
coating.
Weeping of acid etc. from Check product design and
seams and folds. fabrication.
Rust stains Storage near rusty material. Check storage condition. No.
Bulky white Confinement of close Storage dry well-ventilated No.
deposit (wet packed articles under damp conditions, separate articles
storage stain, conditions. with spacer.
white rust). Packing of articles while Dry before packing; include
damp. desic cant.
Expansion of entrapped Check steel quality

hydrogen and moisture in
flaws.
Driving off of hydrogen Use shot blast instead of
Blisters absorbed during pickling. pickle; check steel supply. Yes, if general.
Improper malleabilising (for Check malleabilising
malleable iron castings practice.
only)
Effect sometimes observed Use shot blast instead of Yes, if blistering is

on quenched work notably pickle. Check malleabilising generally wide
malleable castings. May be treatment. Should have no spread.
caused by gas evolved from combined carbon near
Tiny blisters the work resulting from surface of casting.
absorbed hydrogen or
break-down of combined
carbon near surface.
13
APPENDIX “B”
STRIPPING METHOD
(Extracted from IS : 6745-1972)
Cleaning of test piece : The test pieces shall be washed with solvent naptha, trichloro
ethylene or any other suitable organic solvent, then with alcohol and finally dried thoroughly.
Stripping Solutions :
Dissolve 20 g of antimony trioxide (Sb2O3) or 32 g of antimony trichloride (Sb Cl3) in 1000

ml of concentrated hydrochloric acid (specific gravity 1.1).
Immediately before tests, prepare the stripping solution by adding 5 ml of the solution
prepared under clause B-2.1 to 100 ml of concentrated hydrochloric acid (specific gravity
1.16). Mix well.
Procedure – Weigh the cleaned test specimen whose mass is less than 200 g nearest to 0.01
g; for test piece whose mass is between 300 to 1000 g to the nearest 0.1 g; and for test
specimen of over 1000 g to the nearest 0.5 g. After weighing immerse each test piece singly
in test solution prepared as per clause B-2.2 and allow to remain there until the violent
evolution of hydrogen and only a few bubbles are being evolved. This requires about 15 to
30 seconds.
The mass of zinc coating (in g/m2) of surface may be calculated as per the following formula
:
M1 – M2
M = ----------------- x 106
A
Where,
M = mass of zinc coating, in g/m2, of surface.

M1 = original mass, in g, of test piece.
M2 = mass in g, of stripped test piece, and
A = coated area of the test piece, in mm2.
14
Correction Slip No. 1 (May 1986) to RDSO Specification No. ETI/OHE/13 (4/84)
for
Hot Dip Zinc Galvanization of Steel Mast, (Rolled & Fabricated)
1. Clause 6.1 shall be revised as under :
6.1 LOT : All the material of the same type in a coating bath whose characteristics
are intended to be uniform shall be grouped together to constitute a lot.
6.1.1 Sample shall be taken from each bath and tested for conformity of coating.
2. Table 1 under clause 6.2 shall be revised as under :
TABLE 1
Scale of Sampling.
---------------------------------------------------------------------------------------------------
Lot size Sample size Permissible no. of defective
Units
---------------------------------------------------------------------------------------------------
Up to 25 3 0
26 – 50 5 0
51 – 100 8 0
101 and above. 13 1

---------------------------------------------------------------------------------------------------
15
Corrigendum Slip No. 2 (4/90) to RDSO Specification No. ETI/OHE/13 (4/84)
for
1. Appendix B
1.1 Clause B-1, 1st line, Read

‘trichloro ethylene’ in place of ‘trichloro ethylen’.
1.2 Clause B-2, Read ‘Stripping Solution’ in place of ‘Stripping solutions’.
1.3 Clause B-2.1, Read ‘Hydrochloric Acid (Specific Gravity 1.16)’ in place of
‘Hydrochloric Acid (Specific Acid 1.12)’.
1.4 Clause B-3, Line No. 3, Read ‘Clause B-2.1’ in place of ‘Clause B-2.2’.
1.5 Clause B-3, Insert the word ‘ceases’ in last line of the clause between ‘hydrogen
and ‘and’.
16
Addendum / Corrigendum Slip No. 3 (4/90) to RDSO
for
1. Clause 2
Add new item as SN (viii) below the para.
viii) ASTM : A 153 - Specification of zinc coating (Hot-dip)

(1982) on Iron and Steel hardware.
2. Clause 2
SN (i) Read “IS : 4759 – 1984” in place of “IS : 4759 – 1979”.
3. Clause 4.1, Delete last line “(Structural ------------ 610) and add the following in the
respective columns :
Steel Components less than 5 mm thick all 460
Structural Tubes all 425”.
17
SPECIFICATION
FOR
SOLID CORE CYLINDERICAL POST

INSULATOR FOR 110 kV
No. ETI / OHE / 64 (10/88)
18
SPECIFICATION NO.ETI/OHE/64(10/88)
GOVERNMENT OF INDIA
SPECIFICATION
FOR
SOLID CORE SYLINDERICAL POST
INSULATOR FOR 110 kV
ISSUED BY

19
GOVERNMENT OF INDIA
RESEARCH DESIGN AND STANDARDS ORGANISATION
MANAK NAGAR
LUCKNOW – 226 011
SPECIFICATION FOR SOLID CORE CYLINDRICAL POST INSULATORS FOR

SYSTEMS WITH NOMINAL VOLTAGES OF 220 kV, 132 kV, 110 kV AND 66 kV.
1.0 SCOPE :
1.1 This specification applies to out-door type solid core cylindrical post insulators for a
nominal system voltage of 220 kV/ 132 kV/ 110 kV/ 66 kV for use in isolators
(disconnectors) or bus bar or fuse supports in un-attended Railway traction
substations in any part of India.
1.2 This supersedes specification No. ETI/OHE/64 (6/87) “Solid core post insulators, 220
kV”.
2.0 GOVERNING SPECIFICATION :
2.1 The insulator shall unless otherwise specified conform to I.S.:2544-1973 “Porcelain
post insulators for system with nominal voltages greater than 1000 volts” and
I.S.:5350 (Part II) – 1973 “Dimensions of indoor and outdoor porcelain post
insulators and post insulator units for systems with nominal voltage greater than 1000
V – Part II Outdoor cylindrical post insulators” which shall be applied in the manner
altered, amended or supplemented by the subsequent clauses of this specification.
2.2 In the preparation of this specification assistance has been derived from the
following:
(i) IEC:168-1979 Tests on indoor and outdoor post insulators

of ceramic material or glass for systems with
nominal voltages greater than 1000 V.
(ii) IEC:276-1979 Dimensions on indoor and outdoor post

insulators and post insulator units for systems
with nominal voltages greater than 1000 V.
(iii) IEC:815-1986 Guide for the selection of insulators in

respect of polluted conditions.
(iv) JIS-C-3802-1964 Permissible limits of visual defects for
insulating porcelains.
20
(v) IS:2108-1977 Black heart malleable iron castings.
(vi) ETI/OHE/13 (4/84) Specification for hot dipzinc galvanisation of

R.D.S.O. of steel masts (rolled & fabricated), Tubes
and fittings used on 25 kV AC OHE.
(vii) ETI/OHE/15 (11/83) Specification for solid core insulators for of

R.D.S.O. 25 kV single phase 50 Hz overhead traction
lines.
3.0 GENERAL REQUIREMENTS :
3.1 The insulator shall be of solid core construction. The porcelain shall be sound, free
from defects, thoroughly vitrified and smoothly glazed and should be preferably
manufactured from alumnia and shall not engage directly with metal fittings. The
glaze shall uniformly cover all the exposed porcelain of the insulator and be brown in
colour. It shall be suitable for use in medium / heavily polluted atmospheres subjected
to dust, smoke and effluents from chemical plants, marine and saline atmospheres.
3.2 The solid core cylindrical post insulators would be subjected to vibrations on account
of trains running on nearby railway tracks. The amplitude of these vibrations which
occur with rapidly varying time periods in the range of 15 to 70 ms lies in the range
of 30 to 150 microns at present with the instantaneous peak going upto 350 microns.
3.3 The physical characteristics of the insulator shall be :-
For nominal voltage of 66 kV 110 kV 132 kV 220 kV
(i) Overall height in mm 770±1 1200±1 1500±2.5 2300±3.5

(ii) Maximum diameter
of the insulating part
in mm 195 210 270 300
(iii) Top metal fitting
pitch circle diameter
in mm 127 127 127 127
(iv) Bottom metal fitting
pitch circle diameter 127 127 127 200
(v) Minimum creepage
distance in mm. 1810 3075 3625 6125
3.4 The fixing arrangements shall be in accordance with Clause 6 of IS: 5350 (Pt-II) -
1973.
3.5 The caps of the insulator shall be of malleable cast in conforming to Grade BM:340
of IS:2108-1977. All ferrous parts shall be hot dipped galvanised in accordance with
21
Research Design and Standards Organisation specification no. ETI/OHE/13 (4/84)
and weight of zinc coating shall be not less than 1000 gm/ square meter.
3.6 Caps of the insulator shall normally be so sealed on to porcelain with portland cement
as not to cause fractures loosening by expansion or contraction.
3.7 The shed profile of the insulator shall conform to the parameters laid down in
IEC:815.
3.8 The maximum values for the tolerances of parallel eccentricity and angular deviation
shall not exceed the value specified in the second edition of IEC Publication 273-
1979, when measured in accordance with the directions contained in Appendix A of
the second edition of IEC Publication 168-1979.
3.9 The 220 kV insulator shall consist of a stack of not more than 2 units.
4.0 TEST VOLTAGES :
4.1 The test voltages for the insulator shall be as under:
(i) Visible discharge test 53 kV 88 kV 106 kV 176 kV

(ii) Wet one minute power
frequency withstand
voltage (rms) 160 kV 230 kV 275 kV 460 kV
(iii) Impulse voltage
withstand value 350 kVp 550 kVp 650 kVp 1050 kVp
4.1 The power frequency voltage shall be expressed as peak value divided by 1.414. The
impulse voltage shall be expressed as peak value.
4.2 The visible discharge tests voltage, wet one minute power frequency withstand
voltage (rms) and impulse voltage withstand value are referred to the reference
atmospheric conditions as given in I.S:2544-1973.
5.0 MECHANICAL LOADS :
5.1 The minimum failing load shall be as under:

(i) Min failing load in bending 4 kN 4 kN 4 kN 4 kN

(ii) Min failing load in tension 35 kN 50 kN 60 kN 80 kN
(iii) Min failing load in torsion 2 kNM 3 kNM 3 kNM 3 kNM
(iv) Min failing load in compression 70 kN 100 kN 120 kN 160 kN
22
5.2 The insulator shall be capable to accept the following minimum bending moment M
at the top metal fixing :
M = 0.5 P h for 66 kV, 110 kV, and 132 kV post insulators

M = 0.2 P h for 220 kV post insulators
Where P = minimum bending failing load specified in clause – 5.1 and

h = total height specified in clause – 3.2 of this specification.
5.3 The successful tenderer shall ensure that a linear progression in the strength of the
insulator has been obtained from the above values of M bending moment at the top to
P h at the bottom.
Note: This aspect shall be verified during the prototype and acceptance tests.
6.0 TESTS :
6.1 Type Test
The following shall constitute the type tests which shall be conducted as per
I.S: 2544-1973 unless otherwise specified at the works of the manufacturer or at
reputed testing laboratory in the presence of the Indian Railway’s repersentative/s on
the prototype sample.
a) Verification of dimensions.
b) Visual examination.
c) Visible discharge test.
d) Impulse voltage withstand test.
e) Wet one minute power frequency voltage withstand and wet one minute
power frequency maximum voltage withstand test.
f) Temperature cycle test.
g) Mechanical strength tests for:
i) Bending
ii) Tensile
iii) Torsion
iv) Compression
h) Porosity test.
i) Galvanising test.
6.1.1 The test at (e) above shall be conducted in accordance with Clause-9.7 of Research
Design and Standards Organisation specification No. ETI/OHE/15 (11/83).
6.1.2 The test at (b) above shall be conducted as per JIS-C-3802-1964 “ Permissible limits
of visual defects for insulating porcelains”.
23
6.1.3 For the 66 kV, 110 kV and 132 kV insulator, all the above tests shall be conducted on
at least three samples individually. For testing the mechanical strength at least three
samples should be subjected individually to the bending, torsion, tensile and
compression tests, after undergoing temperature cycle test.
6.1.4 For 220 kV insulators, the nature of tests and the number of samples (with the
description) on which the tests shall be conducted are detailed below:
No. of samples Tests of Clause 6.1
i) Three post insulators each consisting

of 2 units (a) to (e) and (g)(i)
ii) Three top insulator units (g) (ii) to (iv)
iii) 12 top insulator unit and
2 bottom insulator units (f)
iv) Porosity test will be conducted
on fragments of three porcelain
pieces from the insulator during
mechanical strength test.
v) Galvanising test shall be
conducted on three caps each
of top and bottom insulator
broken during the mechanical
strength test.
New Clause 6.1.5 Add the following paragraph under this new clause:
Type tests shall be conducted on the first prototype unit manufactured

after all the design and drawings have been approved and clearance
given by RDSO to this effect.
Before giving the call to RDSO/ the Chief Electrical Engineer for
inspection and testing of the prototype of the system, the manufacturer
shall submit a detailed test report consisting of schematic circuit
diagrams for each of the tests and nature of the test, venue of the test
and duration of each test and the total number of days required to
complete the test at one stretch. Once the schedule is approved, the
tests shall invariably be done accordingly. However, during the
process of type testing or even later, RDSO representative reserves the
rights to conduct any additional test(s) besides those specified therein,
on any equipment/ sub-system or system so as to test the system to his
satisfaction or for gaining additional information and knowledge. In
case any dispute or disagreement arises between the manufacturer and
RDSO / The Chief Electrical Engineer during the process of testings as
24
regards the type tests and/or the interpretation and acceptability of the
type test results, it shall be brought to the notice of the Director
General (Traction Installation), RDSO / The Chief Electrical Engineer
as the case may be, whose decision shall be final and binding.
Bulk manufacture of the solid core cylindrical post insulators shall be

taken up only after specific written approval is given by the Purchaser
to the successful tenderer on the basis of the tests conducted on the
prototype unit manufactured according to approved design and
drawings.
6.1.8 If the prototype of any insulator conforming to this specification has been approved
for earlier supplies to Indian Railways, testing of prototype again for that particular
type of insulator may be waived provided that no changes in the design or material(s)
used has been made.
6.2 Acceptance Test
6.2.1 The following shall constitute the acceptance tests:
a) Verification of dimensions.
b) Temperature cycle test.
c) Mechanical strength tests
d) Porosity test.
e) Galvanisation test.
6.2.2 The number of insulators to be selected for the lot size offered shall be as per table-3
of IS.: 2544-1973. The insulator so selected shall be subjected to tests as detailed
below
6.2.2.1 For 66 kV, 110 kV & 132 kV Solid core cylindrical post insulators:
Test (a) - On all Samples
Test (b) - On all Samples
Test (c) At least three samples shall be subjected to bending test in the case
of lot size upto 3200 and at least five samples in the case of lot size
greater than 3200. The remaining samples shall be divided more or
less equally for the other three mechanical tests viz. Torsion, Tensile
and Compression.
Test (d) Fragments from all the broken insulator shall be subjected to this test.
If any sample fails in this test, the lot shall be rejected.
25
Test (e) On any three samples of MCI caps selected at random after mechanical
strength test.
6.2.2.2 For 220 kV Solid core cylindrical post insulators:
Test (a) - On all post insulators each consisting of two units.
Test (b) - On all units.
Test (c)- At least three bottom units shall be subjected to bending test in the case of
lot size upto 3200 and at least five bottom units in the case of lot size
greater than 3200. The bending test shall be conducted on the bottom unit
with an extension piece to enable the load to be applied at a distance from
the unit corresponding to its position of maximum stressing in the stack.
Remaining tests shall be on top units and they shall be divided more or less
equally among the other three mechanical tests viz. Torsion, Tensile and
Compression.
Test (d) & (e) - Same as for 66 kV, 110 kV & 132 kV solid core cylindrical post
insulators.
6.3 Routine Tests
6.3.1.1 Every insulator shall be subjected to the following routine tests at the
manufacturer’s works as per IS:2544-1973 except where otherwise specified.
The manufacturer shall maintain a record of all routine tests conducted and
produce the record on demand at the time of inspection for prototype or
acceptance testing.
(a) Visual examination

(b) Routine mechanical test.
(c) Ultrasonic test – This test is to be conducted as per Clause 9.14 of RDSO’s
specification No. ETI/OHE/15 (11/83).
(d) Porosity test.
6.4 Acceptance Criteria
6.4.1 Prototype Tests:
The prototype test samples should meet the requirements of all the prototype tests at a
time.
6.4.2 Acceptance Tests:
26
If the samples fail to meet the requirements of mechanical strength test and porosity
test the lot shall be rejected. If the samples fail in test other than mechanical strength
and porosity tests, double sampling may be done if the lot is otherwise acceptable.
If the samples do not meet the requirement in the double sampling, the lot shall be
rejected.
7.0 TECHNICAL DATA AND DRAWINGS :
7.1 The tenderer shall furnish along with his offer, in the performa attached as Annexure
‘A’, the guaranteed performance data and other technical particulars of the insulator.
7.2 The tenderer shall specifically indicate in a statement attached with his offer, his
compliance with each clause and sub-clause of this specification. A separate
statement shall be attached with the offer indicating reference to the clauses where the
tenderer deviates therefrom together with detailed remarks / justification. If either the
statement of compliance or statement of deviations is not attached with offer, it is not
likely to be considered. If there are no deviations, a ‘NIL’ statement shall be attached.
New Clause 7.3 Add the following paragraph under this new clause:
The information furnished in Schedule of guaranteed technical

performance, data and other particulars shall be complete in all
respects. If there is any entry like “shall be furnished later” or blanks
are left against any item, the tender is not likely to be considered as
such omissions causes delays in finalising the tender.
7.4 The successful tenderers shall be required to submit for approval, the dimensional
drawing as per Indian Railways standard in sizes of 210mm x 297mm or any integral
multiple thereof.
7.5 After approval, two copies of reproducible prints shall be supplied to The Director
General (Traction Installation), Research Design and Standards Organisation,
Lucknow (India).
8.0 PACKING AND DISPATCH
8.1 Insulator shall be supplied securely packed in wooden cases. Only one insulator unit
shall be packed in a case so as to faciliate manual loading and un-loading.
8.2 In case of the overseas supplies, packing shall be sea-worthy.
27
Specn. ETI/OHE/64 (10/88)
Annexure – A.
SCHEDULE OF GUARANTEED PERFORMANCE TECHNICAL
AND OTHER PARTICULARS.
Description Unit of measurement Value /

S.No Information to
be furnished by
the bidder.
(1 ) (2) (3) (4)
1. Name of the manufacturer
2. Country of origin
3. Manufacturer’s Type designation
4. Standard specification on which performance data is based
5. Type of porcelain
6. Overall height in mm mm
7. Maximum diameter of shed in mm mm
8. PCD of top metal fitting mm
9. PCD of bottome metal fitting mm
10. Creepage distance (minimum guaranteed) mm
11. Grade & specification of metal fittings
12. Corona initiation voltage …kV (rms)
13. Corona extinction voltage ….kV (rms)
14. Mass of zinc coating of metal fittings g/sq.m
15. Rated voltage kV
16. Visible discharge test voltage kV
17. Dry lightning impulse withstand voltage. kVp
18. Wet one minute power frequency withstand voltage kV (rms)
19. Maximum tolerance of parallelism, eccenticity and angular
deviation
20. Minimum failing load in bending kN
21. Minimum failing load in tension kN
22. Ultimate tensile breaking load …kN
23. ….kNm
Ultimate breaking torsional moment
24. …MHz
Frequency of ultrasonic wave
25. Minimum failing load in torsion kNm
26. Minimum failing load in compression kN
27. Minimum bending moment at top metal fitting kNm
28. Shed profile parameters
29. Progression in bending strength kNm
30. Ultimate breaking bending load …kN
31. Speed of propagation of ultrasonic wave obtained …m/s
32. …Kg
Weight of unit
28
SEPTEMBER 1989
Addendum / Corrigendum Slip No.1 to Specification No.ETI / OHE/64

(10/88) for Solid core Cylindrical Post Insulator for 110 kV.
********
New Clause 6.1.5 - Add the following paragraph under this new Clause.
Type test shall be conducted on the first prototype unit

manufactured after all the design & drawings have been
approved and clearance given by RDSO to this effect.
New Clause 6.1.6 - Add the following paragraph under this new clause.
Before giving the call to RDSO/ The Chief Electrical Engineer

for inspection and testing of the prototype of the system, the
manufacturers shall submit a detailed test report consisting of
schematic circuit diagrams for each of the test and nature of the
test, venue of the test and duration of each test and the total
number of days required to complete the test on one stretch.
Once the schedule is approved , the test shall invariably be
done accordingly. However, during the process of type testing
or even later, RDSO representative reserves the rights to
conduct any additional test(s) besides those specified therein,
on any equipment/sub system or system so as to test the system
to his satisfaction or for gaining additional information and
knowledge. In case any dispute or disagreement arises
between the manufacturer and RDSO/The Chief Electrical
Engineer during the process of testing as regards the type tests
and/or the interpretation and acceptability of the type test
results, it shall be brought to the notice of the Director General
(Traction Installation), RDSO/The Chief Electrical Engineer as
the case may be, whose decision shall be final and binding.
New Clause 6.1.7 - Add the following paragraph under this new Clause.
Bulk manufacturer of the solid core cylindrical post insulators

shall be taken up only after specific written approval is given
by the purchaser to the successful tenderer on the basis of the
tests conducted on the prototype unit manufactured according
to approved design and drawings.
29
STANDARDS ORGANISATION
SPECIFICATION
FOR
25Kv ac SINGLE POLE AND DOUBLE
POLE ISOLATORS FOR RAILWAY
ELECTRIFICATION
No. ETI / OHE / 16 (1 / 94)
30
SPECIFICATION No.ETI/OHE/16 (1/94)
GOVERNMENT OF INDIA
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAKNAGAR LUCKNOW
Technical Specification
For
25kV ac Single Pole and
Double Pole Isolators for
Railway Electrification
ISSUED BY

LUCKNOW – 226011
31
GOVERNMENT OF INDIA
MANAKNAGAR LUCKNOW
Specification No. ETI / OHE / 16 (1 / 94)
SPECIFICATION FOR 25 Kv ac SINGLE POLE AND DOUBLE POLE ISOLATORS
FOR RAILWAY ELECTRIFICATION
1. SCOPE
1.1 This specification applies to single-pole as well as double-pole isolator with earthing
switch for outdoor use in 25 kV a.c. 50 Hz single phase overhead equipment, traction
substantions and switching stations. The specification also applies to the operating
mechanism of the isolator and earthing switch. The isolator shall be mounted on a
mast / structure as required.
1.2 The isolator shall be complete with all parts, fittings and accessories including
mounting frame work and operating mechanism but excluding the insulators,
necessary for its efficient operation. All such parts. Fittings and accessories shall be
deemed to be within the scope of this specification, whether specifically mentioned or
not. The isolat6or shall be of proven design.
2. GOVERNING SPECIFICATIONS.
2.1 The isolator and earthing switch shall unless otherwise specified herein, conform to
the latest version of the Indian Standards specifications / IEC recommendations /
Research Designs and Standards Organisation (RDSO) specifications as indicated
below and the Indian Electricity Rules, wherever applicable :
i) IS:1570 (Pt. II) – 1979 - Carbon steels (unalloyed steels).
ii) IS:2071 (Pt. I) – 1974 & (Pt. II) – - General definitions and test
1976 requirements and test procedures.
iii) IS: 2108 – 1977 - Black heart malleable iron castings.
iv) IS: 2544 – 1973 - Porcelain post insulators for systems

with nominal voltage greater than 1000
volts.
v) IS: 5561 – 1970 - Electric power connectors.

vi) IS : 7608 – 1975 - Phosphor bronze wires (for general
32
engineering purposes).
vii) IS : 7906 – 1975 - Helical compression springs
viii) IS : 9921 – 1985 - Alternating current disconnectors

(Pt. I, II, III & IV) (Isolators) and earthing switches for
voltage above 1000v.
ix) IEC : 129 – 1975 - Alternating current disconnectors
(Isolators) and earthing switches.
x) ETI / OHE / 13 (4 / 84) - Specification for hot dip zinc coating

on steel masts (rolled and fabricated)
tubes and fittings used on 25 kV ac
OHE.
xi) ETI / OHE / 18 (4 / 84) - Specification for steel and stainless
steel bolts, nuts and washers.
xii) ETI / OHE / 64 (10 / 88) - Specification for Solid Core
Cylindrical post insulators for system
with nominal voltages of 220 kV, 132
kV, 110 kV & 66 kV.
2.2 Any deviation from this specification proposed by the tenderer, calculated to improve
upon the performance, utility and efficiency of the equipment will be given due
consideration, provided full particulars of the deviation with justification therefor are
furnished. In such a case, the tenderer shall quote according to this specification and
deviation, if any, proposed by him shall be quoted as an alternative (s).
In case of any contradiction between the provisions of Indian Standards Specification

/ recommendations of the IEC and this specification, the latter shall prevail.
3 SERVICE CONDITIONS
3.1 The isolator is intended to be used as outdoor line sectioning switches. The isolator
shall be used in normally polluted atmosphere subject to dust smoke and effluents
from chemical plants. It may also be used in coastal areas.
3.2 Environmental conditions:
i) Maximum temperature of air in shade - 45 C
ii) Minimum temperature of air in shade - 0C
iii) Maximum relative humidity - 100%
iv) Annual rain fall - Ranging between 1750mm and

6250 mm
33
v) Number of thunderstorm days per - 85 (maximum)
annum
vi) Number of duststorm days per - 120 (maximum)

annum
vii) Maximum wind pressure - 200 kgf / m
viii) Altitude - Not exceeding 1000 m.
The isolator shall be subjected to vibrations on account of trains running on nearby railway
tracks. The amplitude of these vibrations, which occur with rapidly varying time periods in
the range of 15 to 70 ms, lies in the range of 30 to 150 microns with the instantaneous peak
going upto 350 microns.
4. DEFINITIONS
4.1 Isolator.
It is a mechanical switching device which provide, in the open position, an isolating

distance between the two contacts in accordance with specified requirements.
An isolator is capable of opening and closing a circuit when either negligible current
is broken or made, or when no significant change in the voltage across the terminals
at each pole of the disconnector (isolator) occurs. It is also capable of carrying
currents under normal circuit conditions and carrying, for a specified time, currents
under abnormal conditions such as those of short circuit.
4.2 Earthing Switch.

A mechanical switching device for earthing part of a circuit, capable of withstanding
for a specified time currents under abnormal conditions such as those due to short
circuit, but is not required to carry current under normal conditions of the circuit.
4.3 Main circuit.

All the conducting parts of an isolator or earthing switch included in the circuit
which is designed to close or open.
4.4. Pole.
The portion of an isolator or earthing switch associated exclusively with one

electrically-separated conducting path of its main circuit and excluding those portions
which provide means of mounting and operating all poles together.
4.5 Closed position
34
The position in which the predetermined continuity of the main circuit is secured.
4.6 Open position.
The position in which the predetermined clearance between open contacts in the
main circuit is secured.
4.7 Position indicating device.
A device which indicates, at the location of the isolator or earthing switch, whether
the contacts of the main circuit are in open or closed position.
4.8 Interlocking device.
A device which makes the operation of the isolator or earthing switch dependent upon
the position or operation of one or more other pieces o equipment.
4.9 Ambient temperature.

The temperature determined under prescribed conditions, of the air surrounding the
complete switching device (e.g. for enclosed switching devices, it is the air outside
the enclosure).
4.10 Operation cycle.
A succession of operations from one position to another and back to the first position
through all other operations, if any.
4.11 Dependent Manual Operation.
An operation solely by means of directly applied manual energy, such that the speed
and force of the operation are dependent upon the action of the operator.
4.12 Rated value.
A stated value of any one of the characteristic value that serve to define the working
conditions for which the isolator or earthing switch is designed and built.
4.13 Normal current.
The current which the main circuit of the isolator is capable of carrying continuously
under specified conditions of the use and behavior.
4.14 Short – time withstand current.
35
The current that an isolator or the earthing switch can carry in the closed position
during a short specified time period under prescribed conditions of the use and
behavior.
4.15 Permissible duration of short-circuit current.
The time during which an isolator or earthing switch in the closed position can carry a
short-circuit current of specified value.
4.16 Permissible peak withstand current.
The value of peak current that an isolator or earthing switch can withstand in the
closed position under prescribed conditions of use and behavior.
4.17 Rated 1 min power frequency withstand voltage.
The r.m.s. value of sinusoidal alternating voltage at power frequency which the
insulation of the isolator or earthing switch withstands under specified test
conditions.
4.18 Rated impulse withstand voltage.
The peak value of the standard (1.2/50 u s) impulse voltage wave which the insulation
of the isolator or earthing switch can withstand under specified test conditions.
4.19 Clearance.
The distance between the conducting parts along a string stretched the shortest way
between these conducting parts.
4.20 Clearance between poles.
The clearance between any conducting parts of the adjacent poles.

4.21 Clearance to earth.
The clearance between any conducting parts and any parts which are earthned or
intended to be earthed.
4.22 Clearance between open contacts (gap).
The total clearance between the contacts or any conducting parts thereto, of a pole of
an isolator or earthing switch in the open position.
4.23 Isolating distance.
36
The clearance between open contacts or any conducting parts connected thereto in a
pole of an isolator meeting safety requirements.
5. RATING AND OTHER PARTICULARS
i. Type - Manually operated, horizontally

mounted on pole, vertical break type
and suitable for outdoor
ii. Number of phases - One
iii. Number of poles - One or two (as specified by the

purchaser).
iv. Isolating distance (In air). - 500 mm (min.)
v. Rated voltage - 25 kV (nominal)
vi. Rated current :
i. Type – I - 1250 A
(Isolator used at sectioning and parallelling post & Sub-sectioning and

parallelling post)
ii. Type II - 1600 A
(Isolator used at Feeding post & Traction sub-station)

vii. Rated frequency. - 50 Hz. +/-3 %
viii. Rated short time - 20 kA
Withstand current (Both for main & - (r.m.s.) for 3 s.

earthing switch
ix. Rated peak withstand current (both - 50 kA
for main & earthing switch) for 3 s.
x. Temperature rise :
The temperature rise of any part of an isolator shall not exceed the maximum
temperature rise given below under the conditions specified in the test clauses –
12.5
Nature of parts Temperature in Temperature rise in degree

degree celsius celsium
37
i. Copper contacts in air:
bare copper or tinned 75 35
aluminium alloy
ii. Terminals of isolators 90 50
to be connected to
external conductors by
screws or bolts – bare
iii. Metal parts acting as The temperature shall not
springs reach a value where the
elasticity of the materials is
impaired. Fr pure copper the
temperature limit is 75 deg.
C.
xi. Rated impulse (1.2 / 50 micro
– second) withstand voltage:
i. To earth and between. 250 kV (peak)

The poles
ii. Across the isolating 290 kV (peak)
distance.
xii. Wet power frequency 1 min

withstand voltage:
i. To earth 95 kV (r.m.s.)
ii. Across isolating

distance 110 kV (r.m.s.)
6. DESIGN CONSTRUCTION AND MOUNTING.
6.1 The support and operating rod insulators shall be of solid core type in accordance
with the latest specification of RDSO viz No. ETI / OHE / 15 and shall be procured,
if included in the order, only from the approved manufacturers as per drawings
approved by RDSO.
Note : The insulators shall be supplied by Railways. The tenderers may,

therefore quote rates without insulators.
6.2 The isolator shall be robust in construction and so engineered as to ensure smooth
operation at all times. The isolator, both single and double pole, shall be
supplied fully assembled on a suitable rigid frame. For double pole isolators, the
cross channels for mounting shall also form part of supply. The support and frame
work shall be designed for a wind pressure of 200 kgf/m acting on 150% of the
projected area in addition to all other loads. During the opening and operations of the
isolator there shall be no shock. There shall also not be a backlash tending to open
38
the isolator after closing, due to the jerk, if any. All poles of the isolator shall
required, for the proper alignment of the pole after mounting. All movable joints
shall be provided with brass bushes / bearings, which shall be entirely maintenance
free.
6.3 The blades of the isolator shall be of electrolytic high conductivity copper tubes of
adequate strength and cross section to IS : 91 (Part V) – 1980 to withstand thermal
and bending stresses particularly under short circuit fault conditions.
6.4 Flexible braided copper, where used, shall have corrosion resistant coating such as
tinning or silvering. The connection between the flexible braid and rotating and fixed
parts shall be by means of not less than two bolts to prevent any tendency of rotation.
6.5 For reasons of safety, the isolator should be so designed that no dangerous leakage
current can pass from the terminals of one side to any of the terminals of the other
side.
6.6 The frame (isolator mounting channel) of each isolator shall be provided with an
earthing terminal for connecting to an earthing conductor having clamping screws,
suitable for earth fault conditions. The diameter of the clamping screws shall be not
less than 12 mm. The connecting point shall be marked with “Earth” ( ) symbol.
6.7 When installed, the isolator shall be able to bear on terminals the total forces
(including wind load and electrodynamic forces on the attached conductors) related to
the application and rating without impairing their reliability or current carrying
capacity.
6.8 The isolator shall be constructed so as to permit it being locked both in the open as
well as closed positions. It shall not be possible to lock the isolator in any
intermediate position.
6.9 The fixed contacts of isolator shall be of extruded, rolled or drawn copper strips. The
contacts shall be spring loaded. Only nonferrous or stainless steel components shall
be used in the contact assembly.
6.10 The springs used in the contact assembly of the isolator shall be or phosphor bronze
conforming to IS : 7608 – 1975. To avoid current passing through the springs, nylon
strip of suitable size shall be provided for insulation. The characteristics of the
springs shall conform to IS: 7906 (Pt. II) – 1976 and their mechanical properties shall
not be affected in any manner on account of rise in temperature during operation.
6.11 Bolts, nuts locknuts and other fasteners of 12 mm dia and less shall be of stainless
steel. Fastners of higher size may be made of hot dip galvanised steel. All fasteners
shall be procured from approved manufacturers, a list of which may be obtained from
Central organisation for Railway Electrification Allahabad. The fasteners shall
confirm to RDSO specification No. ETI / OHE / 18.
39
6.12 The mounting arrangement and the operating mechanism shall be such that with the
isolators mounted in the working position, the hinge pin of the operating handle is at a
height of 1.1 m from ground level. The height of base of the rigid frame referred in
clause 6.2 would vary, depending on the type of mast / or structure on which the
isolator is mounted. The heights for typical masts / structures are given below.
------------------------------------------------------------------------------------------------------------
Location Height of isolator mounting channel from ground level in mm
----------------------------------------------------------------------------
SP DP
------------------------------------------------------------------------------------------------------------
RSJ / BFB mast. 8310 8160
RSJ with super mast. 9425 9275
R. Portal 9535 9385
N. Portal 9485 9335
O. Portal 9585 9435
Two Track Cantilever 9560 9410
SS, SSP, SP, FP 3262 --

5425 5525
(When busbar height is 5968 mm)
6.13 The isolator shall be supplied with operating pipe in exact length for the particular
mast/structure, the length being obtained from the purchaser for each type of
mast/structure.
6.14 The operating pipe shall not have any joint and shall be supplied with four guides
unless otherwise specified in the purchase order. The operating pipe shall be obtained
only from approved manufacturers, a list of which may be obtained from Central
Organisation for Railway Electrification / Allahabad.
6.15 All Malleable cast iron parts shall be of black heart malleable cast iron grade BM –
340 conforming to IS : 2108 – 1977.
6.16 All ferrous parts shall be hot dip galvanised in accordance with specification No. ETI
/ OHE / 13 (4 / 84).
6.17 The Isolator shall be provided with a terminal pad at each end as shown in Annexure
“B” attached. The terminal pad shall have few holes as indicated for being connected
to a terminal connector.
40
6.18 The general arrangement of the isolator shall be as shown in Annexure ‘B’. The
essential dimensions are also indicated in the Annexure ‘B’.
7. OPERATION
7.1 The operating mechanism shall be such that it is possible to fasten the base to which
the operating handle is attached, to either of the two mutually perpendicular vertical
faces of the supporting structure on which the isolator is mounted.
7.2 The operating handle of the isolator shall be so designed as to work in the vertical
plane. The isolator shall close when the handle is moved upwards. The free end of
moving contact shall be fully housed in the fixed contact when the handle is moved
fully upward in which position the isolator can be locked.
7.3 The design of the single pole isolator shall be such as to permit coupling of isolators
for gang operation from a single operating handle. Not more than two single pole
isolators are required to be coupled.
7.4 Suitable “OFF” and “ON” plates shall be provided on the operating handle to indicate
when the isolator is open and closes respectively.
7.5 The general arrangement of operating mechanism shall be shown in Annexure “B”.
8. LOCKING
8.1 A bolt type integral lock and / or inter lock, as specified by the purchaser, of approved
type shall be fitted on the isolator to enable the operating handle of the isolator to be
locked effectively in the “open” as well as in the “close” position. It shall not be
possible to withdraw the key from the integral lock except when the isolator is
locked either in the open or in the closed position.
8.2 The operating mechanism shall be so designed as to permit padlocking, in addition to

the integral lock and / or interlock, for locking the operating handle of the isolator
both in the open as well as in the closed positions.
8.3 The addition to locking arrangement described in Clause 8.1, the design of operating
mechanism shall permit its operation in a predetermined sequence related to the
operation of other switchgear with the help of suitable interlocks.
8.4 The internal mechanism of integral lock and interlock shall be of stainless steel or non
– ferrous material. It shall be of robust construction. The outer housing of the
interlock and integral lock shall be chrome plated steel and the construction shall be
such that it is not prone to theft. The integral lock and interlock shall be obtained
only from the approved manufacturers.
41
8.5 Each lock shall be supplied with two keys.
Key / lock number shall be inscribed on the keys / locks.
9. EARTH CONTACT ASSEMBLY
9.1 The design of the isolator shall be such that it is possible to incorporate an additional
pair of contacts so as to effectively earth the fixed contact of the isolator in open
position even at a later date.
9.2 The design of the isolator frame shall permit the provision of the earth contact
assembly without calling for modification to the frame itself. Two holes of 15.5 + 0.5
mm dia shall be provided on the – 0.0 mounting channel for connecting the earthing
terminals.
9.3 The earth contact assembly shall be rated for the short time current specified in Clause
5 (viii) & (ix).
10. ARACING HORN
10.1 The single pole isolator shall be provided with arcing horns which shall be of bright
steel to Gr. 20 – C- 8 of IS : 1570 (Pt. II) – 1979. The arcing horns shall make
contact before the main contacts close and break contact after the main contacts break.
11. TESTS
11.1 Type tests
Only after all designs and drawings have been approved and clearance given by
RDSO / Chief Electrical Engineer to this effect, the manufacturer shall take up the
manufacture of the prototype. It is to be clearly understood their any changes to be
done in the prototype as required by RDSO/Chief Electrical Engineer shall be done
expeditiously.
Before giving the call to RDSO / Chief Electrical Engineer for inspection and testing
of the prototype, the manufacturer shall submit a detailed test schedule consisting of
schematic circuit diagram for each of the test and the nature of the test, venue and
duration of each test and the total number of the days required to complete the test at
one stretch. Once the schedule is approved, the test shall invariably be done
accordingly. However, during the process of type testing or even later, RDSO / Chief
Electrical Engineer’s representative reserves the right to conduct any additional test
(s) beside those specified herein, on any equipment / sub – system or system so as to
test the system to his satisfaction or for gaining additional information and
knowledge. In case any dispute or disagreement arises between the manufacturer and
RDSO / the Chief Electrical Engineer during the process of testing as regards the type
tests and / or the interpretation and acceptability of the type test results, it shall be
42
brought to the notice of the Director General (Traction brought to the notice of the
Director General (Traction Installations), RDSO / Chief Electrical Engineer as the
case may be whose decision shall be final and binding.
The following tests shall be carried out on the prototype unit of the isolator and
earthing switch at the works of the manufacturer / sub- contractor or at a reputed
testing laboratory, in the presence of RDSO / Chief Electrical Engineer’s
representative (s) in accordance with the relevant governing specification and / or as
modified or amplified hereunder against each test :
i. Visual examination of isolator and its parts

ii. Dimensional verification of parts
iii. Assmebly and interchangeability
iv. Measurement of resistance of main circuit and / earth circuit (before and after
mechanical endurance test
v. Temperature rise test (before and after mechanical endurance test)
vi. Mechanical endurance test
vii. Short time rated current test
viii. One minute wet power frequency test across the isolating distance and to earth
ix. Impulse voltage withstand test across isolating distance and to earth
x. Galvanisation test
xi. Chemical analysis of materials – copper contacts, springs, fastners and bushes
xii. Physical tests on springs and fasteners and copper strips.
11.1.1 If the electrical clearances viz. The isolating distance clearance of live parts to ground
and the clearance between the two poles are maintained to Annexure ‘B’ and the
insulators are supplied by the purchaser, high voltage tests (12.8 and 12.9) may be
waived at the discretion of RDSO / CORE / Purchaser.
11.2 Acceptance tests.
11.2.1 For the purposes of acceptance, isolators shall be offered for inspection in lots
containing components for not more than 50 assemblies of same type of isolators.
The isolators offered for inspection shall first be routine tested by the manufacturer
and defective components removed.
11.2.2 The visual examination and measurement of resistance shall be done on all he
isolators offered for inspection. The defective ones shall be either attended to or
removed before further tests are conducted.
11.2.3 The following shall comprise the acceptance test :

i. Visual examination (on every item of the lot)
ii. Dimensional verification of parts (on 10% sample of the lot, minimum one
number)
iii. Assembly and interchangeability (of minimum 3)
iv. Galvanisation test (one sample of each item )
43
v. Measurement of resistance (all samples)
Note : Number of samples drawn for tests may be increased at the discretion of
RDSO / Chief Electrical Engineer’s representative (inspector) during the
inspection.
11.2.4 The inspector may, at his discretion, conduct any or all of the tests (C1, 12, 5) (C1,
12, 11) and (C1, 12, 12) for a particular lot. The manufacturer shall arrange for the
test.
11.2.5 Acceptance criteria.
11.2.5.1 If during dimensional verification of parts, assembly and interchangeability, any

component fails to meet the requirement of this specification, twice the number of
the same shall be taken and the tests repeated. If the component (s) fail to meet the
requirement again, the lot shall be rejected. The manufacturer may sort out the
again, the lot shall be rejected. The manufacturer may sort out the defective pieces
and offer the lot once again. Should there be any failure in the lot offered once
again, the lot shall be rejected totally.
11.2.5.2 If the sample fails to meet the requirements of C1, 12, 10 twice the number of
samples for same component / assembly shall be drawn and subjected to the same
test. Should the sample fail in the re-test, the lot of particular component will be
rejected. The manufacturer may re-assemble the isolators using new components
and offer once again for inspection.
11.2.6 Routine tests.
11.2.6.1 The manufacturer shall carry out the following as routine tests :
i. Visual examination.
ii. Dimensional verification of parts.
iii. Assembly and interchangeability.
11.2.6.2 The manufacturer shall offer record of the routine tests and acceptance tests
carried out by him to ensure quality of raw materials, to the inspector. Unless
these are satisfactory, no acceptance test shall be carried out. Mention of
routine tests and acceptance tests carried out by the manufacturer shall be made
in the test report and salient extracts reproduced.
12 TEST METHODS
12.1 Visual examination.
12.1.1 All components shall be visually examined to check that they are properly
manufactured, do not have sharp edges and corners, the tubes are not crooked or bent
and galvanisation of ferrous components is free from visible defects mentioned in
44
Appendix ‘A’ RDSO specification No. ETI / OHE / 13 latest version. The finish
stainless steel fasteners and pins shall be smooth and bright.
12.2 Dimension verification.
12.2.1 The components of the isolators, particularly –

- moving contact blade
- the spring of the fixed contact
- the housing for fixing contact jaws on the post insulators.
The fixed and moving contact jaws, the operating shaft for the operating pipe and the
contacts shall be checked with respect to the approved drawings. The components
shall be in accordance with the approved drawings.
12.3 Assembly and interchangeability.
12.3.1 The isolator shall be assembled, using the components picked up at random from
different lots. No adjustments shall be required in any component to enable quick
assembly of the isolator. After assembly the isolator shall function smoothly without
any adjustments.
12.3.2 The components such as the housing for the fixed and moving contacts, the housing
for the earth contact assembly shall then be interchanged to ensure that the
components are fully interchangeable. Fixing of different components shall be
without any difficulty and any special adjustment.
12.3.3 The dimensions of the isolator assembly, particularly the following critical ones shall
be verified :
i. Minimum clearance between moving blade and the jaw of the fixed contact at
free end when the isolator is open
ii. The clearance between the earth end of the operating rod insulator with both
the live terminals in closed as well as open positions.
iii. The travel of the moving blade with full travel of operating pipe.
iv. The distance between the centres of all the holes of the isolator assembly for
fixing it on the masts.
v. When the isolator is in fully closed position, the moving contact shall go home
fully into the fixed contact and no portion shall remain projecting beyond the
fixed contact on the upper side. The main contact shall not exert undue
pressure on the stopper.
12.4 Measurement of the resistance of the main circuit / earth circuit.
45
12.4.1 This measurement is made for comparison between the isolator type tested for
temperature rise and all other isolators of the same type subjected to acceptance tests.
12.4.2 The resistance shall be measured with direct current
A direct current of any convenient value between 100 and rated normal current shall
be passed through the main circuit / earthing contact circuit as the case may be and
the voltage drop between the two terminals of each pole of the isolator shall be
measured to obtain the resistance at the ambjent temperature. All values measured /
obtained shall be recorded.
12.4.3 The measurement of resistance shall be made before the temperature rise test.
12.4.4 The test shall also be conducted during acceptance test. The maximum value of
resistance shall not exceed 1.5 times the resistance obtained during type tests or R x
T/t,
whichever is lower, where –

R = Resistance obtained during type test.
T = Permissible temperature rise (35 deg. C)
t = Temperature rise obtained during type tests at hottest spot.
12.4.5 For the purpose of the acceptance test, the measurement of resistance may be made
by using micro-ohm meter calibrated to the satisfaction of the inspector.
12.5 Temperature rise test.
12.5.1 The test for temperature rise of main circuit shall be made on a new isolator with
clean contact pieces. The isolator shall be mounted approximately as under usual
service conditions, including all normal covers of any part of the isolator, and shall be
protected against undue heating or cooling.
12.5.2 Temporary connections to the main circuit shall be such that no appreciable amount
of heat is conducted away from or conveyed to the isolator during the test. In case of
doubt the temperature rise of the terminals of the main circuit and at temporary
connections at a distance of 1 m from the terminals shall be measured. The difference
of temperature shall not exceed 5 deg. C.
12.5.3 The test shall be made with the rated normal current of the isolator (i.e. 1250 A for
isolators for SSP and SP and 1600 A for isolators to be used at FP and TSS) and at
rated frequency (50 Hz) + 3%.
46
12.5.4 The duration of the test shall be made over a period of time sufficient for the
temperature to reach a steady state i.e. when the variation of temperature does not
exceed 1 deg. C per hour over three hours.
12.5.5 The temperature of the different parts shall be measured with thermometers,
thermocouples or other suitable means, placed at the hottest accessible spot. The
following precautions shall be taken when measuring with thermometers or
thermocouples :
i. Thermocouples or the bulbs of thermometers shall be protected against

being cooled from outside during the test. The protected surface area
shall, however, be negligible when compared with the cooling surface
area of the part under test.
ii. Good heat conductivity between the bulb of the thermometers or

thermocouples and the surface of the part under test shall be insured.
iii. Alcohol thermometers shall used as they are accurate for such
purposes.
12.5.6 The time for the whole test may be shortened by preheating the circuit with the higher
value of current.
12.5.7 In case the temperature rise at any part of the isolator exceeds the values specified in
Clauses 5 (x), the isolator shall be deemed to have failed in the test.
12.6 Mechanical endurance test.
12.6.1 The mechanical endurance test shall be conducted in accordance with IS : 9921 (PT
IV) but the number of operating cycles shall be 5000 instead of 1000 as specified
therein. The condition of all parts shall be satisfactory after the test. On successful
completion, the test shall be continued upto 10000 cycles to determine the weak
spots.
12.6.2 For this test, the isolator shall be complete with operating and locking mechanism etc.
12.7 Short time withstand current test.
12.7.1 The test shall be conducted at the current value specified in Clause 5 (viii) for 3 s.
12.7.2 The arrangement for the test as shown in Annexure ‘C’ may be used, both for the
single pole as well as for the double pole isolators and associated earthing switches.
The distance x between the earthing terminals of the disconnector and the nearest
support of the test connections is equal to three times the distance between pole test
connections is equal to three times the distance between pole centres. The distance u
and v are as small as possible but not less than y.
47
12.7.3 The a.c. component of the test current shall be equal to the a.c. component of the
rated short time withstand current of the isolator or earthing switch. The peak current
shall be not less than the rated peak withstand current but shall not exceed it by more
than 5% without the consent of the manufacturer.
12.7.4 The value of the test current and its duration shall be such that –
I21 . t1 = I2 . t
Where –
I1 = r.m.s. component of test current measured in accordance with
Appendix to IS: 9921 (Pt. IV) in A.
I = r.m.s. component of specified short-time current in A (20,000 A).
t = Specified short – time current duration in seconds (3 s)
t1 = Duration of current in s.
Note : This test shall be conducted at Central Power Research Institute. Bangalore
only, unless otherwise approved by RDSO.
12.7.5 During the test to prove its capability of carrying the rated peak withstand current and
the rated short time withstand current, the isolator or earthing switch shall not show
undue stress. After the test, the isolator or earthing switch shall not show any
material deterioration and shall be capable of operating normally.
12.7.6 Visual inspection and no-load operation of the tested isolator or earthing switch are
usually sufficient to check these requirements.
12.7.7 The test may be considered completed successfully if the isolator can be operated
manually after tests. There should be no damage, which may affect its mechanical
and electrical performance.
12.7.8 If after the test, there is any doubt about its current carrying capability, temperature
rise test shall be made before the isolator is reconditioned. The value of temperature
rise shall not exceed the figure given in Clause 5 (x).
12.8 Wet power frequency voltage withstand test.
12.8.1 The isolator and earthing switch shall be subjected to wet power frequency voltage
withstand test in accordance with IS : 2071 (Pt. I & II).
48
12.8.2 The test voltage shall be raised for each test condition to the rated withstand voltage,
duly corrected for the ambient atmospheric conditions, specified in C1. 5 (x11) and
shall be maintained for 1 min. No disruptive discharge shall take place during the 1
min period.
12.8.3 The wet power frequency voltage withstand test shall be conducted in accordance
with IS : 2071 (Pt. I). However, if the water of prescribed resistivity can not be
obtained, water of lower resistivity may be used, provided that the isolator passes the
test. The actual value of resistivity of the water and the rate of precipitation (both
horizontal) and vertical components) shall be stated in the test report.
12.8.4 The test shall be conducted in following conditions :
i. Between isolator and earth : With the isolator in the closed position, the test
voltage shall be applied to one of the 25 kV terminals, the support frame –
work and the other pole connected together and earthed.
ii. Across isolating distance : With the isolator in the open position, the test
voltage duly connected for ambient conditions, shall be applied at the moving
blade (s) and the other two terminals shall be connected to the earth of the
testing transformer. The whole isolator shall be adequately insulated from the
ground to prevent possibility of direct flashover.
Note : If the order is for both single pole and double pole isolators, these tests
would be conducted on a double pole isolator with earthing switch.
12.9 Lightning impulse voltage tests.
12.9.1 If the order is for both single pole and double pole isolators, this test shall be
conducted on a double pole isolator with earth contact assembly. Isolator and
earthing switch shall be subjected to dry lightning impulse voltage test, with both
positive and negative polarities using standard 1.2 / 50 micro-second lightning
impulse according to IS : 2071 (Pt. I).
12.9.2 Impulse voltage test between Isolator and earth with the isolator in closed position
and earthing switch open, 15 consecutive impulses of 250 kV duly corrected for the
ambient atmospheric conditions, shall be applied between one terminal and the frame,
the other pole being connected to the frame. The isolator shall be considered to have
passed the test, if number of disruptive discharges to frame or to the adjacent pole
does not exceed two.
12.9.3 Impulse voltage test across isolating distance.
The isolator shall be in the open position. The frame – work shall be adequately
insulated from earth so as to prevent any disruptive discharges direct to earth.
Lightning impulses of 290 kV duly corrected for ambient conditions shall be applied
49
to the moving blade (s). The remaining two terminals shall be connected to the earth.
The isolator shall be deemed to have passed the test if there is no disruptive discharge
to the opposite terminals.
12.10 Galvanisation test.
12.10.1 In the type test, at least two samples of each type of component which has been
galvanised shall be tested for ensuring that the galvanising done conforms to
specification No. ETI/OHE/13 in regard to adherence, uniformity and mass of zinc
coating. The mass of zinc coating shall be not less than 610 g/m2.
12.10.2 In the acceptance test, one sample of each type of component which has been
galvanised shall be tested for ensuring that the galvanising done conforms to
specification No. ETI/OHE/13 in regard to adherence, uniformity and mass of zinc
coating. The mass of zinc coating shall be not less than 610 g/m2.
12.11 Chemical analysis of materials.
12.11.1 The chemical analysis of phosphor bronze springs, copper tube / strips of moving and
fixed contacts and stainless steel fasteners shall be conducted in accordance with IS :
7608, IS : 191 and RDSO specification No. ETI / OHE / 18 as applicable. The
material shall conform to the requirements specified.
12.11.2 Physical tests on fasteners shall be conducted in accordance with RDSO

specification No. ETI / OHE / 18. The results shall be in accordance with the
requirement laid down in the specification.
12.12 Physical tests on the springs and on copper strips shall be conducted inaccordance
with IS : 7906 (Part II) and IS : 1897 respectively.
13.0 BULK MANUFACTURE
13.1 Only after clear written approval of the results of the tests on the prototype is
communicated by RDSO / Chief Electrical Engineer to the manufacturer, shall be
take up bulk manufacture of the equipment – which shall be strictly with the same
material and process of manufacture as adopted for the prototype. In no
circumstances shall material other than those approved in the designs / drawings and /
or the prototype be used for bulk manufacture on the plea that they had been obtained
prior to the approval of the prototype.
13.2 If the prototype of an isolator and / or earthing switch conforming to this specification
has been approved for earlier supplies to Indian Railways, testing of prototype again
may be waived. Provided that no changes in the design or materials (s) used or
process of manufacture have been made.
13.3 Technical data and drawing.
50
13.3.1 The tenderer shall furnish alongwith his offer the guaranteed performance data and
other technical particulars of the equipment in the proforms attached at Annexure ‘A’.
13.3.2 The information furnished in the Schedule of guaranteed technical performance, data
and other particulars shall be complete in all respects. If there is any entry like “shall
be furnished later” or blanks are left against any item of Schedule of guaranteed
particulars, the tender is not likely to be considered as such omissions cause delay in
finalising the tender.
13.3.3 Reports of the type tests, if conducted on the similar equipment shall also be
furnished.
compliance with each clause and sub-clause of this specification. If any vague
remark on any clause or sub-clause of this specification is given by the tenderer then
the tender submitted by him is not likely to be considered. A separate deviation
statement shall be furnished with the offer drawing attention to the clause (s) where
the tenderer seeks deviation giving detailed remarks / justification thereof. If there
are no deviations, a ‘NIL’ statement shall be furnished.
13.5 The tenderer shall furnish alongwith tender the following drawings :
i) General arrangement drawings showing the outline dimensions of isolators
and earthing switch (whenever provided).
ii) Drawing for support insulators alongwith salient technical particulars.
iii) Drawing for operating mechanism of main isolator.
iv) Drawing for operating mechanism of earthing switch.
13.6 The manufacturer shall be required to submit the following detailed dimensioned
drawings including drawings already mentioned in clause 8.5 above, as per Railways
standards in size of 210 mm x 297 mm or in integral multiple thereof, for approval :
i) details of main contacts.
ii) details of earthing contacts.
iii) interlocking arrangement.
iv) Castell type integral lock
v) mounting details of isolator.
vi) terminal connector.
vii) Loads exerted by the isolator & earthing switch (wherever provided) for
designing the mounting structure. This drawing should furnish complete
information regarding loads and their point of application.
51
13.7 After approval, six copies of approved drawings along with two sets of reproducible
prints shall be supplied to each consignee. Two copies of drawings along with one
set of reproducible prints shall be supplied to the Director General (TI), Research
Design and Standards Organisation, Manaknagar, Lucknow – 226011.
14. INSTALLATION, OPERATION AND COMMISSIONING
Twenty sets of installation, operation and maintenance instructions shall be supplied to

the Purchaser with every order. Two copies of these instructions shall be supplied to
the Director General (TI), RDSO, Lucknow. The information shall necessarily include
–
i) Procedure for erection and precautions to be taken during the process.
ii) The details of maintenance practices to be adopted under normal service

conditions. The number of operations (or the period) after which different
parts of isolator and / or earthing switch requires to be specifically attended to
shall be indicated.
iii) Procedure for overhauling of isolator and / or earthing switch.
iv) Procedure for replacement of parts, like contacts, subject to wear and tear and
deterioration during service.
v) List of spare parts required for 5 years maintenance.
vi) List of special tools required for maintenance / replacement.
vii) Lubrication instructions including type of lubricants and quantity to be used.
15. PACKING AND DESPATCH
15.1 Various components of the isolator and / or earthing switch shall be securely packed
in a proper manner in a wooden crate / box. It shall be ensured that one crate / box
does not contain components of more than one complete isolator and / or earthing
switch. A detailed packing list with weight and overall dimensions of the crate / box
shall be furnished for each crate / box indicating the following : -
------------------------------------------------------------------------------------------------------------
Crate / Box No. Description of each Gross weight Outside
component in the in kg. dimensions
crate / box of crate / box.
------------------------------------------------------------------------------------------------------------
52
15.2 The weight of a crate / box containing all components shall be such that it can be
manually handled conveniently by not more than two persons.
15.3 Necessary instructions for handling and storage shall also be furnished for use at the
receiving end.
This specification supersedes Specification No. ETI / OHE / 16 (10 / 86) Rev – 1.
********************************
53
Annexure – A
Specification No. ETI / OHE / 16 (1 / 94).
SCHEDULE OF GUARANTEED PERFORMANCE DATA

TECHNICAL AND OTHER PARTICULARS.
25 kV a.c. SINGLE POLE ISOLATORS
S. No. Description Unit of

measurement / data.
----------- -------------------------------------------------- -------------------------
1. Name of manufacturer
2. Country of origin.
3. Standard specification on which

performance is based.
4. Manufacturer’s type designation.
5. Rated voltage. kV
6. Rated current :
a) Isolator A
b) Earthing switch A
7. Rated frequency Hz.
8. Rated insulation level
a) Rated one minute power frequency

wet withstand voltage.
i) To earth and between poles kV (rms)
ii) Across isolating distance kV (rms)
b) Rated one minute power frequency

dry withstand voltage.
i) To earch and between poles kV (rms)
ii) Across isolating distance kV (rms)
54
c) Standard lightning impulse
(1.2 / 50 microsecond) withstand
voltage –
i) To earth and and between poles kVp
ii) Across isolating distance kVp
9. Rated short time withstand current

current (for 3 seconds ) –
i) Isolator kA (rms)
ii) Earthing switch kA (rms)
10. Dynamic peak withstand current :
i) Isolator kAp
ii) Earthing switch kAp
11. Maximum temperature rise over an

ambient temperature of 40 deg. C
when carrying its rated current. Deg. C.
i) Copper contacts.
ii) Terminal pad of the isolator

to be connected to terminal
connectors by both.
iii) Metal parts acting as spring
12. Breaking capacity of capacitive

current at rated voltage. A
13. Number of poles Number
14. Number of breaks per pole Number
15. Total length of break per pole mm
16. Centre distance between poles mm
55
17. Minimum clearance in air
a) Between poles mm
b) Between the live part and earth mm
c) Between open contacts of the same

pole. mm
d) Isolating distance mm
18. Contacts
a) Material of the moving contact.
b) Material of the fixed contact.
c) Thickness of silver coating. Micron.
d) Contact pressure. kg.
19. Operating mechanism.
a) Type
b) Can be fitted with power Yes / No
c) Operated device.
d) Height of the operating handle hinge

Pin from ground level. m
d) Weight of the operating mechanism kg
20. Insulator
a) Name of manufacturer.
b) Type designation
c) Standard specification on which

Performance is based. IS
d) Number of stack
e) Weight of one insulator. kg.
56
f) Number of insulators used
i) Support
ii) Rotating / operating
g) Wet power frequency withstand

Voltage (1 minute). kV (rms)
h) Dry power frequency withstand

Voltage (1 minute). kV (rms)
i) Visible discharge test voltage kV
j) Impulse withstand voltage kVp
k) Wet power frequency flashover

voltage. kV (rms)
l) Dry power frequency flashover

Voltage. kV (rms)
m) Puncture voltage kV (rms)
n) Minimum failing load in bending. kN
o) Minimum failing load in tension kN
p) Minimum failing load in torsion kN
q) Minimum failing load in compression kN
r) Creepage distance in air mm
s) Shed profile
21. Type of bearings used in the isolator.
22. Type and material of terminals.
23. Total weight
i) Isolator kg
57
ii) Earthing switch kg
24. Number of closing and opening

operations, the isolator can
perform without deterioration
of its contacts.
Additional information
25. Is contact silver plated ? Yes / No
26. Is pad locking arrangement for

operating mechanism box provided? Yes / No
27. Is mounting arrangement for

interlock (s) on isolator operating
mechanism provided? Yes / No
28. Is integral lock on earth mechanism

provided? Yes / No
29. Is mounting arrangement for interlock
With associated isolator provided? Yes / No
30. Is mechanical interlocking arrangement

between earthing switch and the
isolator provided? Yes / No
31. Is the material of fasteners of 12 mm

dia and below stainless steel? Yes / No
32. Is the material of fasteners above 12

mm dia galvanised stainless steel ?
If not, what is it? Yes / No
33. Is frame work for the isolator made

of steel galvanised? Yes / No
34. Two number of earthing studs

provided for -
a) Isolator frame Yes / No

b) Earthing switch frame Yes / No
c) Operating mechanism box Yes / No
d) Earthing symbols provided Yes / No
58
35. Is height of operating handle hinge
pin in earthing switch from ground
level 1.1 m? Yes / No
36. Is arrangement for keeping the

operating handle for isolator in the
37. Can the isolator be converted to

motor operated one with minor
modification (if yes, sketch to be
shown for modification required)? Yes / No
38. Is the operating mechanism box for

the isolator is weather, dust and
vermin proof? Yes / No
39. Is Open / Closed indicator provided for –
a) Isolator Yes / No
b) Earthing switch Yes / No
40. Is Padlocking provided for –
a) Main rotating shaft of isolator Yes / No

b) Operating handle for earthing
switch. Yes / No.
c) Lid cover for operating mechanism
box. Yes / No.
41. Are the bearings maintenance

free? Yes / No.
****************************
59
Addendum / Corrigendum Slip No. 1 (June 2000) to the technical Specification No.
ETI/OHE/16 (1/94) for 25kV, single pole/double pole isolators for ac traction system.
S. Clause Description As amended

No No.
1 2 3 4
1. 5.0 (vi) Rated current Add under the existing entries and read as :
page-6 i. Type I (a) 1250 A
(b) 3150 A (for continuous)
[Isolator used at sectioning and paralleling post &
sub sectioning and paralleling post]
ii. Type II (a) 1600 A
(b) 6300 A (for 60 sec.)
[Isolator used at feeding post & traction substation]
2. 5.0 (viii) Rated short- The existing entries may read as :
page-6 time withstand i. 20 kA rms (for 3 sec.)
current. (both ii. (a) 50 kA rms (for 3 sec.)
for main & (b) 100 kA rms (for 1 sec.)
earthing switch)
3. 5.0 (ix) Rated peak Add under the existing entries :
withstand current i. 50 kA peak
(both for main & ii. 125 kA peak
earthing switch)
4. 11.1 Type Tests Add a new para after the existing entries :
page-12 “In the event of the tests not being carried through to
completion at one stretch for any reason attributable
to the successful tenderer / manufacturer & it is
required for the representative of the purchaser /
Director General (Traction Installation) Research,
Designs & Standards Organization (DG/TI/RDSO),
Lucknow to go again or more number of times to the
works of the successful tenderer / manufacturer or
other place(s) for continuing and / or completing the
tests on the prototype(s) of the equipment the
successful tenderer / manufacturer shall reimburse to
the purchaser, DG/TI/RDSO, Lucknow the cost for
the representative having to visit to the works or
other place(s) for the tests more than once. The cost
as claimed by the purchaser / DG/TI/RDSO,
Lucknow shall be paid through a demand draft to the
concerned accounts officer of the purchaser /
DG/TI/RDSO, Lucknow as shall be advised to the
successful tenderer / manufacturer.”
60
5. 12.5.3 Temperature The existing clause may be read as :
Page- rise test. “The test shall be made with the rated normal current
16 of the isolator (ie. 1250 A or 3150 A for isolators
used at SSP & SP and 1600 A or 6300 A for isolators
to be used at FP & TSS) and rated frequency
50 ± 3% Hz.”
6. 13.6 Technical data Add a new item after the existing entries.
Page 21 and drawing “viii. Name & rating plate on the isolator (the rated
characteristic shall be in conformity with clause 3.0
of IS : 9921 / part ii).”
7. 13.7 Drawing Add in the 3rd line of the existing entries ie. In
Page 22 between “reproducible print” and shall be
supplied..” “and on floppy along with hard copy
(in ACAD R 14) after final approval of
drawings…”
8. 16.0 Warranty Add a new clause 16.0

Page 23 The successful tenderer / manufacturer shall warrant
that equipment shall be free from defects and faults
in design, material, workmanship & manufacture and
of the highest grade consistent with the established
and generally accepted standards for the equipment
of the type ordered and full conformity with
specification and shall operate properly. This
warranty shall survive inspection of, payment for and
acceptance of the equipment, but shall expire 18
months after the delivery at ultimate destination or
12 months from the date of commissioning and
proving test of the equipment at ultimate destination,
whichever period expires earlier.
9. Item-9 Rated short Add after the existing entries.

of time withstand
Annx.- current. b. Rated short time withstand current (for 1 sec.)
A Page i. Isolators kA rms
25 ii. Earthing switch kA rms.
61
Addendum / Corrigendum Slip No.2 (March 2004) to the Technical Specification
No..ETI / OHE/16 (1/94) for 25 kV Single Pole /double pole isolators to be used in AC
Traction system on Indian Railways.
S.No. Clause Description As amended

No./
Page No.
1. 5.0 (vi)/ Rated current The existing entries shall be replaced with
Page-6 following :
i) Type 1 : 1250A (Isolator used in OHE and at SP,
SSP).
ii) Type II : 1600A (Isolator used at FP & TSS)
iii) Type III : 3150A (Used in OHE, during
transition in DC-AC conversion and in 30
MVA traction substation on Mumbai suburban
section).
2. 5.0(viii)/ Rated short time The existing entries shall be replaced with
Page-6 withstand following :”
current(Both for i) 20 kA rms for 3 sec. For type I & Type II
main & earthing isolators.
switch) ii) 50 kA rms for 3 sec. For Type III isolator.
3. 5.0(ix)/ Rated peak The existing entries shall be replaced with

Page-6 withstand following :”
current (Both for i) 50 kA Peak for Type I & Type II isolators.
main & earthing ii) 125 kA peak for Type III isolator
switch)
4. 5.0(x)/ Temperature rise The existing entries shall be replaced with
Page-7 following :”
The Temperature rise of any part of an isolator shall
not exceed the maximum temperature rise given
below under the conditions specified in the test
clause 12.5.
S.No. Name of parts Temperature Temperature

in ºC rise at an
ambient
temperature
not
exceeding
40ºC
62
RDSO Specification No.ETI / OHE/ 16 (1/94) for 25 kV Isolator SP/DP.
The following amendments are made in addition to the addendum and corrigendum slips
issued to the specification :
S.No. Para No. Amendment
1) In Para 1.2 Delete the words “but excluding the insulators” appearing
in line 2 & 3
2) In Para 3.2 ( vii) Substitute “200 kgf/sqm” with “112.5 kgf/sqm”
3) In Para 6.1 Delete words “and shall be procured ……..by RDSO”

appearing in lines 2, 3 & 4.
Delete the Note under Para 6.1
4) In Para 6.2 In line No.5, substitute “200 kgf/m²” with “112.5 kgf/ m²”
5) In Para 6.13 Delete the words “the length ……..mast/structure” after

mast/structure in line 2.
63
SPECIFICATION
FOR
110KV DOUBLE & TRIPLE POLE

ISOLATOR
No. ETI / PSI / 122 (3 / 89)
64
SPECIFICATION NO. ETI/PSI/122 (3/89)
GOVERNMENT OF INDIA
TECHNICAL SPECIFICATION
FOR
(i) 245 kV
(ii) 145 kV
(iii)123 kV
(iv) 72.5 kV
DOUBLE POLE & TRIPLE POLE ISOLATOR
FOR
RAILWAY TRACTION SUBSTATION.
ISSUED BY
MANAK NAGAR, LUCKNOW – 226 011.
65
GOVERNMENT OF INDIA
Specification No. ETI/PSI/122 (3/89)
245 kV / 145 kV / 123 kV / 72.5 kV DOUBLE POLE AND TRIPLE POLE ISOLATOR.
1. SCOPE
1.1 This specification applies to outdoor, double pole and triple pole, horizontal, single or
double break type isolator for a nominal system voltage of 220 kV / 132 kV / 110 kV / 66
kV for use in unattended railway traction substations, in any part of India. It supersedes
specification Nos. ETI/PSI/88 (4/87), ETI/PSI/20 (6/78), ETI/PSI/20 A (6/79),
ETI/PSI/20 B (7/79), ETI/PSI/41 (1/73), ETI/PSI/50 (8/79) and ETI/PSI/50 B (4/80).
1.2 The isolator shall be manually operated, with or without earthing switch as specified by
the Purchaser in the particular tender and shall be complete with all parts, fittings and
accessories including insulators, mounting attachments, operating mechanism box, etc.
necessary for their efficient operation.
1.3 All such parts, fittings and accessories shall be deemed to be within the scope of this
specification, whether specifically mentioned or not. The isolator shall be of proven
design.
2 GOVERNING SPECIFICATIONS
2.1 The isolator shall, unless otherwise specified herein, conform to the latest version of the
Indian Standard Specifications / IEC recommendations / Research, Designs and
Standards Organisation (RDSO) specifications as indicated below and the Indian
Electricity Rules, wherever applicable:
(i) IS : 1570 (Pt. II) – 1979 - Carbon steels (unalloyed steels).
(ii) IS : 2071 (Pt. I) – 1974 - General definitions and test

& (Pt. II) – 1976 requirements and test procedures.
(iii) IS : 2108 – 1977 - Black heart malleable iron castings.
(iv) IS : 2544 – 1973 - Porcelain post insulators for systems

with nominal voltage greater than 1000
volts.
(v) IS : 5561 – 1970 - Electric power connectors.
66
(vi) IS : 7608 – 1975 - Phosphor bronze wires (for general
engineering purposes)
(vii) IS : 7906 – 1975 - Helical compression springs.
(viii) IS : 9921 – 1885 - Alternating current disconnectors (Pt. I,

II, III & IV) (Isolators) and earthing switches for
voltage above 1000 V.
(ix) IEC : 129 – 1975 - Alternating current disconnectors

(Isolators) and earthing switches.
(x) ETI/OHE/13 (4/84) - Specification for hot dip zinc coating

on steel masts (rolled and fabricated
tubes) and fittings used on 25 kV AC
OHE.
(xi) ETI/OHE/18 (4/84) - Specification for steel and stainless

steel bolts, nuts and washers.
(xii) ETI/OHE/64 (10/83) - Specification for Solid Core

Cylindrical post Insulators for
system with nominal voltages of
220 kV, 132 kV, 110 kV & 66 kV.
2.2 Any deviation from this specification proposed by the tenderer, calculated to improve
consideration, provided full particulars of the deviation with justification thereof are
deviation, if any, proposed by him shall be quoted as an alternative (s).
2.3 In case of any contradictions between provisions of Indian Standard Specification /

recommendations of the IEC and this specification, the later shall prevail.
3.1 Environmental Conditions
(i) Maximum temperature of air in shade 45 degree C
(ii) Minimum temperature of air in shade 0 degree C
(iii) Maximum relative humidity 100%
(iv) Annual rainfall Ranging between

1750 to 6250 mm.
67
(v) Number of thunder storm days per annum 85 (Max.)
(vi) Number of dust-storm days per annum 120 (Max.)
(vii) Maximum wind pressure 200 kg/m2
(viii) Altitude Not exceeding

1000 m.
3.2 The isolator would be subjected to vibrations on account of trains running on nearby
tracks. The amplitude of these vibrations, which occur with rapidly varying time periods
in the range of 15 to 70 ms, lies in the range of 30 to 150 microns with the instantaneous
peak going upto 350 microns.
4 TECHNICAL SPECIFICATION
4.1 Rating and other Technical particulars for isolator.
The isolator shall be designed for the following rating and other technical particulars
:-
---------------------------------------------------------------------------------------------------
S. No. Ratings / Rated System voltages
Particulars ---------------------------------------------------------------
72.5 kV 123 kV 145 kV 245 kV
(1) (2) (3) (4) (5) (6)
---------------------------------------------------------------------------------------------------
i. Type Manually operated, single or double break, upright

mounting with the movement of blade(s) in a horizontal
plane, with or without earthing switch and suitable for
outdoor installation.
ii. Number of Two or three as specified in the particular

Poles specification of tender.
iii. Nominal system 66 kV 110 kV 132 kV 220 kV

Voltage
iv. Highest system 72.5 kV 123 kV 145 kV 245 kV

Voltage
v. Isolating distance 1200 mm 1800 mm 1800 mm 2800 mm

in air (Min.)
68
vi. Rated insulation level:
(a) Rated one minute power

frequency wet withstand
voltage.
1) To earth and 140 kV 230 kV 275 kV 460 kV

between poles (rms) (rms) (rms) (rms)
2) Across isolating 160 kV 265 kV 315 kV 530 kV

distance (rms) (rms) (rms) (rms)
(b) Lightning impulse

(1.2/50 micro-second)
withstand voltage
1) To earth and 325 kVp 550 kVp 650 kVp 1050 kVp
between poles
2) Across isolating 375 kVp 630 kVp 750 kVp 1200 kVp
distance
vii. Rated frequency 50 Hz 50 Hz 50 Hz 50 Hz

±3% ±3% ±3% ±3%
viii. Rated normal 1250 A 1250 A 1250 A 1250 A

current
ix. Rated short time 31.5 kA 31.5 kA 31.5 kA 31.5 kA

withstand current (rms) (rms) (rms) (rms)
for one second
x. Dynamic peak of 80 kA 80 kA 63 kA 80 kA
the time withstand
current.
xi. Maximum temperature

rise over an ambient
temperature of 40 deg. C
when carrying its
rated current.
a) Copper contacts 35 35 35 35
Deg. C Deg. C Deg. C Deg. C
b) Terminal pad of 50 50 50 50
69
the isolator to Deg. C Deg. C Deg. C Deg. C
be connected to
terminal connectors
by bolts
c) Metal parts acting The temperature shall not reach a value where the
as spring elasticity of the metal parts acting as springs gets
impaired.
4.2 The isolator shall be capable of breaking capacitive current of busbars, bushings, very
short lengths of overhead lines, cables and no-load current of the transformer. Such
currents are not likely to exceed 6 Amps.
4.3 Rating and other Technical particulars for earthing switch.
The earthing switch shall be designed for the following rating and other technical
particulars :-
---------------------------------------------------------------------------------------------------
S. No. Ratings / Rated System voltages
Particulars ---------------------------------------------------------------
72.5 kV 123 kV 145 kV 245 kV
(1) (2) (3) (4) (5) (6)
---------------------------------------------------------------------------------------------------
i. Type Manually operated, vertically mounted, vertical air

break type and suitable for outdoor installation.
ii. Rated voltage Associated with 245 / 145 / 123 / 72.5 kV isolators,
as the case may be.
iii. Rated frequency 50 Hz 50 Hz 50 Hz 50 Hz

±3% ±3% ±3% ±3%
iv. No. of poles Two or three as specified in the tender.
v. Rated short time 31.5 kA 31.5 kA 31.5 kA 31.5 kA

withstand current (rms) (rms) (rms) (rms)
for one second
vi. Dynamic peak of 80 kA 80 kA 63 kA 80 kA

the short time
withstand current.
70
5 TYPE, CONSTRUCTION AND MOUNTING
5.1 Isolator.
5.1.1 The isolator shall be robust in construction and so engineered as to ensure smooth
operation at all times.
---------------------------------------------------------------------------------------------------
S. No. Clearance / 72.5 kV 123 kV 145 kV 245 kV
Distance
---------------------------------------------------------------------------------------------------
1. Distance between 2000 mm 3000 mm 3000 mm 4500 mm
pole centers.
---------------------------------------------------------------------------------------------------
5.1.2 The moving blades shall rotate through 90 degree from their fully closed position to
fully open position, so that the break is distinct and clearly visible from ground level.
5.1.3 The isolator shall be designed to minimize the shock during opening and closing
operations and shall not have a backlash tending to open the isolator after closing due
to jerk. The isolator shall be so designed that it can not come off its open / close
position by vibrations, shocks or any other means except when specifically operated
with the help of its operating handle.
5.1.4 The rotating blade(s) on the moving poles shall operate simultaneously. An
arrangement for necessary adjustment to achieve this feature shall be provided.
5.1.5 Main Contacts
1. The isolator shall have heavy duty self aligning and high pressure contacts of
modern design.
2. The contacts of the isolator shall be in the form of reverse loop so that during
passage of short circuit current they exert additional pressure on the moving
contacts.
3. The blades of the isolator shall be of rotating type at its longitudinal axis by
the
turn and twist mechanism provided in the moving contact assembly.
4. The moving and fixed contact assemblies shall be so designed as to ensure:-
a) electro dynamic forces withstand ability during short circuit without

any risk of dislodging of moving contact from the fixed contact;
b) thermal withstand ability during short circuit;
71
c) constant contact pressure even when the live parts of the insulator
stacks are subjected to tensile stress due to linear expansion of
connected busbar conductor, either because of temperature variation or
strong winds.
d) Wiping and self cleaning action during closing and opening, and
e) Self aligning ensuring smooth closing of the isolator.
5.1.6 Earthing Switch

1. The earthing switch shall be manually operated.
2. The moving contact shall be made of electrolytic high conductivity copper of

adequate strength to withstand all thermal and bending stresses at the time of
short circuits.
3. The fixed contacts shall be identical to the main isolator fixed contacts except
for silver plating.
4. The earthing of the moving contact shall be affected by flexible copper braids
of adequate cross section to safely carry the short circuit current specified in
clause 4.1 above.
5. The earthing switch of all poles of the isolator shall be mounted on the same
shaft and operated by a single and common operating handle, which shall be
distinct and separate from that used for operating the isolator.
6. The moving contacts of the earthing switch shall close home simultaneously
in the fixed contacts.
7. Suitable counterweights shall be provided in the operating mechanism of the

earthing switch, so that while opening the moving contact it does not come to
rest with a jerk.
5.1.7 Terminal pad and terminal connectors.
1. The isolator shall be provided with hard drawn, extruded or rolled electrolytic
copper terminal pad on either end and to be connected to the terminal
connectors.
2. The terminal connectors shall be of bimetallic type to prevent electrolytic

corrosion and shall conform to RDSO’s standard drawings, which are
enclosed with this specification. These shall be procured from RDSO’s
approved manufacturers.
72
5.1.8 Base channels
The isolator shall be complete with its steel mounting frame fabricated out of
channels. The frame work shall be designed for a wind pressure of 150 kg/ sqm.
acting on the whole of the projected area in addition to the other loads.
5.1.9 Material for various components
1. The blades of the isolator shall be of electrolytic high conductivity copper

with the ends silver plated (minimum thickness 10 microns) and of adequate
strength to withstand all thermal and bending stresses, particularly, at the time
of passage of short circuit currents.
2. The fixed contacts of the isolator shall be made out of copper, either extruded,
rolled or drawn. They shall be silver plated (minimum thickness 10 microns).
3. Bolts, nuts and other fasteners of 12 mm dia or less shall be of stainless steel.
Higher sizes of fasteners may be of hot-dip galvanized steel to RDSO’s
specification no. ETI/OHE/13 (4/84). Spring washers wherever used shall be
of phosphor bronze. The fasteners shall be procured from RDSO’s approved
manufacturers.
4. All ferrous parts used in the manufacture of the isolator shall be hot-dip
galvanized to RDSO’s specification no. ETI/OHE/13 (4/84).
5.1.10 Earthing
1. The frame of the isolator shall be provided with two earthing studs of size M
16, complete with flat washer, nut and locknut, for connection to the earth mat
with the help of MS flat. The earthing stud shall be marked with “Earth”
symbol.
2. Two numbers each of earthing terminals shall be provided for earthing the
operating mechanism boxes of the isolator and the earthing switch.
5.1.11 Operating Mechanism.
5.1.12 Isolator
1. The isolator shall be suitable for being conveniently operated manually from
the ground level without any strain. The design shall permit the length of
operating rod to be so adjusted that, with the isolator mounted in working
position, the rotating shaft of the operating mechanism on which the operating
handle would be connected is at a height of 1.1 m from the ground level.
73
2. Operating mechanism shall be provided with a sealed type reduction gear unit
so as to facilitate easy operation of the isolator. Means for greasing the gear
assembly shall be available for periodical maintenance of the unit.
3. Suitable arrangement shall be made on the inner side of the operating

mechanism door for keeping the operating handle when not in use.
4. A mechanical ON / OFF indicator shall be provided on the operating

mechanism box for indicating the isolator position. This indicator should be
visible from a distance.
5. The operating mechanism shall be designed in such a way so that, with

minimum modifications, the isolator can be converted from manual to motor
operated.
6. The operating mechanism and accessories shall be enclosed in a weather, dust

and vermin proof cabinet of sheet steel construction having a minimum
thickness of 2 mm. The operating mechanism box shall be hot-dip galvanized
to RDSO’s specification no. ETI/OHE/13 (4/84).
5.1.13 Earthing Switch
1. Earthing switch shall be suitable for being conveniently operated manually

from ground level without any strain. The design shall permit the length of
operating rod to be so adjusted that, with the earthing switch mounted in
working condition, the hinge pin of the operating handle is at a height of 1.1
m from the ground level.
2. The operating handle shall rest in the vertical position, both when the earthing
switch is in Open / Close position.
3. A mechanical ON / OFF indicator for earthing switch position, when the

operation of the earthing switch is complete, shall be provided on the earthing
switch assembly. This indicator should be visible from a distance
4. A weather, dust and vermin proof cabinet of sheet steel construction having a
minimum thickness of 2 mm shall be provided for housing the interlock and
integral lock. The cabinet shall be hot-dip galvanized to RDSO’s specification
no. ETI/OHE/13 (4/84).
5.1.14 Cylindrical post insulators (Support insulators).
1. The cylindrical post insulators shall conform entirely to RDSO’s specification

no. ETI/OHE/64 (10/88) including the latest amendment. However, the salient
characteristics of the insulators are given below for ready reference.
74
---------------------------------------------------------------------------------------------------
S. No. Particulars Rated System voltages
---------------------------------------------------------------
72.5 kV 123 kV 145 kV 245 kV
(1) (2) (3) (4) (5) (6)
---------------------------------------------------------------------------------------------------
(i) Nominal system 66 kV 110 kV 132 kV 220 kV
voltage
(ii) Overall height 770 1200 1500 2300
±1% ±1% ± 2.5 % ± 2.5 %
(iii) Maximum diameter 195 mm 210 mm 270 mm 300 mm

of insulating part
(iv) Top metal fitting 127 mm 127 mm 127 mm 127 mm

(v) Bottom metal fitting 127 mm 127 mm 127 mm 200 mm

(vi) Minimum creepage 1810 3075 3625 6125

distance mm mm mm mm
(vii) Visible discharge 53 kV 88 kV 106 kV 176 kV

test voltage
(viii) Wet 1 minute 160 kV 230 kV 275 kV 460 kV

power frequency (rms) (rms) (rms) (rms)
withstand voltage
(ix) Impulse voltage 350 kVp 550 kVp 650 kVp 1050 kVp
withstand value
(x) Minimum failing 4 kN 4 kN 4 kN 4 kN

load in bending
(xi) Minimum failing 35 kN 50 kN 60 kN 80 kN

load in tension
(xii) Minimum failing 2 kNm 3 kNm 3 kNm 3 kNm

load in torsion
(xiii) Minimum failing 70 kN 100 kN 120 kN 160 kN

load in compression.
---------------------------------------------------------------------------------------------------
75
2. The insulator shall be procured only from RDSO approved manufacturers.
5.2 Locking and interlocking.
5.2.1 Isolator
1. The operating mechanism box shall have provision for a padlock for locking
its door.
2. The isolator shall have provision for locking its main rotating shaft with the
help of padlock, both in ‘Open’ as well as in ‘Closed’ positions. The pad
locking in any intermediate position shall not be possible.
3. Besides the above, the isolators shall have two locking mechanisms, for the
purpose of interlocking with the associated circuit breaker(s). The interlocking
shall be as per Scheme – I and II detailed in Drg. No. ETI/PSI/5212 attached
with this specification. The locks for this purpose shall not be in the scope of
supply by the successful tenderer. However, mounting arrangement for these
locks shall be provided by the manufacturer in such a way that it is possible to
insert the key(s) from outside for operation of lock(s). The successful tenderer
shall coordinate with manufacturer of circuit breaker and the Purchaser for
this purpose.
5.2.2 Earthing switch
1. The operating mechanism box shall have provision for a padlock for locking
its lid.
2. A mechanical interlock shall be provided in the operating mechanism of

isolator and earthing switch, so that operation of earthing switch is possible
only when the isolator is locked in open position. This interlock shall also
prevent closing of isolator unless earthing switch is locked in open position.
3. An integral lock shall be fitted in the operating mechanism box of the earthing
switch for locking the operating mechanism both in ‘Open’ as well as
‘Closed’ positions.
4. The design of the earthing switch shall be such as to permit use of a padlock
for locking the operating handle of the earthing switch both in ‘Open as well
as ‘Closed’ positions.
5.2.3 The locking mechanism mentioned in clause 5.4.2 (3.) shall be housed within the
operating mechanism box. It shall however, be possible to insert the key from outside
for operation of lock.
5.2.4 The integral lock as mentioned in 5.4.2 (3) shall be procured from RDSO’s approved
suppliers.
76
5.2.5 Bearings.
5.2.6 The design and construction of various bearings shall embody all the features
required to withstand the climatic conditions specified to ensure reliable operation
even after long periods of inaction. The bearings used shall be of maintenance free
construction for entire life of the isolator.
5.2.7 Support structure.
1. The support structure shall not form part of the tender and shall be arranged
by the Purchaser. Details if the drilling schedule of the holes for the purpose
of mounting the isolators on the support structure shall be ascertained by the
successful tenderer from the purchaser before manufacturing the prototype
unit.
2. The isolator and the earthing switch (wherever provided) shall be mounted
rigidly in upright position on the support structure. The height of the support
structure from the ground level, for all types of isolators shall be 3000 mm.
5.2.8 Tandem pipes.
5.2.9 For smooth operation of the isolator, and to avoid bucking and bending of the tandem
pipes of the isolators, while opening or closing, an arrangement as indicated in Sketch
No. ETI/PSI/SK/322 enclosed with the specification, shall be provided. An adjustable
turn buckle / nut shall be provided (as shown in the sketch), for adjusting the length
of the tandem pipe(s) at site.
5.2.10 Name Plate.
5.2.11 The isolator and the earthing switch shall be provided with a separate nameplate each,
which shall be water proof and corrosion proof, and mounted such that it is clearly
visible by a person standing on the ground. Following information shall be indicated
indelibly on these nameplates:
Isolator
- Name of Manufacturer
- Type designation
- Serial Number
- Rated voltage
- Rated current
77
- Basic Insulation level
- Rated short time withstand current for one second
- Weight
Earthing Switch
- Name of Manufacturer
- Type designation
- Serial Number
- Rated voltage
- Rated short time withstand current for one second
6. TESTING
6.1 Type tests.
Only after all the designs and drawings have been approved and clearance given by
RDSO to this effect, the manufacturer shall take up the manufacture of the prototype
for RDSO inspection. It is to be clearly understood that any changes required to be
done in the prototype as required by RDSO shall be done expeditiously.
Following tests shall be carried out on the prototype unit of the isolator and earthing
switch at the works of the manufacturer / sub-contractor or at a reputed testing lab., in
the presence of Indian Railways representative(s) in accordance with the relevant
governing specification (and as modified or amplified hereunder against each test).
Isolator
a) General visual inspection and dimensional verification to check its conformity

with the approved drawings.
b) Dielectric tests
- One minute power frequency voltage wet withstand test :
This test shall be carried out in accordance with clause 3.1 of IS 9921
(Pt.4) – 1985. The values of the test voltages shall be as specified in item
(vi. (a)) of clause 4.1 hereof.
- Standard lightning impulse voltage withstand test :
78
This test shall be carried out as per clause 3.1 of IS 9921 (Pt. 4) – 1985.
The values of the test voltages shall be as specified in item (vi. (b)) of
clause 4.1 hereof.
c) Temperature rise test
This test shall be carried out in accordance with clause 3.2 of IS 9921 (Pt.
4) – 1985. The temperature rise shall not exceed the values specified in Clause
4.1, item (xi.) hereof.
d) Measurement of contact resistance on each pole of the isolator
i) This test shall be conducted before carrying out temperature

rise test and shall be repeated after carrying out mechanical
endurance test. The measured resistance after carrying out
mechanical endurance test shall not vary by more than 20 %
of the resistance measured before carrying out temperature
rise test.
ii) The measurement of contact resistance shall be carried out as

per clause 3.2.5 of IS 9921 (Pt. 4) – 1985.
e) Short time withstand current test
This test shall be conducted in accordance with clause 3.3 of IS 9921 (Pt. 4)
– 1985. The rated value of short time withstand current and dynamic peak
withstand current shall be as specified in item (ix) and item (x) of Clause 4.1,
hereof.
f) Mechanical endurance test
This test shall be conducted in accordance with clause 3.5.3 of IS 9921

(Pt. 4) – 1985.
Earthing switch (wherever provided)

a) Short time withstand current
This test shall be conducted in accordance with clause 3.3 of IS 9921
(Pt. 4) – 1985.
b) Measurement of contact resistance of each earthing contact both before as well
as after mechanical endurance test:
This test shall be conducted in accordance with clause 3.2.5 of IS 9921 (Pt. 4) – 1985.
The measured resistance after carrying out mechanical endurance test shall not vary by
more than 20 % of the resistance measured before carrying out mechanical endurance
test.
79
a) Mechanical endurance test
This test shall be carried out in accordance with clause 3.5.3 of IS 9921
(Pt. 4) – 1985.
Galvanisation test
Two samples / cut pieces of each type of galvanized component shall be tested for
conformity to RDSO Spec. No. ETI/OHE/13 (4/84).
Chemical composition and physical tests on contact material, fasteners and springs.
The manufacturer shall submit test certificates to prove the conformity of the
components as per following specifications :
i) Chemical composition of copper - IS : 191 - 1967

tube / strip
ii) Chemical composition of stainless - RDSO Spec. No.

steel fasteners. ETI/OHE/18 (4/84).
iii) Physical tests on fasteners - - do –
iv) Physical tests on springs - IS : 7906 (Pt. 2) – 1985
v) Physical tests on copper - IS : 1897 – 1983.

strips / tubes.
6.2 Routine tests.

The isolator and the earthing switch (wherever provided) shall be subjected to the
following routine tests at the manufacturer’s works:
a) General visual inspection and dimensional verification to check its

conformity with the approved drawings.
b) Power frequency voltage dry withstand tests (on the isolator only)
(Pt. 4) – 1985.
c) Measurement of contact resistance

(Pt. 4) – 1985.
d) Mechanical operating test

(Pt. 4) – 1985.
80
e) Assembly and interchangeability test
The isolator and earthing switch (wherever provided) shall be assembled using
components picked up at random from different lots. No adjustment shall be
permitted in any component while assembling the isolator and earthing switch. The
isolator shall function smoothly after assembly.
7. The manufacturer shall maintain complete record of the quality assurance test carried
out by him to ensure quality of raw materials and show them to the Inspector of the
Purchaser as demanded.
8. BULK MANUFACTURE:
8.1 Only after clear written approval of the results of the tests on the prototype is
communicated by RDSO / Purchaser to the manufacturer, shall he take up bulk
manufacture of the equipment which shall be strictly with the same material and
process as adopted for the prototype. In no circumstances shall material other than
those approved in the designs / drawings and / or the prototype be used for bulk
manufacture on the plea that they had been obtained prior to the approval of the
prototype.
8.2 If the prototype of an isolator or earthing switch conforming to this specification has
been approved for earlier supplies to Indian Railways, testing of prototype again may
be waived provided that no changes in the design or material(s) used have been made.
8.3 Technical Data and Drawings :
8.3.1 The tenderer shall furnish along with his offer the guaranteed performance data and
other technical particulars of the equipment in the proforma attached at Annexure ‘A’
hereof. All the ratings guaranteed shall have to be proved by tests / test reports.
8.3.2 The information furnished in the schedule of guaranteed technical performance data
and other particulars shall be complete in all respects. If there is any entry like “shall
be furnished later” or blanks are left against any items of Schedule of guaranteed
particulars, the tender is not likely to be considered as such omissions causes delays
in finalizing the tender.
8.3.3 Reports of type tests, if conducted on the similar equipment shall also be furnished.
8.3.4 The tenderer shall specifically indicate in a statement attached in his offer, his
compliance with each clause and sub-clause of the Specification. If any vague remark
on any clause or sub-clause of this specification is given by the tenderer, then the
tender submitted by him is not likely to be considered. A separate deviation statement
shall be furnished with the offer drawing attention to the clause(s) where the tenderer
seeks deviation giving detailed remarks / justification thereof. If there are no
deviations, a ‘NIL’ statement shall be furnished.
81
8.4 The tenderers shall furnish along with tender the following drawings:
i) General arrangement drawings showing the outline dimensions of

isolators and earthing switch (wherever provided).
ii) Drawing for support insulators along with salient technical particulars.
iii) Drawing for operating mechanism of main isolator.
iv) Drawing for operating mechanism of earthing switch.
8.5 The successful tenderer shall be required to submit the following detailed
dimensioned drawings including drawings already mentioned in clause 8.5 above, as
per Railways standards in size of 210 mm x 297 mm or in integral multiple thereof,
for approval :
i) Drawing showing details of main contacts.
ii) Drawing showing details of earthing contacts.
iii) Drawing of interlocking arrangement.
iv) Drawing of Castell type integral lock.
v) Drawing showing the mounting details of isolator.
vi) Drawing of terminal connector.
vii) Drawing showing the loads exerted by the isolator & earthing switch
(wherever provided) for designing the mounting structure. This
drawing should furnish complete information regarding loads and their
point of application.
8.5.3 After approval, six copies of approved drawings along with two sets of reproducible
prints shall be supplied to each consignee. Two copies of along with one set of
reproducible prints shall be supplied to the Director General (TI), Research, Designs
and Standards Organisation, Manak Nagar, Lucknow-226 011.
9. INSTALLATION, OPERATION & MAINTENANCE:
Twenty sets of installation, operation and maintenance instructions shall be supplied

to the Purchaser with every order. Two copies of these instructions shall be supplied
to the Director General (TI), RDSO, Manak Nagar, Lucknow. The information shall
necessarily include :-
i) Erection procedure and precautions to be taken while erecting the

equipment.
82
ii) The maintenance procedure to be adopted under normal service
conditions. It is desirable that the manufacturer should specify the
number of operations (or the time) after which different parts of
isolator or earthing switch are to be maintained.
iii) Information regarding complete overhauling of isolator and earthing

switch.
iv) Replacement instructions of parts which are subject to deterioration

during service for instance, contacts.
v) List of spare parts required for 5 years maintenance.
vi) List of special tools required for maintenance / replacement.
vii) Lubrication instructions including type of lubricants and quantity to be

used.
10. PACKING AND DISPATCH:
10.1 Various components of each isolator shall be securely packed in wooden crates and
boxes. It shall be ensured that one crate / box does not contain components of more
than one isolator. General packing list, together with weight and overall dimensions
of packing cases shall be furnished for each isolator indicating the following:
---------------------------------------------------------------------------------------------------
Crate / Description of item / Approx. gross Approximate
Box No. components in the weight in kg. outside
crate / box dimensions.
---------------------------------------------------------------------------------------------------
10.2 As far as possible, the gross weight of the crate / box shall be so kept that it should be
possible to do manual handling by two / three persons.
10.3 Necessary instructions for handling and storage shall also be furnished for use at the
receiving end.
83
Annexure – A to Specification
No. ETI/PSI/122 (3/89)
SCHEDULE OF GUARANTEED PERFORMANCE, TECHNICAL AND

OTHER PARTICULARS
------------------------------------------------------------------------------------------------------------
measurement
------------------------------------------------------------------------------------------------------------
3. Standard specification on which

performance is based.
5. Rated voltage kV
6. Voltage rating class kV

(highest system voltage)
7. Rated current
a) Isolator A
b) Earthing switch A
9. Rated insulation level

a) Rated one minute power frequency
wet withstand voltage
(i) To earth and between poles kV (rms)

(ii) Across isolating distance kV (rms)
b) Rated one minute power frequency

dry withstand voltage
(i) To earth and between poles kV (rms)

(ii) Across isolating distance kV (rms)
84
c) Standard lightning impulse
(1.2 / 50 micro second)
withstand voltage
(i) To earth and between poles kVp

(ii) Across isolating distance kVp
10. Rated short time withstand

current (for 1 second)
(i) Isolator kA (rms)

(ii) Earthing Switch kA (rms)
11. Dynamic peak withstand current :
(i) Isolator kAp

(ii) Earthing Switch kAp
12. Maximum temperature rise over an

ambient temperature of 40 deg. C
when carrying its rated current. Deg. C
(i) Copper contacts.
(ii) Terminal pad of the isolator

to be connected to terminal
connectors by both.
(iii) Metal parts acting as spring.
13. Breaking capacity of capacitive

current at rated voltage. A
14. Number of poles Number
15. Number of breaks per pole Number
17. Centre distance between poles mm
(a) Between poles mm
85
(b) Between the live part and earth mm
(c) Between open contacts of the

same pole mm
(d) Isolating distance mm
19. Contact
a) Material of the moving contact
b) Material of the fixed contact
c) Thickness of silver coating Micron
d) Contact pressure kg.
20. Operating mechanism
a) Type
b) Height of the rotating shaft on

which operating handle shall be
connected m
c) Thickness of the steel metal for

operating mechanism box m
d) Gear ratio
e) Number of turns the handle is to

be rotated to fully close the
isolator from its fully open
position Number
f) Weight of the operating mechanism kg.
21. Insulator
(a) Name of manufacturer
(b) Type designation
(c) Standard specification on which

performance is based. IS
(d) Number of stack
86
(e) Weight of one insulator. kg.
(f) Number of insulators used

(i) Support
(ii) Rotating / operating
(g) Wet power frequency withstand

voltage (1 minute) kV (rms)
(h) Dry power frequency withstand

voltage (1 minute) kV (rms)
(i) Visible discharge test voltage kV
(j) Impulse withstand voltage kVp
(k) Wet power frequency flashover

voltage kV (rms)
(l) Dry power frequency flashover

voltage kV (rms)
(m) Puncture voltage kV (rms)
(n) Minimum failing load in bending kN
(o) Minimum failing load in tension kN
(p) Minimum failing load in torsion kN
(q) Minimum failing load in compression kN
(r) Creepage distance in air mm
(s) Shed profile
22. Type of bearings used in the isolator
23. type of material and terminals.
24. Total weight

(i) Isolator kg
(ii) Earthing Switch kg
25. number of closing and opening
87
operations, the isolator can
perform without deterioration
of its contacts.
Additional information
26. Is the contact silver plated? Yes / No
27. Is the pad locking arrangement for

28. Is the mounting arrangement for

interlock(s) on isolator operating
mechanism provided? Yes / No
29. Is integral lock on earth mechanism

provided? Yes / No
30. Is the mounting arrangement for

interlock with associated isolator
provided? Yes / No
31. Is the mechanical mounting arrangement

between earthing switch and the
isolator provided? Yes / No
32. Is material of fasteners of 12 mm dia

and below stainless steel? Yes / No
33. Is material of fasteners of above 12 mm

dia galvanized iron? Yes / No
34. Is frame work of the isolator made out

of steel galvanized? Yes / No
35. Two number each of earthing studs

provided for:
(a) Isolator frame Yes / No
(b) Earthing switch frame Yes / No
(c) Operating mechanism box Yes / No
(d) Earthing symbol provided Yes / No
36. Is the height of operating handle hinge

pin in earthing switch from ground
level 1.1 m. Yes / No
88
37. Is arrangement for keeping the
operating handle for isolator in the
38. Can the isolator be converted to

motor operated one with minor
modification (if yes, sketch to be
shown for modification required)? Yes / No
39. Is the operating mechanism box for

the isolator is weather, dust and
vermin proof? Yes / No
40. Is ON / OFF indicator provided for
(i) Isolator Yes / No
(ii) Earthing Switch Yes / No
41. Is padlocking provided for
(a) Main rotating shaft of isolator Yes / No
(b) Operating handle for earthing switch Yes / No
(c) Cover for operating mechanism box Yes / No
42. Are the bearings used for maintenance

free design? Yes / No
43. Are the drawings as per clause 8.5

submitted along with the tender? Yes / No
89
APRIL – 1990
Addendum / Corrigendum Slip No.1 to Specification No.ETI / PSI /122 (3/89) for 245
kV, 145 kV, 123 kV, 72.5 kV, Double Pole and Triple Pole Isloator for Railway Traction
Substations.
********
Page 4, Clause 4.1 - Read the existing value of 25 KA (rms) under

Sl.No.(ix) Column 5 as 31.5 kA (rms)
&
Page 6, Clause 4.3.1

Sl.No.(v)
90
RDSO Specification No. ETI / PSI / 122 / (3/89) for Double Pole & Triple Pole Isloator
110 kV.
issued to the specification.
Sl.No. Para No. Amendment
1. Para 3.1(ii) Substitute 0ºC with 5ºC

3.1 (vii) Substitute 200 kg / sq.m with 112.5 kg / sq.m
2. 5.1.7.2 In line 3, add the word “preferably” after the word “procured”
3 5.1.9.3 In line 4, add the word “preferably” after the word “procured”
4. 5.4.4 In line 2, add the word “preferably” after the word “procured”
5. 5.6.1 In line 1 & 2, delete the words “and shall be arranged by the
purchaser”
6. 6.1 In line 2, 3 & 4 add the word “purchaser /” “before the word
“RDSO”
7. 9 In line 1, substitute “twenty” with “three”
91
SPECIFICATION
FOR
SOLID CORE PORCELAIN INSULATORS
FOR
25kV A.C. 50 Hz SINGLE PHASE OVERHEAD
TRACTION LINES
NO.ETI/OHE/15 (9/91)
92
SPECIFICATION NO. ETI / OHE / 15 (9/91)
GOVERNMENT OF INDIA
MANAK NAGARLUCKNOW – 226 011
SPECIFICATION
FOR
SOLID CORE PORCELAIN INSULATORS
FOR
25 kV AC, 50 Hz, SINGLE PHASE OVERHEAD
TRACTION LINES
ISSUED BY

MANAK NAGARLUCKNOW – 226 011
93
ETI/OHE/15 (9/91)
SPECIFICATION FOR SOLID CORE PORCELAIN INSULATORS FOR 25 kV AC,

50 Hz, SINGLE PHASE OVERHEAD TRACTION LINES.
1. SCOPE :
1.1 This specification covers the requirements and method of test for solid core porcelain
insulators, both for normal and polluted zones, used on single phase overhead electric
traction lines having a nominal voltage of 25 kV, (line-earth) AC at 50 Hz. The
system voltage may, however, go up to 27.5 kV.
1.2 This specification supersedes the one issued in November 1988.
1.3 Reference has been made in this specification to the latest edition of the following
Indian and other standard specifications:
(i) IEC Publication 383 - Tests on insulator on ceramic material or glass

for
overhead lines with a nominal voltages greater
than 1000 V.
(ii) IEC Publication 507 - Artificial pollution tests on high voltage

Insulators
to be used on a.c. systems.
(iii) IEC Publication 575 - Thermal mechanical performance tests and

mechanical performance test on string insulator
units.
(iv) IEC Publication 591 - Sampling rules and acceptance criteria when
applying statistical control methods for
mechanical and electromechanical tests on
insulators of ceramic material or glass for
overhead lines with a nominal voltage
greater than 1000 V.
(v) IEC Publication 672-2 - Specification for ceramic and glass

Insulating materials.
Part 2: Methods of test.
(vi) IEC Publication 815 - Guide for the selection of insulators in respect
of polluted conditions.
94
(vii) IEC Publication 36 B - Insulators for overhead lines – AC power arc
tests (Secretariat) 102 on insulator sets for overhead lines with a
nominal voltage greater than 1000 volts (draft).
(viii) IS:2071 (Part I to III) - Methods of high voltage testing.
(ix) IS:2108 - Specification for black heart malleable iron

castings.
(x) IS:4218 - ISO metric screw threads.

(Part I to VI)
(xi) IS:8704 - Methods for artificial pollution tests on high

voltage
Insulators for use on a.c. systems.
(xii) JIS-C-3802 - Permissible limits of visual defects for

insulating
porcelains.
(xiii) ETI/OHE/13 (4/84) - Specification for hot dip zinc galvanisation of

issued by Research of steel masts (rolled and fabricated), tubes and
Designs and Standards fittings used on 25 kV AC OHE.
Organization (RDSO)
1.4 In case of any conflicts between the contents of the above IEC, BIS, JIS
specifications and this specification, the latter shall prevail.
1.5 Any deviations from this specification, calculated to improve the performance, utility
and efficiency of the insulator proposed by the Tenderer, will be given due
consideration, provided that full particulars with justification therefore are furnished.
In such a case the tenderer shall quote according to this specification and indicate the
deviation(s) separately in a “Statement of Deviations”, with the prices, if any, for
such deviations.
2. TERMINOLOGY :
2.0 For the purpose of this specification, the following definitions shall apply.
2.1 Solid core Porcelain Insulator : An insulator consisting of a porcelain element of solid
core construction and associated metal fittings intended to give support to a live part
which is to be insulated from earth or from another live part.
2.1.1 Stay Arm Insulator : The insulator which forms part of the horizontal member, known
as the stay arm of the cantilever assembly from which the traction conductors are
95
suspended, and which insulates that member from the mast or structure to which the
cantilever is attached.
2.1.2 Bracket Tube Insulator : The insulator which forms part of the inclined member,
known as the bracket tube, of the cantilever assembly from which the traction
conductors are suspended, and which insulates that member from the mast or
structure to which the cantilever is attached.
2.1.3 9-Tonne Insulator : The insulator is normally, though not exclusively, used as a strain
insulator for anchoring of conductors. It is also used in a vertical position to support
25 kV feeder wire.
2.1.4 Operating Rod Insulator : The insulator used in the operating rod of a 25 kV isolator
for opening and closing of the isolators.
2.1.5 Post Insulator : A post insulator is used for supporting rigidly the live contacts of 25
kV isolator switches, the 25 kV bus bars at sub-stations / switching stations, the 25
kV bus bars over portals and at such other locations.
2.1.6 Sectioning Insulator : The insulating element of a piece of equipment (called section
insulator assembly) which is used for separating adjacent sections of the overhead
traction line belonging to different elementary electrical sections in the normal
condition and which provides a continuous mechanical and electrical path for passage
of the pantograph of electric rolling stock.
2.2 Standard Insulator : This insulators is used in zones in which pollution level is either
light or there is no pollution. Such an insulator has a creepage distance of 850 mm
and is termed as “Standard Insulator”.
2.3 Polluted Zone Insulator : This insulator is used in medium and heavily polluted zones.
Such an insulator has a creepage distance of 1050 mm and is termed as “Polluted
Zone Insulator”.
Note :- IEC Publication 815 prescribes from the point of view of pollution level, four
levels of pollution from light pollution to very heavy pollution, for the
purpose of standardization. In order avoid a multiplicity of types of insulators
to suit each pollution level it is considered advantageous to standardize two
types of insulators, one for light pollution or where there is no pollution and
the other for medium or heavy pollution as indicated in clause 2.2 and 2.3
respectively. At present only stay arm, bracket tube and 9-tonne insulators are
being developed for use in zones where the pollution level is medium and / or
heavy.
2.4 Dry Lightning Impulse Withstand Voltage : The lightning impulse voltage which the
insulator withstands dry, under the test conditions prescribed in clause 6.1.5.4.
96
2.5 Wet Power Frequency Withstand Voltage : The power frequency voltage which the
insulator withstands wet, under the test conditions prescribed in clause 6.1.5.5.
2.6 Mechanical Failing Load : The greatest mechanical load which under the prescribed
conditions, causes separation or breakage of metal fittings or total breakage of the
insulator.
2.7 Creepage Distance : The shortest distance along the contours of the external surfaces of
the ceramic insulating part of the insulator between those parts which normally have
the operating voltage between them. The distance measured over the surface of the
cement used as jointing material shall not be considered as forming part of the
creepage distance.
2.7.1 If high resistance coatings are applied to the parts of the insulator, such coatings shall
be considered as effective insulating surfaces and distances over them shall be
included in the creepage distance. The surface resistivity of such high resistance
coatings is usually about 106 ohm, but may be as low as 104 ohm.
2.8 Bulk Density : The quotient obtained by dividing the mass of the test specimen by the
apparent volume (including open and closed pores).
2.9 Lot of Insulators : All the insulators of the same type and design manufactured under
identical conditions of production, offered for acceptance. A lot may consist of the
whole or part of the quantity ordered.
2.10 Batch of Insulators : A batch of insulator shall be the complete number of insulators
manufactured at one time for the purpose of conducting prescribed type tests during
the process of inspection and testing of prototype. Along with this batch of insulators,
shall also be manufactured the required number of test specimens for the same
purpose. A special marking shall be given to identify the batch of insulators and test
specimens manufactured together.
2.11 Type Tests : Tests carried out to prove conformity with the requirement of the
specification. These tests are intended to prove the general quality and design of a
given type of insulator. They shall be repeated when the design or the material of the
insulator is changed.
2.12 Acceptance Tests : These tests are for the purpose of verifying the mechanical
characteristics as well as the required properties of the ceramic portion of insulator
and other characteristics as considered necessary. They are made on insulators picked
up at random from lots happened for acceptance.
2.13 Routine Tests : These tests are for the purpose of eliminating insulators with
manufacturing defects. They are made on every insulator offered for acceptance.
97
3. STANDARD ATMOSPHERIC CONDITIONS
3.1 Standard atmospheric conditions for tests on insulators shall be as given below:
Temperature t 20 °C.
Barometric pressure b 1013 mbar.
Absolute humidity h 11 g of water per m3 corresponding to 63% relative
humidity at 20 °C.
Note: A pressure of 1013 mbar corresponds to a pressure of 760 mm of mercury at 0

°C.
If the height of the barometer is h mm of mercury and the temperature of the
mercury is t °C, the atmospheric pressure in mbar is:
1013 h
P = ----------- (1 – 1.80 x 10-4 x t)
760
3.2 Electrical test shall, however, be carried out under conditions obtaining at the time of
the tests. The barometric pressure, air temperature and humidity at the time of tests
shall be recorded for the purpose of calculating the corrections to test voltages in
accordance with Appendix “A”.
4. REQUIREMENTS
4.3 General.
4.3.1 The insulators covered by this specification are shown in Fig. 1 to 9 attached and are
for the general guidance of the manufacturers. The dimensions indicated in these
Figures are essentially to be followed to ensure interchangeability.
4.3.2 The porcelain shall be sound, free from defects, thoroughly vitrified and fully glazed.
All the six types of insulators for normal zone and the three types of insulators for
polluted zone shall be manufactured with aluminous porcelain only. The quality of
the porcelain as well as the process by which the insulator is manufactured shall be
such that when the insulator is subjected to flashover at the minimum arc current of 6
kA for 0.2 s followed by 2 kA for 0.2 s followed after a pause of 60 s by a further 6
kA for 0.2 s, it shall not part.
4.3.3 Since the insulator is of aluminous porcelain, its dimensions both of core and shed
shall be such that its weight shall be a minimum for the creepage distance specified
and the mechanical and electrical characteristics it is required to meet.
4.3.4 The values of essential ceramic properties of the insulator are indicated in the
Table – 1.
98
TABLE –1
CERAMIC PROPERTIES
Property Value
i) Bulk density 2.50 g/cm3 (minimum) on test specimen.

2.45 g/cm3 (minimum) on fired porcelain.
ii) Modulus of elasticity 100 GPa (minimum)
iii) Flexural strength

Unglazed 140 MPa (minimum)
Glazed 160 MPa (minimum)
4.3.5 The sheds of an insulator shall be of equal diameter and with lips at the extremities
for all type of insulators, except for the sectioning insulator which has a symmetric
shed profile. The shed profile shall be free from ribs on the underside so as to avoid
accumulation of dust and pollutants.
4.3.6 The glaze shall be brown in colour, unless otherwise specified. It shall cover the
entire porcelain of the insulator.
4.3.7 The dimensional parameters characterizing the insulator profile shall generally
conform to IEC Publication 815.
4.3.8 The ends of the porcelain shell shall be either straight and sanded or conical and
glazed. If the ends are conical, the angle shall be 4° to 12°. Similarly, the internal
angle of the metal fittings shall be 4° to 12°.
4.3.9 The metal fitting shall be made of black heart malleable cast iron conforming to
Grade BM: 340 of IS: 2108 or of spheroidal graphite cast iron to Grade: 400/12 of IS:
1865 with the prior approval of RDSO.
4.3.10 All metal fittings shall be hot-dip galvanized in accordance with specification no.
ETI/OHE/13 (4/84). The minimum weight of zinc coating shall be as follows:
Standard insulators : 160 g/m2 for all types of metal fittings including stay
arm
insulator hook.
Polluted zone insulators: (i) 1000 g/m2 for all types of metal fittings.
(ii) 750 g/m2 for stay arm insulator hook.

The metal fittings shall be galvanized after machining. The galvanized surface shall
be smooth. The mass of zinc coating on stay arm insulator hook shall not be
applicable to the threaded portion of the hook.
99
Note : The threads of the tapped holes in the metal fittings of stay arm, operating rod
and post insulators shall be cut after galvanization and protected against corrosion by
application of suitable grease. The threads of all other metal fittings shall be cut
before galvanization. All the tapped holes shall be suitable for galvanized bolts and
shall conform to IS: 4218 (Part I to VI).
4.3.11 The jointing of the metal fittings with the porcelain shell shall be with Portland
cement which shall neither react chemically with the metal fittings nor cause their
fracture on account of expansion or contraction causing loosening of the metal
fittings. During the jointing process care shall be taken to ensure that the porcelain
shall and the metal fittings are properly aligned and that no part of the porcelain shall
comes in direct contact with the metal fittings. It is permissible to use cork sheet or
thick paper between the metal fitting and the porcelain shell to absorb any mechanical
shocks.
4.4 Voltages for High Voltage tests.
4.4.1 The values of voltages at Standard Atmospheric Conditions for the various high
voltage tests on the insulators shall be as given in Table – 2.
4.4.2 One of the requirements of the insulator is to withstand artificial pollution test.
The insulator shall withstand 30 kV for 15 minutes at ESDDs of 0.05 mg/cm2 and
0.15 mg/cm2 for standard and polluted zone insulators respectively when tested in
accordance with clause 6.1.5.6.
TABLE –2
VALUES OF VOLTAGES FOR HIGH VOLTAGE TESTS
Type of Visible Wet power frequency Dry lightning impulse

insulator discharg withstand voltage test withstand voltage test
e test Insulator Insulator Positive Negative
vertical horizontal wave wave
kV (rms) kV (rms) kV (rms) kV (peak) kV (peak)
Stay arm 35 100 125 240 260
Bracket tube 35 100 125 240 260
9-tonne 35 100 125 240 260
Operating rod 35 100 125 240 260
Post 35 100 -- 240 260
Sectioning 35 -- 125 240 260
Note : These values apply to both standard and polluted zone insulators.
4.5 Minimum Mechanical Failing Loads and Bending and Torsional Moments.
4.5.1 The minimum mechanical failing loads and bending and torsional moments shall be
in accordance with Table – 3.
100
TABLE –3
MINIMUM MECHANICAL FAILING LOADS AND
BENDING AND TORSIONAL MOMENTS
Type of insulator Tension Tension with 80 Bending Torsional

(kgf) mm eccentricity of moment moment
load (kgf) (kgf.m) (kgf.m)
Stay arm 5400 --- 100 ---
Bracket tube 5400 --- 170 ---
9-tonne 9900 --- 210 ---
Operating rod 2200 --- 70 ---
Post 6000 --- 370 550
Sectioning --- 5000 --- ---
4.6 Marking.
4.6.1 The porcelain shell as well as the metal fittings of each insulator shall be legibly and
indelibly marked. The marking on the porcelain shell shall be with 10mm figures
while that on metal fittings shall be with 6 mm relief figures to show the following:
a) Name or trade mark of the manufacturer,
b) Month (optional for the metal fittings) and year of manufacture,
c) Part number, and
d) Any other identification marks specified by the purchaser.
4.6.2 The marking on the porcelain shell shall be by printing and shall be applied before
firing.
5. DRAWINGS AND THEIR APPROVAL:
5.1 The successful tenderer shall submit three prints in each of the following drawings
showing all the details in scale 1 : 1, separately for each type of insulator (in the
proforma for the drawing enclosed) as per Railway Standards in sizes of 210 mm x
297 mm or any integral multiple thereof for approval for the purpose of prototype test
only.
i) Assembly drawing of the insulator.

ii) Porcelain shell drawing.
iii) Metal fittings drawings.
5.2 The drawing approved for the prototype tests only shall be modified, if need be, as a
result of changes necessitated during testing or as desired by the purchaser. The
101
modification shall be first got approved by the Purchaser / Director General (Traction
Installation) Research, Design and Standards Organization, Lucknow and then
incorporated in the drawing and each such modification shall be got signed on the
drawings by the Purchaser / Director General (Traction Installation) Research, Design
and Standards Organization, Lucknow. If there are no modifications at all the
drawings approved for prototype tests shall be treated as final.
5.3 After the insulator has passed all the type tests the successful tenderer shall submit the
original tracings of all the drawings which have been approved for prototype tests
only along with two sets of reproducibles to Director General (Traction Installation)
Research, Design and Standards Organization, Lucknow (India) and they will be
signed by the authority concerned of the Purchaser / Director General (Traction
Installation) Research, Design and Standards Organization, Lucknow in token of
approval for bulk manufacture.
6. TESTS :
6.1 Type Tests
6.1.1 Once a purchase order is placed for supply of insulators the designs and drawings
shall be furnished to the Purchaser / Director General (Traction Installation)
Research, Design and Standards Organization, Lucknow as the case may be within
the period stipulated in the order. Only after the designs and drawings have been
approved for prototype tests and a written advice given to that effect, shall the
successful tenderer/manufacturer take up manufacture of the batch of the insulators
and test specimens for prototype tests. It is to be clearly understood that any change
or modification required by the above authorities to be done in the batch of insulators
shall be done expeditiously, not withstanding approval having already been given for
the designs and drawings. Such change or modification shall be incorporated in the
drawing as indicated in Clause 5.2 above.
6.1.2 Prior to giving a call to the Purchaser / Director General (Traction Installation)
Research, Design and Standards Organization, Lucknow, for inspection and testing of
the prototype, the successful tenderer/manufacturer shall submit a detailed test
schedule consisting of schematic circuit diagrams for each of the tests and the number
of days required to complete all the tests at one stretch. Once the schedule is
approved, the tests shall invariably be done accordingly. However, during the process
of type testing or even later, the purchaser reserves the right to conduct any additional
test(s), besides those specified herein, on any insulator so as to test the insulator to his
satisfaction or for gaining additional information and knowledge. In case any dispute
or disagreement arises between the successful tenderer / manufacturer and
representative of the Purchaser / Director General (Traction Installation) Research,
Design and Standards Organization, during the process of testing as regards the
procedure for type tests and/or the interpretation and acceptability of the results of
type test, it shall be brought to the notice of the Purchaser / Director General
(Traction Installation) Research, Design and Standards Organization, as the case may
be, whose decision shall be final and binding. Only after the prototype is completed
102
and ready in each and every respect, shall the successful tenderer / manufacturer give
the actual call for the inspection and testing with at least 15 days notice for the
purpose.
6.1.3 The batch of insulators and test specimens to be offered for type tests shall be not less
than the following:
Post insulator : 55 insulators and 9 test specimens *
Sectioning insulator : 35 insulators and 9 test specimens *
All other types of insulators : 45 insulators and 9 test specimens *
(* Out of the 9 specimens, 6 shall be glazed and 3 shall be unglazed)
6.1.3.1 The distribution of insulators for specific type tests shall be as follows:
Post Sectioning Others

------ ------------ --------
(a) Mechanical load test 30 10 20
(b) Mechanical performance test 10 10 10
(c) Thermal mechanical performance test 3 3 3
(d) High voltage electrical tests 3 3 3
(e) Power arc test 3 3 3
(f) Artificial pollution test 1 1 1
(g) Visual examination and verification
(h) of dimensions 5 5 5
------- ---------- --------
Total 55 35 45
------- ---------- --------
6.1.4 Sequence for conducting the prototype tests:
Out of the batch of insulators, indicated in clause 6.1.3.1 of this specification of

mechanical load tests and mechanical performance test shall be picked up at random and
subjected to temperature cycle test. Only after passing the temperature cycle test, shall the
insulator be subjected to mechanical load and mechanical performance tests. Only if the
insulators pass the mechanical load and mechanical performance tests, shall other tests be
taken up. If they do not pass these tests, all the remaining insulators shall be destroyed in
the presence of the Inspecting Official and the manufacturer shall offer a fresh batch of
insulators of improved quality for type tests. After completion of mechanical load and
mechanical performance tests, the thermal mechanical performance test, high voltage
electrical tests, power arc test and artificial pollution test shall be taken up at the works of
the manufacturer or at any reputed laboratory, as the case may be. In case any of the tests
is to be conducted at any independent laboratory, the insulators required for that test shall
be sealed by the Inspecting Official before he leaves the manufacturer’s works. It shall be
103
ensured that the identification marks given on the seal, porcelain shell and the metal
fittings are indicated in the test report given by the independent laboratory.
6.1.5 The following type tests shall be carried out on the batch of the insulators at the works of
the successful tenderer / manufacturer or at reputed testing laboratory in the presence of
representative of the Purchaser / Director General (Traction Installation) Research,
Design and Standards Organization, Lucknow and in accordance with the relevant
procedures laid down in this specification:
1. Visual examination.
2. Verification of dimensions.
3. Visible discharge test.
4. Dry lightning impulse withstand voltage test.
5. Wet power frequency withstand voltage test and wet power frequency
maximum withstand voltage test.
6. Artificial pollution test
7. Temperature cycle test.
8. Mechanical load test.
9. Mechanical performance test.
10. Thermal mechanical performance test.
11. Porosity test.
12. Galvanization test.
13. Verification of eccentricity.
14. Determination of Bulk density.
15. Test of Flexural Strength.
16. Test of modulus of elasticity.
17. Analysis of chemical composition.
18. Power arc test.
Note : i) Temperature cycle test shall be conducted on 20 insulators in case of sectioning

insulator, on 40 insulators in the case of post insulator and on 30 insulators in the
case of all other types of insulators. Only after passing this test, shall the insulators be
subjected to mechanical load and mechanical performance test.
ii) In the mechanical load test, 10 insulators each shall be tested for tensile, bending,
torsion and eccentric loading as applicable to the type of the insulator indicated in
clause 6.1.3.1.
iii) The mechanical performance test shall be conducted on 10 insulators.
iv) The Artificial pollution test shall be conducted on one insulator.
v) The galvanization test shall be conducted on 3 samples of metal fitting of the

insulators broken in the mechanical load test and mechanical performance test for
each type of insulator. This test shall be conducted on 3 samples of the hook in case
of stay arm insulator.
104
vi) Test for Flexural strength shall be conducted on 3 glazed and 3 unglazed test
specimens separately.
vii) Test of Modulus of elasticity shall be conducted on 3 glazed test specimens.
viii) The porosity test shall be conducted on at least three fragments or pieces of
porcelain from the insulators broken in the mechanical load and mechanical
performance tests.
ix) Analysis of chemical composition shall be done on one fragment of the

unglazed test specimen broken in the test for flexural strength and on one
fragment of the insulator broken in the mechanical load and mechanical
performance tests.
x) All other tests shall be conducted on three insulators or three broken insulators
or three fragments or pieces of porcelain from the insulators broken in the
mechanical load and mechanical performance tests as applicable to the type of
test.
6.1.5.1 Visual examination :
The insulator shall be visually examined to see that it is free from physical
distortion of shape and that the vitrified glaze is hard and smooth and the
surface is free from cracks and any other defect likely to be prejudicial to
satisfactory performance in service. The visual defects shall not exceed the
limits permissible for the appropriate class of insulator as specified in JIS: C
3802. The cement for jointing shall be finished flush with the edge of the
metal fittings and in any case shall not project more than 2 mm above the
edge. The exposed surface of the cement shall not show any sign of crack or
blow hole. The metal fittings shall be smooth without any excrescence.
6.1.5.2 Verification of dimensions :
The dimensions of the insulator shall be verified to see that they are in
accordance with the approved drawings. Unless otherwise specified, a
tolerance of +/- (0.03 d + 0.3) mm shall be permissible on any dimension of
the porcelain shell only, “d” being the dimension in mm.
6.1.5.3 Visible discharge test :
The room in which the test is to be done shall be darkened completely and a
period of at least five minutes shall be allowed for the observer to become
accustomed to the darkness. A power frequency voltage of the value specified
in TABLE-2 shall be applied in accordance with the procedure laid down in
Appendix “B” and maintained at that value for five minutes. During the
period, there shall be no signs for visible corona. The voltage shall then be
105
raise gradually and the value at which corona first appears shall be recorded.
The voltage shall then be reduced gradually, and the value at which the corona
just disappears shall also be recorded.
6.1.5.4 Dry lightning impulse withstand voltage test :
The insulator shall be tested dry under the conditions described in Appendix
“B”. The impulse generator shall be adjusted to apply a standard 1.2/50 wave
at the specified impulse withstand voltage adjusted for the atmospheric
conditions at the time of test. Fifteen such voltage waves shall be applied to
the insulator. If there is no flashover or puncture, the insulator shall be
deemed to have passed the test. However, two flashovers on the external
insulation is permissible. The insulator shall pass the impulse withstand
voltage test with voltages of both positive and negative polarity. The
insulators shall not be damaged by these tests, but slight marks on the surface
of the insulating parts or chipping of the cement used for jointing of metal
fitting shall be permissible.
The original oscillogram recorded during the test shall form part of the type
test report.
6.1.5.5 Wet power frequency withstand voltage test and wet power frequency
maximum withstand voltage test :
The insulator shall be arranged as described in Appendix “B” and exposed for
at least 1 minute before application of voltage and throughout the test to
artificial rain produced in accordance with clause 3.3 of IS: 2071 (Part-I). The
test voltage to be applied to the insulator shall be the specified wet power
frequency withstand voltage adjusted for the atmospheric conditions at the
time of test. A voltage of about 75 % of the test voltage so determined shall be
applied and then increased gradually to reach the test voltage in a time of not
less than 5 s. The test voltage shall be maintained at this value for 1 minute.
The insulator shall not flashover or puncture while the test voltage is applied.
The test shall then be repeated at successively higher voltage in step of 2.5 kV
or 5 kV until the insulator is unable to withstand the applied voltage for a
period of 1 minute. The voltage, corrected as described in Appendix “A”, of
the test immediately preceding the last test shall be taken as the maximum wet
power frequency withstand voltage.
6.1.5.6 Artificial pollution test :
The artificial pollution test shall be carried out at the declared maximum
withstand Equivalent Salt Deposit Density (ESDD) at 30 kV in accordance
with IS: 3704 or IEC Publication 507, using solid layer (Steam fog) method.
The insulator shall be in the vertical position during the test. The sectioning
106
insulator however shall be tested in the horizontal position. The leakage
current shall be recorded. If the insulator does not pass the test at the specified
value of ESDD, the test shall be repeated at lower values.
6.1.5.7 Temperature cycle test :
The insulators for this test shall be complete along with their metal fittings.
They shall be completely immersed in a water bath maintained at a
temperature of at least 70 °C above that of cold water and left submerged for a
period of T minutes, the value of T being given by the formula T = 15 + 0.7
M, where M is the mass of one insulator in kg. The insulators shall then be
withdrawn as quickly as possible and completely immersed, without being
placed in an intermediate container, in a bath of cold water for the same
period of T minutes.
This process of heating and cooling cycle shall be performed five times in
succession. The time taken to transfer all the insulators from one bath to the
other should be as short as possible and shall not exceed 30 s. The quantity of
water in the two baths shall be sufficient so as not to cause a temperature
variation of more than 5 °C between the water in the two baths when the
insulators are immersed.
Each insulator shall then be examined with the naked eye to see that the
porcelain shell has not cracked, the glaze is not damaged and the metal fittings
are not loose. Each insulator shall then be struck lightly with a wooden mallet
to verify that there is no crack or loosening of the metal fittings.
6.1.5.8 Mechanical failing load tests :
These tests shall comprise tensile, bending, eccentric loading and torsion tests.
6.1.5.8.1 Tensile Test : This test shall be done on all the insulators except the sectioning
insulator. The load shall be applied to the insulator in line with its axis. It shall
be increased at a rate agreed to between the manufacturer and the purchaser to
60 % of the specified minimum tensile failing load. It shall be maintained at
this value for one minute and then raised at the same rate until separation or
breakage of metal fitting or total breakage of the insulator occurs. The
separation or breakage of metal fitting or total breakage of the insulator or any
permanent deformation in the insulator and its components shall not occur
before the load reaches the minimum tensile failing load specified in TABLE-
3.
6.1.5.8.2 Bending Tests : This test shall be done on all the insulators except the
sectioning insulator. One end of the insulator shall be rigidly fixed in a
suitable fixture so as not to cause the failure of the metal fitting of this end
during the test which is for the porcelain shell only. The load shall be applied
107
to the other end of the insulator in line with the diameter and in a direction
perpendicular to the axis of the insulator and shall be increased at a rate
agreed to between the manufacturer and purchaser to 60 % of the specified
minimum failing bending moment, taking into account the distance between
the top of the fixture and the point at which the load is applied. It shall be
maintained at this value for one minute and then raised at the same rate until
the total breakage of the porcelain shell occurs. The failing bending moment
shall be calculated by multiplying the value of the load in kgf. and the
distance from the point of application of load to the point of breakage in m
and this value shall not be less than the minimum bending moment specified
in TABLE-3.
NOTE: (1)The choice of the end to be fixed rigidly shall be left to the manufacturer.
(2)The recommended rates of increase of load in the tensile and bending

tests are:
Tensile test : 200 to 300 kgf / s

Bending test : 15 to 30 kgf / s.
6.1.5.8.3 Eccentric loading test : This test shall be done only on the sectioning insulator.
The load shall be applied by means of suitable jigs such that the line of
application of the load is 80 mm away from and parallel to the longitudinal
axis of the insulator (See Fig. 10). Care shall be taken to ensure that during the
test, the jigs do not move and the distance of the load from the center line of
the insulator does not become less than 80 mm. The load shall be increased at
a rate agreed to between the manufacturer and the purchaser to 60 % of the
specified minimum eccentric tensile failing load. It shall be maintained at this
value for one minute and then raised at the same rate until separation or
breakage of metal fitting or total breakage of the insulator occurs. The
separation or breakage of metal fitting or total breakage of the insulator or any
permanent deformation in the insulator and its components shall not occur
before the load reaches the minimum eccentric tensile failing load specified in
TABLE-3
6.1.5.8.4 Torsion test : This test shall be done only on the post insulator. The insulator
shall be subjected to a torsional load without causing any bending whatsoever.
Depending upon the length of the lever arm used for imparting the torsion, the
load corresponding to the minimum torsional failing moment shall be
calculated and 60 % of the value of load so calculated shall be gradually
applied at the end of the lever arm and maintained at that value for one
minute. The load shall then be raised at the same rate till breakage of the
porcelain shell takes place. The torsional moment shall be calculated with the
load at which the porcelain shell breaks by multiplying the load and the lever
arm length and that breakage shall occur at a torsional moment not less than
the minimum specified in TABLE-3.
108
6.1.5.9 Mechanical performance test :
This test shall be done on all the insulators in accordance with clause 4 of IEC
Publication 575. The insulators shall be subjected to a tensile load (eccentric
tensile load in the case of sectioning insulator) equal to 60% of the specified
minimum failing load and immediately removed. This shall be done 4 times in
quick succession. Thereafter the insulator shall be subjected to the tensile test
(eccentric tensile test in the case of sectioning insulator) in accordance with
clause 6.1.5.8. The separation or breakage of the metal fittings or the total
breakage of the insulator or any permanent deformation in the insulator and its
components shall occur not below the specified minimum failing load
specified in TABLE-3. In case of the sectioning insulator, the line of
application of the load shall be 80 mm away from and parallel to the
longitudinal axis of the insulator.
6.1.5.10 Thermal Mechanical Performance Test :
This test shall be done on all the insulators in accordance with clause 3 of IEC
Publication 575. before starting the thermal cycle, the insulators shall be
subjected at room temperature to 60% of the tensile load (eccentric tensile
load in the case of sectioning insulator) specified in TABLE-3. It shall then be
subjected to four 24-hour cycles of cooling and heating of 12 hours duration
each while maintaining the load. Each 24 hours cycle shall comprise cooling
to –30 +/-5 °C and then heating to +40 +/-5 °C, the temperature figures being
of the surrounding air. The sequence shall be first cooling and then heating.
The test equipment shall be such as to permit the minimum and maximum
temperatures being maintained during at least four consecutive hours of the
cycle. The tensile load shall be completely removed and re-applied towards
the end of each heating period, the last one excepted. On completion of the
fourth 24 hour cycle and cooling to room temperature, the tensile load shall be
removed. On the same day, after removal of the load, the insulator shall be
subjected individually to mechanical load test in accordance with clause
6.1.5.8. The separation or breakage of the metal fittings or the total breakage
of the insulator or any permanent deformation in the insulator and its
components shall occur not below the specified minimum failing load
specified in TABLE-3. In the case of the sectioning insulator, the line of
application of the load shall be 80 mm away from and parallel to the
longitudinal axis of each insulator, both during the thermal cycles and during
the mechanical load test.
6.1.5.11 Porosity Test :
Fragments or pieces of porcelain from the insulator broken during any of the
above tests shall be taken for this test. The unglazed area of the fragments
shall be at least 75% of the total surface while some of the fragments shall be
109
taken from the central parts of the ends of the porcelain. They shall be
immersed in 1% alcoholic solution of fuchsin (1g fuchsin in 100g of
methylated spirit) under a pressure not less than 150 kg/cm2 for a period such
that the product of the test duration in hours and the test pressure in kg/cm2 is
not less than 1800. The fragments or pieces shall then be removed from the
solution, washed, dried and broken. Examination of the freshly broken
surfaces with the naked eye shall not reveal any dye penetration. Any dye
penetration into small cracks formed during the initial breaking process shall
be neglected.
6.1.5.12 Galvanization Test :
The uniformity, adherence and mass of zinc coating shall be tested in

accordance with specification no. ETI/OHE 13 (4/84) and the results of the
tests shall meet the requirements specified. The mass of zinc coating shall be
as specified in clause 4.1.10 herein.
6.1.5.13 Verification of eccentricity :
Insulators which have undergone mechanical load test shall be examined to

verify the eccentricity of the metal fittings with respect to the porcelain shell
by breaking the porcelain shell as near to the edge of the metal fitting as is
possible. The eccentricity shall be not more than 2 mm in any case.
6.1.5.14 Determination of Bulk Density :

This test shall be conducted in accordance with clause 4 – Method B of IEC
Publication 672-2. The test specimen shall consist of at least three fragments
of total mass between 50g and 80g. Chips liable to become detached during
further handling shall be eliminated and any dust shall be carefully removed
by brushing under a water jet. The mass (m1) in g of the dry test specimen
shall be determined. It shall be placed in a vessel on a wide-mesh brass netting
located 1 cm from the bottom and covered with distilled water. The distilled
water shall then be heated upto the boiling point and maintained at that
temperature for 30 minutes. It shall then be allowed to cool to ambient
temperature. The test specimen shall be removed, wiped lightly with a damp
cloth to remove water on the surface only and the mass (m2) in g of the
specimen when suspended in distilled water at about 23 °C shall be
determined. The mass (m3) in g in air of the soaked sample shall be
determined. The bulk density shall be calculated as follows :
m1 x pw
Bulk density = --------------- where pw is the density in g/cm3 of water at
the
m3 – m2 test temperature.
The test shall be made on at least three samples of unglazed test specimens
broken in the test for flexural strength and on al least three samples of
110
porcelain shell obtained from the insulators broken during the mechanical load
tests. The results of the tests shall be not less than the value specified in
TABLE-1 for each sample of test specimen and porcelain shell.
6.1.5.15 Test for Flexural Strength :

This test shall be conducted in accordance with clause 5 of IEC Publication
672-2. the method of test shall be Method A – Three point bend method. The
choice of the shape of test specimens shall be left to the manufacturer. The
test shall be conducted both for the unglazed as well as glazed test specimens
and the value for flexural strength for each specimen shall be not less than the
value specified in TABLE-1.
6.1.5.16 Test for Modulus of Elasticity :

This test shall be conducted in accordance with clause 6 of IEC Publication
672-2 or by dynamic method with ultrasonic resonance frequency
measurement using elastosonic non-destructive testing equipment. The value
of the Modulus of Elasticity for each specimen shall be not less than the value
specified in TABLE-1
6.1.5.17 Analysis of chemical composition :

One fragment or piece from the core of the insulator broken during
mechanical load tests and one fragment or piece of porcelain of the unglazed
test specimen broken during the test for flexural strength shall be subjected to
complete chemical analysis. The test report shall be submitted along with the
type test and acceptance test reports.
6.1.5.18 Power arc test :

The power arc test comprises flashing over at the maximum arc current of 6
kA for 0.2 s followed by 2 kA for 0.2 s followed after a pause of 60 s by 6 kA
for 0.2 s and the insulator shall not part. It is understood that facilities
available at present in the country do not permit of the test being conducted in
the sequence required and therefore, the power arc test shall be done at 6 kA
for 0.2 s followed after a pause of 60 s by 2 kA for 0.2 s followed after a
pause of 60 s by 6 kA for 0.2 s, till such time as this sequence is modified.
The insulator shall not part at the end of the test. Chipping / breakage of sheds
shall however, be permitted. After completion of the test the insulator shall be
subjected to mechanical load test in accordance with clause 6.1.5.8 of this
specification. The original oscillograms recorded during the test shall form
part of the type test report.
6.1.6 ACCEPTANCE CRITERIA

6.1.6.1 A single batch of insulators and test specimens manufactured and offered for
type tests in accordance with clause 6.1.3 shall pass all the type tests
stipulated in clause 6.1.5 hereof.
111
6.1.6.2 Apart from passing all the type tests, the quality index calculated on the basis
of the results of the mechanical load test and mechanical performance test
shall be equal to or more than the Acceptance Constant given in IEC
Publication 591.
6.1.7 Only after approval of the original tracings of drawings incorporating

changes, if any, necessitated during the type tests and clear written approval of
the results of the tests on the prototype is communicated by the Purchaser /
Director General (TI) Research, Design and Standards Organization, to the
manufacturer, shall he take up bulk manufacture of the insulator – which shall
be strictly with the same materials and process of manufacture as adopted for
the prototype. In no circumstances shall materials other than those adopted in
the design / drawings and/or during the manufacture of prototype be used for
bulk manufacture on the plea that they had been obtained prior to the approval
of the prototype.
6.1.8 If the prototype of an insulator conforming to this specification has already

been approved in connection with previous supplies to Indian Railways, fresh
testing of prototype of the insulator may be waived at the discretion of the
Purchaser, provided that no changes whatsoever in the design or materials or
process of manufacture have been made. However, the Purchaser reserves the
right to test any insulator if he deems it necessary to do so in the light of
experience gained from previous supplies.
6.1.9 Notwithstanding approval having been accorded to manufacture the bulk of

the insulators on the basis of the results of the type tests, the Purchaser
reserves the right to conduct any type and number of tests, including
destructive tests at any time during the process of bulk manufacture – without
prior advice to the manufacturer. All facilities shall be made available to the
Purchaser to conduct such tests – without any charge.
6.2 Acceptance Tests
6.2.1 The following shall constitute the acceptance tests.
1. Visual examination
2. Verification of dimensions
3. Temperature cycle test
4. Mechanical load test
5. Mechanical performance test
6. Porosity test
7. Galvanization test
8. Verification of eccentricity
9. Determination of Bulk density
10. Analysis of Chemical composition.
6.2.1.1 The tests shall be conducted as laid down in the relevant clauses hereof.
112
6.2.2 CUSTOMER HOLD POINT
The manufacturer shall within 30 days after the placement of a purchase order
furnish the Quality assurance plan to Director General (Traction Installation)
Research, Design and Standards Organization, Lucknow, who shall indicate in the
Quality Assurance Plan the CUSTOMER HOLD POINT / POINTS (CHP) beyond
which the next step in the manufacturing process will not be taken up and shall
advice the CHP to the Purchaser / Inspecting O fficial, as the case may be, as well
as to the manufacturer. The lot size to be offered for the acceptance tests shall be
decided by the manufacturer. The Inspecting Official shall pick up at random 5% of
the lot offered and conduct the test prescribed immediately preceding the first CHP.
If the sample passes the test, the Inspecting Official shall give written permission to
the manufacturer to proceed with the next step in the manufacturing process. This
written permission shall form part of the acceptance test report. This procedure shall
be repeated for each CHP. If during the test immediately preceding a CHP the
sample fails, the manufacturer shall be advised in writing by the Inspecting Official.
The manufacturer shall rectify the defect and offer the insulators again for tests.
This written advice will also form part of the acceptance test report. A distinct
numbering shall be given to identify the manufacturing / firing schedule. The
format on the report of CHP shall be supplied to the Inspecting Official by Director
General (TI) Research, Design and Standards Organization, Lucknow
6.2.3 The number of insulators (sample size) to be picked up at random from the lot
offered for acceptance tests shall be in accordance with the TABLE-4.
NOTE : If the order is for a small quantities, the sample size shall be 3% of the quantity
ordered subject to a minimum of 3 and a maximum of 15 insulators in case of stay
arm, bracket tube, 9-tonne, operating rod and post insulators and in the case of
sectioning insulators, the sample size shall be 2% of the quantity ordered subject to
a minimum of 2 and a maximum of 10 insulators. The insulators picked up at
random in accordance with the above sample size shall be equally distributed for
mechanical load and mechanical performance tests given in TABLE-3.
113
TABLE – 4
NUMBER OF INSULATORS (SAMPLE SIZE) TO BE SELECTED.
-------------------------------------------------------------------------------------------------------------
Stay arm, Bracket tube, 9-Tonne and Operating rod insulators
Lot size Sample size
i) Less than 800 15

ii) 801 to 3200 20
iii) 3201 to 8000 25
iv) 8001 and above 30
Post insulator
i) Less than 500 15

ii) 501 to 800 25
iii) 801 and above 35
Sectioning insulator
i) Less than 500 10

ii) 501 to 800 15
iii) 801 and above 25
------------------------------------------------------------------------------------------------------------
6.2.4 If the lot of insulators offered for acceptance tests are manufactured in more
than one manufacturing / firing schedule, then the number of insulators to be
picked up at random in accordance with Clause 6.2.3 shall be proportionately
distributed among the manufacturing / firing schedules giving specific serial
numbers to identify the manufacturing / firing schedule and subjected to
different tests as under:
6.2.4.1 Three insulators shall be visually examined and their dimensions verified.
6.2.4.2 Then all the insulators shall be treated for temperature cycle test.
114
6.2.4.3 If all the insulators pass the temperature cycle test, then the number of
insulators as indicated in TABLE-5 shall be tested for mechanical load and
mechanical performance tests.
6.2.4.4 At least one fragment of porcelain from each of the insulators broken during
the mechanical load test and the mechanical performance test shall be tested
for porosity.
6.2.4.5 At least 3 samples of each type of metal fittings from the insulators broken in
the mechanical load test and the mechanical performance test shall be tested
for galvanization. In the case of stay arm insulator, at least 3 hooks shall be
tested for galvanization.
6.2.4.6 At least one fragment of porcelain from each insulator broken during the
mechanical load test and the mechanical performance test shall be tested for
bulk density while any one fragment of porcelain broken during the
mechanical load test and the mechanical performance test shall be analyzed
for chemical composition.
6.2.4.7 At least 3 insulators broken during the mechanical load test and the
mechanical performance test shall be verified in regard to eccentricity.
TABLE – 5
DISTRIBUTION OF INSULATORS FOR MECHANICAL LOAD AND

MECHANICAL PERFORMANCE TESTS
------------------------------------------------------------------------------------------------------------
No. of samples Distribution
-----------------------------------------------------------------------------------------------------------
Bending Tensile Mechanical Performance
test test test
-------------------------------------------------------------------------------------------------------------
15 5 5 5
20 10 5 5
25 15 5 5
30 20 5 5
--------------------------------------------------------------------------------------------------------------------------------
115
Post insulator
------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------
Bending Torsion Mechanical Performance
test test test
------------------------------------------------------------------------------------------------------------
15 5 5 5
25 10 10 5
35 15 15 5
------------------------------------------------------------------------------------------------------------
Sectioning insulator
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------
Eccentric tensile Eccentric Mechanical
test Performance test
------------------------------------------------------------------------------------------------------------
10 5 5
15 10 5
20 15 5
------------------------------------------------------------------------------------------------------------
6.2.5 ACCEPTANCE CRITERIA
6.2.5.1 If any insulator fails either in the porosity test or in the test for determination
of the bulk density, the lot shall be rejected and every insulator of the lot shall
be destroyed in the presence of the Inspecting Official.
6.2.5.2 If the lot of insulators offered for acceptance tests are manufactured in more
than one manufacturing/ firing schedule and if only one insulator of any of the
manufacturing/ firing schedules fails either in the mechanical load test or in
the mechanical performance test, a re-test procedure shall be followed in
accordance with clause 6.2.6 of this specification. If more than one insulator
manufactured in a particular manufacturing/ firing schedule fails either in the
mechanical load test or in the mechanical performance test or in both the tests
116
taken together, then all the isolators manufactured in that manufacturing/
firing schedules shall be destroyed in the presence of the Inspecting Official.
The manufacturer shall have the option to offer all the remaining insulators of
the lot manufactured in the manufacturing/ firing schedules other than the one
rejected and destroyed as a fresh lot again or to manufacture more insulators
afresh to obtain the full lot size and then offer the insulators along with the
above left over insulators as a fresh lot later. If the failure is only to hooks
failing in the case of stay arm insulator (both standard and polluted zone), then
all the hooks of the lot obtained by the manufacturer shall be destroyed in the
presence of the Inspecting Official and the lot shall be offered again with
hooks of improved quality.
6.2.5.3 Despite the insulators passing in the mechanical load test and in the
mechanical performance test, if the quality index calculated on the basis of the
results of mechanical load test and mechanical performance test is less than
the ACCEPTANCE CONSTANT indicated in the IEC Publication 591, the lot
shall be rejected and every insulator of the lot shall be destroyed in the
presence of the Inspecting Official.
6.2.5.4 If the results of test(s) other than the mechanical load test, mechanical
performance test, determination of bulk density and porosity tests, do not meet
the requirements of this specification, then the balance samples shall be
subjected to the particular test(s) in which it had failed. If all the remaining
samples meet the requirements of the specification the lot shall be accepted.
6.2.5.5 When a lot is rejected and every insulator of the lot is destroyed in the
presence of the Inspecting Official, the procedure given in clause 6.2.7 of this
specification shall also be complied with by the Inspecting Official.
6.2.6 Re-test procedure :

If only one insulator fails either in the mechanical load test or in the
mechanical performance test the remaining insulators of the lot shall first be
subjected to the routine mechanical load test and those insulators which do not
pass the test shall be destroyed in the presence of the Inspecting Official.
From out of those insulators which have passed the routine mechanical load
test, a fresh sample size equal to twice the quantity indicated in clause 6.2.3
shall be picked up at random and subjected to the acceptance tests, the
insulators for each test being twice that indicated in clause 6.2.3. If any failure
occurs in any test including meeting the ACCEPTANCE CONSTANT
indicated in IEC Publication 591, the lot shall be rejected.
6.2.7 If any lot is rejected after following the re-test procedure given in clause 6.2.6,
the insulators forming the lot shall be destroyed in the presence of the
Inspecting Official. If part of the quantity of insulators manufactured during a
particular manufacturing/ firing schedule has been included in forming the lot
offered for acceptance tests and that the lot fails for any reason after the re-test
117
procedure, then the remaining insulators of that manufacturing/ firing
schedule shall be considered as suspect and therefore they shall be destroyed
in the presence of the Inspecting Official, even though they are not included in
the lot. Full details in regard to the rejection and destruction of insulators
under this clause shall be advised to Director General (Traction Installation)
Research, Design and Standards Organization, Lucknow, and the Purchaser.
6.2.8 The following shall form part of the acceptance test report.
6.2.8.1 The written consent given by the Inspecting Official in regard to the passing
of the insulators at each CHP.
6.2.8.2 A certificate by the Inspecting Official to the effect that he has checked the
records of the routine tests conducted by the manufacturer.
6.2.8.3 A statement from the manufacturer, countersigned by the Inspecting Official,

showing the rejection rate of insulators in the routine tests conducted by the
manufacturer for each manufacturing/ firing schedule for the lot offered.
6.2.9 The test report shall also include the details of number of insulators
manufactured in each manufacturing/ firing schedule for the lot offered. If the
lot has been formed out of insulators manufactured in more than one
manufacturing/ firing schedule, then the samples to be picked up at random
for acceptance tests shall be more or less equally distributed between the
different manufacturing/ firing schedules. Serial numbers shall be given to the
insulators to identify the manufacturing/ firing schedule from which they have
been picked up and this shall also be clearly indicated in the acceptance test
report.
6.2.10 A copy of the acceptance test report shall be sent immediately after
acceptance or rejection of a lot, as the case may be, to Director General
(Traction Installation) Research, Design and Standards Organization,
Lucknow, and the Purchaser.
6.2.11 The manufacturer shall, as far as practicable, offer the insulators manufactured
in one manufacturing/ firing schedule in one lot for acceptance tests. In case
the insulators manufactured in a particular manufacturing/ firing schedule
have to be divided into two lots for acceptance tests and in case one of the two
lots has been accepted based upon the results of the acceptance tests
while the other lot is rejected subsequently, then the insulators of the lot
already accepted become suspect and therefore the manufacturer shall have to
replace, free of cost, all the insulators dispatched against the accepted lot
under advise to Director General (Traction Installation) Research, Design and
Standards Organization, Lucknow, and the Purchaser.
118
6.3 Routine Tests :
6.3.1 The following shall constitute the routine tests :

1. Routine porosity test.
2. Ultrasonic test.
3. Routine mechanical load test.
4. Visual examination.
Note : Every insulator shall pass the routine tests in the order given above. The tests shall
be conducted by the manufacturer. The Purchaser shall have the right to witness routine tests.
The detailed record shall be maintained of the number of insulators tested, number rejected
and other essential data for the purpose of examination by the Inspecting Official.
6.3.1.1 Routine Porosity Test :

The porcelain shall have been manufactured with an extension at the top end
having a diameter equal to that of the core and of length at least half the
dimension of the diameter. This extension piece shall be carefully cut off and
then broken into fragments. The porcelain shell and the fragments shall be
marked for identification that they belong to one porcelain shell. Some
fragments from the central portion of the extension shall be tested for porosity
as per clause 6.1.5.11. If any of the fragments so tested shows porosity, the
porcelain shell from which the fragments were obtained shall be rejected and
destroyed. If none of the fragments shows any porosity, then the porcelain
shell from which the fragments have been obtained shall be considered as
having passed the test. Such porcelain shells shall be affixed with a clear label
or stamp on the glazed portion so as not to be covered by the metal fittings.
6.3.1.2 Ultrasonic Test :

This test shall be made on every porcelain shell after the extension piece
required for routine porosity test has been cut off, the ends of the shell
machined and prior to fitment of the metal fittings. Using a suitable ultrasonic
testing equipment which can produce ultrasonic waves of frequency between
0.8 and 5 MHz and the speed of propagation of the waves not less than 5800
m/s, the porcelain shell shall be tested both in the longitudinal direction as
well as in the transverse direction using appropriate probes. There shall be no
defective echo between the initial echo and the back wall echo and the
amplitude of the back wall echo shall be equal to the initial echo. Any
porcelain shell which does not comply with this acceptance criteria and shows
cracks or internal flaws of any nature shall be rejected and destroyed. The test
may be repeated on the insulators after fitment of the metal fittings. Every
insulator passing in the ultrasonic test shall be affixed with a clear label or
stamp on the glazed portion so as not to be covered by the metal fittings.
119
6.3.1.3 Routine Mechanical Load Test :
All insulators except for sectioning insulator shall be subjected to axial tensile
load of 60% of the value specified in TABLE-3. In the case of sectioning
insulator, the tensile load shall be applied eccentric as indicated in clause
6.1.5.8.3. If any insulator cracks or its metal fittings loosen or deform or
crack, it shall be rejected. If the metal fitting gets marked at the locations
where they are connected to the fixtures in the testing machine / mechanism,
such marks shall not be regarded as deformations. Every insulator passing in
the routine mechanical load test shall be affixed with a clear label or stamp on
the glazed porcelain so as not to be covered by the metal fittings
6.3.1.4 Visual Examination :
The visual examination shall be conducted as per clause 6.1.5.1.
7. INFORMATION TO BE GIVEN BY THE TENDERER
7.1 The tenderer shall furnish along with his offer, the schedule of Guaranteed
Performance, Technical and Other Particulars (SOGP) in the proforma at Appendix-
“C”, for each type of insulator. The particulars shall be correct and complete in all
respects. If there is any entry like “shall be furnished later” or a blank is left against
any item, the offer is not likely to be considered as the evaluation of the offer is
rendered difficult as it cannot be compared with other offers, if any.
7.2 The tenderer shall specifically indicate in a “Statement of Compliance” attached with
the offer his compliance with each and every clause of this specification. In case the
tenderer wishes to deviate from any clause of this specification he may do so giving
reference to the clause(s) with the reason / justification for the deviation. This shall be
in the form of a separate statement called the “Statement of Deviations”. If there is no
deviation at all, a specific “Nil” “Statement of Deviations” shall be attached with the
offer. If the “Statement of Compliance” and “Statement of Deviations” are not
attached with the offer, it is not likely to be considered for the reason that it is an
incomplete offer which cannot be properly evaluated and compared with other offers,
if any.
7.3 The tenderer / manufacturer shall also furnish the following information with the
tender bid :
7.3.1 A detailed drawing indicating all dimensions of the insulator and showing also the
actual creepage distance, guaranteed electrical and mechanical particulars and other
parameters of the insulator profile in accordance with IEC Publication 815.
7.3.2 A detailed drawing indicating all dimensions of the porcelain shell including every
dimension of shed profile, spacing, creepage distance and type of porcelain.
120
7.3.3 A detailed drawing of each of the metal fittings indicating the internal angle and all
other dimensions.
7.3.4 Details of the manufacturing process, the Quality Assurance Plan being adopted and
other facilities including testing facilities available at the tenderer’s / manufacturer’s
works.
7.3.5 Micrographs of the porcelain, results of petrographic tests of materials proposed for
the porcelain of the insulators and results of autoclave test for compatibility of glaze
with the porcelain.
7.3.6 A note describing the salient features of the design of the insulators, profile of the
sheds of the porcelain shell and the jointing process between porcelain shell and
metal fittings.
8. PACKING
8.1 The insulators shall be securely packed in wooden crates. Not more than two
insulators shall be packed in a crate so as to facilitate manual loading and un-loading
by one person.
9. AFTER SALES SERVICE
9.1 The manufacturer shall make necessary arrangements for closely monitoring the
performance of the insulators through periodical (preferably once in two months)
visits to the offices of the consignees to whom they have been dispatched for
interaction with the operating and maintenance personnel of the Indian Railways.
9.2 The manufacturer shall respond promptly and in a workman like manner to any call
given by Indian Railways for any assistance by way of attending to failures,
investigation into the causes of the failures including tests, if any, to be done and such
other items with a view to seeing that the insulator serves the purpose for which it is
intended.
121
APPENDIX “A”
CORRECTION OF TEST VOLTAGES FOR ATMOSPHERIC CONDITIONS
A – 1. GENERAL
A – 1.1 Variation in barometric pressure and humidity of the atmosphere cause

variation in the electric strength of the air and hence in the flashover voltage
of an insulator exposed to atmosphere.
A – 2. CORRECTION FACTORS
A – 2.1 When the atmospheric conditions around an insulator during test differ from
the reference conditions, adjustments are required to be made to certain of the
test voltages by the application of the following correction factors in
accordance with TABLE A-1 at the end of this Appendix.
(a) Correction factor (d) for air density:
0.289 p
d = ------------ (d lies between 0.95 and 1.05)
273 + t
where p = atmospheric pressure in mbar, and

t = temperature in °C
For a wider range of density and for higher accuracy, the factor k shall
be used instead of factor d. The values of factor k corresponding to
various values of factor d are given below :
d k
------- --------
0.70 0.72
0.75 0.77
0.80 0.82
0.85 0.86
0.90 0.91
0.95 0.95
1.00 1.00
1.05 1.05
1.10 1.09
1.15 1.13
122
(b) Correction factor (h) for humidity : Figure A-1 attached gives the
values of absolute humidity value for wet and dry bulb temperatures
(when the velocity of air over the wet bulb exceeds 3 m/s) for the
standard atmospheric pressure of 1013 mbar. For better accuracy, a
correction should be applied to the absolute humidity value obtained
from Figure A-1 for any deviation of ambient atmospheric pressure
from the standard value of 1013 mbar. This correction is obtained from
Figure A-2 as follows:
Locate the point corresponding to the deviation of ambient

atmospheric pressure from 1013 mbar on the left hand side of Figure
A-2B and join it with the right hand side top corner by a straight line.
Then locate the point on the curve in Figure A-2A corresponding to
the observed value of the difference of dry and wet bulb temperatures.
Draw a vertical line through this point to intersect the straight line
drawn in Figure A-2B. Read the correction to be applied to humidity
from the right hand side of Figure A-2B corresponding to the point of
intersection. The correction is positive for a positive deviation and
negative for negative deviation from the standard atmospheric
pressure.
For the corrected value of absolute humidity thus obtained, the

correction factor (h) of TABLE A-1 shall be determined from Figure
A-3.
TABLE A-1
CORRECTION OF VOLTAGES FOR ATMOSPHERIC CONDITIONS.
TYPE OF TEST ADJUSTMENT REQUIRED

---------------------- ------------------------------------
Dry lightning impulse Voltage applied shall be the
withstand voltage appropriate value specified in TABLE
– 2 multiplied by k and divided by h.
Wet power frequency Voltage applied shall be the

withstand voltage appropriate value specified in TABLE
– 2 multiplied by k.
Wet power frequency Measured voltage shall be divided by

maximum withstand voltage k.
123
APPENDIX “B”
HIGH VOLTAGE TESTS
B – 1. ARRANGEMENT OF INSULATOR
B–1–0 GENERAL - The insulator shall be clean and dry and in thermal
equilibrium with its surroundings.
B – 1.1 Insulators tested in vertical position :
B – 1.1.1 The insulator shall be hung vertically from an earthed support by means of a
wire rope or metal rod. The distance between the top of the insulator metal
fitting and the point of support shall be less than 1m. At the lower end of the
insulator shall be attached, if required, a metallic rod of weight adequate to
ensure that the insulator remains in vertical position during test.
B – 1.1.2 No object shall be nearer to the axis of the insulator than 1 m or 1.5 times the
length of the insulator whichever is the greater.
B – 1.1.3 The test voltage shall be applied between the metal rod at the bottom of the
insulator and the earthed point of suspension.
B – 1.2 Insulators tested in horizontal position :
B – 1.2.1 The insulator shall anchored by means of a cable or metal rod connected to
earth. The distance between the top of the insulator metal fitting and the point
of anchorage shall be less than 1m.
B – 1.2.2 The other end of the insulator shall be provided with a metal rod about 1 m
long and the whole arrangement maintained in an approximately horizontal
position by any convenient means.
B – 1.2.3 No object shall be nearer to the axis of the insulator than 1 m or 1.5 times the
length of the insulator whichever is the greater.
B – 1.2.4 The test voltage shall be applied between the end of the metal rod and the
earthed point of anchorage.
B–2 HIGH VOLTAGE TEST
B – 2.1 The high voltage test shall be conducted in accordance with IS:2071 (Part I
to III).
124
B–3 PRECAUTIONS AGAINST EXCESSIVE HUMIDITY
B – 3.1 Special precautions shall be taken to avoid condensation on the surface of the
insulator when the relative humidity is high. For example, the insulator shall
be maintained at the ambient temperature at the test location for a sufficient
period to attain thermal equilibrium before commencing the test. Except by
agreement between the manufacturer and the purchaser, the test shall not be
made if the relative humidity exceeds 85%.
125
APPENDIX “C”
Appendix to Specification No. ETI/OHE/15 (9/91)
SCHEDULE OF GUARANTEED PERFORMANCE TECHNICAL

AND OTHER PARTICULARS.FOR SOLID CORE PORCELAIN INSULATORS
FOR
25 kV, AC, 50 Hz, SINGLE PHASE OVERHEAD TRACTION LINES
Description Unit of measurement

S.No
3. Standard specification on which performance data is

based
4. Manufacturer’s type designation
5. Type of porcelain
6. Bulk density
For test specimen g/cm2
For insulator g/cm2
7. Flexural strength of test specimen
Unglazed MPa
Glazed MPa
8. Modulus of elasticity of test specimen GPa
9. Creepage distance (minimum guaranteed) mm
10. Grade and specification of metal fittings.
11. Mass of zinc coating of metal fittings. g/cm2
12. Rated voltage KV
13. Corona initiation voltage kV (rms)
14. Corona extinction voltage kV (rms)
15. Dry lightning impulse withstand voltage kV (peak)
126
16. Wet power frequency withstand voltage. kV (rms)
17. Wet power frequency maximum withstand voltage kV (rms)
18. Maximum value of Equivalent Salt Deposit Density mg/cm2

(ESDD) at 30 kV (rms)
19. Minimum tensile breaking load (eccentric tensile in kgf
case of sectioning insulator)
20. Minimum breaking bending moment kgf.m
21. Minimum breaking torsional moment kgf.m
22. Ultimate tensile breaking load (eccentric tensile in kgf

case of sectioning insulator)
23. Ultimate breaking bending moment kgf.m
24. Ultimate breaking torsional moment kgf.m
25. Sequence of power arc test offered
26. Tensile and bending strength after completion of kgf / kgf.m

power arc test.
27. Frequency of ultrasonic wave MHz.
28. Speed of propagation of ultrasonic wave obtained m/s
29. Weight of unit kg
127
ADDENDUM & CORRIGENDUM SLIP NO. 1
to RDSO’s Specification No. ETI/OHE/15 (9/91)
for
“Solid core porcelain insulators for 25 kV AC, 50 Hz, Single phase
overhead traction lines”.
Para 4.1.4 Delete the entire para and rewrite as given below:
The minimum alumina content shall be 45%. No quartz powder shall be

added as raw material. The values of essential ceramic properties of the
insulator are indicated in the Table - 1.
TABLE –1
CERAMIC PROPERTIES
Property Value
i) Bulk density 2.60 g/cm3 (minimum) on test specimen.

2.50 g/cm3 (minimum) on fired porcelain.
ii) Modulus of elasticity 105 Gpa (minimum)
iii) Flexural strength

Unglazed 140 Mpa (minimum)
Glazed 160 Mpa (minimum)
Para 4.3.1 Delete Table – 3 of para 4.3.1 and rewrite as follows:
TABLE –3
MINIMUM MECHANICAL FAILING LOADS AND
BENDING AND TORSIONAL MOMENTS
Type of insulator Tension Tension with 80 Bending Torsional

(kgf) mm eccentricity of moment moment
load (kgf) (kgf.m) (kgf.m)
Stay arm 7000 --- 200 ---
Bracket tube 7000 --- 200 ---
9-tonne 9900 --- 210 ---
Operating rod 2200 --- 70 ---
Post 6000 --- 370 550
Sectioning --- 5000 --- ---
Para 6.1.3.1 (g) Delete the words “Visual examination and”.
128
Para 6.1.5 (vii) Add the following :
If the facility for conducting this test on glazed test specimen is not available,
the test shall be conducted on insulators as per DIN 40658 Part II.
Para 6.1.5.1 Delete the entire para and rewrite as follows :
The insulator shall be visually examined to see that it is free from physical
distortion of shape and that the vitrified glaze is hard and smooth and the
surface is free from cracks or any other defect likely to be prejudicial to
satisfactory performance in service. The cement for jointing shall be finished
flush with the edge of the metal fittings and in any case shall not project more
than 2 mm above the edge. The exposed surface of the cement shall not show
any sign of crack or blow hole. The metal fittings shall be smooth without any
excrescence. Before accepting the lot for tests, each insulator shall be checked
for the following defects in case of type tests and 15% of the lot of insulators
shall be checked for these defects in case of acceptance tests.
3 Glaze Defects – The glaze defects shall not exceed the limits permissible for the
appropriate class of the insulator as specified in JIS-C-3802.
4 Tilt, Mis-alignment and Threads of Metal Fittings – Generally no tilt of metal fitting is
acceptable for all types of insulators. However, a maximum tolerance of 2 mm for the
tilt of metal fitting shall be permitted if the tilt could not be avoided totally. Wherever
thread cutting is required in the metal fittings, each insulator shall be checked for the
diameter of thread and depth of threaded portion as per the specification / approved
drawing using suitable gauges. The mis-alignment shall be checked for each isolator
separately for the following types of insulators as detailed below:
(a) Stay arm insulator :
i) Tube side metal fitting : Each insulator shall be checked for the
diameter of transverse holes and the distance between the transverse
holes as well as from the ends of metal fittings using suitable gauges.
ii) Stay arm insulator hook : Each hook shall be checked for the diameter
of thread and length of the threaded portion as per specification using
suitable Go and No Go gauges.
(b) Bracket insulator :
i) Tube side metal fitting : Each insulator shall be checked for the
machining of the hole as per the specification using suitable gauge and
U bolts.
(c) Sectioning insulator :
129
Each metal fitting shall be checked for the critical dimensions of the
metal fittings using suitable gauges.
The insulators which do not comply with the requirements of the

specification / approved drawings in case of the above defects shall be
rejected and destroyed in presence of the inspecting official. The
details of rejection such as batch number and quality shall form part of
the type / acceptance reports.
th
Para 6.1.5.8.1 In the 5 line correct existing “60%” as “70%”.
Para 6.1.5.8.2 In the 9th line correct existing “60%” as “70%”.
Para 6.1.5.8.3 In the 9th line correct existing “60%” as “70%”.
Para 6.1.6.3 Add new para :
The results of failing bending moment in mechanical load test shall be

computed for (X-3) and this value shall not be less than the specified
minimum failing bending moment.
The visual examination shall be conducted as per clause 6.1.5.1 on 15% of the
lot offered and then other acceptance tests shall be conducted on the samples
selected from the lot for conducting acceptance tests. If any failure occurs, a
further quantity of 30% of the lot shall be visually examined. If any insulator
fails in the retest, the entire lot shall be rejected.
The lot offered shall be considered for acceptance tests only after the lot has
been inspected and cleared of CUSTOMER HOLD POINTS indicated in the
approved Quality Assurance Plan of the manufacturer.
Para 6.2.4.1 Rewrite as follows :
The dimensions of three insulators shall be verified.
If any insulator fails either in the porosity test or in the test determination of
the bulk density or in the minimum percentage of alumina content, the lot
presence of the Inspecting Officer.
130
Para 6.2.5.4 The existing para 6.2.5.4 to be renumbered as 6.2.5.5 and the following shall
form para 6.2.5.4 :
The results of failing bending moment in mechanical load test shall be

computed for (X-3 ) and this value shall not be less than the specified
minimum failing bending moment.
Para 6.2.5.5 Renumber as 6.2.5.6.

Para 6.2.10 Delete the entire para and rewrite as follows :
A copy of the acceptance test report shall be sent immediately by the
manufacturer after acceptance or rejection of a lot as the case may be, to
Director General (Traction Installation), Research Designs and Standards
Organization, Lucknow and the Purchaser.

Routine Mechanical Load Test:
All insulators except for sectioning insulator shall be subjected to axial tensile
load of 70 % of the value specified in Table-3. In the case of sectioning
insulator, the tensile load shall be applied eccentric as indicated in clause
6.1.5.8.3. If any if any insulator cracks or its metal fittings loosen or deform or
crack, it shall be rejected. If the metal fitting gets marked at the locations
where they are connected to the fixtures in the testing machine / mechanism,
such marks shall not be regarded as deformations. Every insulator passing in
the routine mechanical load test shall be affixed with a clear label or stamp on
the glazed porcelain so as not to be covered by the metal fittings.

The visual examination shall be conducted on each insulator as per clause
Encl: Nil
Lucknow – 226 011,
Dated : 24-05-99.
131
to RDSO’s Specification No. ETI/OHE/15 (9/91) for
Para 4.1.2 Delete the second sentence and rewrite as given below:
All the six types of insulators for Normal zone and the three types of
insulators for Polluted zone shall be manufactured with aluminous porcelain
only and they shall be fired in shuttle kiln only with precise temperature
control.
Para 4.1.11 Delete the second sentence and rewrite as given below :
The jointing process shall be done by a mechanized method and care shall be
taken to ensure that the porcelain shell and the metal fittings are properly
aligned and that no part of the porcelain shall come in direct contact with the
metal fittings.
Para 6.3.1 Add the following as Sl. No. 3
Routine temperature cycle followed by wooden mallet test.
Renumber Sl. No. 3 and 4 as Sl. No. 4 and 5.
Para 6.3.1.2 Add the following in the ninth line after the words “using appropriate probes”
The ultrasonic test in the longitudinal direction shall be done on both sides.
Para 6.3.1.3 Add the new para

The routine temperature cycle test shall be conducted as per clause 6.1.5.7 on
each shell manufactured. The number of heating and cooling cycle shall be
three and the period of immersion in hot and cold bath shall be 15 minutes.
After completion of the routine temperature cycle test, each shell shall be
subjected to a wooden mallet test on both ends. The insulators which fail in
this test shall be rejected and destroyed. Every insulator passing in the routine
temperature cycle test shall be affixed with a clear label or stamp on the
glazed portion so as not to be covered by the metal fittings.
Para 6.3.1.3 Renumber as 6.3.1.4

Para 6.3.1.4 Renumber as 6.3.1.5
---------------- :o:----------------
Encl: Nil
Lucknow – 226 011,
Dated : 04-02-2000.
132
for
The acceptance tests shall be conducted by the authorized representative of

the Director General (Traction Installation), Research Designs and Standards
Organization, Lucknow. The manufacture shall combine different orders for
different types of insulators placed on him and plan to offer the lots for
acceptance tests by RDSO for not more than five times in a year.
Para 6.2.2 Delete the entire para and rewrite as follows:
CUSTOMER HOLD POINT.
During the development of prototype as per this specification, the

manufacturer shall furnish the Qquality Assurance Plan to Director General
(Traction Installation), Research Designs and Standards Organization,
Lucknow who shall indicate in the Quality Assurance Plan the CUSTOMER
HOLD POINT / POINTS (CHP) beyond which the next step in the
manufacturing process will not be taken up. The lot size to be offered for the
acceptance tests shall be decided by the manufacturer as per guidelines given
in clause 6.2.1.2. The Inspecting Official shall pick up at random a minimum
of 5% of the lot offered and conduct the test prescribed for clearance of the
CHP. If the samples pass the test, the Inspecting Official shall give written
permission to the manufacturer to proceed with the next step in the
manufacturing process. This written permission shall form part of the
acceptance test report. This procedure shall be repeated for each CHP. If
during the test for CHP the sample fails, the manufacturer shall be advised in
writing by the Inspecting Official. The manufacturer shall rectify the defect
and offer the insulators again for tests. This written advise will also form part
of the acceptance test report. A distinct numbering shall be given to identify
the manufacturing / firing schedule. The format of the report on CHP, framed
by Director General (Traction Installation), Research Designs and Standards
Organization, Lucknow, shall be followed.
The validity of the approval of QAP shall be till the validity of the prototype
approval accorded. Whenever the extension of the approval of
prototype is sought or whenever a repeat prototype test is conducted, as the
case may be, the QAP shall be submitted by the manufacturer for approval of
RDSO.
133
The tests for clearance of each CHP shall be conducted by the authorized
representative of Director General (Traction Installation), Research Designs
and Standards Organization, Lucknow during the manufacture of insulators.
After clearance of all the CHPs indicated in the QAP, the acceptance tests
shall be conducted by the authorized representative of Director General
(Traction Installation), Research Designs and Standards Organization, for
accepting the lot as mentioned in para 6.2.1.2 above.
---------------- :o:----------------
Encl: Nil
Lucknow – 226 011,

Dated : 29-02-2000.
134
for
Para 6.1.5 Add the following test at S.No.19
Analyses by X-Ray Diffractomery (XRD) and Scanning Electron Microscopy and

Energu Dispensive X-Ray Analysis IM & EDXA)
Add under Note at S.No.(xi) as under
These analyses shall be conducted on one insulator broken in the mechanical load
and mechanical performance tests. Three pieces of porcelain out of the insulator
selected will be sealed by the Inspecting Official One sealed Piece will be sent to
the Independent Organisation/ Institution for conducting the test and submitting the
report. One sealed piece shall be retained by the manufacturer and one sealed piece
shall be retained at RDSO.
Para 6.1.5 19 Add New Para
XRD and SEM & FDXA Analyses
Atleast three fragments will be taken from the pofeclain piece sealed for the purpose
of conducting XRD and SEM & EDXA analysis. Each fragment shall be
individually subjected to the above analyses. Resulting to be based on the values
obtained during the analysis at live different on each fragment and reported as
aggregate or range for each
SEM & EDXA Analysis : By this method, the Microstructure and Chemical
composition analysis will be made and the following will be evaluated.
i) Total % A/203 (Alumina )

ii) Percentage impurities viz. Fe203, DO2, CaO
iii) Percentage of Mulhte & other Alumino Silicates
iv) licrostructural Details For Free Alumina in glassy matrix, parosify, defects and
for variation in composition between different regionsin the glassy matrix apart from
the free alumina phase.
XRD Analysis By this method, the followings will be evaluated
j) Percentage free a – Alumina (Corundum Phase )

ii) Percentage free a – Quartz (Quartz Phase )
135
Para 6.1.6.4 Add New Para
No Acceptance Criteria has been specified at present for the results of XRD
and SEM & EDXA analysis. Data will be accumulated and after study of
sufficient data the limiting values shall be specified.
Para 6.2.1 Add the following test at S.No.11
11. Analyses by X-Ray Diffractometry (XRD) and Scanning Electron Microscop

and Energy Dispensive X-Ray Analysis (SEM & EDXA ).
Para 6.2.3.1 Add New Para
The sample size for conducting XRD and SEM & EDXA analysis will be
atleast one insulator for every 1000 insulators or part thereof offered for CHP
clearance. The insulators shall be selected normally from the firing cycles in
which large number of insulators have been fired. Three pieces out of each
insulator selected will be sealed by the Inspecting Official One sealed piece
will be sent to the Independent Organisation/Institution for conducting the
test and submitting the report. One sealed piece shall be retained by the
manufacturer and one sealed piece shall be retained at RDSO. The results of
the analyses shall be submitted while offereing the assembled insulators for
final inspection. The authority for issue of Inspectiion Certificate for the Final
Inspection without the receipt of the results of the analyses shall be with
Director General/TI, RDSO, Lucknow.
Para 6.2.5.7 Add New Para as below :
No Acceptance Criteria has been specified at present for the results of XRD
and SEM & EDXA Analysis. Data will be accumulated and after study of
sufficient data the limiting values shall be specified.
…………..
136
to RDSO’s Specification No. ETI/OHE/15 (9/91) FOR
4.1.9 Replace contents of entire para with contents as below :
4.1.9 Metal fittings shall be made of black heart malleable cast iron conforming to
Grade BM : 340 of IS : 2108 or spheroidal graphite cast iron to Grade :400/12 of
IS:1865 or Forged steel fittings to BS-970(Part-II). Approval of the type test of an
insulator implies employment ofmetal fitting of the particular insulator implies
employment of metal fitting of the particular make & design approved during type
test. In event of insulator manufacturer employing alternate material or make of
metal fitting all prototype test will be required to be repeated.
In addition to the above, RDSO may carry out the checks on incoming metal
fittings.
Para 6.2.1 Delete S.No.11
Para 6.2.1.2 Delete the entire para
Para 6.2.2 Replace contents of entire para with contents as below :
6.2.2 CUSTOMER HOLD POINT
1.0 Stage inspection at CUSTOMER HOLD POINT (CHP) for shells and metal fittings
will not be carried out for insulators manufactured by sources appearing in Part-I
category of RDSO’s list of approved vendors. This clause is to be read in conjuction
with clause 6.2.3(b)
1.1 For insulators from Part-II sources, CHP will be conducted by the nominated
Inspecting agency.
2.0 For CHP inspection, the inspecting official shall pick up at ramdom a minimum of
5% of the lot offered and conduct the test prescribed for clearance of the CHP. If the
samples pass the test, the Inspecting official shall give written permission to the
manufacturer to proceed with the next step in the manufacturing process. This
written permission shall form part of the acceptance test report. This procedure shall
be repeated for each CHP. If during the test for CHP the sample fails, the
manufacturer shall be advised in writing by the Inspecting official. The
manufacturer shall rectify the defect & offer the insulators again for test. This
written advise will also form part of the acceptance test report. A distinct numbering
shall be given to identify the manufacturing/ firing schedule. The format of the
137
report on CHP, issued by Director General (Traction Installation), Research
Designs and Standards Organisation, shall be followed.
Para 6.2.2.1 Replace contents of entire para with contents as below :-
Para 6.2.2.1 Prototype approval shall be accorded for a period of 12 months only. Thereafter
extensions for periods of 12 months may be tranted on application by the
manufacturer. The approval of QAP shall also be valid till the expiry of the prototype
approval. Whenever an extension of the approval of prototype is sought of whenever
a repeat prototype test is conducted, the QAP shall be submitted by themanufacturer
for approval of RDSO.
In addition a quality audit shall be done minimum twice a year for checking quality of
the manufacturing/process”.
Para 6.2.2.2 Delete the entire para.
Para 6.2.3 Replace contents of entire para with contents as below :
“ Sampling Plans shall be as under :
(b) When CHP inspection is required to be carried out, the sampling plan will be as per
Table 4A and as under.
The number of insulators (sample size) to be picked up at ramdom (by any random
number generation method ) from the lot offered for acceptance tests as tabulated
below :
NOTE :- If the order is for a smallquantities, the sample size shall be 3% of the quantity
ordered subject to a minimum of 3 and a maximum of 15 insulators in case of stay arm,
bracker tube, 9-tonne, operating rod and post insulators and in the case of sectioning
insulator, the sample size shall be 2% of the quantity ordered subject to a minimum picked
up at ramdom in accordance with the above sample size shall be equally distributed for
mechanical load and technical performance tests given in TABLE-5.
TABLE-4A
NUMBER OF INSULATORS (SAMPLE SIZE) TO BE SELECTED
Sl.No. Lot size Sample size

i Less than 800 15
ii 801 to 3200 20
iii 3201 to 8000 25
iv 8001 and above 30
138
Post Insulator

i Less than 500 15
ii 501 to 800 25
iii 801 and above 35
Sectioning Insulator

i Less than 500 10
ii 501 to 800 15
(b) For Regular (Part-I) sources, where CHP inspection is not required to be carried out,
the sampling plan will be as per Table 4B, as under.
The number of insulators (sample size) to be picked up at random (by any random
number generation method) from the lot offered for acceptance tests shall be in
accordance with the TABLE-4B.
TABLE-4B
NUMBER OF INSULATORS (SAMPLE SIZE) TO BE SELECTED
Stay arm, Bracket tube and 9-Tonne Insulators.

i Less than 800 20
ii 801 to 3200 25
iii 3201 to 8000 30
iv 8001 and above 35
Post Insulator and Operating rod insulators

i Less than 500 5%(Min. 6Nos. & Max. 25 Nos.)
ii 501 to 800 35
Sectioning Insulator

i Less than 500 3%(Min. 4 Nos. & Max. 15 Nos.)
ii 501 to 800 25
6.2.3.1 Delete the entire para.

6.2.4.7 Replace contents of entire para with contents as below :
139
Atleast 3 Insulators broken during the mechanical load test and the mechanical
performance test shall be verified in regard to eccentricity.
TABLE-5
DISTRIBUTION OF INSULATORS FOR MECHANICAL LOAD AND

MECHANICAL PERFORMANCE TEST
Stay arm, Bracket tube & 9-Tonne
No. of Samples Distribution

Develop Regular Bending Test Tensile Test Mechanical
mental Performance
Develop Regular
test
mental
15 20 5 10 5 5
20 25 10 15 5 5
25 30 15 20 5 5
30 35 20 25 5 5
Post Insulator and Operating rod Insulators.

Develop Bending Test Torsion for Post) or Mechanical
mental Tensile (for Operating Performance
Regular rod) Test test
Develop Regular Develop Regular
mental mental
15 25 5 10 5 10 5
25 35 10 15 10 15 5
35 45 15 20 15 20 5
Sectioning Insulator :

Eccentric Tensile Test Eccentric Mechanical
Performance Test
Develop Regular Develop Regular Develop Regular

mental mental mental
10 15 5 10 5 5
15 20 10 15 5 5
20 25 15 20 5 5
Para 6.2.5.3 Replace contents of entire para with contents as below :

Despite the insulators passing in the tensile load test and in themechanical
performance test, if the quality index calculated on the basis of the results of
tensile load test and mechanical performance test is less than the
140
ACCEPTANCE CONSTANT indicated in the IEC Publication 591, the lot
presence of the Inspecting Official.
6.2.5.3.1 Add new Para
Despite the Insulators passing in the bending moment test, if the value of X-
3on-1 is not achieved, the lot of insulators shall be destroyed in the presence
of the Inspecting Official.
Para 6.2.6 Replace contents of entire para with contents as below :-

Re-Test Procedure :
If only one insulator fails either in the tensile load test or in the mechanical
performance test the remaining insulators of the lot shall first be subjected to
the routine tensile load test and those insulators which do not pass the test
shall be destroyed in the presence of the inspecting Official. From out of
those insulators which have passed the routine tensile load test, a fresh sample
size equal to twice the quantity indicated in clause 6.2.3 shall be picked up at
random and to the acceptance tests, the insulators for each test being, twice
that indicated in clause 6.2.3. If any occurs in any test including meeting the
ACCEPTANCE CONSTANT indicated in IEC Publication 591, the lot shall
be rejected.
Para 6.2.6.1 Add new para

If only one insulator fails in the beinding moment test, the remaining
insulators of the lot shall first be subjected to the routine bending moment test
at 70% of the specified load and those insulators which do not pass the test
shall be destroyed in the presence of the Inspecting Official. From out of
those Insulators which have passed the routine bending moment test, a fresh
sample size equal to twice the quantity indicated in clause 6.2.3 shall be
picked up at random and to the acceptance tests, the insulators for each test
being twice that indicated in clause 6.2.3.
If more than one insulator failed in bending moment test lot shall be destroyed
in the presence of the Inspecting Official.
However, if all insulators passed, but the value of X-3on-1 not achieved the
whole lot shall be destroyed in the presence of the Inspection Official.
6.2.12 Add New Para

The manufacturer shall offer for acceptance tests of batches/firing cycle same
or dated later but not of those batches which are prior to the last inspected lot.
………..
Encl : Nil
Lucknow – 226011
Dated 01.09.2004
141
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144
145
146
147
148
149
150
151
152
153
154
SPECIFICATION
FOR
220kV OR 132kV OR 110kV OR 66kV OR

25kV
POTENTIAL TRANSFORMERS
NO.TI / SPC / PSI / PTs / 0990
155
MAY 2003
SPECIFICATION NO. TI / SPC / PSI / PTs / 0990
GOVERNMENT OF INDIA
MANAK NAGAR, LUCKNOW – 226011
FOR
220kV OR 132kV OR 110kV OR 66kV OR 25Kv
POTENTIAL TRANSFORMERS
ISSUED BY

MANAK NAGAR, LUCKNOW 226011
156
ANNEXURES
ANNEXURE-1 DRAWING FOR GENERAL SCHEME OF POWER SUPPLY FOR

TRACTION SUBSTATION.
ANNEXURE-2 TERMINAL CONNECTOR FOR PRIMARY SIDE (RIGID TYPE)
ANNEXURE-3 TITLE FORMAT SHEET FOR DRAWINGS.
ANNEXURE-4 SCHEDULE OF GUARANTEED PERFORMANCE, TECHNICAL

ANNEXURE-5 TERMINAL PLATE DETAIL
ANNEXURE-6 LIST OF ABBREVIATION
157
Specification No. TI/SPC/PSI/PTs/0990
POTENTIAL TRANSFORMERS, 220kV or 132kV or 110kV or 66kV or 25kV.
1.0 SCOPE
1.1 This specification applies to outdoor type single phase, oil immersed 220kV or
132kV or 110kV or 66kV or 25 kV (Type I & II) Potential Transformers (PT) to be
installed at unattended / attended railway traction substations / switching stations for
operation of protective devices, metering and indication.
1.2 The potential transformers shall be complete with all parts and accessories necessary
for their efficient operation. All such parts and accessories shall be deemed to be
within the scope of this specification, whether specifically mentioned or not.
1.3 This specification supersedes the earlier specification no. ETI/PSI/35 (4/75),
ETI/PSI/56 (3/80) and ETI/PSI/08 (10/92) which was meant for 132kV, 66kV and 25
kV potential transformers respectively, while this specification has been prepared to
cater the need of potential Transformer for system voltages of 220kV, 132kV, 110
kV, 66kV or 25 kV latest modification / test suggested by IS : 3156-1992 have been
incorporated in this specification. Hence, the equipment approved (includes prototype
approval) as per either of these above superseded specifications, shall be considered
as approved as per this specification also. This specification is a combined
specification for all type of PTs, used in traction distribution system.
1.4 The PT shall be erected by the purchaser / Indian Railways. However, in case a defect
/ deficiency noticed, the manufacturer / successful tenderer, will have to depute his
engineer for necessary remedial action without any cost to the Railways.
2. SERVICE CONDITIONS
2.1 The potential transformers are intended for use in normally polluted moist tropical
climate and in areas subject to heavy rain and lightning in India. The maximum
ambient temperature may reach 50 °C in shade, the daily maximum average ambient
in shade reaching 40 °C, with maximum humidity upto 100%.
2.2 The potential transformers are required to be used for connection between phase
conductors and earth of a 220 or 132 or 110 or 66 or 25 kV three phase or one phase
system with neutral effectively earthed, for operation of protection schemes and for
connection to metering / indicating instruments.
158
3. GOVERNING SPECIFICATION
3.1 In the preparation of this specification assistance have been derived from the
following standards and codes of practices (latest version) and Indian Electricity
Rules, wherever applicable:
1. IS : 5-1994 : Colours for ready mixed paints and enamels
2. IS : 335-1993 : New insulating oils
3. IS : 2062-1992 : Specification for structural steel (Standard quality).
4. IS : 1271-1985 : Classification of insulating materials for electrical

machinery and apparatus in relation to their thermal
stability in service.
5. IS : 1367-1996 : Technical supply conditions for threaded steel

fasteners.
6. IS : 1570-1991 : Stainless and heat resisting steels.
7 IS : 1554 (Pt I)-1988 : Specification for PVC insulated (Heavy duty)

electrical cables for working voltage upto and including
1100 volts.
8. IS : 1866-1991 : Code of practice for maintenance and supervision of

mineral insulating oil in the equipment.
9. IS : 3024-1996 : Specification for electrical steel sheets (oriented).
10. IS: 3156-1992 : Specification for Voltage transformer

(Part 1 to 4)
11. IS : 4253 (Pt II)-1989 : Cork and Rubber
12. IS: 5561-1992 : Specification for Electric Power connectors
13. IS : 5621-1988 : Specification for hollow insulator for use in

electrical equipments.
14. IS : 9224-1993 : Specification for low voltages fuses.

(Part I & II)
15. IS : 10028-1991 : Code of practice for selection, installation and

(Part I to III) maintenance of transformer.
159
16. IS : 11322-1990 : Method of Partial discharge measurement in
instrument transformer.
3.2 In case of any conflict between the contents of the above specifications and this
specification, the latter shall prevail.
3.3 Any deviation from this specification, to improve the performance, utility and
efficiency of the equipment, proposed by the Tenderer, will be given due
consideration, provided full particulars with justification thereof, are furnished.
4. ENVIRONMENTAL CONDITIONS
4.1 The Potential Transformer shall be suitable for outdoor use in moist tropical climate
and in areas subject to heavy rainfall, pollution due to industry and saline atmosphere
and severe lightning. The limiting weather conditions which the transformer has to
withstand in service are indicated below:
i) Maximum ambient air temperature 50 °C.
ii) Average ambient air temperature over 40 °C.

a period of 24 hours.
iii) Maximum relative humidity 100 %
iv) Annual rainfall Ranging from 1750 mm to

6250 mm.
v) Maximum number of thunder storm 85

days per annum.
vi) Maximum number of dust storm 35

days per annum.
vii) Number of rainy days per annum 120
viii) Basic wind pressure 200 kgf/mm2
ix) Altitude Not exceeding 1000 m.
x) Minimum ambient air temperature 0 °C
4.2 The Potential Transformer would also be subjected to vibrations on account of trains
running on nearby railway tracks. The amplitude of these vibrations which occur with
rapidly varying time periods in the range of 15 to 70 milli-second lies in the range of
30 to 150 microns at present, with the instantaneous peak going upto 350 microns.
160
These vibrations may become more severe as the speeds and loads of trains increase
in future.
5. TRACTION POWER SUPPLY SYSTEM
5.1 General Scheme
5.1.1 The single phase 50 Hz power supply for railway traction system at 25 kV is obtained
from 220/132/110/66 kV three phase grid system through a step down, single phase
power transformer, the primary winding of which is connected to two of the phases,
the three phase effectively earthed transmission line network of the State Electricity
Board or Railways. The primary voltage of the Traction transformer being 220 kV or
132 kV or 110 kV or 66 kV and no load secondary voltage being 27.5 kV (Nominal
secondary voltage is 25 kV). In order to reduce the imbalance on the three-phase
transmission line are tapped in a cyclic order for feeding the successive traction sub
stations (TSS). The distance between adjacent TSS is normally between 50 km to 80
km depending upon density of traffic, gradient in the section and other factors.
5.1.2 One terminal of the 25 kV secondary winding of the traction transformer is connected
to the OHE through circuit breakers / interrupters and the other terminal is solidly
earthed and connected to the appropriate traction rail(s). The current flows through
the OHE, to the locomotives and returns through the rail(s) and earth to the TSS. The
sections where booster transformers and return conductor are provided the current
returns through these; the traction rail(s) and partly through the earth in the vicinity of
TSS. Approximately midway between two adjacent TSS a dead zone known as
‘neutral section’ or ‘phase break’ is provided to separate the two sections of OHE by
different phases. The power fed to the OHE on one side of the TSS is controlled by a
feeder circuit breaker while the power fed to the OHE of each track is controlled by
an interrupter. In the case of a fault on the OHE, the feeder circuit breaker trips isolate
the faulty OHE. A schematic diagram No. ETI.PSI/702 – 1 showing general
arrangement at a TSS is at Annexure 1.
5.1.3 Normally power supply from a TSS extends upto the SP on either side of the TSS, but
in case of an emergency necessitating total shut down of the substation, power supply
from the adjacent TSS on either side of the failed substation can be extended upto the
failed substation by closing the bridging interrupters at the two Sectioning &
Paralleling post (SPs).
5.2 Nature of Load on the 25 kV System
The traction load is of frequent and rapidly varying nature and fluctuates between no
load and overloads. The load cycle varies from day to day due to non-uniform pattern
of traffic.
161
5.3 Electrical Parameters
5.3.1 The OHE is made up of a stranded cadmium copper catenary of 65 mm2 cross section
or a stranded aluminum alloy catenary of 116 mm2 cross section and a grooved contact
wire of 107 mm2 or 150 mm2 cross section, making up a total of 150 mm2 or 210mm2
copper equivalent. The OHE impedance values are generally taken as under:
(i) Single track OHE without return conductor 0.41 ∠ 70° Ohm/km
(ii) Double track OHE without return conductor 0.24 ∠ 70° Ohm/km
(iii) Single track OHE with return conductor 0.70 ∠ 70° Ohm/km
(iv) Double track OHE with return conductor 0.43 ∠ 70° Ohm/km
(v) Add booster transformer impedance @ 0.15 Ohms per booster

where these are provided transformer.
(vi) Percentage impedance of traction (12 +/- 0.5)%
transformer at 27 kV. (21.6 MVA base)
5.4 Scheme of Protection.
5.4.1 The scheme of protection to be provided at each of the TSS shall comprise of the
following :
a) Protection of the 220/27 kV or 132/27 kV or 110/27 kV or 66/27 kV traction

transformer installed at TSS.
b) Protection of the 25 kV overhead equipment.
5.4.2 The following relays / instrument shall be fed by the potential transformer of 52 kV
class metering and indicating protection of transformer and feeder:
(i) Relays / instruments fed by protection type PTs.

a) Admittance (Mho) relay for distant protection
b) Admittance (Mho) relay for wrong phase coupling.
c) Voltmeter at control relay panel at TSS to indicate 220kV or 132kV or
110 kV or 66 kV or 25 kV bus voltage.
d) Transducer for telemetry of voltage.
(ii) Relays / instruments fed by line indication type PTs
a) Catenary indication relay.
b) Transducer for telemetry of line voltage
(iii) Supply to metering.
162
6. RATING AND GENERAL DATA
6.1 The potential transformer shall be designed for the following rating and other
particulars:
(i) Type : Core type, single phase, outdoor

installation, oil immersed, self-cooled
suitable for mounting on structural steel
supports.
(ii) System voltage :
a) Nominal system : 220 132 110 66 25

voltage kV (rms)
b) Highest system : 245 145 123 72.5 52
voltage kV (rms)
(iii) Rated frequency : 50 Hz. ± 3%.
(iv) (i) Rated primary voltage kV (rms) : 220/ 3 or 132/ 3 or 110/ 3 or 66/ 3
For 25 kV :
(a) 27.5 kV – Where the no-load voltage
of OHE and SCADA system are
calibrated at 27.5 kV.
(b) 25 kV – Where the existing OHE
voltage having SCADA and the
relevant meters for indication /
protection calibrated at 25 kV.
(ii) Rated secondary voltage, V : 110/ 3 for 220kV or 132kV or 110kV or

66kV
For 25 kV :
(a) 100 V (type I for line indication)
(b) 110 V (type II for protection ).
(v) Rated burden at 0.8 power factor (VA) :
(a) For 220 kV or 132kV

or 110kV or 66kV 30 VA
(b) 25 kV (i) 30 VA (For type I)

(ii) 100 VA (For type II)
(vi) Class of insulation A
163
(vii) Rated voltage factor 1.2 for 30 sec.
(viii) Rated Insulation level
a) Highest system : 245 145 123 72.5 52

voltage kV (rms)
b) Rated power frequency : 395 275 230 140 95
withstand voltage kV (rms)
c) Lightning impulse : 950 650 550 320 250
withstand voltage kV (peak)
(ix) Temperature rise limits The temperature rise over an ambient of

(temperature measured by 50ºC shall not exceed the value indicated
resistance method) below:
(a) Winding : 45 ºC.
(b) Oil : 35 ºC.
(c) Current carrying parts in air : 40 ºC.
(x) Bushings (Porcelain Housing) :
i) Type Single piece construction and free from

ribs on the under side
ii) Highest voltage for
equipment, kV rms 245 145 123 72.5 52
iii) Minimum creepage
distance in air, mm 6125 3625 3075 1813 1300
6.2 Accuracy Class
The potential transformers of 220kV or 132kV or 110 kV or 66 kV shall have the

following accuracy as per clause of IS : 3156-1992.
(i) For the burden varying between 25% and 100% of the rated burden and with
the applied primary voltage varying from 90% to 110% of the rated voltage,
the ratio error shall not exceed +/- 1% and the phase angle error +/- 30
minutes.
(ii) With the applied primary voltage varying between 5% and 120% of the rated
voltage and with burden 25% to 100% of the rated burden at a power factor of
0.8 lagging, the ratio error shall not exceed +/- 3% and the phase angle error
+/- 120 minutes.
164
The potential transformers of 25kV (Type-I & Type-II) shall have the following
accuracy as follows :
(i) For type – I, potential transformer (line indication) shall conform to accuracy
class 6P of IS 3156 (Part III)-1992. Relevant details are indicated below :
At rated frequency, for any voltage between 5% and 120% of the rated voltage
and with burdens between 25% and 100% of the rated burden at a power
factor of 0.8 lagging the voltage error and phase displacement shall not exceed
+/- 6% and +/- 240 minutes respectively.
(iii) For type – II, potential transformers (protection) shall conform to accuracy
class 1.0 of IS: 3156 (Part-II)-1992 and to accuracy class 3P of IS : 3156
(Part-III)-1992. Relevant details are indicated below :-
At rated frequency, for any voltage between 80% and 120% of rated voltage
and with burdens 25% and 100% of rated burden at a power factor of 0.8
lagging, the voltage error and phase displacement shall not exceed +/- 1% and
+/- 40 minutes respectively.
At rated frequency, for any voltage between 5% and 120% of the rated voltage
and with burdens between 25% and 100% of the rated burden at a power
factor of 0.8 lagging, the voltage error and phase displacement shall not
exceed +/- 3% and +/- 120 minutes respectively.
7. CONSTRUCTIONAL FEATURES
7.1 The core shall be built up of high grade, cold rolled grain oriented, non-ageing steel
laminations conforming to IS : 3024-1996, the laminations shall be coated on both
sides with suitable insulation, capable of withstanding short circuit forces.
7.2 One terminal of the primary winding shall be connected to the phase conductor of the
220kV / 132kV / 110kV / 66 kV / 25kV system and the other terminal brought out
through a 3.6 kV class bushing and connected to the tank externally by means of a
suitable tin coated copper link. The tank shall be provided with two terminals suitable
for taking double earth connections by means of 50 mm x 6 mm MS flat.
Both the ends of the secondary winding shall be brought out and terminated on
suitable insulated terminals which shall be fully protected by a weather-proof
terminal box designed to accommodate cartridge fuses as mentioned in Clause 7.6
below and fitted with a cable gland suitable for 2.5 sq.mm PVC insulated and PVC
sheathed 1.1 kV grade conforming to IS:1554 (Part I)-1998 Copper cable.
7.3 The connection between primary terminal and primary winding shall be by means of
flexible copper wire and shall be provided with crimped copper lugs, nuts and bolts
for proper fixing. For better mechanical strength and reliability, it is preferable that
165
primary winding lead connection with the terminal plate are provided at two / three
places as shown in the sketch at Annexure – 5.
7.4 The potential transformer shall be of sealed construction with inert gas (Nitrogen)
above the insulating oil, and adequately protected against any leakage of gas or oil. A
pressure release device capable of releasing abnormal internal pressure shall however,
be provided. The number of gasketted joints shall be restricted to the minimum
7.5 Class ‘A’ insulation, immersed in insulating oil shall be used. The transformer shall
be supplied complete with insulating oil conforming to IS:335-1993 and ready for
commissioning. The characteristics of insulating oil before energizing the new
potential transformer shall conform to the parameters as stipulated in IS: 1866-1991.
7.6 Cartridge type fuse links conforming to BS:9224 (Part-II)-1993 shall be provided in
the weather proof terminal box for the secondary circuit with continuous current
rating of 4A except for 25 kV PT (Type – I) of 2A.
7.7 The tank shall be of welded mild steel construction designed to withstand internal
stresses due to short circuits. All cover seats, flanged joints, threaded connections and
pipe fittings shall be properly machined, fitted and gasket to ensure oil tightness. The
construction of the tank shall be such as to shed off any rain water.
7.8 A port shall be provided on the oil expansion chamber to serve the purpose of oil
filling and also for fixing the nitrogen gas filling assembly. The nitrogen gas filling
assembly shall be screwed into the oil filling port and shall have its own leak-proof
sealing. A screwed cap shall be provided on the oil filling port with gasket or ‘O’ ring
provided at suitable location. The internal and external threads provided on the oil
filling port shall be of an adequate length and shall conform to the “precision grade”
as defined in IS: 1367-1996.
7.9 The oil draining pipe provided on the bottom tank shall have suitable internal threads
over an adequate length and a threaded plug should be screwed into this pipe. The
assembly of the threaded pipe and plug shall conform to the “precision grade” as
defined in IS: 1367-1996. In addition, a gasket or ‘O’ ring shall be provided at
suitable location in the assembly.
7.10 All the bolted mechanical and electrical connections in the transformer shall be
positively prevented from loosening in the service due to vibration. Standard locking
arrangements shall be employed for this purpose.
7.11 The electrical joints (if any) within the transformer winding shall be minimum, and
shall be brazed.
7.12 The transformer assembly shall be dried under vacuum till appropriate values of
insulation resistance have been obtained. It shall then be impregnated under vacuum
with transformer oil conforming to IS:335-1993.
166
7.13 No Grading ring shall be used in the construction of the 25 kV PT.
8. PORCELAIN HOUSING AND TERMINAL CONNECTORS
8.1 The porcelain housing shall be of single piece construction i.e. there shall be no joint
in the porcelain body. The shed profile shall have a lip at the extremities but free from
ribs on the underside.
8.2 The design and construction of the porcelain housing shall be such that stresses due to
expansion and contraction in any part there of shall not lead to its deterioration /
breakage.
8.3 The porcelain housing shall conform to IS:5621-1988 and shall withstand the
ollowing test voltages:-
a) Highest system voltage for : 245 145 123 72.5 52

equipment, kV (rms)
b) Rated short duration wet/dry: 460 275 230 140 95
power frequency withstand
voltage kV (rms)
c) Rated lightning impulse: 1050 650 550 320 250
withstand voltage kV (peak)
8.4 The primary terminal of potential transformer shall preferably be of stainless steel and
suitable for vertical take off for fixing a rigid type terminal connector. This terminal
plate shall be carefully welded at the location where it passes through the top plate of
the expansion chamber. The joint between the terminal plate and the oil expansion
chamber shall have adequate mechanical strength and shall be proof against leakage
of nitrogen gas and ingress of moisture.
8.5 The terminal connector shall be as per Research Designs and Standard Organization
(RDSO), drawing No. ETI/PSI/P/11120 and shall conform to IS:5561-1992. The
terminal connector drawing is placed at Annexure-2. Terminal connectors shall be
procured only from RDSO’s approved manufacturers.
9. FASTENERS
9.1 All fasteners of 12 mm diameter and less, exposed to atmosphere shall be of stainless
steel and those above 12 mm diameter shall preferably be of stainless steel or of mild
steel hot dip galvanized. The material of the stainless steel fasteners shall conform to
IS: 1570 (Part V)-1991 Grade 04, Cr 17 Ni 12 MO 2.
10. PAINTING
(i) All steel surfaces in contact with insulating oil shall be properly treated and
then painted with heat resistant, oil insoluble insulating varnish.
167
(ii) All steel surfaces exposed to atmosphere shall be properly treated and then
painted with one primer coat of zinc chromate and two coats of enamel gray
paint to shade 631 of IS: 5-1994.
11. RATING PLATE
11.1 The potential transformer shall be provided with a rating plate (both in Hindi and
English) of weather proof material, fitted in a visible position, showing the items
indicated below. The lettering / numbering on the plate shall be indelibly marked by
etching / engraving.
(i) Type designation of potential transformer

(ii) Governing specification
(iii) Manufacturer’s name and country of origin
(iv) Manufacturer’s serial number
(v) Year of manufacture
(vi) Rated voltage factor and corresponding rated time
(vii) Rated frequency
(viii) Highest voltage for equipment
(ix) Rated voltage
(a) Primary
(b) Secondary
(x) Rated output and corresponding Accuracy class
(xi) Maximum temperature rise over an ambient of 50 Deg. C
(a) of oil
(b) of winding
(xii) Rated Insulation levels
(xiii) Total weight
(xiv) Connection diagram.
12. PARTS, FITTINGS AND ACCESSORIES
The following accessories shall be provided with each potential transformer :
(i) Rating and diagram plate

(ii) Terminal marking plate
(iii) Weather proof terminal box
(iv) Lifting lugs
(v) Cable gland to take cable 2.5 mm2 / 1100 V grade PVC insulated / PVC
sheathed (Heavy Duty) Copper cables.
(vi) Oil filling port and nitrogen gas filling valve
(vii) Oil drain pipe with plug
(viii) Two equipment earthing terminals
(ix) Pressure relief device
(x) Terminal connector
168
(xi) Oil level sight gauge (tough acrylic plastic)
(xii) Plain rollers
(xiii) Adjustable arcing horn.
13. DRAWINGS
13.1 The successful tenderer shall submit the following detailed dimensioned drawings
along with three prints of each as per Railway Standards in sizes of 210 mm x 297
mm or any integral multiple thereof for scrutiny / approval. A format to title sheet to
be adopted for preparation of these drawings is attached at Annexure- 3.
(i) Outline general arrangement showing overall dimensions of the PT, position
of terminals and base mounting channels.
(ii) Cross sectional view showing core, winding, expansion chamber and
connection of primary side terminal to primary winding.
(iii) Detailed drawing of porcelain housing indicating shed profile, creepage
distance and salient electrical and mechanical technical parameters.
(iv) Clamping arrangement for porcelain housing.
(v) Details of Pressure relief device
(vi) Details of Oil filling port and Nitrogen gas filling valve
(vii) Details of Secondary terminal assembly
(viii) Details of Secondary terminal box
(ix) Details of Primary terminal plate
(x) Details of Oil drain plug arrangement
(xi) Details of cable gland, ‘O’ ring and gaskets used.
(xii) Details of oil level indicator
(xiii) Rating and diagram plate (English and Hindi version).
(xiv) Insulation details for active part.
(xv) Arrangement of earthing terminal
13.2 The provisionally approved drawings shall be modified, if need be, as a result of
changes necessitated during type testing or as desired by the Purchaser. The
modification shall be first got approved from the Purchaser / Director General
(Traction Installation) Research Designs and Standards Organisation,
[DG(TI)RDSO], Lucknow and then incorporated in the drawing and each such
modification shall be got signed by the authority concerned on the drawings. If there
are no modifications at all the provisionally approved drawings shall be finally
approved.
13.3 Six copies of approved drawings alongwith two sets of reproducibles shall be sent to
each consignee(s), as indicated in the purchase order. Besides two copies of
drawings alongwith one set of reproducible tracings shall be supplied to
CEE/CORE/ALD and one set of drawing to DG / TI / RDSO, Lucknow.
169
13.4 The successful tenderer shall also be required to supply at least two copies of the
“Inspection and Maintenance Manual” for potential transformer to each consignee,
CEE/CORE/ALD and two copies to DG (TI) RDSO, Lucknow – 226 011.
14. TESTING OF TRANSFORMER
14.1 General
14.1.1 Once a purchase order is placed for supply of a potential transformer (PT) the designs
and drawings shall be furnished to the Purchaser/DG (TI), RDSO, Lucknow as the
case may be within the period stipulated in the purchase order. Only after all the
designs and drawings as well as quality assurance plan (QAP) have been approved for
prototype tests and written advice given to that effect, successful tenderer /
manufacturer shall take up manufacture of the prototype of the potential transformer.
It is to be clearly understood that any change or modification required by the above
authorities to be done in the prototype shall be done expeditiously, not withstanding
approval having already been given for the designs and drawings. Such change or
modification shall be incorporated in the drawing as indicated in Clause 13.0.
14.1.2 Prior to giving a call to the Purchaser/DG (TI), RDSO, Lucknow, for inspection and
testing of the prototype, the successful tenderer / manufacturer shall submit a detailed
test schedule containing procedures and schematic circuit diagrams for each of the
tests and the number of days required to complete all the tests at one stretch. Once the
schedule is approved, the tests shall invariably be done accordingly. However, during
the process of type testing or even later, the purchaser reserves the right to conduct
any additional test(s), besides those specified herein, on any equipment / item so as to
test the equipment / item to his satisfaction or for gaining additional information and
knowledge. In case any dispute or disagreement arises between the successful
tenderer / manufacturer and representative of the Purchaser / DG(TI), RDSO,
Lucknow, during the process of testing as regards the procedure for type tests and/or
the interpretation and acceptability of the results of type tests, it shall be brought to
the notice of the Purchaser / DG(TI), RDSO, Lucknow, as the case may be, whose
decision shall be final and binding. Only after the prototype transformer is completed
the actual call for the inspection and testing with at least 15 days notice for the
purpose.
14.1.3 In the event of the test not being completed at one stretch for any reason attributable
to the successful tenderer / manufacturer and it is required for the representative of
the Purchaser / Director General (Traction Installation), Research Designs &
Standards Organisation DG (TI) RDSO, Lucknow to go again or more number of
times to the works of the successful tenderer / manufacturer or other place(s) for
continuing and / or completing the tests on the prototype(s) of the equipment, the
successful tenderer / manufacturer shall reimburse to the Purchaser / DG (TI) RDSO,
Lucknow, the costs for the representative having to visit to the works or other place(s)
for the tests more than once. The cost as claimed by the Purchaser / DG (TI), RDSO,
170
Lucknow, shall be paid through a demand draft to the concerned accounts officer of
the Purchaser / DG (TI), RDSO, Lucknow, as shall be advised to the successful
tenderer / manufacturer. However, it shall be reviewed by Purchaser / DG (TI),
RDSO, Lucknow, based upon the factual conditions / circumstances at the time of
conducting tests.
14.1.4 The type tests shall be carried out on the prototype transformer at the works of the
successful tenderer / manufacturer or at a reputed testing laboratory in the presence of
the representative of the Purchaser / DG (TI), RDSO, Lucknow, in accordance with
the relevant specifications and as modified or amplified by this specification.
14.2 Type Tests
14.2.1 The type tests shall be carried out on the prototype PT at the works of the successful
tenderer / manufacturer or at any reputed laboratory in the presence of the
representative of the Purchaser / DG (TI) RDSO, Lucknow, and in accordance with
the relevant specifications and as altered, amended or supplemented by this
specification.
(i) Temperature rise test.

(ii) Lightening Impulse test
(iii) Chopped Lightening Impulse test
(iv) High voltage wet power frequency withstand test
(v) Determination of errors
(vi) Short Circuit withstand capability test.
14.2.1.1 Temperature Rise Test
This test shall be done in accordance with clause 9.5 of IS: 3156 (Part-I)-1992.
The maximum temperature rise of the PT after continuous operation shall not
exceed the following values over an ambient temperature of 500 C.
(i) For windings 450 C (by resistance method)
(ii) For insulating oil 350 C (by thermometer).
14.2.1.2 Lightning Impulse Test
The test shall be done in accordance with Clause 9.6 of IS: 3156
(Part-I)-1992. The PTs shall withstand an impulse test voltage of :
i) Highest voltage for equipment kV (rms) 245 145 123 72.5 52

ii) Lightning impulse withstand 950 650 550 320 250
voltage, kV (peak).
171
14.2.1.3 Chopped Lightning Impulse Test
This test shall be carried out on primary winding in accordance with Clause
9.8 of IS: 3156 (Part-I)-1992 and the test voltage are same as under clause
14.2.1.2.
14.2.1.4 High Voltage Wet Power Frequency Withstand Test
The test shall be conducted in accordance with Clause 9.7 of IS:

3156 (Part-I)-1992. The test voltage shall be applied as under :
i) Highest voltage for equipment kV (rms) 245 145 123 72.5 52
ii) Rated power frequency withstand 395 275 230 140 95

voltage (wet), kV (rms).
14.2.1.5 Determination of Errors
Determination of errors shall be carried out in accordance with IS: 3156 (Part-
II)-1992 & IS: 3156 (Part-III)-1992 in conformity with clause 6.2 of this
specification.
14.2.1.6 Short Circuit Withstand Capability Test
The test shall be conducted in accordance with Clause 9.9 of IS: 3156 (Part-I)-
1992.
14.3 Type Test on Accessories
14.3.1 Porcelain Housing
The porcelain housing shall be tested in accordance with IS: 5621-1988 and
shall also meet the requirements of clause 8 of this specification.
14.3.1.1 Terminal Connectors
The terminal connectors shall be tested in accordance with IS: 5561-1992.
14.3.1.2 Pressure Relief Device
The pressure relief device shall be subjected to air pressure test and leakage
test. The pressure relief device should operate at a pressure between 2.5 to 4.5
kg/cm2.
14.3.2 Insulating Oil
172
The sample of insulating oil drawn from the prototype unit shall be tested in
accordance with IS: 335-1993.
14.4 Routine Tests
14.4.1 The following routine tests shall be performed on each PT including prototype in in
accordance with IS: 3156 –1992.
(i) Visual Examination
(ii) Verification of polarity of terminal markings.
(iii) Measurement of winding resistance
(iv) Measurement of insulation resistance
(v) Power frequency dry withstand test on primary winding
(vi) Power frequency dry withstand test on secondary winding
(vii) Determination of errors
(viii) Partial discharge measurement (Applicable for nominal system voltage above
66 kV).
14.4.1.1 Visual examination
A general examination shall be made to check that the potential transformer

conforms to the approved drawing, various items are accessible for
maintenance, the quality of workmanship and finish are of acceptable
standards and all parts, fittings and accessories are provided.
14.4.1.2 Verification of terminal marking and polarity
Terminal markings and polarity shall be verified as per clause 9.2 of IS:3156
(Part – I)-1992.
14.4.1.3 Measurement of winding resistance
The resistance of primary and secondary windings shall be measured and

computed at 75°C.
14.4.1.4 Measurement of insulation resistance
The insulation resistance between primary and secondary windings and

between secondary winding and earth shall be measured with 500 V megger.
14.4.1.5 Power Frequency Dry Withstand Test on Primary Winding
This test shall be done in accordance with clause 9.3 of IS:3156 (Part – I)-
1992. The test voltage shall be applied as under :
i) Highest voltage for equipment, kV (rms) 245 145 123 72.5
173
52
ii) Rated short duration power frequency 395 275 230 140
95 withstand voltage, kV (rms).
The induced over voltage withstand test shall be done in accordance with
clause 9.3.2.2 of IS:3156 (Part – I)-1992. As one end of the primary winding
is solidly earthed in these PTs, separate source withstand voltage test can’t be
conducted.
14.4.1.6 Power Frequency Dry Withstand Test on Secondary Winding
This test shall be conducted in accordance with clause 9.4 of IS:3156

(Part – I)-1992. The test voltage applied shall be 3 kV rms for one minute
between secondary winding terminals and earth.
14.4.1.7 Determination of Errors (Accuracy Class)

Determination of errors shall be carried out in accordance with IS:3156 (Part
– II and III)-1992 and it shall meet the requirement indicated in clause 6.2 of
this specification.
14.4.1.8 Partial Discharge Measurement

This test shall be conducted in accordance with IS : 11322 – 1990.
14.5 In the event of the potential transformer failing in any one of the tests, further tests
will not be carried out by the representative of the Purchaser/ DG/TI/RDSO. The
manufacturer; after carrying out the necessary rectification / modifications as
required on the potential transformer with the further approval from the Purchaser /
DG(TI) RDSO, offer a fresh prototype for carrying out all the tests stipulated above.
15 TECHNICAL DATA AND DRAWINGS.
15.1 The tenderer shall furnish alongwith his offer, in the proforma at Annexure – 4, the
Schedule of Guaranteed Performance and Other Particulars (SOGP) for the potential
transformer. The particulars shall be correct and complete in all respects. If there is
any entry like “shall be furnished later” or a blank against any item, the offer is not
likely to be considered as the evaluation of the offer is rendered difficult and cannot
be compared with other offers, if any.
15.2 The tenderer shall specifically indicate in a “Statement of Compliance” attached with
the offer, his compliance with each and every clause of this specification. In case the
reference to the clause(s) with the reasons/justification for the deviation. This shall be
in the form of a separate statement called the “Statement of Deviations”. If there is no
deviation at all, a specific “NIL” “Statement of Deviations” shall be attached with the
offer. If the “Statement of Compliance” and “Statement of Deviation” are not
174
incomplete offer which cannot be properly evaluated and compared with other offers,
if any.
15.3 The tenderer shall furnish the following drawings, alongwith the offer :
(i) Outline general arrangement drawing giving the overall dimensions of the
potential transformer along with a cross sectional view.
(ii) Rating and diagram plate.
(iii) Internal arrangement of the PT including cross-sectional views.
16. SPARES
Wherever required, the tenderer shall quote apart from main equipment, separately
for recommended spares required for five years operation
The tenderer shall also quote separately for the following essential spares.
(i) Primary porcelain housing
(ii) Primary terminal connector
17. TRANSPORTATION OF THE POTENTIAL TRANSFORMER
17.1 The potential transformer may be transported according to the transport facilities
available for the route, viz. by rail, road or sea. All parts, fittings and accessories
which are liable to damage during transit shall be removed and packed / crated
separately. Detached parts may be packed / crated and sent with potential
transformer along with the check list, so that all the parts are available at the
destination with the unit. The packing has to be done properly so that no damage
occurs during transit.
17.2 The various components of each potential transformer shall be securely packed in
wooden crates / boxes. General packing list, together with weight and overall
dimensions of packing cases shall be furnished for each transformer indicating the
following particulars :
--------------------------------------------------------------------------------------------------
Crate No. Description of Item / Approx. gross Approx. outside
component in the crate weight in Kg. Dimensions
17.3 As far as possible, the gross weight of the crate / box shall be so kept that it can be
conveniently handled by two persons.
17.4 In case of overseas supplies, packing shall be sea-worthy.
17.5 Necessary instructions for handling and storage of all items shall be included along
with the packing lists.
175
18.1 The successful tenderer shall make necessary arrangements for closely monitoring the
performance of the potential transformers through periodical (preferably once in two
months during the warranty period) visits to the location where they have been
erected for observations and interaction with the operating and maintenance personnel
of the Indian Railways. Arrangements shall also be made by the successful tenderer
for emergency / standby spare parts being kept readily available to meet exigencies
warranting replacement so as to keep the transformer in service with least down time.
18.2 The successful tenderer shall respond promptly and in workman like manner to any
call given by Indian Railways for any assistance by way of attending to failures,
investigation into the causes of failures including tests, if any, to be done and such
other items with a view to seeing that the potential transformer serves the purpose for
which it is intended. Besides technical guidance to ensure proper operation and
maintenance of the potential transformer shall be constantly rendered.
19. WARRANTY
19.1 The successful tenderer/manufacturer shall warrant that all equipment shall be free
from defects and faults in design, material, workmanship and manufacture and of the
highest grade consistent with the established and generally accepted standards for the
equipment of the type ordered and in full conformity with the specifications and shall
operate properly.
19.2 This warranty shall cover inspection of, payment for and acceptance of the equipment,
but shall expire 24 (Twenty Four) months after the delivery at ultimate destination, or
18 (Eighteen) months from the date of commissioning and proving test of the
equipment at ultimate destination in India, whichever period expires earlier, except in
respect of complaints, defects and/or claims notified to the successful tenderer /
manufacturer within 3 (Three) months of the expiry of such date. Any approval or
acceptance by the Purchase of the equipment shall not in any way limit the successful
tenderer/manufacturer’s liability.
19.3 The successful tenderer/manufacturer’s liability in respect of any complaint, defects

and/or claims shall not be limited to the furnishing and installation of replacement of
parts free of any charge or the repair of defective parts only to the extent that such
replacement or repairs are attributable to or arise from faulty workmanship or
material or design in the manufacture of the goods, provided that the defects are
brought to the notice of the successful tenderer/manufacturer within 3 (Three) months
of their being first discovered during the warranty period of 3 (Three) months form
the date of expiry of warranty period, or at the option of the Purchaser, to the payment
of the value, expenditure and damage as hereafter mentioned.
19.4 The successful tenderer/manufacturer shall, if required, replace or repair the

equipment of such portion thereof as is rejected by the Purchaser free of cost at the
ultimate destination or at the option of the Purchaser, successful
tenderer/manufacturer shall pay to the Purchaser value thereof at the contract price or
in the absence of such price at a price decided by the Purchaser and such other
176
expenditure and damages as may arise by reason of the breach of the conditions
herein specified.
19.5 All replacement and repairs that the Purchaser shall call upon the successful
tenderer/manufacturer to deliver or perform under this warranty shall be delivered
and performed by the successful tenderer/manufacturer, promptly and satisfactorily
and in any case within 2 (Two) months of the date of advice to this effect.
19.6 If the successful tenderer/manufacturer so desires, the parts that are removed may be
taken over by him or his representative for disposal as he deems fit at the time of
replacement with good parts. No claim whatsoever shall lie on the Purchaser
thereafter for the parts so removed.
19.7 The warranty herein contained shall not apply to any material which shall have been
repaired or altered by the Purchaser or on his behalf in any way without the consent
of the successful tenderer/manufacturer, so as to affect the strength, performance or
reliability or to any defects to any part due to misuse, negligence or accident.
19.8 The decision of the Purchaser in regard to successful tenderer/manufacturer’s liability

and the amount, if any, payable under this warranty shall be final and conclusive.
**************
177
____________________________________________________________________
SCHEDULE OF GUARANTEED PERFORMANCE, TECHNICAL AND OTHER

PARTICULARS.
---------------------------------------------------------------------------------------------------------------
S. No. Description Unit of Value / formation
Measurement 220kV/132kV/
110kV/66kV/25kV.
(type I & II)
---------------------------------------------------------------------------------------------------------------
3. Standard governing specification
4. Manufacturer’s Type designation
5. Rated (System) voltage
(a) Highest system voltage for equipment kV rms.
(b) Rated primary winding voltage kV rms.
(c) Rated secondary winding voltage kV rms
7. Insulation resistance between secondary Mohm

Winding & earth and between primary
& secondary winding.
8. Rated burden VA
9. Rated voltages and transformation ratio
10. Class of accuracy.

Ratio error (%) and phase angle error (minute)
(a) for voltage varying from 90% to 110%
or 80% to 120% of rated voltage.
(b) for voltage varying from 05% to 120%
of rated voltage.
11. Rated voltage factor
12. Maximum temperature rise after continuous
178
full load operation of:
(a) oil by thermometer °C
(b) winding by resistance °C
13. Winding particulars
(a) Type of primary winding

(b) Current density in primary winding A/mm2
(c) Size and no. of turns of conductors
for primary / secondary winding
(d) Class of insulation
(e) Rated insulation level
(i) Impulse withstand voltage kV peak.
(ii) Power frequency induced
withstand voltage kV rms.
(f) Resistance of primary winding at 75°C Ohms
(g) Resistance of secondary winding at 75°C Ohms.
14. Core particulars

(a) Type of core
(b) Flux density at rated voltage and frequency Tesla
(c) Thickness of steel laminations mm
(d) Whether CRGO steel stamping used? yes/no.
15. Porcelain housing / bushing particulars.

(a) Name of manufacturer
(b) Standard Governing Specification
(c) One minute dry power frequency withstand kV rms.
(d) One minute wet power frequency withstand kV rms.
(e) Lightning impulse withstand kV peak.
(f) Under oil flashover or puncture withstand,
Power frequency voltage kV rms.
(g) Under oil flashover or puncture withstand,
Impulse voltage kV peak.
(h) Creepage distance in air mm
(i) Weight of bushing / porcelain housing kg
16. LT. Fuse Particulars :
(a) Make & Type (cartridge & rewirable)

(b) Continuous current rating A
(c) Fusing current A
(d) Governing specification
17. Weights and dimensions :

(t) Net weight of core kg
179
(u) Net weight of copper kg
(v) Net weight of Primary winding kg
(w) Net weight of Secondary winding kg
(x) Quantity of insulating oil (volume) l
(y) Weight of insulating oil kg
(z) Total weight of potential transformer with oil kg
(aa) Overall dimensions of the assembled transformer
(i) Height (topmost) mm
(ii) Length mm
(iii) Breadth mm
18. Whether the PT is of sealed construction with

inert gas at top ? Yes / No
19. Whether terminal connectors will be provided? Yes / No
20. Are the exposed fasteners of 12 mm dia or less of stainless steel? Yes / No
21. Are the exposed fasteners of more than 12 mm dia. exposed to

atmosphere are of stainless steel or of MS hot dip galvanized? ----
22. Is the porcelain housing of single piece construction? Yes / No
23. Is the shed profile of porcelain housing free from under ribs,
but has a lip? Yes / No
24. Pressure release device are provided or not? Yes / No
25. Whether deviation statement submitted? Yes / No
26. Is the warranty as per clause 19.0? Yes / No
27. Is the list of spares furnished? Yes / No
28. Are all the drawings required as per Clause - 15.3 attached? Yes / No
************
180
LIST OF ABBREVIATIONS
ABBREVIATIONS FULL FORM OF THE ABBREVIATION
OHE
Over Head Equipment
PT Potential Transformer
TSS Traction Sub Station
SP Sectioning and Paralleling Post

(Switching Station)
QAP Quality Assurance Plan
DG (TI) Director General (Traction Installation)
181
RDSO Specification No.TI/SPC/PSI/PTS/0990 for Potential Transformers
issued to this specification.
S.No. Clause No. Amendment
In the title of the specification add “or 22 kV ‘after “25 kiV”.
1. Clause 1.1 Add in 2nd line, “or 22 kV” aftaer 25 kV (Type-I & II)
2. Clause 1.3 Deleted.
3. Clause 1.4 Deleted
4. Clause 2.1 In 3rd line, substitute 50ºC with 45ºC and in 4th line, substitute
40ºC with 35ºC
5. Clause 4.1 I) Change 50ºC to 45ºC

ii) Change 40ºC to 35ºC
vii) Change 200 Kgf/m2 to 112.5 Kgf/ m2
x) Change 0ºC to 5ºC
6. Clause 5.1.1 In line No.9, substitute 50 km to 80 km with “6.5.km to 25 km”
7. Clause 5.1.2 In line 11, substitute the word “interrupter” wotj “circuit
breaker”
8. Clause 5.3.1 Add at the end.

However the confifguratiion of OHE at the particular TSS is
242 sq.mm. catenary and 193 sqmm contact wire.
9. Clause 5.4.2 (i) (a)

Substitute the words “Admittance (Mho) relay for distance
protection” with
“Directional parallelogram characteristics time graded distance

relay”
10. Clause 6.1 Add another column to the table at the right hand side and read
the following
(ii) (a) 22
(b) 24
182
(iv) (i) or 22/3 kV
(ii) or 22/3 V
(v) (a) Add “or 22 kV” after the word “66kV”
Add another column to the table at the right hand side and read
the following.
(viii) (a) 24 kV
(b) 50
(c) 125
(ix) Change 50ºC in line 1 to 45ºC

(x) Add another column to the table at the right hand side
and read the following.
(ii) 22kV
(iii) 1300mm
11. Clause 6.2 Add in line 1 after 66kV “or 22kV”
12. Clause 7.2 In line 2 add

“/22 kV” after 25kV
13. Clause 8.3 Add another column to the table at the right hand side and read
the following.
a) 24
b) 50
c) 125
14. Clause 13.2 Deleted
15. Clause 13.3 Delete the sentence staring the “Besides two
copies:…….upto………….”Lucknow”.
16. Clause 13.4 Delete 3rd line.
17. Clause 14.1.1 In line 4 & 5, delete words staring with “for prototype
tests”…….till…….”to that effect”.
183
18. Clause 14..1.2& Delete
14.1.3
19. Clause 14.1.4 In line 1 delete the word ”prototype”.
20. Clause 14.2.1 In line 1 delete the word ”prototype”.
21. Clause 14.2.1.1 In line substitute 50ºC with 45ºC.
22. Clause 14.2.1.2 Add another column to the table at the right hand side
(i) 24
(ii) 125
(i) 24
(ii) 50
24. Clause 14.4.1 In line 1, delete the works”including prototype” before

the works “in accordance”.
(i) 24
(ii) 50
26. Clause 14.5 Delete
27. Clause 16.0 Delete line 3,4 & 5
28. Clause 19.2 Change the existing clause as follows “The warranty
shall expire 36 (Thirty six) months after the delivery of
equipment at the ultimate detination or 24 (twenty four)
months from date of commissioning of the equipment
whichever period occurs first.”
29. Clause 19.3 In line 8 delete the wors from “or” onwards till end.
30. In annexure 4, in the heading of the column 4 add / 22kV after 25kV (Type-I & II)
184
Addendum/Corrigendum Slip No.2 (May 2003) to the specification
No.TI/SPC/PSI/PTs/0990 for Potential transformer on 110 kV side of 30 MVA
transformer at railway traction sub-stations which may be operated in parallel on the
25 kV side.
S.No. Clause No./ Description As amended

Page No.
1 6.1 (4)-ii Page 9 Rated secondary voltage Read 110 V in place
of 110/√3 V
( B.P. Singh )
For Director General/TI
185
Addendum/Corrigendum Slip No.3 (August 2005) to the specification
No.TI/SPC/PSI/PTs/0990 for Potential transformer on 110 kV side of 30 MVA
transformer at railway traction sub-stations which may be operated in parallel on the
25 kV side.

Page No.
1. Annexure-7 Details of 110 kV potential New Annexure-7
transformers to be used in Mumbai added.
area. This is to be read along with
details given in the subject
specifications.
( B.P. Singh )
Director/TI-I
ANNEXURE-7
186
1. SCOPE
This part of specification cover design, manufacture, testing, inspection, packing and supply
of 110 kV potential transformers to the specification given below to be used in Mumbai area
at traction sub-station with 30 MVA transformers and required to be operated in parallel with
adjacent traction sub-stations.
2.0 RATING AND OTHER PARTICULARS
1. Type Single phase, oil filled natural air cooled

outdoor.
2. Nominal system voltage, kV 110 kV
3 Highest operating voltage 123 kV
4 Rated frequency 50 Hz +/- 3%
5 Neutral earthing Effectively grounded
6 Maximum temperature rise of 45 °C over an ambient of 50°C
windings immersed in oil
7 One minute 50 Hz withstand 230 kV (rms)
voltagae/induced over voltage
8 Impulse withstand voltage, positive 550 kV peak
and negative polarity 1.2/50
microsecond wave.
9 Minimum creepage distance of 3813
insulator (31mm/kV), mm
10 P.T.Ratio
1) Rated primary voltage, kV (rms) 100 kV -- 110 kV
√3 √3
2) Rated secondary voltage V 110 V & 110 V
√3 √3
11 Application Metering on winding 1,
Protection on winding 2.
12 Rated Burden 100 (Winding –1)
200 (Winding – 2)
13 Rated P.F. 0.8
14 Accuracy Class 0.2 for winding 1 and
3P for winding 2
15. Rated voltage factor 1.2 Continuous & 1.5 for 30 Sec.
16. The ratios corresponding to 110 kV 110 V - 110 V
√3 √3 √3 and
100 kV 110 V - 110 V
√3 √3 √3
should be achieved by providing tap on lthe secondary windings.
17. The neutral terminal for the HT winding should be brought out through a bushing
rated for 3.6 kV.
3.0 CONSTRUCTIION
187
The Potential transformers shall be hermetically sealed. They shall be suitable for
upright mounting on steel structures. They shall be provided with nitrogen cushions.
4.0 GENERAL
4.1 The Potential transformers shall be designed to withstand forces corresponding to a

seismic acceleration 0.1 g.
4.2 Potential transformers shall be provided with unthreaded stud/flat terminals made of
tinned copper at top for connections to consumer’s 110 kV bus comprising of IPS
pipes.
4.3 The PT secondary shall be provided with disconnecting tupe links and necessary
fuses either in the secondary terminal box or in a separate junction box.
4.4 Design and construction of Potential transformers shall be sufficient to withstand the
thermal and mechanical stresses that they may be subjected to while in service. The
core lamination shall be of high grade steel or other equivalent alloy. The exciting
current shall be as low as possible and the Potential transformer shall be capable of
maintaining its rated accuracy for burdens and saturation limits specified in Part one.
The secondary terminal shall be brought out in a weather-proof terminal box. The
terminal box shall be provided with glads suitable for 2 Nos. 1100 V grade, steel wire
armoured, PVC sheathed multicore, 2.5/4 sq.mm cables.
4.6 Polarity marks shall be indelibly marked on the primary terminals of the Potential
transformer and on the secondary lead terminations at the associated terminal block.
For PT the secondary fuses shall be incorporated in the secondary terminal box.
4.7 Potential transformer shall be provided with nameplate showing particulars and
diagram of the connections. They shall be made of non-corrosive material, shall be
indelibly marked and firmly fixed on to the body of Potential transformer.
4.8 The potential transformers shall be supplied complete with insulating oil conforming
to IS : 12463 and railway requirements. The insulating oil shall be procured from the
manufacturers approved by RDSO. The successful tenderer/manufacturer shall
submit test certificates as per IS:12463 for oil.
4.9 All ferrous parts exposed to atmosphere including main tank, secondary terminal box
& top metallic should be hot dip galvanized.
4.10 Equipment covered under this specification shall withstand seismic acceleration force
corresponding to 0.1 g.
188
4.11 The tenderer shall furnish their compliance or otherwise against each clause/sub-
clause of the technical specification. If the tenderer wishes to deviate from the
provision of any clause/sub-clause, he shall furnish the full details with justification
for such deviation.
4.12 Detailed drawings of PT alongwith SOGP shall be furnished for RDSO’s approval
before manufacture is taken up.
5.0 TESTS
The following Type & Routine tests as per RDSO specification

No.TI/SPC/PSI/PTs/0990 with A&C slip No.1 & 2, IS: 3156 and relevant IEC shall
be conducted on the potential transformer required for Mumbai area under DC-AC
conversion.
5.1 Type tests.
5.1.1 Temperature rise test

5.1.2 Lightning impulse test
5.1.3 Chopped Lightning impulse test
5.1.4 Hiigh voltage wet power frequency withstand test
5.1.5 Determinatiion of errors
5.1.6 Short circuit withstand capability test
5.1.7 Determination of capacitance dissipation factor.
5.2 Routine tests.
5.2.1 Visual examination

5.2.2 Verification of polarity and terminal markings
5.2.3 Measurement of winding resistance
5.2.4 Measurement of insulation resistance
5.2.5 Power frequency dry withstand test on primary winding
5.2.6 Power frequency dry withstand test on secondary winding
5.2.7 Determination of errors
5.2.8 Partial discharge measurement
5.2.9 Oil leakage test.
189
SPECIFICATION
FOR
25kV DROP OUT FUSE SWITCH
AND
OPERATING POLE
No. ETI / PSI / 14 (1 / 86)
190
GOVERNMENT OF INDIA
MINISTRY OF TRANSPORT
SPECIFICATION
FOR
25kV DROP OUT FUSE SWITCH

AND
OPERATING POLE
ISSUED BY

MANAK NAGAR, LUCKNOW 226 011.
191
GOVERNMENT OF INDIA
(DEPT. OF RAILWAYS)
--------
Specification No. ETI/PSI/14(1/86)
25 kV DROP OUT FUSE SWITCH AND OPERATING POLE
1. SCOPE
5.1 This specification applies to outdoor, expulsion, drop out type fuse switches for
protection of 25 kV / 230 V, 10 KVA and 100 KVA LT supply transformers at the
various traction installations.
5.2 The specification also covers insulated operating poles for opening / closing the fuse
link from ground level under live condition of the fuse switch.
5.3 The fuse switches and operating poles shall be complete with all parts and accessories
necessary for their efficient operation. All such parts and accessories shall be
deemed to be within the scope of this specification, whether specifically mentioned or
not.
6.0 SERVICE CONDITIONS
6.1 The fuse switches are required to be used as isolating links-cum-fuses for protection
of the 25 kV / 230 V, 10 KVA and 100 KVA, 50 Hz single-phase LT supply
transformers at traction substations, switching stations and way side railway stations.
The transformer and fuse switch are mounted on the same mast, the line end or upper
terminal of the fuse switch being connected to the substation switching station busbar
or traction overhead equipment as the case may be, and the outgoing end or lower
terminal, to the transformer.
6.2 Weather Conditions

The weather conditions under which the drop out fuse switch and operating pole are
used vary widely. The limiting conditions which have to be withstood in service are
indicated below :
- Maximum temperature of air in shade 450C

- Minimum temperature of air in shade 00C
- Maximum temperature attainable by an 650 C

object exposed to sun
- Maximum relative humidity 100%
192
- Average Annual rainfall 1750 to 6250 mm.
- Number of thunder storm days / annum 85 days Max.
- Average number of dust-storm days / annum 35 days Max
- Number of rainy days / annum 120 days Max
- Maximum wind pressure 200 kg/m2
- Altitude Not exceeding
1000 m.
6.3 In some area, the drop out fuse switch and operating pole are also subject to chemical
pollution from the effluent gases of chemical / fertiliser plants and to saline
atmosphere on the lines near sea.
7.0 GOVERNING SPECIFICATION
7.1 The fuse switches shall, unless otherwise specified, conform to IS:9385(Part-II)-1980,
which shall be applied in the manner altered, amended or supplemented by this
specification and the latest Indian Electricity Rules, wherever applicable.
7.2 The synthetic resin bonded glass fibre tube for operating pole shall conform to BS
8953-1976 (latest version).
7.3 Any deviation from this specification, calculated to improve the performance, utility
and efficiency of the equipment proposed by the tenderer, will be given due
consideration, provided full particulars with justification thereof, are furnished.
8.0 RATING AND OTHER PARTICULARS OF THE FUSE SWITCH
8.1 The fuse switches shall be designed for the following rating and other
particulars:
(i) Type Outdoor, expulsion rewirable dropout type.
(ii) Rated voltage 25 kV subject to rise up to 27.5 kV
(iii) Rated current 1 Amp / 5 Amp
(iv) Rated breaking capacity 5000A at a recovery voltage of 27.5 kV
(v) Rated frequency 50 Hz
(vi) Number of poles One
8.2 The fuse links shall be continuously rated for 1 Amp. In case of 10 kVA transformer
and 5 Amp in case of 100 kVA transformer. The fuse link rated for 1 Amp shall
blow off within one second for a fault current of 10 A and fuse link rated for 5 Amp
shall blow off within 0.5 sec. For a fault current of 75 Amp. The fuse link shall be of
materials which effectively resist deterioration under normal climatic condition. The
fuse link shall be mechanically robust to ensure that no damage results in from
normal handling or operation of the associated equipment. A minimum tensile
strength of 7 Kg shall be ensured, for the fuse link. The fusing element shall be
protected with a strong fibre sleeve so as to prevent damage to the fuse carrier tube at
193
the time of operation. Suitable end terminals shall be crimped / soldered on fuse
link to ensure its proper fixing in position. The length of fuse link shall be 650 mm.
9.0 TYPE, CONSTRUCTION AND MOUNTING OF THE FUSE SWITCH
9.1 The fuse switch shall be of robust construction ensuring no damage from normal
operation, handling and vibration and free operation at all times.
9.2 The fuse shall be of the rewirable, expulsion type in which the length of the break is
increased by expulsion of part of or full fuse element and in which the arc quenching
is assisted by the movement of gases from the fuse carrier. The mounting shall be
such that in the event of the fuse blowing out, the fuse link or carrier drops down and
hangs suspended from the lower contact.
9.3 The fuse link shall be designed for use as an isolator blade to be operated with a
protable insulated operating pole from ground level. It shall also be possible to
remove the fuse link bodily from the fuse switch, when it is hanging from the lower
contact, with the operating pole.
9.4 The fuse carrier shall be of synthetic resin bonded glass fibre tube conforming to
BS:3953-1976. The tube shall be of 500 mm length having an inside dia. of 16mm
and an outside dia of 32mm.
9.5 The fuse switch shall be complete with its mounting frame. Bolts, nuts and other
fasteners of 12 mm dia. and less shall be of stainless steel. Higher size of fasteners
may be made of galvanised steel.
9.6 All ferrous parts shall be hot dip galvanised and other parts including top and bottom
contacts shall be made of tin bronze. The zinc coating shall satisfy the requirements
of IS:2633-1972 and tin bronze of IS: 306-1968
9.7 The fuse switch shall be suitable for mounting on the vertical face of a structural steel
support, with four 16 mm dia. bolts spaced vertically 450 mm apart and horizontally
340 mm apart.
9.8 The fuse switch shall be provided with terminals suitable for connection to 19/2.10
mm (10.5 mm dia.) cadmium copper wire on the line side. At the load side the
terminals shall cater for connection to 2 SWG (7 mm dia.) copper wire.
9.9 The fuse switch shall strictly conform to Drg. ETI/PSI/082 for general assembly and
Drg. No. ETI/PSI/038 for part details. These drawings are enclosed with the
specification. The workmanship shall be good and the castings of different
components shall be free from any defects and shall have a good finish. The
manufacturer’s monogram shall be stamped on different components for an easy
identification.
194
6. SUPPORT INSULATORS
6.1 The support insulators shall be of solid core construction conforming to the
provisions and requirements of IS:4318-1967, as applicable to Post Insulators. The
insulators shall be procured from the approved manufacturers only.
6.2 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly
glazed. The caps shall be made of black heart malleable cast iron conforming to
grade BM 340 of IS: 2108-1977 and the ferrous parts shall be hot dip galvanised.
7. OPERATING POLE
7.1 The operating pole shall be designed for opening / closing as well as removal / refixing
of the fuse carrier from ground level under live conditions of the fuse switch.
7.2 The operating pole shall have a total length of about 6 m made of four pieces with
necessary joints in brass metal caps, to facilitate quick assembly.
7.3 Suitable attachment made of aluminium alloy to engage the fuse link shall be provided
at the top end of the pole.
7.4 The main insulation in the operating pole shall comprise glass fibre insulating piece of
not less than 500 mm long at the top end, and rigidly fixed on to the supporting piece
below. The remaining portion of the operating pole below the insulating piece shall
be made of either Permali wood encased in PVC sleeving or synthetic resin bonded
glass fibre tube coated with three coats of polyurethene. In case of Permali wood,
the PVC sleeving shall maintain a firm bond with the wood base, the joint between
the sleeve and the wooden pole being impervious to ingress of moisture.
7.5 The operating pole shall be robust in construction and light in weight. The complete
assembly, which shall not be too flexible, shall be capable of taking a cantilever load
of 2 kg without cracking or breaking.
7.6 The operating pole shall strictly conform to Drg No. ETI/PSI/039 enclosed with the
specification.
7.7 A suitable canvas carrying case, to hold the four pieces of the pole, with a strap for
slinging, shall be provided with each operating pole for packing and transport.
8. TESTS
8.1 All the tests on the drop out fuse switch and operating pole assembly shall be carried
out at the manufacturer’s works. The electrical tests may be carried out at any
195
reputed laboratory where testing facilities are available subject to prior approval of
the Purchaser. The manufacturer shall arrange without making claim or charges, all
the necessary apparatus, labour assistance etc. required to conduct the specified tests.
8.2 Type tests.
8.2.1 The following type tests shall be carried out on the prototype fuse switch:
(i) Visual examination and general observations.
(ii) Dimensional measurements
(iii) One-minute dry and wet power frequency withstand voltage test
(a) To earth 95 kV (rms)
(b) Across isolating distance 110 kV (rms)
(iv) Lightning impulse withstand voltage test (positive and negative polarity)
(a) To earth 190 kV (peak)
(b) Across isolating distance 235 kV (peak)
(v) Breaking capacity test at 5 kA with a recovery voltage of 27.5 kV
(vi) Test for current / time characteristics for fuse link.
8.2.2 The following type tests shall be carried out on the prototype operating pole:
(i) Visual examination and general observations.

(iii) One-minute dry and wet power frequency voltage withstand test at 105 kV
(rms) on main insulating piece in vertical position.
(iv) Lightning impulse withstand voltage test (positive and negative polarity) at
250 kV (p) on main insulating piece in vertical position.
(v) One-minute dry power frequency voltage withstand test on permali
wood/glass fibre portion of operating pole at 40 kV (rms) across ferrules
clamped on pole at 300 mm apart.
(vi) Cantilever load test:

(a) The complete assembly of operating pole shall be subjected to a
cantilever load of 8 kg on the top end, the base being clamped
horizontally at intervals of 300 mm and 1000 mm from the bottom
end. The deflection of the top end from the horizontal level shall be
196
measured and recorded. The operating pole should withstand this test
without any permanent deformation.
(b) Base remaining clamped, the load shall then be removed from the top
end. The deflection at the top end measured from the horizontal level
should not exceed 300 mm.
(vii) Impact test : With a load of 8 kg tied at the top end, the completely assembled
operating pole shall be lifted up and the top of the pole swung over an angle of
460 from vertical 20 times. There should be no sign of cracking, distortion
or damage at the end of the test.
(viii) Mechanical endurance test :
(a) The operating pole assembly shall be tested for mechanical endurance
by assembling and dissembling the operating 300 times each time
pulling out and putting back the fuse carrier tube on to the DO fuse
switch. After this test, there shall be no surface defects in the glass
fibre tube. Also, no loosening of joints should take place.
(b) The cantilever load test shall be repeated after the mechanical
endurance test and it shall be verified that deflection do not exceed the
values measured/specified in para 8.2.2(vi) above.
(ix) Determination of weight of assembly.
8.2.3 If the prototype of the fuse switch and operating pole conforming to this specification
has already been approved in connection with previous supplies to Indian Railways,
fresh prototype testing may be waived if the equipment had passed the prototype tests
earlier and no changes in the design or material have been made.
9. Routine test:
All the fuse switches and operating poles shall be subjected to the routine tests
detailed below at the manufacturer’s works :
(i) Visual examination
(iii) One-minute dry power frequency withstand voltage test on fuse switch at 95
kV (rms).
(iv) One-minute dry power frequency withstand voltage test on the fibre glass
insulating piece of the operating pole at 105 kV (rms).
(v) Cantilever load test on operating pole as per clause 8.2.2(vi)
9.1 Technical data and drawings:
9.2 The tenderer shall furnish guaranteed performance, technical and other particulars for
the equipment offered in the proforma attached as Annexure-A.
197
9.3 The tenderers shall indicated their compliance or otherwise against each clause and
sub-clause of the Technical Specification. The tenderers shall for this purpose
enclose a separate statement, if necessary, indicating the annexure and clause
reference and compliance or otherwise. Wherever the tenderer deviates from/the
provisions of the clause, he shall furnish his detailed remarks.
(This specification supersedes specification No. ETI/PSI/14(11/78) and No.

ETI/PSI/14(7/82).
Encl : Annexure-A and

Drawings No. ETI/PSI/032 Mod-D
ETI/PSI/038 Mod-B
ETI/PSI/039 Mod-B
198
Annexure –A to
Specification No. ETI/PSI/14(1/86)

PARTICULARS
Description Unit of measurement
3. Standard Governing Specification.
4. Manufacturer’s type and designation
5. Rated voltage kV
6. Rated current A
7. Rated breaking capacity kA
8. Total operating time at the rated breaking current ms
9. Operating time
a) at 10 A for 1 A fuse link ms

b) at 75 A for 5 A fuse link ms
10. Minimum fusing current for the fuse element
a) 1 A fuse link A
b) 5 A fuse link A
11. Insulation level of fuse switch
a) One minute wet power frequency withstand kV (rms)

(i) To earth
(ii) Across isolating distance
b) Impulse withstand kV (peak)

(i) To earth
(ii) Across isolating distance
12. Insulator particulars
199
a. Name of manufacturer
b. Standard Governing Specification.
c. Manufacturer’s type and designation
d. One minute dry power frequency withstand kV (rms)
e. One minute wet power frequency withstand kV (rms)
f. Impulse withstand kV (peak)
i) Positive polarity
ii) Negative polarity
g. Minimum failing loads
i) In tension kgf
ii) In bending kgf.m
iii) In torsion kgf.m
iv) In compression kgf
h. Weight of each insulator kg
13. Materials of fuse switch contacts
14. Temperature rise of contact at rated current above ºC

ambient
a) Across isolating distance

b) Live parts to earth.
16. Type of terminal connectors

17. Type of fuse switch
(whether outdoor / dropout, expulsion type).
18. Fuse link particulars

i. Name of manufacturer
ii. Standard Governing Specification.
iii. Manufacturer’s type and designation
iv. Rated current
v. Rated breaking capacity at a recovery voltage of
27.5 kV.
vi. Minimum tensile strength in kg. Kg
19. Material of fuse carrier tube and the name of its

manufacturer
200
20. Weight of fuse switch assembly kg
21. Particulars of operating pole:
a. Name of manufacturer
b. Manufacturer’s type and designation
c. Material of insulating pieces
i) Top piece
ii) Other pieces
d. Material of top attachment

e. Insulation strength of insulating piece:
i) One minute wet power frequency withstand kV (rms)
ii) Impulse withstand kV (peak)
f. One minute dry power frequency withstand across kV (rms)

ferrules 30 cm apart on permali wood / glass fibre
portion on the pole.
g. Weight of the operating pole assembly. kg.
201
ADDENDUM / CORRIGENDUM SLIP NO. 1 OF TRACTION INSTALLATION,
DIRECTORATE, SPECIFICATION NO. ETI/PSI/14 (1/86) FOR 25 kV DROPOUT
FUSE SWITCH AND OPERATING POLE.
The existing paras 8.2.2 (vi) & (viii) at page 7 shall be reread as under:-
8.2.2 (vi) Cantilever load test:-
a) The complete assembly of operating pole shall be subjected to a cantilever

load of 2 kg on the top end, the base being clamped horizontally at intervals of
300 mm and 1000 mm from the bottom end. The deflection of the top end
from the horizontal level shall be measured and recorded. The operating pole
should withstand this test without any permanent deformation.
b) Base remaining clamped, the load shall then be removed from the top end.
The deflection at the top end measured from the horizontal level should not
exceed 300 mm.
8.2.2 (viii) Mechanical endurance test:-
a) The operating pole assembly shall be tested for mechanical endurance by

assembling and disassembling the operating pole 200 times, each time putting
out and putting back the fuse carrier tube on to the DO fuse switch. After this
test, there shall be no surface defects in the glass fibre tube. Also, no
loosening of joints should take place.
b) The cantilever load test shall be repeated after the mechanical endurance test
and it shall be verified that deflection do not exceed the value measured /
specified in para 8.2.2 (vi) above.
202
RDSO Specification No. ETI / PSI / 14 / (1/86) 25 kV Dropout Fuse Switch
and operating pole.
1. Para 2.2 Minimum Temperature of air in Shade : Substitute 0ºC with 5ºC
Maximum wind pressure : Substitute 200 kg / m2

With 112.5 kg / m2
2. Para 8.2.3 In line 5, delete “Indian”
203
STANDARDS
ORGANISATION
SPECIFICATION
FOR
25 kV, 240V, 5kVA AND 10KVA, & 50 KVA,

50Hz. SINGLEPHASE, OIL FILLED
AUXILIARY TRANSFORMERS
No. ETI / PSI / 15 (08 /2003)
204
MINISTRY OF RAILWAYS,
GOVERNMENT OF INDIA,
SPECIFICATION
FOR
25 kV / 240 V, 5 KVA AND 10 KVA, 50 KVA, 50 Hz.

SINGLE PHASE, OIL FILLED
AUXILIARY TRANSFORMERS
FOR
RAILWAY AC TRACTION SYSTEM
ISSUED BY
GOVERNMENT OF INDIA,
MANAK NAGAR,
LUCKNOW 226 011.
205
For 25 KV/ 240 V, 5 ,10,25 and 50 KVAAuxiliary Transformer.

25 KV/ 240 V, 5 KVA ,10 KVA, 25 KVA & 50 KVA OIL FILLED
AUXILIARY TRANSFORMER.
1.0 SCOPE
1.1 This specification applies to 25 KV/ 240 V, 50 Hz a.c. (i) 5 kVA and (ii) 10 kVA (iii)
25 KVA and ( iv) 50 KVA oil filled single phase, auxiliary transformer (AT) for
installation at 220/27 kV, 132/27 kV, 110/27 kV and 66/27 kV Railway’s traction
substations, switching stations and other outdoor locations. The voltage on the
primary side will vary from 19 kV (minimum) to 27.5 kV (maximum) and the AT
should deliver the rated power within this specified voltage range at any of the
provided taps.
1.2 The AT shall be complete with all parts, fittings and accessories necessary for its
efficient operation. All such parts, fittings and accessories shall be deemed to be
1.3 This specification supersedes the earlier specification no. ETI/PSI/15 (11/92) with
A&C Slip No.1 to 2 which was meant for 5 kVA, 10 kVA and 50 kVA AT.
1.4 The AT shall be erected by the Purchaser/Indian Railways. However, in case, a

defect/deficiency is noticed, the manufacturer / successful tenderer will have to
depute his engineer for necessary remedial action without any cost to the Railways.
2.1 The AT shall, unless otherwise specified, conform to the following standards and
codes of practices (latest version) which shall be applied in the manner altered,
amended or supplemented by this specification and Indian Electricity Rules, wherever
applicable:
1. IS : 5 Colours for ready mixed paints and enamels.
2. IS : 226 Specification for structural steel (standard quality)
3. IS : 335 Specification for New Insulating Oils.
206
4. IS : 1271 Classification of insulating materials for
electrical machinery and apparatus in relation to
their thermal stability in service.
5. IS : 1367 Technical supply conditions for threaded steel

fasteners.
6. IS : 1554 Specification for PVC insulated (heavy duty),

(Part I) electrical cables for working voltage upto
and including 1100 volts.
7. IS : 1570 Schedule for wrought steel for general

(Part V) engineering purposes.
8. IS : 1576 Specification for solid press board for electrical

purposes.
9. IS : 1866 Code of practice for maintenance and

supervision of insulating oil in service.
10. IS : 2071 Methods of high voltage testing.
11. IS : 2074 Ready mixed paint, air drying red oxide zinc
chrome, priming.
12. ISO/EN : 12944 Protective Paint Systems.
13. IS : 2026 Specification for Power Transformers.

(Part I to IV)
14. IS : 2099 Specification for bushings for alternative

voltages above 1000 V.
15. IS : 2927 Brazing alloys.
16. IS : 3024 Specification for electrical steel sheets (oriented).
17. IS : 3347 Dimensions for porcelain transformer bushings.
18. IS : 3639 Specification for fittings and accessories for

power transformer.
19. IS : 4253 pecification for Cork and Rubber.

(Part II)
20. IS : 5561 pecification for Electric Power connectors.
207
21. IS : 5621 Specification for Hollow insulators for use in
22. IS : 6600 Guide for loading of oil immersed transformers.
23. IS : 8570 Press paper for electrical purposes.
24. IS : 8572 Paper covered flexible/stranded copper

conductor for transformer leads.
25. IS : 9224 Specification for low voltage fuses.
26. IS : 10028 Code of practice for selection, installation and

(Part I toIII) maintenance of transformers.
27. IEC : 76 Power Transformers.
28. IEC : 137 Bushing for alternating voltage above 1000 V.
29. IEC : 815 Guide for the selection of insulator in respect of

polluted conditions.
2.2 In case of any conflict between the contents of the above specifications and the
contents of this specification, the latter shall prevail.
2.3 Any deviation from this specification, proposed by the tenderer, intended to improve
the performance, utility and efficiency of the equipment, will be given due
consideration, provided full particulars of the deviation with justification thereof, are
the deviation, if any, proposed by him shall be quoted as an alternative(s).
3.0 ENVIRONMENTAL CONDITIONS
3.1 The AT shall be suitable for outdoor use in moist tropical climate and in areas
Subject to heavy rainfall, pollution due to industry and marine atmosphere and severe
lightning. The limiting weather conditions which the AT has to withstand in service
are indicated below:
i) Maximum ambient air temperature 50 °C.
ii) Average ambient air temperature over 35 °C.

a period of 24 h.
iv) Annual rainfall Raining from 1750 mm to

6250 mm.
208
v) Maximum number of thunder storm 85
days per annum.
vi) Maximum number of dust storm 35

days per annum.
vii) Number of rainy days per annum 120
viii) Basic wind pressure 200 kgf/mm2
ix) Altitude Not exceeding 1000 m.
3.2 The AT shall be subjected to vibrations on account of trains running on nearby railway
tracks. The amplitude of these vibrations which occur with rapidly varying time
periods in the range of 15 to 70 ms lies in the range of 30 to 150 microns at present,
with the instantaneous peak going upto 350 microns. These vibrations may become
more severe as the speeds and loads of trains increase in future.
4.1 The AT shall be suitable for pole mounting along the railway track for supplying
power to electric signaling and/or substation/switching station loads.
5.0 RATING AND GENERAL DATA
5.1 The rating and other particulars of the auxiliary transformer shall be as follows:
(i) Type Double wound, single phase,

ONAN(oil natural air natural)
cooled, step-down transformer for
outdoor installation.
(ii) Rated voltage for primary winding

a)Nominal Voltage 25kV
b)Minimum Voltage 19kV
c)Maximum Voltage 27.5kV
iii) Rated voltage for secondary 240 V.

winding.
iv) Rated current – at rated nominal voltage

(a) For primary winding
(i) 0.2 A for 5 kVA.
(ii) 0.4 A for 10 kVA.
(iii) 1.0 A for 25kVA
(iv) 2.0 A for 50kVA
209
(b) For secondary winding
(i) 21 A for 5 kVA.
(ii) 42 A for 10 kVA.
(iii) 105 A for 25kVA
(iv) 210A for 50kVA
v) The maximum current at the lowest primary voltage at extreme tap position must
be worked out and the conductor sizes must be decided accordingly.
vi) Rated frequency 50 Hz +/- 3%.
vii) Rated power at rated nominal

voltage (i) 5 kVA
(at all tap positions) (ii) 10 kVA
(iii) 25kVA
(iv) 50kVA
viii) Insulation level of winding Primary Secondary
(a) Rated lightning impulse 190 kV --

withstand voltage peak
(b) Rated short duration power 70 kV rms 3 kV rms
frequency withstand voltage
(c) Rated induced over voltage 80 kV rms
ix) Tappings Off-circuit tap changer to give the

rated secondary winding voltage for a
primary winding voltage variation of
plus 5% to minus 10% from nominal
voltage of 25kV in steps of 5%. Tapping
may be provided either on primary or
secondary windings. All tappings shall
be capable of carrying maximum full
load current continuously at lowest
primary voltage.
x) Polarity Subtractive
xi) Temperature rise limits The temperature rise over an ambient

temperature of 50ºC at maximum full
load current at lowest primary voltage
shall not exceed the value indicated
below:
a) Winding : 50ºC (measured by the

resistance method).
210
b) Insulating oil : 40ºC (measured by
thermometer).
c)Current carrying parts in air : 40ºC.
d)Hot spot temperature : not to exceed

115ºC.
xii) Impedance voltage at rated 5 %.

current at 75ºC
xiii) Type of cooling “ONAN”
xiv) Temperature class of insulation Class A for all the windings.
xv) Current density for primary & 2.5 A/mm2

secondary windings (max).
xvi) Maximum permissible losses
a) No load loss (i) 50 W for 5 kVA

(at max. primary voltage of
27.5kV) (ii) 60 W for 10 kVA.
(iii) 80W for 25kVA
(iv) 150 W for 50kVA
b) Load loss at 75ºC (i) 200 W for 5 kVA

(at max. current at lowest
primary voltage of 19kV) (ii) 300 W for 10 kVA.
(iii)500W for 25kVA
(iv)950W for 50kVA
xvii) Minimum creepage distance (i) 900 mm for 35 kV class,

of the porcelain housing (ii) 90 mm for 3.6 kV class.
xviii) Acoustic sound level when not more than 75 db at a distance of

energized at rated voltage 0.3 m from the transformer.
And at no load.
(xix) Maximum permissible efficiency At 50% of rated load.
6.0 SALIENT DESIGN FEATURE
6.1 General Construction.
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6.1.1 The dimensions of the 5kVA, 10kVA, 25kVA and 50kVA auxiliary transformers
shall not exceed those shown in drawing at Annexure 2. The AT shall be provided
with two hot dip galvanized channels at the bottom of the steel enclosure in order to
make it suitable for mounting on the mast and the disposition of primary bushing
and secondary bushings shall be as shown in the above drawing. The fixing hole
distances and slot dimensions on the transformer base channels shall be strictly
adhered to.
6.1.2 The overall dimensions of the AT shall be kept, as low as possible and in any
case shall not exceed the values given below.
(i) Length x Width : 650 x 500 mm for 5 and 10kVA( Also shall not exceed the
values as per drawing at Annexure -3)
(ii) Length x Width : 825 x 700 mm for 25kVA( Also shall not exceed
the values as per drawing at Annexure -3)
(iii) Length x Width : 1000 x 900 mm for 50kVA( Also shall not exceed
the values as per drawing at Annexure -3)
(iv) Height of the top most point of the primary bushing (mm) - 1700
(v) Height of the top most point of any part including conservator tank should
not exceed 1950mm
6.2 Transformer tank.
6.2.1 The tank for the auxiliary transformer shall be constructed from good commercial
grade low carbon steel suitable for welding with a single tier construction, so shaped
as to reduce welding to the minimum while fabricating. The tank shall be adequately
strengthened to permit hoisting of the transformer filled with oil by a crane or other
means.
6.2.2 Welded joints shall be made using the latest welding techniques.
6.2.3 The tank shall be provided with lifting lugs suitable for lifting the transformer filled
with oil. The lifting lugs shall be provided on the side walls of the tank. Separate
lifting arrangement for the tank cover and the core shall be provided.
6.2.4 The rubberised cork / nitrile gaskets or any other gaskets shall conform to IS
: 4253 (Part II).
6.2.5 Silicagel breather shall be suitably clamped to the tank. Silicagel breather shall have
flange type of connecting arrangement. The silicagel container shall be made of a
seamless tough acrylic tube and so designed as to facilitate easy replacement and
filling and removal of silicagel. The colour of silicagel shall be visible to a person
standing on the ground.
6.2.6 Auxiliary transformer shall be provided with the channel at the bottom of the tank in
order to make it suitable for pole mounting as shown in the drawing at Annexure-3.
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The centre to centre fixing hole distance and slot dimentions on the base channel shall
be rigidly complied with. Undirectional rollers shall also be provided on the
transformers base channel.
6.3 Core.
6.3.1 The core shall be made of high permeability cold-rolled grain oriented / non- ageing
electrical silicon steel laminations conforming to IS:3024. The flux density in any
part of the core and yoke with the primary winding excited at the rated voltage and
rated frequency shall not exceed 1.55 tesla.
6.3.2 The laminations used for stacking the core, shall be free from defects due to storage /
atmospheric effects. Both sides of the laminations shall be coated with suitable
insulation, capable of withstanding stress relief annealing. In assembling the core, air
gaps shall be avoided.
6.3.3 The core shall be electrically connected to the tank to drain off any electro static
potential that may have built up.
6.3.4 Yoke / core clamping bolts shall have adequate threaded length beyond the face of the
nuts for tightening at a later stage, if need arises. Each of the core clamping bolts and
the core clamping frame work shall be insulated from the core laminations and tested
after completion of the core assembly to ensure that they withstand a voltage of 2 kV
r.m.s, with respect to core for a duration of 60 s.
6.4 Windings.
6.4.1 Primary and secondary windings shall be of spiral / helical type and shall have class
‘A’ insulation. These shall be made of continuous electrolytic copper conductor.
6.4.2 Normally, no joint shall be used in the winding conductor. If a joint becomes
inescapable, it shall be brazed with high silver alloy grade Ba Cu Ag6 conforming to
IS : 2927 or electrically butt-welded.
6.4.3 The auxiliary transformer windings shall have the following insulating levels:
S.No. Primary Secondary
a) Rated voltage between winding 25 kV 240 V

and earth.
b) Rated short duration power 70 kV rms 3 kV rms

frequency withstand voltage.
c) Rated lightening impulse 190 kV peak --

withstand voltage.
d) Induced over-voltage with stand 80 kV rms --
213
6.4.4 As the AT is subject to frequent short circuit currents while in normal operation, the
winding shall be specially designed and suitably brazed to withstand electro magnetic
forces without any injury. Windings shall be so assembled as to be magnetically
balanced with respect to each other to minimize mechanical stresses.
6.4.5 The winding assembly shall be thoroughly dried in vacuum, shrunk to final dimensions
and impregnated under vacuum with insulating oil conforming to IS : 335.
6.4.6 All leads and connections shall be mechanically strong, adequately insulated, protected
against mechanical injury and rigidly clamped to withstand dynamic stresses due to
short circuit.
6.5 Bushings and Terminal Arrangement.
6.5.1 The bushings shall comply with IS : 2099 and IS : 3347. The line terminal of the
primary winding shall be brought out through 36 kV class bushing for connection to
the overhead equipment and the neutral terminal brought out through a 3.6 kV class
bushing and connected to the tank externally by means of a suitable tin coated copper
link. The steel enclosure of the AT shall be connected to earth during service.
6.5.2 The 3.6 kV bushing and connection of the link to the tank shall be covered by a sheet
steel of not less than 2 mm thickness welded on to the tank and should have a captive
bolted cover.
6.5.3 The porcelain housings of both bushing shall comply with the requirements laid down
in IS : 5621 and shall be of a single piece construction i.e. there shall be no joint in
the porcelain housing. The shed profile shall have a lip at the extremities, but free
from ribs on the underside so as to avoid accumulation of dust and pollutants and to
permit easy cleaning.
6.5.4 The design of the bushing shall be such that stresses due to expansion and contraction
in any part of the bushing shall not lead to its deterioration.
6.5.5 The bushing shall be free from corona.
6.5.6 Primary and secondary bushings shall be provided with identical tinned copper stems
of 20 mm diameter for 36 kV class bushing and 12 mm diameter for 3.6 kV class
bushing. The stem shall be threaded to metric size at suitable places as per IS : 1367.
6.5.7 The bushings shall withstand the following test voltages.
214
S.No. Primary Secondary
(line end) (including neutral end
of primary winding
bushing)
(a) Highest voltage for 36 kV rms 3.6
equipment Um. kV rms
(b) Rated short duration

wet power frequency 70 kV rms 10 kV rms
withstand voltage.
(c) Rated lightening impulse
190 kV peak 40 kV peak
withstand voltage.
(c) Minimum creepage
distance 900 mm 90 mm
6.5.8 The adjustable arcing horns shall be provided on the primary bushing side. The horn
gap setting shall be variable between 125 to 250 mm.
6.5.8 The secondary terminal box shall be suitable for following cable sizes for the
different ATs.
S.No. AT Type Cable Size

1 5 KVA 2X25 Sq.MM Al. Cable
6.5.10 The primary and secondary bushings and terminal connectors shall be procured from
Research Designs and Standards Organisation’s (RDSO) approved manufacturers
only.
7.0 INSULATING OIL
7.1 The auxiliary transformers shall be supplied complete with insulating oil conforming to
IS : 12463. The transformer shall be shipped with windings and core completely under
oil. The insulating oil shall be procured from the manufacturers approved by RDSO.
The successful tenderer / manufacturer shall submit test certificates as per IS : 12463
for oil.
7.2 The Characteristics of insulating oil before energisation of the new AT and during its
maintenance and supervision in service shall conform to the parameters stipulated in IS :
1866.
215
8.0 FASTENERS
8.1 All fasteners of 12 mm diameter and less, exposed to atmosphere shall be of stainless
steel and those above 12 mm diameter shall preferably be of stainless steel or of mild
steel hot dip galvanised. The material of the stainless steel fasteners shall conform to
IS: 1570 (Pt.V) Grade 04, Cr 17 Ni 12 Mo 2.
9.0 PAINTING
9.1 All steel surfaces in contact with insulating oil shall be painted with heat resistant, oil
insoluble insulating varnish.
9.2 All steel surfaces exposed to weather shall be properly descaled/grit blasted. The
epoxy and polyurethane protective paints as per ISO/EN 12944 have to be provided
for proper protection against corrosive and coastal environments and give life of
approx. 12-15 years. The external surfaces of the AT shall be given first coat of
epoxy zinc rich (having minimum 83% metallic zinc) primer (50 micron thickness),
intermediate coat of epoxy chemical and corrosion resistant paint (100 micron
thickness) and final coat of polyurethane paint (50 micron thickness). The total dry
film thickness of the paints shall be minimum 200 micron. The shade of paint shall
be garay as shade 631 of IS : 5
10.0 SOURCES OF SUPPLY FOR WINDING WIRE, GASKETS AND ‘O’ RINGS.
10.1 The winding wire, gaskets and ‘O’ rings used in the manufacture of the AT shall
be procured only from suppliers having BIS certification for the items.
10.2 The successful tenderer / manufacturer shall be required to furnish the following
information in respect of winding wire, gaskets and ‘O’ rings:
(i) Source of supply
(ii) Reference to standard specification to which the material conforms.
(iii) Reports of type tests carried out in terms of relevant Indian Standard
Specification.
11.0 RATING PLATE
11.1 The auxiliary transformer shall be provided with a rating plate (both in Hindi and
English) of weather proof material, fitted in a visible position, showing the items
indicated below:
(i) Type of transformer

216
(iii) Manufacturer’s name
(a) Manufacturer’s serial number
(iv) Year of manufacture
(v) Rated output
(vi) Rated frequency
(vii) Highest voltage for equipment
(viii) Rated voltage
(a) Primary
(b) Secondary
(ix) Rated current
(a)Primary
(b) Secondary
(x) Maximum temperature rise over an ambient of 50 Deg. C
(a) of oil
(b) of winding
(xi) Total weight
(xii) Class of insulation
(xiii) Insulation levels
(xiv) Connection diagram indicating the taps.
The letters / figures on the plate shall be indelibly marked by etching, engraving or
stamping.
12.0 FITTINGS AND ACCESSORIES
12.1 The following fittings and accessories shall be supplied with each AT :
(i) Conservator with oil filling hole and cap

(ii) Drain hole with plug for conservator
(iii) Oil level indicator
(iv) Silicagel breather with oil seal
(v) Upper filter valve
(vi) Lower filter cum drain valve
(vii) Adjustable arching horn of range 125 – 250 mm
(viii) Rating plate with connection diagram indicating the taps.
(ix) Lifting lugs (for complete transformer)
(x) Air release device
(xi) Thermometer pocket
(xii) Lifting lugs (for cover, core and windings)
(xiii) Oil sampling valve (20 mm) with plug
(xiv) Two earthing terminals
(xv) Terminal connectors for both HV & LV terminals
(xvi) Off circuit tap changer with locking arrangement and tap position indicator.
217
13.0 DRAWINGS
13.1 A format of the title sheet to be adopted by the successful tenderer / manufacturer for
preparation of the drawings is attached at Annexure- 4..
13.2 The successful tenderer / manufacturer shall submit for approval the following
detailed dimensioned drawings to the Purchaser / Director General (Traction
Installation), Research, Design and Standards Organisation (DG(TI), RDSO)
Lucknow as per Indian Railway .Standards in sizes of 210 mm x 297 mm or any
integral multiple thereof.
(bb) Outline general arrangement of the AT showing plan, front elevation, side
elevationdetails as well as salient guaranteed particulars indicated therein.
(ii) Internal arrangement of the AT indicating primary and secondary bushing lead
connections, core to core and core to tank earthing.
(iii) Cross sectional view of the core and windings with material specifications.
(iv) Details of ‘O’ rings and gaskets.
(v) Details of oil level indicator.
(vi) Bushing for primary side including cross sectional view, shed profile, arcing
horns and salient electrical and mechanical characteristics.
(vii) Bushing for secondary side including cross sectional view, shed profile and
salient electrical and mechanical characteristics.
(viii) Terminal connectors for primary and secondary side bushing terminals.
(viii) Rating plate both in English and Hindi with connection diagram indicating
the taps.
(x) Details of off-circuit tap changer with locking arrangement.
(xi) Details of silicagel breather.
(xii) Any other drawing considered necessary by the successful tenderer /
manufacturer and / or purchaser / (DG(TI)RDSO), Lucknow.
13.3 The provisionally approved drawings shall be modified, if need be, as a result of
changes necessitated during or as a result of type tests or as desired by the purchaser /
FOR DIRECTOR GENERAL/TI-IV (TI), RDSO, Lucknow. The modification shall be
first got approved by the Purchaser / FOR DIRECTOR GENERAL/TI-IV (TI), RDSO,
Lucknow and then incorporating the drawing and each such modification shall be got
signed by the authority concerned on the drawings. If there are no modifications at all
the drawings shall be finally approved.
13.4 Six copies of approved drawings alongwith two sets of reproducibles shall be sent to
each consignee(s), as indicated in the purchase order. Besides two copies of
drawings alongwith one set of reproducible and on floppy along with hard copy (in
Autocad 2000) after final approval of the drawings shall be supplied to shall be
supplied to DIRECTOR GENERAL/TI-IV (TI), RDSO, Lucknow (INDIA)
218
13.5 The successful tenderer / manufacturer shall also be required to supply at least six
copies of the Instruction and Maintenance Manual for AT to each consignee and two
copies to DG (TI) RDSO, Lucknow – 226 011.
14.0 TESTING OF TRANSFORMER
14.1 General
Once a purchase order is placed for supply of a auxiliary transformer the designs and
drawings shall be furnished to the Purchaser/DG (TI), RDSO, Lucknow as the case
may be within the period stipulated in the order. Only after all the designs and
drawings have been approved for prototype tests and a written advice given to that
effect, shall the successful tenderer/manufacturer take up manufacture of the
prototype of the transformer. It is to be clearly understood that any change or
modification required by the above authorities to be done in the prototype shall be
done expeditiously, not withstanding approval having already been given for the
designs and drawings. Such change or modification shall be incorporated in the
drawing as indicated in Clause 13.0.
testing of the prototype, the successful tenderer/manufacturer shall submit a detailed
test schedule consisting of schematic circuit diagrams for each of the tests and the
number of days required to complete all the tests at one stretch. Once the schedule is
approved, the tests shall invariably be done accordingly. However, during the process
of type testing or even later, the purchaser reserves the right to conduct any additional
test(s), besides those specified herein, on any equipment / item so as to test the
equipment / item to his satisfaction or for gaining additional information and
tenderer / manufacturer and representative of the Purchaser / DG (TI), RDSO,
Lucknow, during the process of testing as regards the procedure for type tests and/or
the inspection and acceptability of the results of type tests, it shall be brought to the
notice of the Purchaser / DG (TI), RDSO, Lucknow, as the case may be, whose
decision shall be final and binding. Only after the prototype transformer is completed
the actual call for the inspection and testing with atleast 15 days notice for the
purpose.
14.1.3 In the event of the tests not being carried through to completion at one stretch and if
due to any reason attributable to the successful tenderer / manufacturer and it is
required for the representative of the purchaser / DG (TI) RDSO to go again or more
number of times to the works of the successful tenderer / manufacturer or other
place(s) for continuing and / or completing the tests on the prototype(s) of the
equipment, the successful tenderer / manufacturer shall reimburse to the Purchaser /
DG (TI) RDSO, Lucknow, the costs for the representative having to visit to the works
or other place(s) for the tests more than once. The costs as claimed by the Purchaser /
DG (TI), RDSO, Lucknow, shall be paid through a demand draft to the concerned
219
accounts officer of the Purchaser / DG (TI), RDSO, Lucknow, as shall be advised to
the successful tenderer / manufacturer.
14.1.4 The type tests shall be carried out in accordance with “Quality plan for Auxiliary
Transformer prototype Testing” and with the relevant standards as modified by the
specification where ever applicable, at the works of the successful
tenderer/manufacturer or at a reputed testing laboratory in the presence of the
authorized representative of the purchaser FOR DIRECTOR GENERAL /TI, RDSO,
Lucknow.
14.2 Tests during manufacture.

Following type tests shall be carried out on the prototype unit during manufacture,
(a)Vacuum Test
(b)Pressure Test.
14.2.1 Vacuum Test.

The AT tank only shall be tested at a vacuum of 3.33 kN/m2 (0.033 kg /cm2) for 60
min. The permanent deflection of flat plates after release of vacuum shall not exceed
the value indicated below:
--------------------------------------------------------------------------------------------------
Horizontal length of Permanent deflection
flat plate mm.
--------------------------------------------------------------------------------------------------
Upto and including 750 mm 5.0
751 mm to 1250 mm 6.5
1251 mm to 1750 mm 8.0
1751 mm to 2000 mm 9.5

---------------------------------------------------------------------------------------------------
14.2.2 Pressure Test
Every AT tank and conservator tank shall be subjected to an air pressure

corresponding to twice the normal static level of oil or to the normal static level of oil
pressure plus 35 kN/m2 (0.35 kg /cm2) whichever is lower, as measured at the base of
the tank. The pressure shall remain constant for 1 h to indicate that there is no leakage
from any point.
14.3 Type Tests.
The following type tests shall be carried out on the prototype at the works of the
successful tenderer / manufacturer or at any reputed laboratory in the presence of the
representative of the purchaser / DG (TI) RDSO, Lucknow, and in accordance with
the relevant specifications – altered, amended or supplemented by this specifications.
220
i) Temperature rise test.
ii) Lightening Impulse withstand voltage test.
ii) Short circuit test.
iii) Type tests on accessories
14.3.1 TemperatureRrise Test
The temperature rise test shall be done in accordance with clause 4 of IS : 2026 (Part
II).
The test shall be done continuously without any interruption due to power supply
failure. In case interruptions of power supply do take place for some reason, then the
entire test shall be repeated after steady state conditions are attained.
14.3.1.1 During the temperature rise test, the following shall be ensured:
(i) The ambient temperature shall be measured as per clause 4.1 of IS:2026(Part II).
Only alcohol in glass thermometers shall be used for the measurement.
(ii) The winding temperature shall be determined by the resistance method only.
(iii) The temperature of the top oil shall be measured by an alcohol in glass
thermometer placed in an oil filled thermometer pocket.
(iv) The temperature of the hot-spot in the winding shall be the sum of the
temperature of the top oil and 1.1 times the temperature rise of the winding
above the average oil temperature.
14.3.1.2 The test shall be carried out as described below :
i) A quantum of power equal to the sum of the measured losses viz. no

load and load losses at maximum current, achieved at lowest primary
voltage of 19 kV and at appropriate tap, corrected to 75ºC plus 10% of
such sum shall be fed to the primary winding of the transformer with
the secondary winding short circuited.
ii) The losses so fed to the transformer shall be continuously maintained till
such time as the steady state temperature is reached i.e. the top oil
temperature rise does not vary by more than 1ºC during four
consecutive hourly readings.
iii) On attaining the steady state temperature, the current in the primary
winding of the transformer shall be brought to the rated maximum
current achieved at lowest primary voltage 19 KV which shall be
maintained for 1 h. At the end of the period the power supply to the
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transformer shall be switched off and the time of switching off
recorded.
iv) The measurement of hot resistance shall commence as soon as is

possible after switching off. The first reading of the resistance shall be
taken before the expiry of 90 s from the instant of switching off and
the first 10 readings shall be taken at intervals of 15 s apart.
Thereafter, another 10 readings shall be taken at intervals of 30 s apart.
v) The time at which each of the resistance values is read shall also be
recorded.
vi) The temperatures of the ambient, top oil and radiator inlet / outlet shall
also be recorded at half hourly intervals throughout the test starting
from the instant power supply is switched on to commence the test till
it is switched off.
14.3.2 Lightning Impulse test
This test shall be done as per Clause 12 of IS: 2026 (Part-III). The test impulse shall
be a full standard lightning impulse i.e. 1.2 ± 30% / 50 ± 20% µs. the voltage shall be
applied to the line terminal of the primary winding with the neutral terminal of the
winding earthed through a current measuring shunt. The tank and the terminals of the
secondary winding shall be earthed. The oscillographs for voltage as well as neutral
current shall be recorded. The AT shall withstand a lightning impulse of 190 kV
peak.
14.3.3 Short circuit test
The short circuit test shall be done in accordance with clause 16.11 of IS : 2026
(Part I).
14.3.4 Type Tests on Accessories
The type tests on bushings, terminal connectors and other accessories shall be done as
per the relevant specifications.
14.4 In addition to the above all routine tests detailed in clause 14.7 below shall also be
carried out on the prototype.
14.5 If the prototype of an AT conforming to this specification has already been approved in
connection with previous supplies to Indian Railways, fresh testing of prototype of the
auxiliary transformer may be waived at the discretion of the purchaser, provided that
no changes whatsoever in the design or materials used have been made. However, the
purchaser reserves the right to test an AT against any purchase order if he deems it
necessary to do so in the light of experience gained from previous supplies.
222
14.6 Only after approval of original tracings of drawings incorporating changes, if any, as a
result of the type tests and clear written approval of the results of the tests on the
prototype is communicated by the Purchaser / Director General (TI), Research Designs
and Standards Organisation to the successful tenderer / manufacturer, shall be take up
bulk manufacture of the auxiliary transformer, which shall be strictly with the same
materials and process as adopted for the prototype. In no circumstances shall materials
other than those approved in the design / drawings and/or during the prototype be used
for bulk manufacture on the plea that they had been obtained prior to the approval of
the prototype.
14.6.1 The prototype approval shall be accorded after conducting all the type tests (clause
14,3) and routine tests (clause 14.7) stipulated under this specification and in TIQ
0006 Rev.1 (Quality Plan for Auxiliary Transformer Prototype Testing). The validity
of the Prototype approval shall normally be for a period of two years.
14.7 Routine Tests

Every AT shall be subjected to the routine tests in accordance with relevant parts of
IS : 2026 in the presence of the Purchaser’s representative.
i) Visual Examination
ii) Verification of terminal markings and polarity
iii) Measurement of voltage ratio on all tap positions
iv) Measurement of winding resistance
iv) Measurement of insulation resistance
v) Measurement of impedance voltage on principal tap, short circuit impedance
and load loss.
vi) Measurement of no load loss and current
vii) Induced over voltage withstand test for primary winding
viii) Separate source power frequency withstand voltage test.
A general examination shall be made to check that the AT conforms to the approved
drawings, various items are accessible for maintenance, the quality of workmanship
and finish are of acceptable standards and all parts, fittings and accessories are
provided.
14.7.2 Measurement of winding resistance
The resistance of the windings shall be measured and computed at 75ºC.
14.7.3 Measurement of voltage ratio

Voltage ratio of primary and secondary winding shall be measured on all tap
positions.
14.7.4 Verification of terminal markings and polarity
The markings of the terminals and the polarity shall be verified.
223
14.7.5 Insulation Resistance
The insulation resistance of each of the windings with respect to the earth and
with respect to each other shall be measured by using 2.5 kV megger.
14.7.6 Measurement of impedance voltage, short circuit impedance and load losses.
Load losses shall be measured with rated maximum current achieved at lowest
primary voltage of 19 kVat ambient temperature and computed at 75ºC. The
percentage impedance voltage at principal tap shall be measured with rated current,
(copy of above) at ambient temperature and computed at 75ºC.
14.7.7 Measurement of No-load loss and current
No-load loss and current referred to the primary winding shall be measured at
maximum rated voltage of 27.5 KV.
14.7.8 Induced over voltage withstand test
The secondary winding shall be fed at a convenient voltage and frequency, so as to

obtain 80 kV between the primary terminals which shall be kept open circuited with
one terminal earthed. Duration of the test at full test voltage shall be 60 sec for any
test frequency upto and including twice the rated frequency. When the test frequency
exceeds twice the rated frequency, the duration of the test in second shall be:
120 x Rated Frequency

---------------------------
Test Frequency
But not less than 15 s.
14.7.9 Separate source power frequency withstand voltage test
This test shall be done as per clause 10 of IS : 2026 (Part III). A voltage of 3000V
shall be applied between line terminal of the secondary winding, the other terminal
of the primary winding, the core, the frame and the steel enclosure of the transformer,
connected together and then to earth.
15.0 INFORMATION TO BE GIVEN WITH THE TENDERER
15.1 The tenderer shall furnish along with his offer, in the performa at Annexure-I, the
Schedule of Guaranteed Performance and other particulars (SOGP, Part-I)) for the
AT. The particulars shall be correct and complete in all respects. The values /
information given in this SOGP, Part-I, will be used for technical evaluation of the
tender.
224
15.2 Only the successful tenderer shall furnish the consolidated information as given in the
proforma at Annexure-2, the schedule of Guaranteed Performance, Technical and
Other Particulars (SOGP, Part-II) for the AT. This SOGP, Part-II will have to be
approved by the indenting Railway / RDSO.
15.3 The tenderer shall specifically indicate in a “statement of compliance” attached with
reference to the clause(s) with the reasons / justification for the deviation. This shall
be in the form of a separate statement called the “statement of deviation”. If there is
no deviation at all, a separate “NIL” “Statement of Deviation” shall be attached with
the offer. If the “Statement of Compliance” and “Statement of Deviation” are not
incomplete offer which can not be properly evaluated and compared with other offers,
if any.
15.4 The tenderer shall furnish the following drawings along with the offer:
i) Outline general arrangement drawing giving the overall dimensions of the AT.
ii) Rating and diagram plate.
iii) Internal arrangement of the transformer including cross-sectional views.
15.5 The tenderer shall furnish the following documents as a part of the tender
documents.
i) Quality Assurance Plan for the tendered AT
ii) ISO certification regarding quality system and R&D facilities.
iii) List of essential plants, machinery and testing facilities and should conform to
the P&M as stipulated in RDSO’s STR No.019.
iv) Up-dated calibration certificate for the testing equipment.
v) Type test reports for the relevant rating for the tendered AT.
16.0 SPARES
16.1 Wherever required, the tenderer shall quote apart from main equipment, separately
for recommended spares required for five years operation.
16.2 The tenderer shall also quote separately for the following essential spares:
i) 36 kV bushing.
ii) Primary terminal connector
17.0 AFTER SALES SERVICE

17.1 The successful tenderer shall make necessary arrangements for closely monitoring the
performance of the auxiliary transformers through periodical (preferably once in two
erected for observations and interaction with the operating and maintenance personnel
of the Indian Railways. Arrangements shall also be made by the successful tenderer
for emergency / standby spare parts being kept readily available to meet exigencies
225
warranting replacement so as to keep theAauxiliary Transformer in service with least
down time.
The successful tenderer / manufacturer shall respond promptly and in a workman like
manner to any call given by Indian Railways for any assistance by way of attending
to failures, investigation into the causes of failures including tests, if any, to be done
and such other items with a view to seeing that the auxiliary transformer serves the
purpose for which it is intended. Besides technical guidance to ensure proper
operation and maintenance of the AT shall be constantly rendered.
18.0 WARRANTY
18.1 The successful tenderer / manufacturer shall warrant that all equipment shall be free
from defects and faults in design, material, workmanship and manufacture and of the
highest grade consistent with the established and generally acceptable standards for
the equipment of the type ordered and in full conformity with the specifications and
shall operate properly.
18.2 This warranty shall survive inspection of, payment for and acceptance of the
equipment, but shall expire 24 (Twenty four) months after the delivery at ultimate
destination in India, or 18 (Eighteen) months from the date of commissioning and
proving test of the equipment at ultimate destination in India, whichever period
expires earlier, except in respect of complaints, defects and/or claims notified to the
successful tenderer / manufacturer within 3 (Three) months of the expiry of such date.
Any approval or acceptance of the Purchaser of the equipment shall not in any way
limit the successful tenderer / manufacturer’s liability.
18.3 The successful tenderer / manufacturer’s liability in respect of any complaints, defects
and/or claims shall be limited to the furnishing and installation of replacement parts
free of any charges or the repair of defective parts only to the extent that such
replacement or repairs are attributable to or arise from faulty workmanship or
material or design in the manufacture of the goods, provided that the defects are
brought to the notice of the successful tenderer / manufacturer within 3 (Three)
months of their being first discovered during the warranty period of 3 (Three) months
from the date of expiry of warranty period, or at the option of the Purchaser, to the
payment of the value, expenditure and damage as hereafter mentioned.
18.4 The successful tenderer / manufacturer shall, if required, replace or repair the
equipment of such portion thereof as is rejected by the Purhaser free of cost at the
ultimate destination or at the option of the Purchaser, successful tenderer /
manufacturer shall pay to the Purchaser value thereof at the Contract Price or in the
absence of such price at a price decided by the Purchaser and such other expenditure
and damages as may arise by reason of the breach of the conditions herein specified.
18.5 All replacement and repairs that the Purchaser shall call upon the successful tenderer /
manufacturer to deliver or perform under this warranty shall be delivered and
performed by the successful tenderer / manufacture, promptly and satisfactorily and
in any case within 2 (Two) months of the date of advice to this effect.
226
18.6 If the successful tenderer / manufacturer so desires, the parts that are removed may be
taken over by him or his representative in India for disposal as he deems fit at the
time of replacement with good parts. No claim whatsoever shall lie on the Purchaser
of the successful tenderer / manufacturer, so as to affect the strength, performance or
18.8 The decision of the Purchaser in regard to the successful tenderer / manufacturer’s
liability and the amount, if any, payable under this warranty shall be final and
conclusive.
19.0 TRANSPORTATION OF THE AT.

19.1 The transformer may be transported according to the transport facilities available for
the route, viz. by rail, road or sea. All parts, fittings and accessories which are liable
to damage during transit shall be removed and packed / crated separately. Detached
parts may be packed / crated and sent with AT along with the checklist, so that all the
parts are available at the destination with the unit. The packing has to be done
properly so that no damage occurs during transit.
19.2 The various components of each AT shall be securely packed in wooden crates
and boxes. General packing list, together with weight and overall dimensions of
packing cases shall be furnished for each AT indicating the following:
---------------------------------------------------------------------------------------------------
Crate No. Description of Approx. gross Approx. outside
Item / component weight in kg. dimensional
In the crate
---------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------
19.3 As far as possible, the gross weight of the crate / box shall be so kept that
it can be conveniently handled by two persons.
19.5 Necessary instructions for handling and storage of all items shall be
included along with the packing lists.
**************
227
ANNEXURE-I
For 25 KV/240V, 5 KVA,10 KVA, 25 KVA and 50 KVA Auxiliary Transformer.
PARTICULARS, SOGP-Part-I (GUARANTEED PARTICULARS ARE TO BE
ESTABLISHED BY INSPECTION, ACTUAL TESTS/TEST REPORTS) – Values /
Information are to be furnished by each of the tenderers and this will be used for technical
evaluation of the tenders.
S.No. Description Specified Value/ Information Value/Information to
be furnished by the
bidder
1 Name of the manufacturer
2 Standard specification on
which the performance data
are based.
3 Type designation. Single Phase oil filled ONAN
4 Continuous rating for i. 5 KVA
specified cooling, temperature ii. 10 KVA
rise and ambient temperature. iii. 25 KVA
iv. 50 KVA
5 Rated temperature rise under
normal operating conditions
over a maximum ambient of
50°C.
(i) Of oil by thermometer 40°C.
(ii)Of winding by resistance 50°C.
6 Rated primary voltage 25 KV (may vary from 19 KV
to 27.5 KV)
7 Rated Secondary voltage at all 240 V
the tap positions on the
primary / secondary windings.
8 Losses 5 10 25 50
KVA KVA KVA KVA
No load Loss, watts 50 60 80 150
Load Loss at 75°C, watts 200 300 500 950
Total Loss, watts 250 360 1300 1100
9 Impedance voltage at rated 5%
current for the principal
tapping referred to the primary
at 75°C.
10 Max. permissible efficiency is 50% of the rated load.
to be at
11 Core
Type CRGO
228
Max. Flux density in any part 1.55 Tesla
of lthe core and yoke at
principal tap and winding
excited with rated voltage /
frequency.
12 Max. current density in any of 2.5 A/mm ²
the winding.
13 Class of the insulation Class A
14 Insulation withstand strength
of primary winding with
1.2/50 micro-second wave.
i) Impulse full wave 190 kV (p)
ii) Impulse chopped wave 190 kV (p)
15 Short duration power 70 kV
frequency withstand voltage.
16 Tap changer
Type Off Circuit
No. of plus taps One (+ 5%)
No. of minus taps Two (-5%, -10%)
17 Bushings Primary Primary Secondary
HV end earthed side
Standard specification on BIS 2099 - 1973
which the performance data
are based
Impulse withstand voltage 190 40 40
(Full wave), KV peak
One minute dry / wet power 70 10 10
frequency withstand voltage,
KV rms.
Minimum creepage distance, 900 90 90
mm
18 Dimensions of assembled
transformer
Type of AT 5 10 25 50
kVA kVA kVA kVA
Base to topmost point, mm 1950 1950 1950 1950
Overall breadth, mm 500 500 700 900
Overall length, mm 650 650 850 1000
229
ANNEXURE-2
For 25 KV/240V, 5 KVA,10 KVA, 25 KVA and 50 KVA Auxiliary Transformer.
PARTICULARS, SOGP-Part-II (GUARANTEED PARTICULARS ARE TO BE
ESTABLISHED BY INSPECTION, ACTUAL TESTS/TEST REPORTS)
S.No. DESCRIPTION UNIT OF 5 Kva 10 kVA 25 kVA 50 kVA

MEASURE
MENT
1 Name of the manufacturer
2 Country of origin
3 Reference to specification
based on which
performance data is
prescribed.
4 Normal rated power KVA
5 Rated primary winding kV
voltage
6 Primary voltage Variation kV
Range
7 Rated secondary winding V
voltage at all the tap
positions.
8 Rated frequency Hz
9 Temperature rise over a
maximum ambient
temperature of 50°C.
i) Of oil (by thermometer) °C.
ii)Of winding (by °C.
resistance)
10 Losses
a) No load loss at max. W
rated primary voltage on
principal tapping and at
rated frequency.
b) Load loss at max. rated W
current achieved at min.
primary voltage of 19 kV
and at principal tapping at
75°C.
c) Total Loss at rated W
voltage at principal tapping
and at rated frequency.
S.No. DESCRIPTION UNIT OF 5 Kva 10 kVA 25 kVA 50 kVA
MEASUR
230
EMENT
11 Impedance voltage at rated %
current for the principal
tapping referred to primary
at 75°C.
12 Reactance voltage at rated %
current and rated frequency
referred to primary at 75°C.
13 No load current ata rated A
voltage and rated frequency
rererred to primary.
14 a) Full wave lightning kV
impulse withstand voltage peak
for winding
b)Separate source short
duration power frequency
voltage withstand.
i) Neutral terminal of kV rms.
primary winding.
ii) Secondary winding. kV rms.
a) Induced over Voltage kV rms.
withstand of primary
winding.
15 Efficiency at unity and 0.8
power factor (At 75 °C)
. a) 100% load %
b) 75% load %
c) 50% load %
16 Regulatiion at full load at
75°C.
a) At unity power factor %
b) At 0.8 power factor %
lagging.
17 Core particulars
a) Type of core
b) Flux density at rataed T
voltage and 50 Hz (max.)
c) Thickness of steel mm
laminations.
d) Insulatiion between
corelamination (material)
e) Type of joint between
core limbs and yokes.
f) Whether CRGO steel
stamping used.
g) Conforming to IA
231
specification No.
h) Core bolt insulation flash
over voltage (1 minute )
18 Winding particulars :-
a) Type of winding
i) Primary
ii) Secondary
b)Current density in
winding :
i) Primary winding A/mm²
ii) Secondary A/mm²
c) Size and No. of turns of
i) Primary winding wire
ii)Secondary winding
wire
d) Resistance of
i) Primary winding Ohm.
at 75°C.
ii) Secondary winding Ohm.
at 75°C.
e) Conforming to IS
Specification No.
f) Insulation on winding
conductor.
g) Type of joints in the
winding, if any.
h) Minimum flash over
distance to earth between
i) Secondary winding mm
and core.
ii)Primary winding and mm
yoke.
19 Tap Changer :
a) Type of tap changer
b) No. of plus taps.
c) No. of minus taps.
20 Primary and Secondary Primary Secondary

bushing :
a) Name of the
Manufacturers.
232
b) Manufacturer’s type
designation.
c) Standard specification on
which the performance
data are based :
d) Whether primary
bushings metallised.
e) Rated voltage kV
f) Rated current A
g) Power frequency
withstand voltage :
i) Wet kV rms
ii) Dry kV rms
h) Dry lightning impulse kV peak
withstand voltage (1.2/50
us)
i) Total creepagae distance mm
in air.
j) Recommended horn gap mm
setting.
k) Weight of assembled Kg.
bushing.
l) Dia of the stem. mm
21 Weight and dimensions.

a) Net Weight of core Kg.
b) Net weight of copper in

i) Primary winding Kg.
ii) Secondary winding Kg.
c) Net untanking weight of Kg.

core frame and coils
d) Total weight of complete Kg.

Transformer.
e) Insulating oil :-
i) Net weight Kg.
ii) Total volume L
233
22. Overall dimensions of the
assembled transformer :
i) Height mm
ii)Length mm
iii) Breadth mm
23. Untanking height mm
24 Base mounting details
25. Minimum thickness of Plate

of sheet steel enclosure.
i) Side mm
ii) Top cover mm
iii) Bottom mm
26. Name of suppliers and

conforming IS Specification
No.
i) Terminal connector
ii) Insulating oil
iii) ‘O’ ring and gaskets
iv) Paints/varnish
v) Fasteners :
a) Stainless steel
b) M.S. hot dip
galvanized
vi) Press boards.
vii) Precompressed press
board.
viii) Winding wire
ix) Core material
27. Other particulars.
i) Is the transformer fitted Yes/No
with lifting lugs ?
ii) Is the core electrically Yes/No
connected with the tank ?
iii) What is the number of

joints numbers provided in
the
234
a) Primary winding
b) Secondary winding
iv)Are winding preshrunk ? Yes/No
v) Are arcing horns Yes/No

provided for primary
bushing ?
vi) Are the porcelain Yes/No

housing of bushings of
single piece construction ?
vii) Is the shed profile of Yes/No

porcelain housing of the
bushing free from under
ribs, but has a lip ?
viii) Is clause by clause Yes/No

statement of compliance
attached ?
ix) Are fasteners of 12mm Yes/No

dia-meter and less exposed
to atmosphere of stainless
steel to grade 0.4 CC 17 Ni.
12 MO2 to IS: 1570 (Part
II) ?
x) Are the fasteners of Stainless
more than 12 mm diameter steel / Hot
exposed to atmosphere dip
stainless steel or MS hot galvanized
dip galvanized ?
xi) Are all the drawings Yes / No

required as per clause 15.4
attached ?
xii) Is warranty as per Yes/No

clause 18.0 ?
xiii) Is the list of spares
furnished or not ? Yes/No
235
236
237
STANDARDS
ORGANISATION
SPECIFICATION
FOR
110 KV LIGHTNING ARRESTOR
No. ETI / PSI / 137 (8/89)
238
GOVERNMENT OF INDIA
SPECIFICATION
FOR
110 kV LIGHTNING ARRESTOR
ISSUED BY

239
GOVERNMENT OF INDIA
SPECIFICATION NO. ETI / PSI / 137 ( 8 / 89)
LIGHTNING ARRESTER – METAL OXIDE GAPLESS TYPE
1.0 SCOPE
1.1 This specification covers the design, manufacture, testing and supply of metal oxide
gapless type lightning arresters intended for outdoor installation for protection of 220
kV / 25 kV or 132 kV / 25 kV or 110 kV / 25 kv or 66 kV / 25 kV single phase, 50 Hz
transformers and other equipments of 245 / 132 / 110 / 66 kV class installed in
traction sub-stations.
2.1 As no national or international standard has been finalized on the subject till date, the
lightning arresters alongwith its accessories shall generally conform to the draft
circulated by IEC TC 37 (Secretariat) 68 WG – 4, January 1987 on non-linear metal
oxide surge arresters without gaps for a.c. system and latest amendment thereof,
except where specified otherwise.
2.2 Assistance has been taken from the following standards / documents also while
preparing this specification:
i) IS : 1570 (Pt. V) - 1972 - Stainless and heat resisting steels.
ii) IS : 2099 – 1973 - Bushing for alternating voltages above

1000 volts (1st Rev. ) with Ameniment
No. 1
iii) IS : 2629 – 1966 - Recommended practice for hot dip

galvanizing of iron & steel.
iv) IS : 2633 – 1972 - Methods of testing uniformity of coating

on zinc coated articles (1st Rev.).
v) IS : 3070 (Pt. I) – 1985) - Non-linear resistor type lightning arresters

(2nd Rev.).
240
vi) IS : 5358 – 1969 - Hot-dip galvanised coating on fasterners.
vii) IS : 5621 – 1980 - Hollow insulators for use in Electrical

equipment (1st Rev.)
viii) IS : 5561 – 1970 - Electric power connectors.
ix) IS : 8704 – 1978 - Methods for artificial pollution test on high

voltage insulators for use on a.c. systems.
x) IEC Publication 99 - Lightning arresters. Pt. I ; Non-Linear

resistor type arresters for ac systems.
2.3 Equipment meeting any other authoritative standards which ensures an equal of better
quality than the standard mentioned at para 2.1 above shall also be accepted. The
salient points of comparison between standard mentioned at para 2.1 above and other
standards adopted shall be clearly brought out in the tender and a complete set of
such standards (in English language) shall be supplied by the Tenderer alongwith the
tender.
2.4. Any deviation from this specification calculated to improve the performance, utility
consideration, provided full particulars with justification thereof are furnished.
3.0 TRACTION POWER SUPPLY SYSTEM.
3.1 General :
The signal phase, 50 Hz power supply for railway traction at 25 kV is obtained from
220 / 132 / 110 / 66 kV three phase grid system through a step down single phase
power transformer, the primary winding of which is connected to between two of the
phases of three phase effectively earthed transmission line net work of the electricity
board. In order to reduce the imbalance on three three phase grid system, the two
phases of the three phase transmission line are tapped in a cyclic order, for feeling
successive substations. The distance between adjacent substation is normally
between 40 to 50 km depending upon the density of the traffic and gradients of the
section etc.
3.1.1 One terminal of the 25 kV secondary winding of the traction transformer is connected
to the overhead equipment (OHE) and the other terminal is solidly earthed and
connected to the appropriate running returns through the rail (s) and earth to the
substation. Where booster transformers and return conductors are used the return
current flows through these and partly through the earth in the vicinity of the
241
substation. Approximately midway between two adjacent substations a dead zone
known as the “neutral section” is provided to separate the different phases. The
power to the OHE on one side of the substation is controlled by an interrupter. In
case of a fault on the OHE the feeder circuit breaker isolates it. The incoming 220 /
132/ 110 / 66 kV supply voltage may vary between + 10% and – 12.5% as per I.E.
Rule No. 54. A arrangement at a traction substation is at Appendix – A.
3.2 Protection system :
3.2.1 The following relays are provided for the protection of 220 kV side of traction
transformer :
a) Differential protection.
b) IDMT over current protection.
c) Restricted earth fault protection.
3.3 Insulation levels :
Basic insulation levels of the sub-station equipment on the 220 / 132 / 110 / 66 kV
side is as under :
------------------------------------------------------
220kV 132kV 110kV 66kV
-----------------------------------------------------
a) One minute power frequency : 395 275 230 140
with stand voltage in kV (rms)
b) 1.2 / 50 micro second impulse : 950 650 550 325

withstand voltage in kVp
3.4 Impedance of traction transformer :
The percentage impedance of 20 MVA, 220 / 25 kV on 132 / 25 kV or 110 / 25 kV or

66 / 25 kV traction transformer at the principal tap position is ( 2 +/ - 0.5 ) %. Only
one transformer is in service at a time.
3.5 Short Circuit level :
The short circuit level varies between limits indicated in the table below :
-------------------------------------------------------------------------------------------------------
Nominal system voltage
Item ----------------------------------------------------------
220kV 132kV 110kV 66kV
-------------------------------------------------------------------------------------------------------
Maximum fault MVA 10,000 5,000 5,000 3,500
-------------------------------------------------------------------------------------------------------
242
4.1 The equipments would be in use in moist tropical climate and in areas subjected to
heavy rain-fall and severe lightning in India. The atmospheric conditions are given
below :
Max. temperature of air in shade - 45 deg.C
Min. temperature of air in shade - 0 deg . C
Average ambient air temperature 35 deg. C

over a period of 24 hours
Max. relative humidity. - 100 %
Average annual rain fall - 1750 to 6250 mm
Max. no. of thunder – storm days - 85
Max. number of dust storm days per - 35

per annum.
Max. number of rainy days per year. - 120
Basic wind pressure. - 200 Kg / sq.mm.
Max. altitude. - 1000 metres.
4.2 The lightning arrester would also be subjected to chemical pollution from the effluent
gases of chemical plants exhaust of steam / diesel locomotives and to saline
atmosphere in coastal areas.
4.3 Vibrations :
The lightning arrester being installed on steel structure located by the side of railway
tracks, are subject to vibrations with the passage of trains. The amplitude of these
vibrations lies in the range of 30 to 150 microns, with instantantaneous peaks going
up to 350 microns. These vibrations occur with rapidly varying time periods in the
range of 15 to 70 ms.
243
5.0 TECHNICAL SPECIFICATION.
5.1 Rating and other particulars of the lightning arresters.

i) System Three phase a.c. system, solidly earthed.
ii) Nominal system voltage 66kV 110kV 132kV 220kV
(phase to phase)
iii) Permissible variation 66 + 10% 110 + 10% 132 + 10% 220 + 10%
-12.5% - 12.5% - 12.5% -12.5%
iv) Rated frequency 50 Hz 50 Hz 50 Hz 50 Hz
v) Type of lightning Non linear, metal oxide resistor type,
arrester. without gaps.
vi) Line discharge class class 3 class 3 class 3 class 3
vii) Continuous operating 50kV rms 80kV rms 95 kV rms 168 kv rms
voltage capability
(phase to earth).
viii) Maximum discharge 160kVp 250kVp 350kVp 550kVp

voltage at nominal
discharge current.
ix) Nominal discharge 10 kA 10kA 10kA 10kA

current (8 / 20 wave).
x) Power frequency 117kV rms 174kV rms 228kV rms 380kv rms
voltage withstand for
arrester insulator.
xi) Pressure relief class Class – A Class – A Class – A Class – A
244
5.2 Construction :
5.2.1 The lightning arrester shall comprise of a number of non-linear resistor blocks,
housed inside the porcelain housing. Suitable provision to arrest the relative
movement of blocks shall be provided inside the porcelain housing. Lightning
arrester shall be of hermetically sealed construction to prevent moisture ingress. The
arrester shall have means for relieving internal pressure to prevent explosive
shattering of the housing. The pressure relief device shall explosive shattering of the
housing. The pressure relief device shall be of the Class – A as per IS : 3070 (Pt. I).
5.2.2 The arresters shall be provided, if necessary with metal guard ring, circular in shape
to modify electrostatically the voltage gradient.
5.2.3 The arrester shall have base support suitably designed for mounting on a base plate
over a steel supporting structure as per details given in following table :
----------------------------------------------------------------------------------------------------------------
220kV 132kV 110kV 66kV
--------------------------------------------------------------------------------------------------------------
No. of bolts 6 (60 deg. 3 (120 deg. 3 (120 deg. 3 (120 deg.
apart) apart) apart) apart)
Size of bolts. M – 12 M – 16 M – 16 M – 16
Pitch Circle diameter. 254 mm 222 mm 222 mm 222 mm
5.2.4 The arrester shall be provided with a terminal connector conforming to IS : 5561.
The connector shall be of robust design and as per approved drawing suitable for
securing in ACSR –Zebra conductor (28.62 mm diameter) on the live side. Suitable
provision on the earth side of the arrester shall be made for connecting two numbers
45 x 6 mm MS flats. An earthing pad with two holes of 13.5 mm dia is preferable.
All the hardware required for mounting the lightning arrester, insulating base and
surge monitor etc. shall be supplied by the manufacturer.
5.2.5 All ferrous parts used in manufacture of lightning arrester, its assembly and the
insulating base shall be hot-dip galvanised. Hardware of diameter less than 12 mm
shall be made out of stainless steel conforming to grade 04 Crl7Nil2 Mo2 of IS : 1570
Pt. V and those above or equal to 12 mm shall preferably be of stainless steel or of
mild steel hot dip galvanised to RDSO’s specification No. ETI / OHE / 18 (4/84).
245
5.3 Insulating base :
One number insulating base made from best available porcelain shall be supplied by
the manufacturer alongwith each arrester. The insulating base shall also have same
mounting dimensions as of the lightning arrester mentioned in Clause 5.2.3.
5.4 Surge monitor :
5.4.1 To monitor the healthiness of the lightning arrester, each arrester shall be provided
with a surge monitor. Surge monitor shall be designed to record directly the number
of surges handled by the lightning arrester on a cyclometric counter, and also indicate
the leakage current passing through the lightning arrester on an ammeter
continuously. No push button shall be provided in the ammeter circuit for taking the
reading of the leakage current. Surge monitors shall be interchangeable and suitable
for outdoor service. Suitable terminal connectors and leads etc. shall be supplied
alongwith the surge monitor so that these can be installed at a convenient height for
ease of visibility. Suitable provision on the earth side of the surge monitor shall be
made for connecting two numbers 45 x 6 mm M.S. flats as indicated in Para 5.2.4
above. The design of surge monitor shall be as indicated in Para 5.2.4 above. The
design of surge monitor shall be such that in the eventuality of its failure, the
lightning arrester base should automatically be connected to the earth system.
5.5 Tenderer shall quote separately for :
i) surge monitor, and
ii) insulating base.
5.6 Name Plate
Each lightning arrester shall be provided with name plate legibly and indelibly
marked with the following information :
ontinuous operating voltage.
i) Rated voltage.
ii) Rated frequency.
iii) Nominal discharge current.
iv) Long duration discharge current.
v) Pressure relief class.
vi) Manufacturer’s name or trade-mark, type and identification.
vii) Year of manufacture.
viii) Purchase order number.
5.7 The lightning arrester shall be suitable for outdoor installation where the maximum
temperature attainable by an object exposed to sun is 65 deg. C. If required, the
manufacturer shall use a porcelain of light colour instead of brown colour to avoid
over-heating of the internal components of the arrester, for its satisfactory service.
246
6.0 TYPE TESTS
Following type tests shall be carried out in accordance with draft IEC TC 37 WG4
January 87 to prove the general quality of design and its conformity with the
specifications.
i) Power frequency reference voltage test.
ii) Residual voltage tests :
a) Steep current impulse residual voltage test,

b) Lightning impulse residual voltage test,
c) Switching impulse residual voltage test.
iii) Long duration current impulse withstand test.

iv) Operating duty tests :
a) Accelerated ageing test,

b) Heat dissipation behaviour of test samples,
c) Switching surge operating duty test,
d) Evaluation of thermal stability in operating duty test.
e) Power frequency voltage versus time characteristics of arrester.
v) Pressure relief test,

vi) Artificial pollution test,
vii) Insulation withstand tests:
a) Lightning impulse voltage test,

b) Power frequency voltage test.
viii) Other miscellaneous tests :

a) Galvanising test on metal parts,
b) Porosity test on porcelain components,
c) Temperature cycle test on porcelain housing,
d) Visual Examination of porcelain housing.
247
6.1 Power frequency reference voltage test :
This test shall be carried out at power frequency voltage and at an ambinet
temperature of 20 + / - 15 dec. C. The reference voltage shall be measured at defined
current at the knee of the current voltage characteristic of the arrester. The crest value
of the resistive component of the above defined arrester current shall be in the range
of 1 to 20 mA, depending on the nominal discharge current and / or long duration
discharge class of the arrester.
In addition, the resistive and capacitive component of the leakage current shall be
measured at continuous operating voltage.
6.2 Residual voltage tests
The test shall be made on three samples of complete arrester or arrester sections. The
time between discharge must be sufficient to permit the sample to return to
approximately ambient temperature. The maximum envelope of the test points shall
be drawn in a residual voltage / discharge current curve.
6.2.1 Steep current impulse resiudal voltage test :
A current impulse with 1 micro-second virtual front time shall be used with limites in
the adjustments of equipment of + / - 10%. The virtual time to half value on the tail
shall be not longer than 20 micro second. One current impulse with peak value equal
to the nominal discharge current of the arrester + / - 5% shall be applied to each
sample.
6.2.2 Lightning impulse residual voltage test :
A 8/20 current impulse shall be used with limits on the adjustments of equipment
such that the measured values are from 7 micro second to 9 micro-second for the
virtual front time and from 18 micro-second to 22 micro-second for the time to half
value on the tall. Three current impulses shall be applied to each sample with peak
values of approximately 0.5, 1.0 and 2.0 times the nominal discharge current of the
arrester.
6.2.3 Switching impulse residual voltage test :
Two current impulses of approximately 250 and 1000 Amps (peak) + / - 5% having a
virtual front time greater than 30 micro-second but less than 100 micro-second, and a
virtual time to half value on the tail of roughly twice the virtual front time shall be
applied to each of the three samples.
6.3 Long duration current withstand test :
This test shall be carried out on three new samples of complete arresters, arrester
sections or resistor elements, as per clause 59.1.2 of IEC – TC 37 WG 4 January 1987
(Draft). The rated voltage of the test samples shall be at least 3 kV and need not
exceed 6 kV. The test shall consist of 18 discharge operations divided into six groups
of 3 operations. Intervals between operations shall be 50 to 60 seconds and between
groups such that the device cools to near ambient temperature.
248
6.4 Operating duty tests :
Two test shall be made on three samples of complete arresters or arrester sections.
The rated voltage of the test samples shall be at least 3 kV and need not exceed 12
kV. The power frequency test voltage to be applied to the test arrester section shall
be the voltage of the complete arrester divided by the total number of similar arrester
sections.
6.4.1 Accelerated ageing test :
This test procedure is designed to determine the voltage value UC* and UR* used in
the operating duty tests (See Annexure – B), which will allow those tests to be carried
out on new resistors.
6.4.1.1 Test procedure
Three resistor samples shall be stressed at a voltage equal to the continuous operating
voltage of the sample for 1000 house, during which the temperature hall be controlled
to keep the surface temperature of the resister at 115 + / - 4 dec. C.
During this accelerated ageing the resistor may be in the surrounding medium used in
the arresters. In this case, the procedure shall be carried out on single resistors in a
closed chamber where the volume of the chamber is at least twice the volume of the
resister and where the density of the medium in the chamber is not less than the
density of the medium in the arrester.
If the manufacturer can prove that this procedure carried out in open air is equivalent
to the procedure carried out according to the above paragraph, then the procedure can
be carried out in open air.
The relevant voltage for this procedure is the corrected maximum continuous
operating voltage (UCT) which the resisters must support in the arrester including
voltage unbalance effects. This voltage should be determined from the formula :
UCT = UC (1 + 0.03L)
where L is the total length of the arrester in metres, and UC is the continuous
operating voltage of the arrester.
The ageing procedure described above shall be carried out on 3 typical samples of
resistor elements.
6.4.1.2 Determination of elevated rated and continuous operating voltages.
The three test samples shall be heated to 115 + / - 4 deg. C and the resistor power
losses P1CT shall be measured at a voltage UCT, 1 to 2 hours after the voltage
application. The resister power losses P2CT shall be measured after 1000 h (-0 + 100
h) of ageing under the same conditions without intermediate de-energising of the test
samples. Within the temperature range allowed both measurements shall be made at
the same temperature + / - 1 deg. C.
249
If P2CT is greater than P1CT the ratio KCT = P2CT / P1CT, is determined for each sample.
In such case, when testing for the operating duty tests the continuous operating
voltage UC and the rated voltage UR shall be increated to UC* and UR* respectively, in
order to match the increase of power losses due to ageing. If P2CT is equal or less than
P1CT, UC and UR should be used without any correction.
UC* and UR* are the highest of three values respectively, determined in the following
way :
On three new resistors at ambient temperature the power losses P1C and P1E shall be
measured at UC and UR respectively. Thereafter the voltage shall be increased to UC*
and UR* so that the corresponding power losses P2C and P2R fulfil the relation:
P2C P2R
------ = KCT : ---------- = KCT
P1C P1R
Where KCT is the biggest of three power loss ratios determined in the ageing test.
The measuring time should be short enough to avoid increased power loss due to
heating.
6.4.2 Heat dissipation behaviour of test sample
The test samples shall meet the requirements of Clause 60.3 of IEC – TC – 37 WG –
4 (Draft) January 1987.
6.4.3 Switching surge operating duty test :
6.4.3.1 General
Before the switching surge operating duty test, the lightning impulse residual voltage
at nominal discharge current of each three test samples (resister elements) shall be
determined at ambient temperature.
Thereafter, the samples shall be exposed to a conditioning test consisting of twenty
current impulses with a time interval between the impulses of 50 to 60 seconds and
having an 8 / 20 impulse shape and peak value equal to the nominal discharge current
of the arrester. This first part of the conditioning may be carried out of the resistor
elements in open air at a still air temperature of 20 + / - 15 deg. C. This is followed
by two high current impulses of 65 kA, 4/ 10 microsecond impulse shape. The
measured peak value of the current impulses shall be within 90% and 110% of the
specified peak value. After this conditioning the sections are stored for future use in
this switching surge operating duty test (Annexure – B).
At the beginning of the switching surge operating duty test the temperature of the
complete section shall be 60 + / - 3 deg. C.
250
The arresters shall be subjected to two long duration current impulses as specified in
clause 6.3. The time interval between the impulses shall be 50 to 60 seconds. The
conditioning impulses and the long duration current impulses shall be applied with
the same polarity.
After the second long duration current impulse the section shall be disconnected from
the line and connected to the power frequency source instantaneously, but not later
than 100 milliseconds after the impulse. The corrected rated voltage (UR) and the
corrected continuous operating voltage (UC) determined from the accelerated against
procedure describe shall be applied for a time period of 10 seconds and 30 minutes
respectively to prove thermal stability or thermal run-away.
Non-linear metal oxide resistor temperature or resistive component of current or
power dissipation shall be monitored during the power frequency voltage application
to prove thermal stability or thermal run-away.
Oscillographic records of the voltage and current through the test, sample shall be
made at the second long duration current impulse. The energy dissipated by the test
sample during the second operation shall be determined from the voltage and current
oscillograms and the energy value shall be reported in the type test report. The
current and voltage shall be registered continuously during the power frequency
voltage, application.
Following the complete test sequence and after the test sample has cooled to near
ambient temperature the residual voltage tests which were made at the beginning of
the test sequences, shall be repeated. The complete test sequence is illustrated in
Annexure – B.
The arrester has passed the test if thermal stability is achieved (Ref : Clause 6.4.4), if
the change in residual voltage measured before and after the test is not hanged by
more than 5 % and if examined of the test samples after the test removals no evidence
of puncture, flashover or crack of the non-linear metal resistors.
6.4.4 Evaluation of thermal stability in the operating duty tests :
The arrester sections subjected to the operating duty tests are considered to be
thermally stable and pass the test if the peak of the resistive component of the
leakage current or power dissipation or resistor temperature is stabilised or steadily
decreases at least during the last part of the 30 minutes of UC* voltage application in
the procedures shown in Annexure – B.
6.4.5 Power frequency voltage versus time characteristics of an arrester :
The manufacturer shall furnish the information as required by Clause 60.7 of IEC TC
37 WG – 4 January 1987 (Draft).
6.5 Pressure Relief Test :
This test shall be carried out as per Clause 7.11 of IS 3070 (Pt. I).
6.6 Artificial Pollution Test :
This test is made to show that the temperature rise of the non-linear metal oxide
resistor elements of the arrester does not exceed the value on which the operating
251
duty tests are based on which the specified life performance characteristics of the
arrester are based.
The salt –fog / solid layer method prescribed in IS : 8704 – 1978 shall be adopted for
carrying out this test.
The testing procedure is as follows :
The complete arrester shall be energised at its continuous operating voltage. At
different salinities which correspond to non-significant pollution, light pollution,
heavy pollution and very heavy pollution (refer IS : 3716 – 1976 – Table – 2), the
steady state temperature on the non-linear metal oxide resistors at different points of
the arrester shall be measured.
The temperature on the non-linear metal oxide resistance may be measured by
thermocouples through holes in the arrester housing, that may to a negligible extent
change the conditions of heat dissipation from the resistors. Alternatively, the
temperature on the non-linear metal oxide resistors can be registered with temperature
sensitive tape built – in on the arrester assembly.
6.7 Insulation withstand test :
This test demonstrate the voltage withstand capability of the external insulation of
separately housed arresters.
6.7.1 Fifteen consecutive impulses at the test voltage value shall be applied for each
polarity. The arrester shall be considered to have passed the test if no internal
disruptive discharges occur and if the number of the external disruptive discharge
does not exceed two for each series of 15 impulses.
6.7.2 Power frequency voltage test :
This test shall be carried out as per Clause 7.5 of IS : 3070 (Pt. I)
6.8 Other miscellaneous tests :
6.8.1 Galvanising test on metal parts :
This test shall be carried out as per Clause 7.15 of IS : 3070 (Pt. I).
6.8.2 Porosity test on Porcelain components :
6.8.3 Temperature cycle test on porcelain housing :
The test shall be carried out as per Clause 7.13 of IS 3070 (Pt. I)
6.8.4 Visual examination of porcelain housing :
252
7.0 Before giving the call to RDSO / The Chief Electrical Engineer for inspection and
testing of the prototype of the system, the manufacturer shall submit a detailed test
schedule consisting of schematic circuit diagrams for each of the test and nature of
the test, venue of the test and the duration of each test and the total number of days
required to complete the test at one stretch. Once the schedule is approved, the test
shall invariably be done accordingly. However, during the process of type testing or
even later, RDSO representative reserves the right to conduct any additional test (s)
besides those specified herein on any equipment / sub-system or system so as to test
the system to his satisfaction or for gaining additional information and knowledge. In
case any dispute or disagreement arises between the manufacturer and RDSO / the
Chief Electrical Engineer during the process of testing as regards the type tests and /
or the interpretation and acceptability of the type test results, it shall be brought to the
notice of the Director General (Traction Installations), RDSO / the Chief Electrical
Engineer as the case may be, whose decision shall be final and binding.
8.0 Bulk manufacture of the lightning arrester shall be taken up only after specific written
approval is given by the purchaser to the successful tenderer on the basis of the tests
conducted on the prototype unit manufactured according to approved design and
drawings.
(a) Measurement of power frequency reference voltage.
(b) Lightning impulse residual voltage test at nominal and twice the nominal
discharge current..
(c) Partial discharge test: The power frequency voltage applied to the arrester
shall be increased up to its rated voltage and after less than 10 seconds
decreased to 1.05 times its continuous operating voltage. At that voltage the
partial discharge level according to IEC Publ. 270 shall be measured. The
measured value shall not exceed 50 pc.
10.0 ROUTINE TESTS
(a) Visual examination.
(b) Measurement of power frequency reference voltage.
(c) Lightning impulse residual voltage test at nominal discharge current of 10 kA.
(d) Measurement of leakage current at continuous operating voltage.
(e) Satisfactory absence from partial discharges and contact noise by any
sensitive method
253
11.0 TESTS ON SURGE MONITOR AND INSULATING BASE
While carrying out the prototype tests on the lightning arrester, following tests shall
also be done on the surge monitor and insulating base :
11.1 Surge monitor :
(i) Tests for satisfactory operation of surge counter while discharging surges.
(ii) Tests for correctness of leakage current meter before and after the passage of
surges.
(iii) Visual examination tests.
The above tests shall also form part of the routine tests.
11.2 Insulating base :
On the prototype insulating base, all tests stipulated vide Clause 6.8 above shall be
carried out. During routine tests, only visual examination of the insulating base shall
be done.
12. TECHNICAL DATA AND DRAWINGS
12.1 The tenderer shall indicate his compliance or otherwise against each clause and sub-
clause of the technical specification. The tenderer shall for this purpose enclose a
separate statement, if necessary, indicating the clause reference and compliance or
otherwise. Wherever the tenderer deviates from the provisions of the clauses, he shall
furnish his detailed remarks.
12.2 The tenderer shall furnish guaranteed performance data, technical and other
particulars for the lightning arresters in the proforma attached as Annexure – A.
12.3 The information furnished in Schedule of guaranteed technical, performance, data and
other particulars shall be complete in all respects. If there is any entry like “shall be
furnished later” or blanks are left against any item, the tender is not likely to be
considered as such omissions causes delays in finalising the tender.
12.4 Drawings showing the overall dimensions of the lightning arrester, a cross-sectional
view indicating non-linear resistor blocks, retainer arrangement, terminal details,
method of connecting high tension on earthing leads and mounting arrangements and
evidence in the form of type test reports for the arrester, if available, shall be
submitted along with the tender.
12.5 The successful tenderer shall be required to submit the above mentioned detailed
dimensioned drawings for approval and shall also furnish six copies of the approved
drawings along with copies of transparent reproducible prints, as per Railway
Standards. (Standard proforma enclosed as Appendix – III – B).
254
12.6 The successful tender shall also be required to submit, copies of the technical
booklets, information manuals, test reports etc.
13.0 TECHNICAL COLLABORATION & INDIGENISATION
Progressive indigenisation of lightning arresters covered by this specification, is

contemplated. Design calculations, detailed manufacturing process and all relevant
information pertaining to transfer of technical know-how in this regard will be carried
out in such a manner between the overseas manufacturer and the Indian Manufacturer
as to ensure that the indigenous content of the lightning arrester made in India
increases progressively and rapidly without sacrificing quality and reliability.
Research Designs & Standards Organisation of the Indian Railways are to be
associated at various stages of indigenisation so as to take into account service
experience stages of indigenisation so as to take into account service experience while
attempting progressive indigenisation.
14.0 WARRANTY
14.1 All lightning arresters supplied against this contract irrespective of origin
(imported/indigenous) shall be guaranteed for trouble-free and fully satisfactory
performance for a period of 24 months from the date of supply or 18 months from the
date of commissioning, whichever is earlier. Details of the warranty clause, the
extent of responsibility on the part of the supplier and other relevant aspects will be
included in the contract. The tenderer may furnish his detailed terms in this regard in
his offer.
14.2 The supplier shall make necessary arrangement for close monitoring of performance
of lightning arresters through periodical visits to traction power sub-station/switching
posts for observations.
14.3 Technical guidance and assistance for proper operation and maintenance, trouble-
shooting investigation and generally all aspects of technical liaison that may be
required, shall also be organised by the supplier.
-----------------
This supersedes Specification numbers ETI / PSI / 53 (8 / 79) ETI / PSI / 42 (8/75),
ETI / PSI / 18 (8/75), ETI / PSI / 82 (2/87) with Addendum & Corrigenum Slip No. 1
issued in March 87 and ETI / PSI / 89 (4 / 87).
……………………………
255
ANNEXURE – A
SPECIFICATION NO. ETI / PSI / 89 (8 / 89) FOR LIGHTNING ARRESTER.
SCHEDULE OF GUARANTEED PERFORMANCE,
TECHNICAL AND OTHER PARTICULARS.
-------------------------------------------------------------------------------------------------------------
Sl.No. Description Unit of measurement
(1) (2) (3)
----------------------------------------------------------------------------------------------------------------
1. Name of the manufacturer.
3. Standard specification on which performance is based.
5. Rated voltage (rms). kV
6. Continuous operating voltage. kV
7. Watt-loss at continuous operating voltage. Watt / kV
256
8. Watt – loss at rated voltage. Watt / kV
9. Leakage current at C.O.V. mA
10. Leakage current at rated voltage mA
11. Rated frequency. Hz
12. Nominal discharge current (8/20 microsecond wave). kV
13. Residual voltage :
a) at 0.5 times nominal discharge current. kV (peak)
b) at nominal discharge current. kV (peak)
c) at twice the nominal discharge current. kV (peak)
14. Switching impulse residual voltage test with 45 x 90 kVp
microsecond current wave of 250 Amp & 1000 Amp.
15. Steep current impulse residual voltage test with 1 kVp
microsecond front time current wave of 10 kA peak.
16. High current impulse withstand (4/10 microsecond wave). kAp
17. Long duration current impulse rating :
257
a) Peak current. A Microsecond.
b) Virtual duration of peak.
c) Line discharge class of arrester.
18. Power frequency voltage withstand of arrester insulation
(rms).
kV
a) Dry.
kV
b) Wet.
19. Lightning impulse withstand voltage of arrester. kVp
20. Type of non-linear resistor disc, size (dia, height) and Dia mm Height mm kV
voltage rating.
21. No. of non-linear discs per section of arrester. No.
22. No. of sections in one arrester. No.
23. Material of retainer use inside lightning arrester bakelite,
ceramic, rubber or other material.
24. Is pressure relief device provided, if so, its class?
258
25. Overall dimensions :
a) Height mm
b) Diameter. mm
26. Net weight
27. Mounting base :
i) No. of holes. No.
ii) Dia of holes. mm
iii) Pitch circle dia. mm
28. Are the live and earth ends of arrester suitable
jumper/flats as specified?
29. Are grading rings provided?
30. V – I characteristic curves of the Zn0 element at different
temperatures.
31. Any other technical data, the manufacturer may like to
furnish.
259
ANNEXURE – B
Operating duty test for 10,000 A arresters line discharge Class 3, Clause 6.4.3.
Residual voltage measurement at In 8 / 20 1 x In 8 / 20
Time interval not specified.
Conditioning test 20 imp at In 8 / 20 20 x In 8 / 20

Conditioning.
1 Minute interval
Time interval not specified.
High current impulse conditioning on sections. 2 x 65 kA 4 / 10
Cooling to ambient temp. High current impulse
conditioning on sections.
Switching surge operating duty test
Hold for future use.
Cool to or preheat to 60 + 30 C
Long duration current impulse.
50 – 60 seconds.
Long duration current impulse.
260
As short as possible. Not longer than 100 m sec.
Rated voltage, 10 seconds. UR *
Continuous operating voltage 30 minutes. UC *
0
Cool to ambient 25 + 10 C
Residual voltage measurement at In 8 / 20 1 x In 8 / 20
Examination of test samples.
In. = nominal discharge current.
261
Sept. ` 1990
ADDENDUM & CORRIGENDUM SLIP NO. 1 TO SPECIFICATION NO. ETI / PSI /

137 (8 /89) FOR METAL OXIDE GAPLESS TYPE LIGHTNING ARRESTER FOR
USE ON 220 kV, 132 kV, 110 kV, 66 kV SIDE OF RAILWAY AC TRACTION SUB-
STATIONS.
__________________________________________________________________________
Page – 7, Artificial pollution test
Clause – 6. 0 (vi) :
Delete the clause.
Page – 12, This clause may be re-read as under : -

Clause – 9. 0 (d) :
“Lightning impulse residual voltage on the complete arrester
or arrester unit at nominal discharge current if possible or at
current value in the range of 0.01 to 0.25 times nominal
discharge current of the lightning arrester”.
Page – 14, This clause may be re-read as under : -

Clause – 10.0 (c) :
“Lightning impulse residual voltage test either on complete
arrester, assembled arrester unit on or single or several
register elements at a suitable lightning impulse current in
the range between 0.01 & 2 times the nominal current at
which the residual voltage is measured”.
Page – 14, Add “ (f) leakage check by any sensitive method to see the
Clause – 10.0 : efficacy of the sealing system”.
----------------------------
262
FEBRUARY 1991.
Addendum & Corrigendum Slip No. 2 to Specification. No. ETI / PSI / 137 (8 / 89) for
metal oxide gapless type lightning arrester for use on 220 kV, 132 kV, 110 kV, 66 kV
side of railway a.c. Traction Sub-stations.
Page – 6 This clause may be re-read as under :

Clause 5.6 (viii) “Month & year of manufacture ”.
“ (X)
Page – 6 Add : manufacturer’s

Clause 5.6 Serial number.”
263
DECEMBER 1991
Addendum & Corrigendum slip No. 3 to Specification No. ETI / PSI / 137 (8 / 89) for
side of Railway a.c. traction Sub-stations.
----------------------------------------------------------------------------------------------------------------
S. No. Clause No. & description. As amended
----------------------------------------------------------------------------------------------------------------
1. Page 5, Clause 5.2.5 Substitute the following for the existing matter : -
“5.2.5 – all ferrous parts used in manufacture of

lightning arrester, its assembly and the insulating
bass shall be hot-dip galvanized. All fasteners of
diameter upto 12 mm shall be of stainless steel
conforming to grade 04 Cr 17 Ni 12 M02 of IS :
1570 Pt. V and those above 12 mm shall
preferably be of stainless steel or of mild steel hot
dip galvanized to RDSO’s specification. No. ETI /
OHE / 18 (4 / 84).”
2. Page No. 13 Substitute the following with the existing matter.

Clause - 6.8.1 “6.3.1 – Galvanising tests on metal parts.
3 samples of the cut pieces of galvanized

component shall be tested for conformity to RDSO
specification. No. ETI / OHE / 13 (4 / 84)”.
3. Page No. 17
Anexure ‘A’ 6. No. 5 Substitute the following with the existing matter : -
“5
(i) Rated voltage (r.m.s.) - kV
(ii) Rated frequency – Hz.”
4. Page. No. 17
Annexure ‘A’ S. No. 11 Substitute the following with the existing matter : -
“11
(i) Rated voltage of the Section (metal
Oxide disc.) – kV
(ii) Maximum power frequency reference
voltage of the section – kV.
(iii) Minimum power frequency reference
voltage of the section – kV
Reference current of the lightning arrester – ma”.
264
AUGUST 1994
metal oxide gapless type lightning arrester for use on 220 kV, 132 kV, 110 kV and
66 kV side of Railway AC traction Sub-station.
----------------------------------------------------------------------------------------------------------------
S. No. Clause No. & description. As amended
----------------------------------------------------------------------------------------------------------------
1. Page 7, Artificial Pollution Test : -

Clause 6.0 (vi)
Add this test. This test is to be carried out as per
ANSI / IEEE C6 2.11.1987.
2. Page 6, Add this clause after clause 5.4.

Clause 5.4.2
“Surge Monitor shall be provided only on 198 kV
Lightning Arrestor.”
3. Page 6, Existing line may be read as under :

Clause 5.3,
Para 1, “Shall be supplied by the manufacturer with
Line 2. 198 kV lightning arrestor only.”
265
APRIL 2001
and 22 kV side of Railway AC traction Sub-station.
S. No. Clause No. & As amended

description
1. Clause 1.1 This clause may be re-read as under :
This specification covers the design, manufacture, testing and

supply of metal oxide gapless type lightning arrester intended for
outdoor installation for protection of 220 kV / 25 kV or 132 kV / 25
kV or 110 kV / 25 kV or 66 kV / 25 kV or 22 kV / 25 kV single
phase, 50 Hz transformer and other equipment of 245/ 132/ 110 /66
/22 kV class installed in traction substation.
2. Clause 3.1 First line of this clause may be re-read as under :
The single phase, 50 Hz power supply for Railway traction at 25kV

is obtained from 220/132/110/66 & 22 kV three phase grid system
through a step down / step up single phase power transformer. The
primary winding of which is connected to between two of the
phases of 3φ effectively earthed transmission line network of the
electricity Board.
3. Clause 3.1.1 Second last line of this clause may be re-read as under :
The incoming 220/132/110/66/22 kV power supply may vary

between +10% and –12.5% as per IE rule no. 5.1.
4. Clause 3.3 Add the following in existing table : 22 kV

i) one minute power frequency 50
withstand voltage in kV rms.
ii) 1.2/50 micro second impulse 125

withstand voltage kVp.
5. Clause 3.4 Impedance of traction transformer. This clause may be re-read as

under :
The % impedance of 20 MVA, 220 kV / 25 kV or 132 kV / 25 kV
or 110 kV / 25 kV or 66 kV / 25 kV or 22 kV / 25 kV traction
transformer at the principal tap position is (12 = / - 0.5 ) %. Only
one transformer is in service at a time.
266
6. Clause 3.5 Add in this clause as under : 22 kV
Maximum fault in MVA 1000
7. Clause 5.1 Add the clause as under :
i. System ------------------------------ do ----------------------------

ii. Nominal system voltage (phase to phase) 22 kV
iii. Permissible variation 22+10%
- 12.5%
iv. Rated frequency 50 Hz
v. Type of lightning arrester ---------- do --------------------------
vi. Line discharge class 2
vii. Continuous operating voltage (phase to earth) 15 kVrms
viii. Maximum discharge voltage at nominal 56 kVp
discharge current.
ix. Nominal discharge current (8/20 wave) 10 kA
x. Power frequency voltage withstand for 50 kVrms
Arrester insulator
xi. Pressure relief class. A
8. Clause 5 Add the existing clause as under :
No. of bolts (equally spaced) 3(120° apart) 3(120° apart)

Size of bolts M-16 M-16
Pitch circle diameter 222 222
267
RDSO Specification No. ETI / PSI / 137 / (8/89) Specification for 110 kV
Lightning Arrestor.
The following amendments are made in addition to the addendum and corrigendum
slips issued to the specification.
1. Para 3.1 In line 8, substitute 40 km and 50 km with 6.5 km and 25

km
2. Para 3.1.1 In line 8, substitute the word “interrupter” with the

word
“Circuit Breaker”.
3. Para 4.1 In line 5, Substitute 0°C with 5°C

In line 12, substitute 200 Kg./sq.mm with 112.5
kg/sq.mm.
4. 5.2.4 In line 5, substitute 45 x 6 mm with 50 x 6 mm
5. 5.4 In line 10, substitute 45 x 6 mm with 50 x 6 mm
6. 5.5 Deleted.
7. 13.0 Deleted.
8. 14.1 In line 3, substitute “24” with “36”
and “18” with “24”
Delete the sentences starting with “Details of the

warranty clause” ………till ……. “in this regard in his
offer”
268
SPECIFICATION
FOR
LIGHTNING ARRESTER –
METAL OXIDE GAPLESS TYPE
No. ETI / PSI / 71 REV.5 (1 / 87)
269
Specification No. ETI/PSI/71 Rev. 5 (1/87)
GOVERNMENT OF INDIA
MANAK NAGAR, LUCKNOW – 226011 (INDIA)
SPECIFICATION
FOR
METAL OXIDE GAPLESS TYPE
LIGHTNING ARRESTER
FOR USE ON 25 KV SIDE OF
RAILWAY TRACTION SUBSTATIONS
AND
SWITCHING STATIONS
ISSUED BY

MINISTRY OF RAILWAYS, MANAK NAGAR,
LUCKNOW – 226011 .
270
GOVERNMENT OF INDIA
RESEARCH, DESIGN & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW 226 011
Specification No. ETI/PSI/71 Rev. 5 (1/87)
LIGHTNING ARRESTER – METAL OXIDE GAPLESS TYPE
1.0 SCOPE
1.1 This specification covers the design, manufacture, testing and supply of metal oxide
gapless type lightning arresters intended for outdoor installation at traction
substations and switching stations on Indian Railways for protection of various
electrical equipments installed at these stations.
GOVERNING SPECIFICATION
As no national or international standard has been finalised on the subject till date,
limited assistance has been taken from the following standards / documents while
preparing this specification :
i) IS : 3070 (Pt.I) – 1985 Non-linear resistor type lightning arresters

(Rev. II).
ii) IEC Publication 99 Lightning arresters. Pt. I; Non-Linear
resistor type arresters for ac systems
iii) IS : 2629 – 1966 Recommended practice for hot dip

galvanising of iron & steel.
iv) IS : 2633 – 1972 Methods of testing uniformity of coating on

zinc coated articles (Rev. I).
v) IS : 5358 – 1969 Hot-dip galvanised coating on fasteners.
vi) IS : 2099 – 1973 Bushing for alternating voltages above 1000

volts (Rev. I) with Amendment No. 1.
vii) IS : 5621 – 1980 Hollow insulators for use in Electrical

equipment (Rev. I).
viii) IS : 5561 – 1970 Electric power connectors.

ix) IEC Draft Specn. No. Methods for artificial pollution test on high
TC 37 WG 4 (April 86) voltage insulators for use on a.c. systems.
x) IS 1570 (pt-V) – 1972 Schedule for wrought steels, stainless and
heat resisting steels (PT-V).
xi) IS 8704 – 1978 Methods for Artificial pollution test on high
voltage insulators for use on ac systems.
271
2.2 Any deviation from this specification calculated to improve the performance, utility
consideration, provided full particulars with justification thereof are furnished.
3.0 TRACTION POWER SUPPLY SYSTEM
3.1 General.
Signal phase, 50 Hz power supply for railway traction at 25 kV is obtained from
132 / 25 kV single phase traction power transformer, the primary winding of which
is connected between any two phases of 132 kV three phase effectively earthed
transmission network of the Electricity Board. Two of the three phase are tapped in
a cyclic order, for feeding successive substations to balance the load on the 132 kV
system. The spacing between adjacent substation is normally between 50 and 80
km. One terminal of the 25 kV secondary winding of the traction transformer is
connected to the overhead equipment (abbreviated as OHE) and the other solidly
earthed and connected to the running rails. The load current flows through the OHE
to the locomotives and returns through rail and earth to the substation. In the middle
of adjacent substations a dead zone known as the “neutral section” is provided to
avoid phase-to-phase short. The power to the OHE on one side of the substation is
fed by one feeder circuit breaker and each track controlled by an interrupter. In case
of fault on the OHE the feeder breaker clears the fault. A typical schematic diagram
showing the general feeding arrangement of a traction system, as well as the
schematic general arrangement at a traction substation, is given in sketch No.
ETI/PSI/702 enclosed at Appendix–II. The incoming 132 kV supply voltage may
vary between ± 12.5% as per the standard clause.
3.2 Protection system.
3.2.1 The following relays are provided for the protection of 220 kVside of traction
transformer :
d) Differential protection, English Electric Relay, Type DDT-12.
e) IDMT over current protection, English Electric Relay, Type CDG-26 on 132
kV side.
f) Restricted earth fault protection, English Electric Relay, Type CAG-14 on
132 kV side.
g) IDMT over current English Electric Relay, Type CDG-16 on 25 kV side.
h) Restricted earth fault English Electric Relay, Type CAG-14 on 25 kV side.
3.2.2 The following relays are provided for the protection of OHE.
a) Differential protection, English Electric Relay, Type YCG-14.
b) Instantaneous over current protection, English Electric Relay, Type CAG-
17.
c) Wrong-phase coupling protection, English Electric Relay, Type YCG-14.
3.3 Insulation levels.

Basic insulation levels of the equipments provided at the substation are given in
Appendix-I.
272
3.4 Impedance on 25 kV OHE.
3.4.1 The OHE is made up of a stranded cadmium copper catenary of 65 mm2 and a
grooved copper contact wire of 107 mm2, making up a total of 150 mm2 copper
equivalent. The values of loop impedance with earth return for the OHE are as
under :
i) Single track OHE - 0.52 / 70º Ohms/km

ii) Double track OHE - 0.32 / 70º Ohms/km
iii) Single track OHE
with return conductor - 0.75 / 70º Ohms/km
iv) Double track OHE
with return conductor - 0.45 / 70º Ohms/km
3.5 Impedance of traction transformer.
The resistance and reactance of earth traction power transformer at the traction
substation are 0.179 Ohms and 5.49 Ohms respectively. Only the transformer is in
service at a time.
3.6 Electrical clearance.
Normally a clearance of 500 mm is provided between any live part at 25 kV and

earth.
3.7 Nature of faults on the OHE System
3.7.1 OHE is subjected to frequent earth faults caused by failure of insulation or snapping
of OHE and its touching the rail or earth, or loose wires carried by birds coming in
contact with OHE below overline structures, miscreant / activities etc. These faults
are cleared by the feeder circuit breaker which operates on any one or both of the
following relays depending on the proximity of the fault:
a) Distance protection Mho relay
b) Instantaneous over-current relay.
3.7.2 Inadvertent coupling of two phases between adjacent substations at the neutral
section or at intermediate switching stations in case of extended feed, causes short
circuit. This is cleared by tripping of one of the feeder breakers at the two ends
through a ‘Mho relay’ known as ‘Wrong phase coupling relay’.
Short circuit level.
The 132 kV source impedance may be based on a three phase symmetrical short
circuit level between 1000 to 2000 MVA. The level of short circuit on the 25 kV
side for a fault in the vicinity of a substation could be around 100 MVA or more.
273
3.8 Surges.
From the tests conducted on the over head equipment it has been established that
short duration switching surges are generated while carrying out various switching
operations. Magnitude of these surges are measured during some tests, is around
120 to 130 kV peak.
4.1 The equipments would be in use in moist tropical climate and in areas subjected to
heavy rain-fall and severe lightning in India. The atmospheric conditions are given
below:
Max. temperature of air in shade - 45 °C
Min. temperature of air in shade - 0 °C
Max. temperature attainable by

an object exposed to sun. - 65 °C
Max. relative humidity - 100 %
Average annual rainfall - 1750 to 6250 mm
Max. no. of thunder-storm days

per annum - 85
Max. number of rainy days

per annum - 120
Max. wind pressure - 200 Kg/sq.m2.
Max. altitude - 1000 meters.
4.2 They are also subjected to chemical pollution from the effluent gases of chemical
plants exhaust of steam / diesel locomotives and to saline atmosphere in coastal
areas.
4.3 Vibrations:
The equipment being installed on steel structure located by the side of railway
tracks, are subject to vibrations with the passage of trains. The amplitude of these
vibrations lies in the range of 30 to 150 microns, with instantaneous peaks going up
to 350 microns. These vibrations occur with rapidly varying time periods in the
range of 15 to 70 ms.
274
5.0 TECHNICAL SPECIFICATION.
5.1 Rating and other particulars.
i) System Single phase a.c. traction.
ii) Nominal system voltage 25 kV (phase to earth)
iii) Possible variation in the 22.5 to 27.5 kV (sometime touching

Traction supply voltage 30 kV)
iv) Rated frequency 50 Hz
v) Type of lightning Non linear, metal oxide resistor type,

arrester. without gap.
vi) Line discharge class Class 3
vii) Continuous operating 35 kV rms

voltage capability
viii) Max. discharge voltage 125 kVp

at nominal discharge current.
ix) Nominal discharge 10 k Amps.

current (8/20 wave)
x) Pressure relief class Class-A
xi) Power frequency 105 kV (rms)

voltage withstand for
arrester insulator.
5.2 Construction.
5.2.1 The lightning arrester shall comprise a number of non-linear resistor blocks, housed
inside the porcelain housing. Suitable provision to arrest the relative movement of
blocks shall be provided inside the porcelain housing. Lightning arrester shall be of
hermetically sealed construction to prevent moisture ingress. The arrester shall have
means for relieving internal pressure to prevent explosive shattering of the housing.
The pressure relief device shall be of the Class-A as per IS:3070 (Pt.1) – 1974.
5.2.2 The arrester shall have base support suitably designed for mounting on a base plate
over a steel supporting structure with three MS 14 bolts in a triangular formation on
a PCD of 274 mm.
5.2.3 The arrester shall be provided with a terminal connector conforming to IS:5561.
The connector shall be of robust design and as per approved drawing suitable for
securing an all-aluminium “Spider” conductor on the live side. Suitable provision
275
on the earth side of the arrester shall be made for connecting two numbers 45 x 6
mm MS flats. An earthing pad with two holes of 13.5 mm dia. is preferable.
5.2.4 All ferrous parts used in manufacture of lightning arrester or its assembly shall be
hot-dip galvanised. Hardware of diameter less than 12 mm shall be made out of
stainless steel conforming to grade 04 Cr17 Ni12 Mo2 of IS:1570 Pt.V – 1972.
5.3 Name Plate.

Each lightning arrester shall be provided with name plate legibly and indelibly
marked with the following information:
i) Continuous operating voltage.
ii) Rated voltage.
iii) Rated frequency.
iv) Nominal discharge current.
v) Long duration discharge class.
vi) Pressure relief class.
vii) Manufacturer’s name or trademark, type and identification.
viii) Year of manufacture.
ix) Purchase order number.
5.4 The lightning arrester shall be suitable for outdoor installation where the maximum
temperature attainable by an object exposed to sun is 65 °C. If required, the
manufacturer shall use a porcelain of light colour instead of brown colour to avoid
overheating of the internal components of the arrester, for its satisfactory service.
6.0 TYPE TESTS

Following type tests shall be carried out in accordance with draft IEC TC 37 WG4
April 86 to prove the general quality of design and its conformity with the
specifications.
i) Power frequency reference voltage test.
ii) Residual voltage tests:
a) Steep current impulse residual voltage test
b) Lightning impulse residual voltage test
c) Switching impulse residual voltage test.
iii) Long duration current impulse withstand test.
iv) Operating duty tests:
a) Accelerated ageing test
b) Heat dissipation behavior of test samples
c) Switching surge operating duty test
d) Evaluation of thermal stability in operating duty test
e) Power frequency voltage versus time characteristics of arrester.
v) Pressure relief test.
vi) Insulation withstand tests:
a) Lightning impulse voltage test
b) Power frequency voltage test.
vii) Other miscellaneous tests:
a) Galvanising test on metal parts
b) Porosity test on porcelain components
c) Temperature cycle test on porcelain housing
d) Visual examination of porcelain housing.
276
6.1 Power frequency reference voltage test:
This test shall be carried out at power frequency voltage and at an ambient
temperature of 20 +/- 15 °C. The reference voltage shall be measured at a defined
current at the knee of the current – voltage characteristic of the arrester. The crest
value of the resistive components of the above defined arrester current shall be in
the range of 1 to 20 mA, depending on the nominal discharge current and/or long
duration discharge class of the arrester.
In addition, the resistive and capacitive component of the leakage current shall be
measured at continuous operating voltage.
6.2 Residual voltage tests:
The test shall be made on three samples of complete arrester or arrester sections.
The time between discharge must be sufficient to permit the sample to return to
approximately ambient temperature. The maximum envelop of the test points shall
be drawn in a residual voltage / discharge current curve.
6.2.1 Steep current impulse residual voltage test:
A current impulse with 1 micro-second virtual front time shall be used with limits
in the adjustments of equipment of +/- 10%. The virtual time to half value on the
tail shall be not longer than 20 micro second. One current impulse with peak value
equal to the nominal discharge current of the arrester +/- 5% shall be applied to
each sample.
6.2.2 Lightning impulse residual voltage test:
A 8/20 current impulse shall be used with limits on the adjustments of equipment
such that the measured values are from 7 micro second to 9 micro second for the
virtual front time and from 18 micro second to 22 micro second for the time to half
value on the tail. Three current impulses shall be applied to each samples with peak
values of approximately 0.5, 1.0 and 2.0 times the nominal discharge current of the
arrester.
6.2.3 Switching impulse residual voltage test:
Two current impulses of approximately 250 and 1000 Amps (peak) +/- 5% having a
virtual front time greater than 30 micro second but less than 100 micro second, and
a virtual time to half value on the tail of roughly twice the virtual front time shall be
applied to each of the three samples.
6.3 Long duration current withstand test:
This test shall be carried out on three new samples of complete arresters, arrester
sections or resistor elements, as per clause 59.1.2 of IEC-TC 37 WG4 April 1986
(Draft). The rated voltage of the test samples shall be at least 3 kV and need not
exceed 6 kV. The test shall consist of 18 discharge operations divided into 6 groups
277
of 3 operations. Intervals between operations shall be 50 to 60 seconds and between
groups such that the device cools to near ambient temperature.
6.4 Operating duty tests:

The test shall be made on three samples of complete arresters or arrester sections.
The rated voltage of the test samples shall be at least 3 kV and need not exceed 12
kV. The power frequency test voltage to be applied to the test arrester section shall
be the voltage of the complete arrester divided by the total number of similar
arrester sections.
6.4.1 Accelerated ageing test:

This test procedure is designed to determine the voltage values UC* and U R* used in
the operating duty tests (see Annexure-B), which will allow those tests to be carried
out on new resistors.

Three resistor samples shall be stressed at a voltage equal to the continuous
operating voltage of the sample for 1000 hours, during which the temperature shall
be controlled to keep the surface temperature of the resistor at 115 + / - 4 °C.
During this accelerated ageing the resistor may be in the surrounding medium used
in the arrester. In this case, the procedure shall be carried out on single resistors in a
closed chamber where the volume of the chamber is at least twice the volume of the
resistor and where the density of the medium in the chamber is not less than the
density of the medium in the arrester.
If the manufacturer can prove that this procedure carried out in open air is
equivalent to the procedure carried out according to the above paragraph, then the
procedure can be carried out in open air.
The relevant voltage for this procedure is the corrected maximum continuous
operating voltage ( UCT ) which the resistors must support in the arrester including
voltage unbalance effects. This voltage should be determined from the formula:
UCT = UC (1 + 0.03L)
Where L is the total length of the arrester in meters, and UC is the continuous
operating voltage of the arrester.
The ageing procedure described above shall be carried out on 3 typical samples of
resistor elements.
6.4.1.2 Determination of elevated, rated and continuous operating voltages -

The three test samples shall be heated to 115 +/- 4 °C. and the resistor power losses
P1CT shall be measured at a voltage UCT, 1 to 2 hours after the voltage application.
The resistor power losses P2CT shall be measured after 1000 h (- 0 + 100 h) of
ageing under the same conditions without intermediate de-energising of the test
samples. Within the temperature range allowed both measurements shall be made at
the same temperature +/- 1 °C.
If P2CT is greater than P1CT the ratio KCT = P2CT / P1CT, is determined for each
sample. In such case, when testing for the operating duty tests the continuous
operating voltage UC and the rated voltage UR shall be increased to UC* And UR*
278
respectively, in order to match the increase of power losses due to ageing. If P2CT is
equal or less than P1CT, UC and UR should be used without any correction.
UC* and UR* are the highest of three values respectively, determined in the
following way:
On three new resistors at ambient temperature the power losses P1C and P1R shall be
measured at UC and UR respectively. Thereafter the voltages shall be increased to
UC* and UR* so that the corresponding power losses P2C and P2R fulfill the relation:
P2C P2R
-------- = KCT : ----- = KCT
P1C P1R
where KCT is the biggest of the three power loss ratios determined in the ageing test.
The measuring time should be short enough to avoid increased power loss due to
heating.
6.4.2 Heat dissipation behaviour of test sample

The test samples shall meet the requirements of clause 60.3 of IEC-TC-37 WG-4
(Draft) April 1986.
6.4.3 Switching surge operating duty test
6.4.3.1 General
Before the switching surge operating duty test, the lightning impulse residual
voltage at nominal discharge current of each three test samples (resistor elements)
shall be determined at ambient temperature.
Thereafter, the samples shall be exposed to a conditioning test consisting of twenty

current impulses with a time interval between the impulses of 50 to 60 seconds and
having an 8/20 impulse shape and a peak value equal to the nominal discharge
current of the arrester. This first part of the conditioning may be carried out on the
resistor elements in open air at a still air temperature of 20 + / - 15 °C. This is
followed by two high current impulses of 65 kA, 4/10 micro second impulse shape.
The measured peak value of the current impulses shall be within 90 % and 110 % of
the specified peak value. After this conditioning the sections are stored for future
use in the switching surge operating duty test (Annexure-B).
At the beginning of the switching surge operating duty test the temperature of the
complete section shall be 60 +/- 3 °C.
The arresters shall be subjected to two long duration current impulses as specified
in clause 6.3. The time interval between the impulses shall be 50 to 60 seconds. The
conditioning impulses and the long duration current impulses shall be applied with
the same polarity.
279
After the second long duration current impulse the section shall be disconnected
from the line and connected to the power frequency source instantaneously, but not
later than 100 millisecond after the impulse. The corrected rated voltage (UR) and
the corrected continuous operating voltage (UC) determined from the accelerated
ageing procedure described shall be applied for a time period of 10 seconds and 30
minutes respectively to prove thermal stability or thermal run-away.
Non-linear metal oxide resistor temperature or resistive component of current or

power dissipation shall be monitored during the power frequency voltage
application to prove thermal stability or thermal run-away.
Oscillographic records of the voltage across and current through the test sample
shall be made at the second long duration current impulse. The energy dissipated by
the test sample during the second operation shall be determined from the voltage
and current oscillograms and the energy value shall be reported in the type test
report. The current and voltage shall be registered continuously during the power
frequency voltage, application.
Following the complete test sequence and after the test sample has cooled to near
ambient temperature, the residual voltage tests which were made at the beginning of
the test sequence, shall be repeated. The complete test sequence is illustrated in
Annexure-B.
The arrester has passed the test if thermal stability is achieved (Ref: Clause 6.4.4), if
the change in residual voltage measured before and after the test is not changed by
more than 5 % and if examination of the test samples after the test reveals no
evidence of puncture, flashover or crack of the non-linear metal oxide resistors.
6.4.4 Evaluation of thermal stability in the operating duty tests
The arrester sections subjected to the operating duty tests are considered to be
thermally stable and pass the test if the peak of the resistive component of the
leakage current or power dissipation or resistor temperature is stabilised or steadily
decreases at least during the last part of the 30 minutes of UC* voltage application in
the procedures shown in Annexure-B.
6.4.5 Power frequency voltage versus time characteristics of an arrester
The manufacturer shall furnish the information as required by Clause 60.7 of IEC
TC 37 WG-4 April 1986 (Draft).
6.5 Pressure relief test:
This test shall be carried out as per Clause 7.11 of IS: 3070 (Pt. I)
6.6 Insulation withstand test:
This test demonstrates the voltage withstand capability of the external insulation of
separately housed arresters.
280
6.6.1 Lightning impulse voltage test
Fifteen consecutive impulses at the test voltage value shall be applied for each
polarity. The arrester shall be considered to have passed the test if no internal
disruptive discharges occur and if the number of external disruptive discharge does
not exceed two for each series of 15 impulses.
6.6.2 Power frequency voltage test
This test shall be carried out as per Clause 7.5 of IS: 3070 (Pt. I)
6.7 Other miscellaneous tests:
6.7.1 Galvanising test on metal parts:
This test shall be carried out as per clause 7.15 of IS: 3070 (Pt. I).
6.7.2 Porosity test on porcelain components:
6.7.3 Temperature cycle test on porcelain housing
6.7.4 Visual examination of porcelain housing
6.8 Artificial Pollution test
This test shall be carried out as per ANSI / IEEEC 62.11.1987.
a) Measurement of power frequency reference voltage
b) Lightning impulse residual voltage test at nominal and twice the nominal discharge
current
281
c) Partial discharge test:
The power frequency voltage applied to the arrester shall be increased upto its rated
voltage and after less than 10 seconds decreased to 1.05 times its continuous
operating voltage. At that voltage the partial discharge level according to IEC Publ.
270 shall be measured. The measured value shall not exceed 50 pC.
8.0 ROUTINE TESTS
(a) Visual examination.
(b) Measurement of power frequency reference voltage
(c) Lightning impulse residual voltage test at nominal discharge current
(d) Measurement of leakage current at continuous operating voltage
(e) Satisfactory absence from partial discharges and contact noise by any sensitive
method
9.0 TECHNICAL DATA AND DRAWINGS
9.1 The tenderer shall indicate his compliance or otherwise against each clause and sub-
clause of the technical specification. The tenderer shall for this purpose enclose a
separate statement, if necessary, indicating the clause reference and compliance or
otherwise. Wherever the tenderer deviates from the provisions of the clauses, he
shall furnish his detailed remarks.
particulars for the lightning arresters in the pro forma attached as Annexure-A.
9.3 Drawings showing the overall dimensions of the lightning arrester, a cross-sectional
view indicating non-linear resistor blocks, retainer arrangement, terminal details,
method of connecting high tension and earthing leads and mounting arrangements
and evidence in the form of type test reports for the arrester, if available, shall be
submitted along with the tender.
9.4 The successful tenderer shall be required to submit the above mentioned detailed
dimensioned drawings for approval and shall also furnish six copies of the approved
drawings along with copies of transparent reproducible prints, as per Railway
Standards. (Standard pro forma enclosed as Appendix – III).
282
9.5 The successful tenderer shall also be required to submit copies of the technical
booklets, information manuals, test reports, etc.
10.0 TECHNICAL COLLABORATION AND INDIGENISATION
Progressive indigenisation of lightning arresters covered by this specification, is

contemplated. Design calculations, detailed manufacturing process and all relevant
information pertaining to transfer of technical know-how in this regard will be
carried out in such a manner between the overseas manufacturer and the Indian
manufacturer as to ensure that the indigenous content of the lightning arrester made
in India increases progressively and rapidly without sacrificing quality and
reliability. Research, Designs and Standards Organisation of the Indian Railways
are to be associated at various stages of indigenisation so as to take into account
service experience while attempting progressive indigenisation.
The information exchanged between the overseas manufacturer and the Indian
manufacturer is not ordinarily required to be passed on to the Indian Railways.
However, the authorised representative of he Indian Railways shall have access to
the above information at the manufacturer’s works overseas or the manufacturer’s
works / Design office in India, whenever it becomes necessary for the purpose of
inspection and acceptance of the product at the manufacturer’s works or for the
purpose of analysis investigation for overcoming difficulties and problems and for
improving the performance reliability in service.
11.0 WARRANTY
11.1 All lightning arresters supplied against this contract irrespective of their origin
(imported / indigenous) shall be guaranteed for trouble-free and fully satisfactorily
performance for a period of 24 months from the date of supply or 18 months from
the date of commissioning, whichever is earlier. Details of the warranty clause, the
extent of responsibility on the part of the supplier and other relevant aspects will be
included in the contract. The tenderer may furnish his detailed terms in this regard
in his offer.
11.2 The supplier shall make necessary arrangements for close monitoring of
performance of lightning arresters through periodical visits to traction power
substations / switching posts for observations.
11.3 Technical guidance and assistance for proper operation and maintenance, trouble
shooting investigation and generally all aspects of technical liaison that may be
required, shall also be organised by the supplier.
283
APPENDIX – I
Various electrical equipments provided at traction substations and switching stations and
their insulation levels:
------------------------------------------------------------------------------------------------------------
Equipment Standard B.I.L
Lightning Power frequency
impulse withstand voltage
withstand for one minute
------------------------------------------------------------------------------------------------------------
1. Traction power for secondary

transformer side 250 kVp 95 kV rms
2. i) 25 kV circuit breaker 250 kVp 95 kV rms
ii) 25 kV current transformer 250 kVp 95 kV rms
iii) 25 kV potential transformer

protection type 250 kVp 95 kV rms
iv) 25 kV booster transformer 250 kVp 95 kV rms
v) 25 kV bus bars 240 kVp --
vi) 25 kV shunt capacitor 250 kVp 105 kV rms
3. i) 25 kV interrupters 190 kVp 80 kV rms
ii) 25 kV potential transformer

line indication type 190 kVp 80 kV rms
iii) 10 kVA/ 25kV/ 230 V LT

supply transformer 190 kVp 80 kV rms
iv) 25 kV single pole isolator 190 kVp 95 kV rms
284
ANNEXURE – A
SPECIFICATION NO. ETI/PSI/71 REV. I (1/87)

FOR LIGHTNING ARRESTERS
SCHEDULE OF GUARANTEED PERFORMANCE

TECHNICAL AND OTHER PARTICULARS
S. No description Unit of
measurement
3. Standard specification on which performance is based
5. Rated voltage (rms) kV
6. Continuous operating voltage kV
7. Watt-loss at continuous operating voltages Watt / kV
8. Watt-loss at rated voltages Watt / kV
9. Leakage current at COV mA
10. Leakage current at rated voltage mA

12. Nominal discharge current (8/20 wave) kA
13. Residual voltage

a) at 0.5 times nominal discharge current kV (peak)
b) at nominal discharge current kV (peak)
c) at twice the nominal discharge current kV (peak)
14. Switching impulse residual voltage test with 40x90 kVp

micro second current wave of 250 amp and 1000 amp
15. Steep current impulse residual voltage test with 1.0 kVp
micro second front time and current wave of 10 kA peak
16. High current impulse withstand (4/10 wave) kAp
17. Long duration current impulse rating:
a) peak current A
b) virtual duration of peak micro-second
line discharge class of the arrester
285
18. Power frequency voltage withstand of arrester insulation
(rms):
a) Dry kV
Wet kV
19. Lightning impulse withstand voltage of arrester kVp
insulation
20. Type of non-linear resistor disc, size (dia, height) and kV
voltage rating
21. No. of non-linear discs per section of arrester. No
22. No. of sections in one arrester. No
23. Material of retainer used inside lightning arrester

bakelite, ceramic, rubber or other material.
24. Is pressure relief device provided, if so, its class.

a) Height mm
b) Diameter mm
26. Net weight Kg
27. Mounting base :

i) No. of holes No.
ii) Dis. of holes mm
iii) Pitch circle dia. mm
28. Are the live and earth ends of the arrester suitable for
jumper / flats as specified?
29. Are grading rings provided?
30. V-I characteristic curves of the ZnO element at different

temperature.
31. Any other technical data, the manufacturer may like to

furnish.
286
ANNEXURE – B
Operating duty test for 10,000 A arresters line discharge Class 3, Clause 6.4.3.
Residual voltage measurement at In 8/20 1 x In 8/20
Time interval not specified
Conditioning test 20 imp. at In 8/20 20 x In 8/20

Conditioning.
1 Minute interval.
Time interval not specified
High current impulse conditioning on sections. 2 x 65 kA

Cooling to ambient temperature. 4/10
High current impulse conditioning on sections.
Hold for future use.
Cool to or preheat to 60 ± 3 °C.
Long duration current impulse

Switching surge operating duty test.
50 – 60 seconds.
Long duration current impulse
As short as possible.
Not longer than 100 msec.
Rated voltage, 10 seconds. UR*
Continuous operating voltage 30 minutes UC*
Cool to ambient 25 ± 10 °C.
Residual voltage measurement at In 8/20 1 x In 8/20
Examination of test samples.
In = nominal discharge current.
287
Addendum & Corrigendum Slip No. 1 to
Specification No. ETI/PSI/71 Rev. 5 (1/87) for
Metal oxide gapless type lightning arrester for use on
25 kV side of Railway Traction Substations and Switching Stations.
Page No. 7 Add “ (viii) Artificial Pollution Test”.

Clause 6
Page No. 12 Add Clause 6.8 as under :

Clause 6 “ 6.8 Artificial Pollution Test :
This test is made to show that the temperature rise of the non-
linear metal oxide resister elements of the arrester does not
exceed the value on which the operating duty tests are based
and on which the specified life performance characteristics of
the arrester are based.
The salt-fog / solid layer method prescribed in IS : 6704 –

1978 shall be adopted for carrying out this test.
The testing procedure is as follows :
The complete arrester shall be energised at its continuous

operating voltage. At different salinities which correspond to
non-significant pollution, light pollution, heavy pollution and
very heavy pollution (refer IS : 3716 – 1976 Table-2), the
steady state temperature on the non-linear metal oxide
resistors at different points of the arrester shall be measured.
The temperature on the non-linear metal oxide resisters may

be measured by thermocouples through holes in the arrester
housing, that to a negligible extent changes the conditions of
heat dissipation from the resistors. Alternatively, the
temperature on the non-linear metal oxide resistors can be
registered with temperature sensitive tape built-in on the
arrester assembly. ”
288
September 1990
Page No. 12 Delete the Clause.

Clause 6.7.1
Page No. 12 Artificial Pollution test .

Clause 6.8 Delete the clause.
Page No. 13 This clause may be re-read as under :-

Clause 7.0 (b) “Lightning impulse residual voltage test on the complete
arrester or arrester unit at nominal discharge current if
possible or at current value in the range of 0.01 to 0.25 times
nominal discharge current of the lightning arrester”.
Page No. 13 This clause may be re-read as under :-

Clause 8.0 (e) “Lightning impulse residual voltage test either on complete
arrester, assembled arrester unit on or single or several
register elements at a suitable lightning impulse current in the
range between 0.01 & 2 times the nominal current at which
the residual voltage is measured”.
Page No. 13 Add “(f) leakage check by any sensitive method to see the
efficiency of the sealing system”.
--------------------------------------------------------------------------------------------------------------
289
Page No. 6 This Clause may be re-read as under:

Clause 5.3 (viii) “Month & year of Manufacture”.
Page No. 6 Add “ (x) Manufacturer’s Serial

Number”
Clause 5.3
----------------------------------------------------------------------------------------------------------------------
290
December 1991
Sl.No. Clause No. & Description As amended

1. Page No. 6 Substitute the following for the existing
Clause 5.2.4 matter :
“5.2.4 – All ferrous parts used in manufacture
of lightning arrester, its assembly and the
insulating base shall be hot-dip galvanised. All
fasteners of diameter upto 12 mm shall be of
stainless steel conforming to grade 04 Cr17
Ni12 Mo2 of IS : 1570 Pt. V and those above
12 mm shall preferably be of stainless steel or
of mild steel hot dip galvanised to RDSO’s
specification No. ETI/OHE/18 (4/84)”
2. Page No. 12 Substitute the following for the existing

Clause 6.7.1 matter :
“6.7.1 – Galvanised tests on metal parts.

3 samples of the cut pieces of galvanised
component shall be tested for conformity to
RDSO Specification No. ETI/OHE/13
(14/84)”
3. Appendix - 1 Substitute the following with the existing

S. No. 3 (iv) matter :
“ iv) 25 kV 250 kVp 95 kV

Single (rms)”Pole
Isolator
4. Annexure ‘A’ Substitute the existing matter with the

S. No. 5 following:
“ 5 (i) rated voltage (r.m.s) – kV

(ii) rated frequency – Hz ”
291
5. Annexure ‘A’ Substitute the existing matter with the
S. No. 11 following:
“ 11 (i) Rated voltage of the section (Metal

Oxide disc) – kV
(ii) Maximum power frequency
reference voltage of the
section – kV
(iii) Minimum power frequency
reference voltage of the
section – kV
(iv) Reference current of the lightning
arrester - mA”
292
August 1994.
Addendum & Corrigendum Slip No. 5 to the

Specification No. ETI/PSI/71 Rev.5 (1/87) for
Sr.No. Clause No. and Description As amended

------------------------------------------------------------------------------------------------------
1. Page 12 Add clause 6.8 as under :-

Clause 6.0 Artificial Pollution Test:
This test is to carried out as per

ANSI / IEEEC, 62.11.1987
--------------------------------------------------------------------------------------------------------------------------------
293
RDSO Specification No.ETI/PSI/71 Rev.5(1/87) for Lightning Arrestor
for use on 25 kV side.
S.No. Para No. Amendment
1. Para 3.1 In line 2, add “110/25 kV, 22/25 kV” after 132/25 kV”
In line 3, 6 & 23 add, “110 kV, 22 kV” after 132 kV”
In line 7, substitute “50 and 80 kms” with 6.5 and 25 kms.
In line 14, substitute “interrupter” with “circuit breaker”
In line 18, add “110 kV, 22 kV” after “132 kV” and delete
the words “between ± 12.5%” as per the standard clause and
add “ as per I.E. rules”
2. Para 3.2.1 (a) In line 1, substitute “220 kV” with the word
“primary”
(b) Substitute “132 kV side” with primary side”
(c) Substitute “132 kV side” with primary side”
3. Para 3.4.1 In line 1, add the word “generally” before the word “made up
of”
At the end of the para add the following :
However, in the section where the TSS is being set up, the
OHE configuration is copper catenary of 193 sqmm and g
roved copper contact wire of 242 sqmm. Based on this, the
loop impedance values may have to be calculated.
294
4. Para 3.5 Modify the para as below
Impedance voltage of traction transformer.
The percentage impedance voltage of traction transformer is

12± 5% Only one transformer is in service at a time.
5. Para 3.7.1 (a) Delete the word “Mho” in line 1 before the word
“relay”
6. Para 3.7.2 Delete the word “Mho” in line 4 before the word “relay”
7. Para 3.8 Modify the para as below
The normal short circuit apparent power for various system

voltagae for primary side of traction transformer is as under :
Highest system Short circuit

Voltage kV apparent power MVA
24 1000
72.5 3500
123 6000
145 10000
245 20000
The level of fshort circuit on the 25 kV side for a fault in the

vicinity of a substation could be around 100 MVA or more.
295
8. 4.1 In line 5, substitute “0ºC” with “5ºC”
In line 1.1, substitute “200 kg/m2 with “112.5 kg/m2
9. 5.2.3 In line 4, substitute “45 x 6” mm with “50 x 6” mm
10. 10.0 ` Deleted
11. 11.1 In line 3, substitute “24” with “36”

In line 3, substitute “18with “24”
Delete the sentence starting with the word “Details of the
warranty clause” …….. till the word “in his offer”
12. Appendix-1 3(i) Delete
296
FOR
CURRENT TRANSFORMERS,
i. 220 kV, 200 – 100 / 5 A;
ii. 132 kV, 400 – 200 / 5 A;
iii. 110 kV, 400 – 200 / 5 A;
iv. 66 kV, 800 – 400 / 5 A;
FOR
RAILWAY AC TRACTION SUBSTATION
No. ETI / PSI / 117 (7 / 88)
297
SPECIFICATION NO. ETI / PSI / 117 ( 7 / 88 )
GOVERNMENT OF INDIA
FOR
CURRENT TRANSFORMERS,
i. 220 kV, 200 – 100 / 5 A;
ii. 132 kV, 400 – 200 / 5 A;
iii. 110 kV, 400 – 200 / 5 A;
iv. 66 kV, 800 – 400 / 5 A;
FOR
RAILWAY AC TRACTION SUBSTATION
JULY 1988
ISSUED BY

GOVERNMENT OF INDIA : MINISTRY OF RAILWAYS

298
SPECIFICATION NO. ETI / PSI / 117 / (7 / 88)
CURRENT TRANSFORMER, 220 kV or 132 kV or 110 kV or 66 kV
1. SCOPE
1.1 This specification applies to outdoor electrically exposed type current transformer
for a nominal system voltage of 220 kV or 132 kV or 110 kV or 66 kV for use in
unattended Railway traction sub-station in any part of India together with associated
electrical/electronics measuring / indicating instrument and protective devices. It
supersedes specification no. ETI / PSI / 102 (8 / 87), ETI / PSI / 40 (8 / 83), ETI /
PSI / 22 (9 / 82) and ETI / PSI / 55 (9 / 79).
1.2 The current transformer shall be complete with all parts, fittings and accessories
including mounting frame work of steel, necessary for its efficient operation. All
such parts, fittings and accessories shall be deemed to be within the scope of this
specification, whether specifically mentioned or not. The current specification,
whether specifically mentioned or not. The current transformer shall be of proven
design.
2. GOVERNING SPELCIFICATION
2.1 Assistance has been taken from the following specifications code of practices (latest
version) in preparation of this specification : -
1) IS : 5 – 1978 Colour for ready mixed paints and enamels.

(3rd Revision)
2) IEC – 185 – 1966 Current transformer.
3) IS : 335 – 1983 Specification for new insulting oil.
4) IS : 1271 – 1958 Classification of insulating material for electrical

machinery and apparatus in relation to their
thermal stability in service.
5) IS : 1570 (Pt. V) Specification of bolt, nut and spring washer.
6) IS : 1576 – 1967 Solid press – board for electrical purposes.
7) IS : 2074 – 1979 Ready mixed paint, air drying red oxide zinc
chrome priming.
8) IS : 2099 – 1985 Bushing for alternating voltages above 1000V.
9) IS : 2705 – 1981 Specification for current transformers : -
Part – I - General requirement,
Part - II - Measuring current transformer,
299
Part - III - Protective current transformer.
10) IS : 2932 – 1974 Enamel synthetic interior (a) under coating

(b) finishing
11) IS : 3024 – 1965 Electric steel sheet

(oriented with amendment No. 1 & 2)
12) IS : 4253 (Pt. II) – 1983 Application guide for current transformer.
13) IS : 4253 (Pt. II) – 1980 Cork & rubber.
14) IS : 5561 – 1970 Electrical power connector.
15) IS : 11322 – 1955 Method for partial discharge measurement in

instrument transformer.
16) RDSO’s Specn No. Steel & stainless steel fastners.

ETI / OHE / 18 (4 / 84) with
correction slip No. 3 (9/87).
17) RDSO’s Specn. No. Specification for hollow porcelain insulator and
ETI / PSI / 70 (11 / 84) bushings.
2.2 Any deviation from this specification proposed by the tenderer calculated to
improve upon the performance, utility and efficiency of the equipment will be given
due consideration, provided full particulars of the deviation with justification
thereof are furnished. In such a case, the tenderer shall quote according to this
specification and deviations, if any, proposed by him shall be quoted as an
alternative / alternatives. In case of any contradiction between the provisions of the
Indian Standards Specification / Recommendations of IEC and this specification the
latter shall prevail.
3.1 Environmental conditions:
i) Maximum temperature of air in the shed 45 degree C
ii) Minimum temperature of air in the shed 0 degree C

iii) Maximum relative humidity 100 percent
iv) Maximum basic wind pressure 200 kg / sqm.
v) Maximum number of thunderstorm 85 days

days per annum
vi) Maximum number of dust storm days per annum 35 days
vii) Annual rainfall Ranging from 1750 mm

to 6250 mm
viii) Altitude Not exceeding 1000 m

300
3.2 The current transformer would be subjected to vibrations on account of trains
running on nearby railway tracks. The amplitude of these vibrations which occur
with rapidly varying time periods in the range of 15 to 70 ms lies in the range of 30
to 150 microns at present with the instantaneous peak going upto 350 microns.
4.1 General Scheme : The single phase, 50 Hz power supply for railway traction at
25 kV is obtained from 220 / 132 / 110 / 66 kV three phase grid system through a
step down single phase power transformer, the primary winding of which is
connected to two of the phases of the three-phase effectively earthed transmission
line net-work of the State Electricity Board. In order to reduce the imbalance on the
three-phase grid system, the two phases of the three-phase transmission line are
tapped in a cyclic order for feeding the successive substations. The distance
between adjacent sub-stations is normally 40 km and 80 km depending upon the
density of the traffic, gradients in the section, etc.,
4.1.1 One terminal of the 25 kV secondary winding of the traction transformer is

connected to the overhead equipment (OHE) and the other terminal is solidly
earthed and connected to the appropriate running rails. The load current flows
through the OHE to the locomotives and returns through the rail (s) and earth to the
substation. Where booster transformers and return conductors are used the return
current flows through these and partly through the earth in the vicinity of the
substation. Approximately midway between two adjacent sub-stations a dead zone
known as the “neutral section” or “Phase break” is provided to separate the different
phases. The power to the OHE on one side of the substation is controlled by a
feeder circuit breaker while that for each track is controlled by an interruptor. In
case of a fault on the OHE, the feeder circuit breaker isolates it. The incoming 220
/ 132 / 110 / 66 kV supply voltage may vary between + 10 % and - 12. 5 % as per I.
E. Rule No. 54. A schematic diagram No. ETI / PSI / 707 MOD ‘A’ showing the
general arrangement at a traction sub-station is at Appendix – A.
4.2 The current transformer shall be on the primary side of the single phase a power
transformer for use with the following electrical / electronic measuring / indicating
instruments / meters and protective devices / relays : -
a) Instantaneous over current relay,

b) Inverse Definite Minimum time lag over current relay,
c) Restricted earth fault – relay,
A panel / Digital type indicating Ammeters will also be connected to these current
transformers.
4.3 Operation of any of the protective devices / relays which serve as the back up
protective system for that on the 25 kV side of the traction power transformer shall
trip the circuit breaker on the primary side of the transformer. A schematic diagram
showing the protection scheme is at Appendix – B.
301
5. RATING AND OTHER PARTICULARS
5.1 The rating and other particulars of the current transformer shall be as follows : -
i) Type Single phase, oil fill natural air cooled.
ii) No. of windings Primary - two

Secondary - two
iii) System voltage
---------------------------------------------------------------------------------------------------
a. Nominal system voltage, kV 220 132 110 66
b. Highest system voltage, kV 245 145 123 72
iv) Rated primary / secondary currents :
b. Highest system voltage, kV 245 145 123 72
c. Primary current, Amp 200- 400- 400- 800-

100 200 200 400
d. Secondary current, Amps 5 5 5 5
v) Rated frequency …… 50 Hz + 3%
vi) Class of insulation …… A
vii) Rated burden ……. 30 VA
viii) Accuracy class ……. 5P to IS : 2705 – 1981 (Part III)
ix) Accuracy limit factor ……. 15
x) Rated short-time current :

Nominal Transformation Short-time Short-time current
system voltage, ratio current rating rating (Dynamic),
kV (thermal) for one kA
second, kA
220 200 – 100 / 5 31.5 78.75

302
132 400 – 200 / 5 25.0 62.5
110 400 – 200 / 5 31.5 78.75
66 800 – 400 / 5 31.5 78.75
xi) Rated insulation level :

b. Rated one minute power frequency 460 275 230 140
withstand voltage, kV (rms)
c. Impulse withstand voltage (1.2 / 50 micro. 1050 650 550 325

Sec. Wave shape), kV (peak)
xii) Terminal Bushing :
b. Rated current, Amps. 800 800 800 800
c. Minimum creepage distance, mm 6125 3625 2075 1813
xiii) Temperature rise see clause 10.1.2
xiv) Rated overload ……. 150 % of full load for 15 minutes.
xv) Knee-point voltage :
C. T. Ratio Knee – point voltage (Minimum)

--------------------------------------------------------------------
Nominal system voltage, kV
--------------------------------------------------------------------
220 132 110 66
---------------------------------------------------------------------------------------------
100 / 5A 2560 V ----- ---- ------
200 / 5A 1280 V 1070 V 1280 V ------
400 / 5A ---- 535 V 640 V 750 V
800 / 5 A ------ ------ ------ 375 V
6. TYPE & GENERAL CONSTRUCTION.
6.1 The current transformer shall be suitable for mounting on steel structures embedded
in concrete foundations close to the circuit breakers.
303
6.2 The current transformer shall be of sealed type either filled with inert gas or
provided with metallic bellows above the cooling and insulating oil. In case of inert
gas filling, a pressure relief device shall be provided.
6.3 The core shall be built – up of high permeability cold rolled grain oriented (CRGO)
silicon steel laminations conforming to IS : 3024, the laminations being coated on
both sides with suitable insulation capable of withstanding stress relief annealing.
6.4 Class ‘A’ insulation immersed in oil shall be used. The current transformer shall be
supplied complete with insulating oil conforming to IS : 335 required for first
filling.
6.5 The current transformer shall have a single core with wound primary. It shall be
possible to change the transformation ratio by series or parallel connecting the
primary windings by means of suitable links externally. The wire used for
secondary winding shall be procured from the reputed manufacturers only having a
certification mark licence from the Bureau of Indian Standards for the purpose.
Super enamelled wire shall preferably be used for secondary winding. Copper
conductor shall be used for all windings.
6.5.1 Normally no joints in the winding shall be allowed. Joints if unavoidable shall be
brazed with high silver alloy grade Ba Cu Ag 6 of IS : 2927 – 1975 or butt –
welded.
6.6 The secondary terminals of the current transformer shall be housed in a weather-
proof terminal box of mild steel of thickness not less than 1.6 mm. The connection
/ disconnection of external cable to / from the terminals shall be easy and
convenient. The cables shall be of 4 sq. mm. Sections 2 core VC insulated & PVC
sheathed and their entry into the terminal box shall be through proper cable glands
fitted on the bottom of the terminal box. The cable glands shall be supplied with
the current transformer.
6.6.1 Facilities for short-circuiting the secondary terminal shall be provided within the
terminal box. The current transformer shall be provided with a standard 10A test
winding.
6.7 All the bolted mechanical and electrical connections in the current transformer shall
be tightened properly to prevent loosening in service due to vibrations.
7. BUSHING AND TERMINAL ARRANGEMENT.
7.1 Outdoor type bushing shall conform to IS : 5621. The basic insulation level shall
have the appropriate value as given in Clause 5.1 (xi) of this specification. The
porcelain housing shall be capable of withstanding all electrical and mechanical
stresses that might be proceeded during the operation of the current transformer
under normal and short-circuit conditions.
7.2 The profile of porcelain shed shall be simple and free from ribs on the underside so
as to avoid accumulation of dust and pollutants and permit easy cleaning.
304
7.3 Porcelain housing / support insulator used shall have creepage distance as given in
Clause 5.1 (xii) – c.
7.4 The bushing / housing terminals shall be provided with rigid type connectors as per
Research Designs & Standards Organisation (RDSO) drawing No. ETI / PSI /
110**** suitable for connection to ‘ZEBRA’ 28.62 mm ACSR conductor. The
connector shall conform to IS : 5561 and its design shall be such so as to be
connected to the equipment terminal pad with a minimum of four 12 mm dia bolts,
nuts and lock nuts which shall all be of stainless steel conforming to nuts which
shall all be of stainless steel conforming to IS : 1670 (Pt. V) Grade 04 Cr 17 Ni 12
Mo2. Each of these bolts shall also have flat washer and spring washer.
7.5 The connectors and porcelain housing shall be procured only from approved
manufacturers.
7.6 For equipment earthing, the steel supporting frame shall be provided with two
earthing terminals of adequate capacity to carry the rated short-circuit current
safely. The earthing terminal shall be connected to 50 mm x 8 mm M.S. flat. The
earthing terminal shall be provided with 17.5 + 0.5 / - 0.0mm dia. Hole for fixing
the earthing flat.
8. PARTS, FITTINGS & ACCESSORIES.
8.1 Apart from the parts, fittings & accessories specifically detailed in the foregoing
clauses, the following shall be supplied with each current transformers :-
(i) Rating plate with diagram of connections and terminal markings.
(ii) Weather-proof terminal box.
(iii) Lifting lugs.
(iv) Pressure release device.
(v) Nitrogen gas filling valve & oil filling port.
(vi) Oil level gauge of prismatic glass.
(vii) Adjustable arcing horns.
(viii) Cable gland (brass nickel plated).
9. PAINTING
9.1 All the steel surfaces which are in contact with insulating oil shall be painted with
heat resistant oil insoluble insulating varnish. All steel surfaces exposed to weather
shall be given one primer coat of zinc chromate and two coats of grey paint to shade
No. 631 of IS : 5. One coat of additional paint shall be given at site by the
manufacturer.
9.2 FASTENERS.
305
All fasteners of 12 mm diameter and less exposed to atmosphere shall be of
stainless steel and those above 12 mm diameter shall preferably be of stainless steel
or of mild steel hot dip galvanised to RDSO’s specification No. ETI / OHE / 18 (4 /
84).
10. TESTING
10.1 Type tests : The following tests shall be carried out at the works of the manufacturer
or at a reputed testing laboratory in the presence of the Indian Railway
representative(s) on the prototype unit of the current transformer, as per IS : 2705
(Pt. I & III) and as modified or amplified as under : -
10.1.1 Visual inspection : It shall comprise :
(a) Checking of the layout, terminal markings, mounting arrangement, labelling

and any other items.
(b) Quality of painting and anti-ruse treatment.
(c) Quality of workmanship and finish as well as provision of all parts, fittings
and accessories.
10.1.2 Temperature – rise test.
This test shall be carried out on the current transformer for higher rating fitted with
approved terminal connector for full-load and for overload specified in clause 5.1
(xiv). The temperature – rise under specified overload shall not exceed the
following values :
(a) Winding - 500 C
(temperature – rise measurement by
the resistance method).
(b) Insulating oil - 400 C

(temperature-rise measurement by
thermo-meter)
(c) Terminal connector - 400 C

(temperature – rise measurement by
thermo-meter)
The above values are with reference to an ambient temperature of 450 C.
10.1.3 Impulse voltage test :

The lightning impulse voltage withstand test shall be done on the primary windings
with test voltages specified in clause 5.1 (xi) .
10.1.4 Short – time current test :

The short-time thermal (rms) and dynamic (peak) current withstand tests shall be
done to verify the ability of the current transformer and the terminal connectors
fitted thereto to withstand the rated short-time current specified in clause 5.1 (x).
306
The current transformer shall be deemed to have passed the test if the conditions
laid down in clause 7.6.3 of IS : 2705 (Pt. I) are satisfied.
10.1.5 Excitation test and plotting of magnetising characteristic curves :

The curve shall be drawn at least upto that point, where an increase of 100 per cent
in voltage results in an increase of 50 per cent in current.
10.2 Type test on accessories.
10.2.1 Porcelain bushing :

The following tests shall be carried out on a prototype unit of 52 kV or 72.5 kV or
123 kV or 145 kV or 245 kV (as the case may be) class bushings in accordance with
IS : 2099 and IS : 5621.
(i) Dry power-frequency withstand voltage test.

(ii) Wet power-frequency withstand voltage test.
(iii) Dry lightning impulse voltage withstand test.
(iv) Thermal stability test.
(v) Temperature-rise test.
(vi) Thermal short time current withstand test.
(vii) Dynamic current withstand test.
(viii) Cantilever load withstand test.
(ix) Measurement of partial discharge quantity (as per IS : 6209).
(x) Tightness test at flange or other fixing device.
(xi) Temperature cycle test.
10.2.2 Tests on terminal connectors :

The terminal connectors shall be from the approved supplier of RDSO. In case
these are not from the approved supplier of RDSO, the following tests shall be
carried out :
i) Visual inspection and verification of dimensions.

ii) Tensile test.
iii) Resistance test.
iv) Temperature-rise test at normal and specified overload.
v) Short-time current test.
vi) Chemical analysis of materials used.
10.3 In addition tot he above tests, all routine tests detailed in clause 10.7 shall be carried
out on the test unit.
10.4 If the prototype of a current transformer conforming to this specification has been
approved for earlier supplied to Indian Railways, the testing of prototype again may
be waived provided that no change in the design or material (s) used have been
made.
10.5 Manufacturers type test certificates in respect of the tests carried out on (a)
Porcelain housing and (b) terminal connector, as per relevant IEC recommendations
/ IS Specifications shall be submitted by the successful tenderer for approval.
307
10.6 The tenderer may quote separately his charges for conducting short-time current
(thermal) and dynamic current withstand tests described in clause 10.1.4, hereof.
No charges shall be payable for any other type and routine / acceptance tests.
10.7 Routine tests / Acceptance tests.

Every current transformer shall be subject to the following tests at the
manufacturer’s works as per IS : 2705 (Pt. I) and IS : 4322.
10.7.1 Verification of terminal markings and polarity.
10.7.2 High voltage power-frequency tests on primary windings,

The windings shall be subject to the following
--------------------------------------------------------------------------------------------------
(a) Nominal system voltage, kV 220 132 110 66
(b) Voltage to be applied between 460 275 230 140

winding & earth, kV (rms)
(c) Voltage to be applied between two 2 2 2 2

sections of primary winding, kV
(rms)
--------------------------------------------------------------------------------------------------
10.7.3 High voltage power-frequency withstand test on secondary winding : - 3 kV (rms)

for one minute.
10.7.4 Accuracy tests :

The accuracy test shall comprise the following : -
(a) Current error & phase displacement at the rated primary current.
(b) Composite error at rated accuracy limit primary current.
10.7.5 Measurement of insulation resistance between primary winding and secondary

winding with a 2500 V Megger; and that between secondary winding & earth with a
500 V megger.
10.7.6 Measurement of secondary winding resistance and its computation at 750 C.
10.7.7 Measurement of partial discharge of windings.
11 TECHNICAL DATA AND DRAWINGS.
11.1 The tenderer shall furnish along with his offer in the proforma attached at Appendix
‘C’, the guaranteed performance data and other technical particulars of the
equipment. Evidence in the form of type test reports for rated insulation level i.e.
rated impulse withstand voltage test, rated power frequency (wet) withstand test,
rated power frequency (dry) withstand test, temperature – rise test and short-time
current withstand test on the current transformer offered shall be furnished.
308
compliance with each clause and sub-clause of this specification. A separate
statement shall be attached with the offer indicating reference to the clause where
the tenderer deviates therefrom together with detailed remarks / justification. If
either the statement of compliance or statement of deviation is not attached with the
offer, it is not likely to be considered. If there are no deviations, a ‘NIL’ statement
shall be attached.
11.3 The tenderer shall furnish the following drawings as per Indian Railways standards
in sizes of 210 mm x 297 mm or any integral multiples thereof. A format of the
title sheet is attached at Appendix ‘D’.
(a) Outline general arrangement drawing giving the overall dimensions of the
current transformer.
(b) Internal arrangement of the current transformer including cross-sectional

views.
11.4 The tenderer shall also furnish the following information along with his offer : -
(a) Excitation characteristic curve.
(b) Manufacturer’s test certificates of : -

(i) Winding wire, (ii) Oil seal gaskets (iii) insulating oil (iv) pressure
release device etc.
(c) The tenderer shall furnish the detailed calculation and basis in support of the
minimum knee point voltage.
11.5 The successful tenderer shall be required to submit for approval the following
detailed dimensioned drawings as per Indian Railways standard in sizes of 210 mm
x 297 mm or any integral multiples thereof :-
(a) General outline drawing showing mounting arrangement, relative position of

primary and secondary terminals, CT earthing and position of various parts,
fittings and accessories.
(b) Cross-sectional view along with its internal details.
(c) Porcelain housing / bushing including its clamping arrangement.
(d) Name and rating Plate with the diagram of connections (both in English and
Hindi).
(e) Details of primary terminals and links used for changing the transformation
ratio.
(f) Secondary terminals and terminal box.
(g) Details of metallic bellow, if provided as well as its operation
(h) Detailed part drawings for :
(i) Oil level gauge ; (ii) Nitrogen gas filling value ;

(iii) Pressure release device ; (iv) Cable gland ;
(v) Terminal connector; (vi) Earthing terminals and
(vii) Oil draining pipe with plug.
309
11.6 After approval, six copies of approved drawings along with two sets of reproducible
prints shall be supplied to each consignee (s). Besides, two copies of drawings
along with one set of reproducible prints shall be supplied to the Director General
(Traction Installation), Research Designs & Standards Organisation, Lucknow
(India).
11.7 The successful tenderer shall supply five copies of the instruction/maintenance
manual for the current transformer to each consignee (s) and two copies to the
Director General (Traction Installation(, Research Designs and Standards
Organisation, Lucknow (lndia).
12. SPARES
The tenderer shall furnish along with his offer a list of spare (with cost)
recommended by him for maintenance of current transformer for a period of two
years.
13. ERECTION, TESTING AND COMMISSIONING.
13.1 The Transformer shall be erected by the purchaser under the supervision of a
competent Engineer of the successful tenderer / manufacturer / supplier. The
current transformer shall be subjected to the specified proving / pre-commissioning
tests by the Railway’s Engineer at site and with which the successful tenderer /
supplier / manufacturer shall also be fully associated. For this purpose, prior
intimation regarding the date and location of tests shall be given by the purchaser
to the supplier / manufacturer / successful tenderer.
14. TRAINING OF INDIAN RAILWAY’S ENGINEERS.
14.1 The offer shall include the training of two Engineers of the Indian Railways free of
cost at the manufacturer’s works in India or abroad and at the maintenance depots /
workshops on a railway system or other public utility where current transformers of
similar / identical design are in operation. The total duration of training for each
engineer shall be 12 weeks of which approximately 6 weeks will be at
manufacturer’s works and 6 weeks on a railway system or other public utility. The
cost of travel to the country of manufacturer and back will be borne by the Indian
Railways. Other details shall be settled at the time of finalising the contract or
Purchase order.
15. WARRANTY.
15.1 Each current transformer supplied against a purchase order / contract in which this
specification is quoted, irrespective of origin (imported or indigenous), shall be
guaranteed for trouble – free and satisfactory performance for a period of 24 months
from the date of supply or 18 months from the date of commissioning at the sub-
station on Indian Railways, whichever period is shorter. Details of warranty clause,
the extent of responsibility and other relevant aspects shall be included in the
purchase order or contract. The tenderer shall furnish detailed terms and conditions
in this regard in his offer.
310
The successful tenderer shall make necessary arrangements for closely monitoring
the performance of the current transformer through periodical (preferably once in
two months during the warranty period) visits to the sub-station for on the spot
detailed observations. Arrangements shall also be made for spare parts to be kept
readily available with the manufacturer / supplier / successful tenderer to meet
exigencies warranting replacement so as to put back the current transformer in
service without unduly long interruption of traction power supply.
16. PACKING AND SHIPMENT.
16.1 The current transformer shall be transported from the manufacturer’s works to the
destination by rail, road or sea as determined in the contract / purchase order. The
parts, fittings and accessories which are liable to damage during transit shall be
separately packed / crated and despatched so as to reach destination along with the
transformer tanks. Any opening created on the current transformer tank by the
removal of any parts, fittings and accessories shall be closed by suitable blanking
plates.
A general packing list, for the various components of each current transformer shall
be furnished. The packing has to be done properly so that no damage may be done
during transit.
311
APPENDIX – ‘C’ to the specification No. ETI / PSI / 117 (7 / 88)

PARTICULARS
--------------------------------------------------------------------------------------------------------
S. No. Description Unit of measurement Data
--------------------------------------------------------------------------------------------------------

3. Standard Governing Specification
5. (a) Nominal system voltage kV
(b) Highest system voltage kV
6. (a) Rated primary current Amp.
(b) Rated secondary current Amp.
(c) Rated transformation ratio
7. Rated burden VA
8. Accuracy class
9. Rated accuracy limit factor
10. Current error at rated primary current Percent
11. Phase displacement at rated primary Minutes

current
12. Composite error at rated accuracy Percent
13. Rated short-time current and duration.
(a) Thermal (Ith) KA (RMS) for

one sec.
312
(b) Dynamic (I dyn) KA (peak)
14. Temperature-rise of the windings (by

resistance method) over an ambient
temperature of 460 C
0
(a) At rated current C
0
(b) At 100% overload for 5 minutes C
15. Partial discharge level PC
16. Particulars of windings :
(a) Primary windings :
(i) Type
(ii) No . of turns
(iii) Current density at rated current Amp / mm2
(iv) Size of conductor
(v) Class of insulation
(b) Secondary windings :
(i) Type
(ii) No . of turns
(iii) Current density at rated current Amp / mm2
(iv) Size of conductor
(vi) Resistance computed to 750 C Ohm
(vii) Insulating materials used
(c) Rated insulation levels :
(i) One minute power frequency kV (rms)

withstand voltage
(ii) Inter-section withstand voltage kV (rms)
of primary windings.
(iii) Impulse withstand voltage kV (rms)
17. Particulars of core :
(i) Type
(ii) Flux density :
(a) at rated primary current Tesla

(b) at 15 times rated primary Tesla
current
(iii) Thickness of steel laminations mm

313
(iv) Whether CRGC steel
stampings are used?
(v) Watt – loss per kg. of steel.
(vi) Knee-point e.m.f.
18. Particulars of porcelain housing/bushing :
(i) Specification to which it conforms.
(ii) Make of manufacturer
(iii) Power frequency withstand voltage

for one minute
(a) Dry kV (rms)

(b) Wet kV (rms)
(iv) Dry lightning impulse withstand

voltage, 1.2 / 50 micro-second wave kV (peak)
shape
(v) Visible power frequency discharge kV (rms)
voltage
(vi) Creepage distance in air
a. Protected mm
b. Total mm
(vii)Weight of porcelain housing/bushing kgs.
(i) Length mm
(ii) Width mm
(iii) Height mm
20. Weights :
(i) Total weight of copper used
(a) Primary winding kgs.

(b) Secondary winding kgs.
(ii) Weight of core kgs.
(iii) (a) Quantity of insulating oil lits.

(b) Weight of insulating oil kgs.
314
(iv) Total weight kgs.
21. Particulars of terminal connector :
(i) Name of manufacturer
(ii) Rated current Amp.
(iii) Temperature-rise above an ambient

of 450 C
0
(a) at rated current C
0
(b) at 150 per cent of rated current C
for 15 minutes
-------------------------
315
29TH NOVEMBER 1988
ADDENDUM / CORRIGENDUM SLIP NO. 1 TO TECHNICAL SPECIFICATION

NO. ETI / PSI / 117 ( 7 / 88) FOR 220 kV or 132 kV or 110 / kV or 66 kV CURRENT
TRANSFORMERS
Page 7, Clause 7.2 Add after the existing entries :
“The porcelain housing shall be of single piece

construction i.e. , without joint in the porcelain
body”.
Page 8, Clause 7.5 In the first line after the word connectors add
“and porcelain housing”.
316
ADDENDUM / CORRIGENDUM SLIP NO. 2 (MARCH 1989) TO TECHNICAL
SPECIFICATION NO. ETI / PSI / 117 ( 7 / 88) FOR CURRENT TRANSFORMERS
220 Kv, 132 kV, 110 kV and 66 kV.
--------------------------------------------------------------------------------------------------------
Sl. CLAUSE NO. & AS AMENDED
No. DESCRIPTION
--------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------
1. Clause 6.5 (Page 7) Replace the existing entries by the following :-

Type & General construction.
“The current transformer shall have a single
core with wound primary. The primary
winding insulated from each other and
connected to terminals P1, P2, C1 & C2. It
shall be possible to change the transformation
ratio by connecting C1 with C2 for series
configuration or P1 with C1 & P2 with C2 for
parallel configuration. For connecting these
terminals in series or parallel configuration,
suitable links of adequate section made of
copper flat shall be provided. The nuts and
checknuts used for connecting these links shall
be made of copper. Only copper conductors
shall be used for primary and secondary
windings.”
2. Clause 10.1 (Page 9) Replace the existing entries by the following :

Testing.
“Only after all the designs and drawings have
been approved and clearance given by RDSO
to this effect, the manufacturer shall take up
manufacture of the prototype unit for RDSO
inspection. It is to be clearly understood that
any changes required to be done in the
prototype unit - as required by RDSO shall be
done expeditiously.
The following tests shall be carried out at the

works of the manufacturer or at a reputed
testing laboratory in the presence of the Indian
Railways representative (s) on the prototype
unit of the current transformer as per IS : 2705
317
(Pt. I & III) and as modified or amplified as
under”.
3. Clause 10.8 (Page 12) Add this new clause 10.8 as under :
Bulk manufacture. “Only after clear written approval of the results
of the tests on the prototype unit is
communicated by RDSO/Purchaser to the
manufacturer, shall he take up bulk
manufacture of the ordered current
transformers – which shall be strictly with the
same material and process as adopted for the
prototype. In no circumstances shall material,
other than those approved in the designs/
drawings and/ or the prototype, be used for
bulk manufacture on the plea that they had
been obtained prior to the approval of the
prototype”.
4. Clause 11.1 (Page 12) Replace the existing entries by the following :
Technical data & drawings. “The information furnished in ‘Schedule of
guaranteed performance, technical & other
particulars’ (Annexure A) shall be complete in
all respects. If there is entry like ‘shall be
furnished later’ or blanks are left against any
item, the tender is not likely to be considered
as such omissions causes delay in finalising the
tender. Evidence in the form of type test
reports for basic insulation level i.e., rated
impulse withstand voltage test, rated power
frequency (wet) withstand test, rated power
frequency (dry) withstand test, temperature
rise test and short time current withstand test
on the current transformer offered shall be
furnished.”
----------------------------
318
22nd December, 1989
Addendum / corrigendum slip No. 3 (Dec. 1989) to Technical Specification

No. ETI / PSI / 117 (7 / 88) for Current Transformers 220 / 132 / 110 / 66 kV.
----------------------------------------------------------------------------------------------------------
S. Clause No. & description As amended
No.
----------------------------------------------------------------------------------------------------------
1. 5.1 (XV) (Page – 6) The existing entries may be deleted.

Knee – point voltage
2. 5.1 (XV) (Page – 6) Add the following line against the existing
entries:
“5.1 (XV) Secondary winding resistance at

750C (max.) : 0.3 ohms.”
3. 7.2 (Page – 7) Bushing & Add after the existing entries (ref.
Terminal arrangement. Amendment No. 1 Nov. 1989) the following
as a separate para :
“The material of clamping rings / flanges used

shall conform to MCI Grade BM – 340 of IS :
2108 or to SGCI Grade : 400 / 12 of IS : 1865
or to Aluminium alloy Grade : 4450 of IS :
617. The mass of zinc coating shall not be
less than 1000 gm / m2.
4. 10.1 (Page - 9) Add after the first para of existing entries (as
Type tests. stipulated in amendment slip No. 2 (March
1989).
“Before giving the call to RDSO / the Chief

Elect. Engineer for inspection and testing of
the prototype of the equipment, the
manufacturer shall submit a detailed test
schedule consisting of schematic / circuit
diagrams for each of the tests and nature of
the test, venue of the test and the duration of
each test and the total number of days
required to complete the test at one stretch.
Once the schedule is approved, the test shall
invariably be done accordingly. However,
during the process of type testing or even
319
later, RDSO representative reserves the right
to conduct any additional test (s) besides
those specified herein, on any equipment / sub
system or system so as to test the equipment
to his satisfaction or for gaining additional
information and knowledge. In case any
dispute or disagreement arises between the
manufacturer and RDSO / the Chief Elect.
Engineer during the process of testing as
regards the type tests and/ or the interpretation
and accept ability of the type test results, it
shall be brought to the notice of the Director
General / Traction Installations, RDSO / the
Chief Elect. Engineer as the case may be
whose decision shall be final and binding.
5. 11.4 (c) (Page – 13) Add after the existing entries :

Tech. data & Drawings.
“For calculations purpose the lead resistance
may be presumed as 0.4 ohms.”.
-------------------------------------
320
Received vide RDSO’s letter No. ETI / PSI / Spec / 10 Dt. 25 / 4 / 90
Addendum / Corrigendum Slip No. 4 (April 1990) to Specification
No. ETI / PSI / 117 (7 / 88) for Current Transformers, 220 / 132 / 110 / 66 kV.
--------------------------------------------------------------------------------------------------------
S. No. Clause No. & As amended
Description
--------------------------------------------------------------------------------------------------------
1. 5.1 (ii), Page – 4, The existing word “two” against

Number of winding. “Secondary”, may be read as “one”.
321
A DDENDUM / C ORRIGENDUM S LIP N O . 5 (J UNE 1990)
To Specification No. ETI / PSI / 117 (7 / 88) for
Current Transformers, 220 / 132 / 110 / 66 kV.
------------------------------------
----------------------------------------------------------------------------------------------------------
Sl. Clause No. & As amended
No. description
----------------------------------------------------------------------------------------------------------
1. 5.1 (x) (Page – 5) For 132 kV nominal system voltage,

Rated short-time current. replace the figures “25.0” and 62.5” in
column 3 & 4 respectively with “31.5” and
“78.75” respectively.
322
Addendum / Corrigendum Slip No. 6 (September – 1992) to the technical specification
No. ETI / PSI / 117 (07 / 88) for current transformer, 220 / 132 / 110 /
66 kV.
---------------------------------------------------------------------------------------------------------
S. No. Clause No. and As Amended.
description.
---------------------------------------------------------------------------------------------------------
1. 10.1 (Page – 9) The existing matters may be replaced by the
Type tests. following :
i) Once a purchase order is placed for supply of a
current transformer the designs and drawings
shall be furnished to the purchaser / Director
General (Traction Installations) Research
Designs and Standards Organisation, {DG (TI),
RDSO} Lucknow, as the case may be, within the
period stipulated in the order. Only after all the
designs and drawings have been approved for
prototype tests and a written advice given to that
affect, shall be successful tenderer /
manufacturer take up manufacture of the
prototype of the transformer. It is to be clearly
understood that any change or modification
required by the above authorities to be done in
the prototype shall be done expeditiously, not
withstanding approval having already been given
for the designs and drawings. Such change or
modification shall be incorporated in the
drawings as indicated in Clause 14.1.
ii) Prior to giving a call to the Purchaser / DG (TI),
RDSO, Lucknow, for inspection and testing of
the prototype, the successful tenderer /
manufacturer shall submit a detailed test
schedule consisting of schematic circuit
diagrams for each of the tests and the number of
days required to complete all the tests at one
stretch. Once the schedule is approved, the tests
shall invariably be done accordingly. However,
during the process of type testing or even later,
the purchaser reserves the right to conduct any
additional test (s), besides those specified
herein, on any equipment / item so as to test the
equipment/ item to his satisfaction or for gaining
additional information and knowledge. In case
any dispute or disagreement arises between the
successful tenderer / manufacturer and
representative of successful tenderer /
323
manufacturer and representative of the purchaser
/ DG (TI), RDSO, Lucknow, during the process
of testing as regards the procedure for type tests
and / or the interpretation and acceptability of
the results of type tests, it shall be brought to the
notice of the Purchaser / DG (TI), RDSO,
Lucknow as the case may be, whose decision
shall be final and binding. Only after the
prototype transformer is completed and ready in
each and every respect, shall the successful
tenderer / manufacturer give the actual call for
the inspection and testing with atleast 15 days
notice for the purpose
iii) In the event of the tests not being carried through
the completion at one stretch for any reason
attributable to the successful tenderer /
manufacturer and it is required for the
representative of the Purchaser / Director
General (Traction Installation), Research
Designs and Standards Organisation, {DG (TI)
RDSO}, Lucknow, to go again or more number
of times to the works of the successful tenderer /
manufacturer or other place (s) for continuing
and / or completing the tests on the prototype (s)
of the equipment, the successful tenderer /
manufacturer shall reimburse to the Purchaser /
DG (TI) RDSO, Lucknow, the costs for the
representative having to visit the works or other
place (s) for the tests more than once. The costs
as claimed by the Purchaser / DG (TI), RDSO,
Lucknow, shall be paid through a demand draft
to the concerned accounts officer of the
Purchaser / DG (TI), RDSO, Lucknow, as shall
be advised to the successful tenderer /
manufacturer.”
iv) The following type tests shall be carried out on
the prototype current transformer at the works of
the successful tenderer / manufacturer or at a
reputed testing laboratory in the presence of the
representative of the purchaser / DG (TI),
RDSO, Lucknow, in accordance with the
relevant specifications and as modified or
amplified as under. :
324
Addendum/Corrigendum slip No. 7 (August 2005) to the RDSO specification No.
ETI/PSI/117(7/88) for 132 kV current transformer to be used in Mumbai area on 110
kV side of 30 MVA transformers at railway traction sub-stations which may be
operated in parallel on the 25 kV side.

Page No.
1. Annexure -C Details of 132 kV current New Annexure - C added

transformers to be used in
Mumbai area. This is to be
read along with details given in
the subject specifications.
(B.P.Singh)
Director/TI-I
for Director General/TI
325
ANNEXURE-C
1.0 SCOPE
This part of specification cover design, manufacture, testing, inspection, packing and
supply, of 145 kV class outdoor, current transformers with CT ratio of 1200-800-400/5A to
the specification given below to be used in Mumbai area on 110 kV side at traction sub-
station with 30MVA transformers and required to be operated in parallel with adjacent
traction sub-stations.
2.0 RATING AND OTHER PARTICULARS
i) Type Single phase, oil filled natural air

cooled outdoor
ii) No. of cores 4
iii) System voltage

a) Nominal system voltage, kV 132
b) Highest system voltage, kV 145
iv) Rated primary / secondary currents

a) Primary current, Amp 1200
b) Secondary current, Amp 5
v) CT Ratio 1200- 800-400/5 A

vi) Rated frequency 50 Hz +/- 3%
vii) Class of insulation A
viii) a)Short time current rating (thermal) 40
for 3 second, kA
b) Short circuit withstand 40
current (3 sec.), kA
c) Short time current rating 100
(Dynamic), kA (peak)
ix) Rated insulation level

a) One minute 50 Hz withstand 275
voltage/induced over-voltage, kV
(rms)
b) Impulse withstand voltage, 650
Positive and negative polarity
(1.2/50 microsecond wave), kV (peak)
x) Minimum creepage distance 4495

of insulator (31mm/kV), mm
326
xi) Temperature rise 500C over an ambient of 500C
Maximum temperature rise of
windings immersed in oil
xii) Rated over load 150% of full load for 15 minutes
xiii) Rated burden & class of accuracy of Core-1 Core-3 Core-2&4

different cores Protection R. met Protection
Burden in VA 40 40
Accuracy Class 5P20 0.2 PS
Instrument Security Factor - <5 -
Knee point Voltage - - >750V
Iex (max) at Vk/2 - - < 100mA
Rct (max) - - < 1.0 Ohm

at max.tap)
2.0
a) Multi-ratio specified shall be obtained by taps on secondary side.
b) The values specified above for metering & protection core shall be met for the lowest
tap. (except Rct and knee point voltage for PS core which is at the highest tap).
c) P1 and P2 markings to be permanently riveted.
d) CTs shall be of dead tank design.
e) Power factor terminal (test tap) shall be provided inside the secondary terminal box.
f) The disposition of various CT cores and detailed drawings alongwith SOGP shall be
furnished for RDSO’s approval before manufacture is taken up.
2.1 Construction
The current transformers shall be hermetically sealed. They shall be suitable for
upright mounting on steel structures. They shall be provided with nitrogen
cushions/stainless steel bellows. CTs shall be suitable for hot line washing. The current
transformer winding shall be housed in a galvanised tank suitable for outdoor duty.
Earthing arrangement shall be provided for CT tank.
327
2.2 Tank Fabrication
Tank shall be fabricated from tested quality low carbon steel suitable for welding
and of adequate thickness. The tank shall be designed to withstand mechanical shocks
during transportation, vacuum filling of oil and continuous internal pressure over normal
hydrostatic pressure of oil and short circuit forces.
The construction of tank shall be designed to prevent ingress of water into or

leakage of oil from the tank. All bolted connections shall be fitted with weather proof, hot
oil resistant gasket in between (Butile Nitrile/ Neoprene Rubber), for complete oil
tightness. If gasket is compressible, metallic stops shall be provided to prevent over-
compression.
Tank fabrication drawings shall be submitted for approval before the manufacturing
is taken up.
2.3 SPECIAL CONSTRUCTION NOTE
After the internal elements such as primary & secondary windings are sealed in the
tank with procelain shell, the assembled CTs shall be subjected to vacuum & heat treatment
and finally filled with degasified oil in vacuum.
3.0 General
3.1 Current transformers shall be provided with unthreaded stud terminals at top for
connections to 110 kV, 50 mm OD aluminium busbar. The primary current terminals shall
be of tinned copper.
3.2 The current transfer area of the terminals shall be adequate to meet the
temperature rise requirements as per IEC 44-1/ IS: 2705 for CTs. The cross-section area of
the terminal shall be indicated in the drawings.
3.3 Mechanical load test on primary terminals: Test reports are to be submitted as
per IEC 44-1.
3.4 The burdens specified for different cores refer exclusively to connected burden
and should exclude the bleeder resistances if any. Current transformer’s guaranteed
burdens and accuracy class are to be intended as simultaneous for all cores.
328
3.5 CTs shall be provided with a capacitance test tap in the HV lead to enable future
monitoring of conditions of HV insulation.
3.6 Earthing terminal shall be provided in the secondary junction box for earthing
of secondary winding of CT.
3.7 The alignment and centre line of CT primary terminals shall be correct so as to
avoid bending of connections.
3.8 The CT secondary terminal box shall be of GI (IP 55) and shall be provided
with collar to prevent entry of moisture & good neoprene gaskets designed to prevent entry
of foreign particles. Junction box shall be sufficiently large to connect 1100V upgrade,
4Cx6 Sq.mm cables through cable glands for all the secondary cores.
3.9 CT secondary terminals shall be terminated to stud type non disconnecting

terminal blocks inside the terminal box. CT secondary terminals shall be provided with
lock nuts.
3.10 All ferrous parts exposed to atmosphere including main tank, secondary
terminal box & top metallic should be hot dip galvanized.
3.11 The current transformers shall be supplied complete with insulating oil
conforming to IS: 12463 and railway requirements. The insulating oil shall be procured
from the manufacturers approved by RDSO. The successful tenderer/manufacturer shall
submit test certificates as per IS: 12463 for oil.
clause of the technical specification. If the tenderer wishes to deviate from the provision of
any clause/sub –clause, he shall furnish the full details with justification for such deviation.
3.13 Detailed drawings of CT alongwith SOGP shall be furnished for RDSO’s

approval before manufacture is taken up.
3.14 This CT shall be used for following additional protective devices/relays.
i) Fiber optic line differential protection

ii) Directional over current relay
iii) LBBU relay (LBB- breaker failure relay)
iv) Busbar differential low impedance type protections relay
v) Energy metering
329
4.0 The following Type &Routine tests as per IEC44-1, IS: 2705 and RDSO specification
no. ETI/PSI/117 (7/88) with A&C slip no. 1 to 6 shall be conducted on the current
transformer required for Mumbai area under DC-AC conversion
4.1 Type tests
1. Visual inspection.
2. Temperature rise test.
3. Impulse voltage test.
4. Short time current test.
5. Excitation test and plotting of magnetizing characteristic curves.
6. Radio interference test.
7. Seismic withstand test.
8. Thermal stability test.
9. Thermal coefficient test i.e. measurement of tan-delta as a function of temperature.
10. The CTs shall be subjected to fast transient test in order to evaluate the aging
characteristics of the CT insulation. This test is to be done to assess the CT
performance in service to withstand the high frequency over voltage generated due
to closing and opening operations of isolators.
330
4.2 Routine Tests
1. Dimensional check
2. Verification of terminal marking and polarity.
3. Power frequency voltage withstand tests on primary winding.
4. Power frequency voltage withstand tests on secondary winding.
5. Accuracy tests
a) Current error and phase displacement at the rated primary current
b) Composite error at rated accuracy limit primary current
6. Measurement of knee point voltage, exciting current and ISF test (only for
metering core).
7. Measurement of winding resistance test.
8. Insulation resistance measurement test.
9. Inter-turn over-voltage test.
10. Partial discharge test (PD value shall be less than 5 pC).
11. Capacitance and tan delta value measurement (tan delta value shall be less than 0.5%).
12. Oil leakage test.
331
RDSO Specification No. ETI / PSI / 117 (07/88) for 110 kV current Transformer
issued to the specification
1. 3.1 (ii) : Substitute 0ºC with 5ºC

2. 3.1 (iv) : Substitute 200 kg/sqm with 112.5 kg/sqm
3. 4.1 : In line no. 8, substitute “40 km and 80 km” with “6.5 km

and 25” km.
4. 4.1.1 : In line no.9 delete “feeder” before circuit breaker
: In line no. 10, substitute “ an interrupter” with “feeder

circuit breaker”
5. 6.2 : In line 1, delete “either” after sealed type

In line 1&2, delete “or provided with metallic bellows” and
Delete the words “In case of inert gas filling”
6. 10.1 : In line 2, substitute the word “Indian Railway” with

“Clients”
In line 3, delete the word “ Prototype”
7. 10.2.1 : In line 1, delete the word “prototype”
8. 10.6 : Delete
9. 11.6 : In line 2, delete the sentence “Besides….. Lucknow(India)”
10. 11.7 : In line 2, delete the words “and two copies……….

Lucknow(India)”
11. 13.1 : In line 1, substitute “Purchaser” with “Contractor”
12. 15.1 : In line 3, substitute “24” with “36” and

In line 4, substitute“18” with “24”
332
SPECIFICATION
FOR
25kV AC, 50 Hz, SINGLE PHASE,
OIL FILLED
CURRENT TRANSFORMER.
WITH CT RATIO OF
(i) 1000 – 500 / 5 A (FOR GENERAL PURPOSE)
(ii) 1500 – 750 / 5 A (FOR HEAVY HAUL DUTIES)
FOR
No. ETI / PSI / 90 (06 / 95)
333
GOVERNMENT OF INDIA
SPECIFICATION
FOR
25 kV AC, 50 Hz, SINGLE PHASE,

OIL FILLED
CURRENT TRANSFORMER
WITH CT RATIO OF
(iii) 1000 – 500 / 5 A (FOR GENERAL PURPOSE)
(iv) 1500 – 750 / 5 A (FOR HEAVY HAUL DUTIES)
FOR
ISSUED BY

LUCKNOW 226 011.
334
GOVERNMENT OF INDIA
SPECIFICATION FOR 25 KV AC, 50 Hz, SINGLE PHASE, OIL FILLED

CURRENT TRANSFORMER.
1.0 SCOPE
1.1 This specification covers the design and testing of outdoor type 25 kV, Current
Transformer (CT) for installation in Railway’s traction substation in any part of
India for operation of protective devices and indicating instruments.
1.2 The CT shall be complete with all parts, fittings and accessories necessary for its
efficient operation. All such parts, fittings and accessories shall be deemed to be
1.3 This specification supersedes the earlier specification no. ETI/PSI/90 (9/87).
The CT shall, unless otherwise specified, conform to the following standards and
codes of practices (latest version) which shall be applied in the manner altered,
amended or supplemented by this specification and Indian Electricity Rules,
wherever applicable:
IS : 5 Colours for ready mixed paints and enamels.
IS : 226 Specification for structural steel (standard quality)
IS : 335 Specification for New Insulating Oils.
IS : 1271 Classification of insulating materials for electrical

machinery and apparatus in relation to their thermal
stability in service.
IS : 1367 Technical supply conditions for threaded steel

fasteners.
IS : 1554 Specification for PVC insulated (heavy duty), (Part I)

electrical cables for working voltage upto and
including 1100 volts.
335
IS : 1570 Schedule for wrought steel for general engineering
(Part V) purposes.
IS : 1866 Code of practice for maintenance and supervision of

mineral insulating oil in equipment.
IS : 2071 Methods of high voltage testing.
IS : 2074 Ready mixed paint, air drying red oxide zinc chrome,
priming.
IS : 2099 Specification for bushings for alternative voltages

above 1000 V.
IS : 2705 Current Transformers.
IS : 2927 Brazing alloys.
IS : 3024 Specification for electrical steel sheets (oriented).
IS : 3347 12 to 17.5 kV bushings (porcelain and metal parts).
IS : 4253 Cork and Rubber.

(Part II)
IS : 5561 Specification for Electric Power connectors.
IS : 5621 Specification for Hollow insulators for use in

IS : 8570 Press paper for electrical purposes.
IS : 8572 Paper covered flexible/stranded copper conductor for

transformer leads.
IS : 9224 Specification for low voltage fuses.
IS : 10028 Code of practice for selection, installation and (Part I

to III) maintenance of transformers.
IS : 11322 Method for partial discharge measurement in

instrument transformers.
IEC : 137 Bushing for alternating voltage above 1000 V.
IEC : 185 Current transformers.
IEC : 815 Guide for the selection of insulator in respect of

polluted conditions.
336
2.3 Any deviation from this specification, proposed by the tenderer, intended to
improve the performance, utility and efficiency of the equipment, will be given due
consideration, provided full particulars of the deviation with justification therefor,
are furnished. In such a case, the tenderer shall quote according to this specification
and the deviation, if any, proposed by him shall be quoted as an alternative(s).
3. ENVIRONMENTAL CONDITIONS
3.1 The CT shall be suitable for outdoor use in moist tropical climate and in areas
subject to heavy rainfall, pollution due to industry and marine atmosphere and
severe lightning. The limiting weather conditions which the transformer has to
withstand in service are indicated below:
i) Maximum ambient air temperature 50 C.
ii) Maximum daily average ambient air 40 C.

temperature.
iv) Annual rainfall Ranging from

1750 mm to 6250 mm.
xix) Maximum number of thunder storm 85

days per annum.
xx) Maximum number of dust storm 35

days per annum.
xxi) Number of rainy days per annum 120
xxii) Basic wind pressure 200 kgf/m.
xxiii) Altitude Not exceeding 1000 m.
337
3.2 The CT is also be subjected to vibrations on account of trains running on nearby
railway tracks. The amplitude of these vibrations which occur with rapidly varying
time periods in the range of 15 ms to 70 ms lies in the range of 30 micron to 150
microns at present, with the instantaneous peak going upto 350 microns. These
vibrations may become more severe as the speeds and loads of trains increase in
future.
General Scheme.
Power is received from the grid network of the State Electricity Board at 220 kV /
132 kV / 110 kV / 66 kV, either at individual traction substation (TSS) or at a single
point of supply from where it is transmitted through Railway’s own transmission
lines to the traction substations, with line sectioning facilities provided as required.
25 kV power supply for traction is drawn through a single phase step down traction
transformer. The primary winding of this transformer is connected to any two
nominated phases of the incoming three phase lines or to the two incoming phase
lines and on the secondary side, either of the two terminals of the 25 kV winding is
connected to the traction overhead equipment, while the other is solidly earthed and
connected to the running traction rails.
Each transformer has its associated circuit breakers on the primary and secondary
sides, with a separate set of 25 kV circuit breakers called “Feeder Circuit Breakers”
for feeding the traction overhead equipment (OHE) lines.
Adjacent TSS are fed from different phases of the three phase system in rotation.
Neutral sections in front of sectioning and paralleling post (SP) are provided in the
25 kV OHE for segregating the different phases. In between the TSS and SP, sub-
sectioning and paralleling post (SSP) are provided for paralleling the up and down
line OHE and also for sectionalizing and fault localization. The attached sketch no.
ETI/PSI/702-1 MOD ‘C’ at Annexure – I, shows the general scheme for traction
power supply system.
The supply to the OHE can be switched ON / OFF through interrupters which do
not open automatically on fault, but can be closed on to a fault. The fault is cleared
by the feeder circuit breaker provided at the traction substation.
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Normally power supply from a TSS extends upto the SP on either side of the
substation, but in case of an emergency necessitating total shutdown of the
substation, power supply from adjacent TSS on either side of the failed substation
can be extended upto the failed substation by closing the bridging interrupters at the
two SPs.
The scheme of protection to be provided at each of traction substations comprises of

the following three systems:
(i) Protection of the 220 / 27 kV or 132 / 27 kV or 110 / 27 kV or 66 / 27 kV

traction transformer installed at the traction substation.
(ii) Protection of the 25 kV overhead equipment.
(iii) Protection of 220 / 132 / 110 / 66 kV transmission lines.
The relays for transformer protection as well as feeder protection shall be suitable
for operation from current transformer. The following relays shall be fed by the CT.
A schematic diagram showing the protection scheme is given at Annexure – II.
(i) Relays / instruments fed by feeder protection CTs.
a) Distant protection relay (MHO)

b) Wrong phase coupling relay (MHO)
c) Instantaneous over current relay.
d) Transducer for telemetry of feeder current.
e) Transducer for telemetry of MVA (maximum demand).
f) Transducer for telemetry of power factor.
g) Restricted earth fault relay.
h) Thermal over-current relay.
i) Ammeter.
(ii) Relays / instruments fed by transformer protection CTs.
a) IDMT over current relay.

b) Restricted earth fault relay.
c) Ammeter.
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5. RATING AND GENERAL DATA
The CT shall be designed for the following rating and other particulars :
(i) Type Oil filled, single phase, natural

air cooled, low reactance, sealed,
outdoor type.
c) Rated voltage 25 kV (varying from 19.0 kV to 27.5

kV, some times touching 30 kV).
d) Highest voltage 52 kV.

for equipment Um.
e) Rated frequency 50 Hz. ± 3%.
f) Rated secondary current 5A
g) Rated transformation ratio (i) 1000 – 500 / 5

(ii) 1500 – 750 / 5
h) Rated burden 60 VA
i) Accuracy class 5P
j) Rated accuracy limit factor 15
k) Rated short time thermal 25 kA.

current
l) Rated dynamic current 62.5 kA

peak
m) Rated insulation level :-

1) Power frequency 95 kV
withstand voltage
2) Impulse withstand 250 kV

voltage, peak.
n) Resistance of secondary Not greater than 0.3 ohm at 75 C.

winding
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o) Class of insulation Class ‘A’.
p) Temperature rise limits The temperature rise over an ambient

temperature of 50 C shall not exceed
the values indicated below:
(a) Winding : 50 C (measured by the

resistance method).
(b) Insulating oil : 40 C (measured by

thermometer method).
(c ) Current carrying parts in air:40 C

(measured by the thermometer).
(d) Hot spot temperature : not to

exceed 115ºC.
q) Terminal bushing :-
1) Voltage class and 52 kV class, 2000 A
rated current
2) Minimum creepage 1300 mm
distance of the porcelain
housing.
6. CONSTRUCTIONAL FEATURES
6.1 The CT shall have a single core with wound primary. The primary winding shall be
spilt in two sections insulated from each other and connected to terminals P1, P2,
C1 & C2. It shall be possible to change the transformation ratio by connecting C1
with C2 for series configuration or P1 with C1 and P2 with C2 for parallel
configuration. For connecting these terminals in series or parallel configuration,
suitable links of adequate section made of copper flat shall be provided. The nuts
and check nuts used for connecting these links shall be made of copper.
Alternatively, tappings on the secondary windings may be offered to give the
specified transformation ratios. In this case suitable shorting link of adequate
section made of copper shall be provided. Only copper conductors shall be sued for
primary and secondary windings.
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6.2 The core shall be built up of high permeability, low loss, cold rolled grain oriented,
non-ageing, electrical silicon steel laminations conforming to IS:3024. The
laminations shall be coated on both sides with suitable insulation, capable of
withstanding stress relief annealing. The laminations for the core shall be free from
waves, deformations and signs of rust. In assembling the core, care shall be taken to
ensure that no air gaps are formed.
6.3 Each of the core clamping bolts and the core clamping frame work shall be
insulated from the core laminations and tested after completion of the core
assembly to ensure that they withstand a voltage of 2 kV rms with respect to core
for a duration of 60 s.
6.4 The CT shall be of sealed construction with nitrogen gas above the insulating oil
and shall be adequately protected against any leakage of nitrogen gas or oil and
ingress of moisture. All joints in the construction of the CT shall be suitably sealed
so as to provide lasting gas, air, oil and water tightness. The number of gasketed
joints shall be restricted to the minimum.
6.5 The CT core and winding shall be dried under vacuum till appropriate values of
insulation resistance and power factor have been obtained. It shall then be filled up
under vacuum with transformer insulating oil conforming to IS:335. The
characteristics of insulating oil before energizing the new CT shall conform to the
parameters as stipulated in IS : 1866.
6.6 The HT terminal of the CT shall be located below the minimum oil level as marked
on the oil level gauge mounted on the oil expansion chamber.
6.7 The port shall be provided on the oil expansion chamber to serve the purpose of oil
filling and also for fixing the nitrogen gas filling assembly. The nitrogen gas filling
assembly shall be screwed into the oil filling port and shall have its own leak proof
sealing. A screwed cap shall be provided on the oil filling port with a gasket or ‘O’
ring provided at suitable location. The internal and external threads provided on the
oil filling port shall be of adequate length and shall confirm to the ‘Precision grade’
as defined in IS : 1367.
6.8 The oil draining pipe provided on the bottom tank shall have suitable internal
threads over an adequate length and a threaded plug should be screwed into the
pipe. The assembly of the threaded pipe and the plug shall conform to the
“precision grade” as defined in IS: 1367. In addition, a gasket or ‘O’ ring shall be
provided at suitable location in the assembly.
6.9 The CT secondary terminal shall be housed in a weather proof terminal box fitted
with a cable gland suitable for 4mm, 2 core, PVC insulated and PVC sheathed
copper cable of 1100 volts grade, conforming to IS:1554 (Part I). Facilities for short
circuiting the secondary terminals shall be provided within the terminal box. An
earthing line shall be provided in the terminal box to enable earthing of one end of
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the secondary winding. The CT shall also be provided with a standard 10 A test
winding.
6.10 Normally, no joint shall be used in the winding conductor. If a joint becomes
inescapable, it shall be brazed with high silver alloy grade Ba Cu Ag6 conforming
to IS : 2927 or electrically butt-welded.
6.11 No grading ring shall be used in the construction of the CT.
6.12 All leads and connections shall be mechanically strong, adequately insulated,
protected against mechanical injury and rigidly clamped to withstand dynamic
stresses due to short circuits.
6.13 All the bolted mechanical and electrical connections in the assembly of CT shall be
provide with standard locking arrangements to prevent their becoming loose in
service due to vibrations etc.
6.14 Alternatively, a fully hermatically sealed CT may be offered. In this case a stainless
steel bellow shall be provided at the top of oil, to take care of expansion /
contraction of oil due to thermal variations. As the oil will not come in contact with
air during the service life of CT, there may not be any necessity to provide Nitrogen
gas cushion at the top of oil. However, the detailed design / drawing for the same
shall be submitted along with complete technical details to assess the suitability of
the design being offered.
7. BUSHINGS AND TERMINAL CONNECTORS
7.1 The porcelain housings shall be of a single piece construction i.e. there shall be no
joint in the porcelain. The shed profile shall have a lip at the extremities, but free
from ribs on the underside so as to avoid accumulation of dust and pollutants and to
7.2 The design of the bushing shall be such that stresses due to expansion and
contraction in any part of the bushing shall not lead to its deterioration / breakage.
7.3 The porcelain housing shall conform to IS:5621 and shall withstand the following
test voltages :-
(i) Rated short duration wet power frequency 95 kV
withstand voltage
(ii) Rated lightning impulse withstand voltage, 250 kVp
peak
7.4 The CT terminals and terminal fittings shall be capable of carrying the rated current
continuously without exceeding the temperature rise limits of any part. They shall
be free from corona and shall not cause radio interference.
7.5 The general construction of the CT and in particular the relative positions of the
primary terminals and their height above base, secondary terminal box, earthing
terminals and the base mounting channel shall conform to sketch placed in
Annexure – III.
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7.6 The bushing / housing terminals shall be provided with a rigid type terminal
connector on the other side. These terminals as per Research, Designs and
Standards Organisation’s (RDSO) drawings indicated below shall be supplied along
with each CT.
(i) Expansion type terminal connector - Drg. No. ETI.PSI/P/11060

MOD ‘E’ (at Annexure IV)
(ii) Rigid terminal connector - Drg. No. ETI.PSI/P/11090

MOD ‘C’ (at Annexure V)
These terminals shall be suitable for 50 mm diameter Aluminium tubular bus bar
and for terminal pad of CT for horizontal takeoff.
7.7 Primary and Secondary bushings and terminal connectors shall be from RDSO’s
approved suppliers only.
8. FASTENERS
8.1 All fasteners of 12 mm diameter and less, exposed to atmosphere shall be of

stainless steel and those above 12 mm diameter shall preferably be of stainless steel
or of mild steel hot dip galvanized to 610 g/m of zinc. The material of the stainless
steel fasteners shall conform to IS: 1570 (Pt.V) Grade 04, Cr 17 Ni 12 MO 2.
9. PAINTING
All steel surfaces exposed to weather shall be given one primer coat of zinc chromate
after descaling the surface and two coats of enamel gray paint to shade 631 of IS: 5.
10. SOURCES OF SUPPLY FOR WINDING WIRE, GASKETS AND ‘O’ RINGS.
10.1 Polyveniyl Acetal enamel or polyester enamel wire shall be used for secondary
winding. Wires, gaskets and ‘O’ rings certified only by Bureau of Indian Standards
(BIS) shall be use din the manufacture of the CT.
10.2 The successful tenderer / manufacturer shall be required to finish the following
information with respect to the winding wire, gaskets and ‘O’ rings:
(i) Source of supply
(ii) Reference to standard specification to which the material conforms.
(iii) Reports of type tests carried out in terms of the relevant Indian Standard
specification.
11. RATING PLATE
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The CT shall be provided with a rating plate (both in Hindi and English) of weather
proof material. The entry on the plate shall be indelibly marked by etching,
engraving or stamping. The following items shall be shown on the rating plate :
(i) Type of transformer

(iii) Manufacturer’s name and country of origin
(iv) Manufacturer’s serial number and type designation
(v) Year of manufacture
(vi) Rated output and corresponding accuracy class
(vii) Rated frequency
(viii) Highest voltage for equipment
(ix) Rated current
(x) Rated transformation ratio
(xi) Maximum temperature rise over an ambient of 50 ºC
(a) of oil
(b) of winding
(xii) Total mass
(xiii) Rated Insulation level
(xiv) Connection diagram.
12. PARTS, FITTINGS AND ACCESSORIES
12.1 The following parts, fittings and accessories shall be supplied with each CT :
(i) Rating and diagram plate

(ii) Terminal marking plate
(iii) Weather proof terminal box
(iv) Cable gland to take wire, 4mm / 1100 V grade PVC insulated, PVC
sheathed unarmoured, heavy duty copper cables to IS :1554 (Part-I)
(v) Lifting lugs
(vi) Two glavanised earthing terminals
(vii) Terminal connectors
(viii) Plain rollers
(ix) Oil filling port and nitrogen gas filling value
(x) Oil drain pipe with plug
(xi) Pressure relief device
(xii) Oil level sight gauge (tough acrylic plastic / prismatic).
12.2 The parts, fittings and accessories for the CT shall be only those manufacturers
approved by RDSO. If any item from fresh manufacturers / sources are proposed to
be used, it shall have to be type tested in the presence of RDSO’s representative and
approval obtained before procuring the item for use.
13. DRAWINGS
The successful tenderer / manufacturer shall submit for approval the following
detailed dimensioned drawings to the Purchaser / Director General (Traction
Installation), Research, Design and Standards Organisation (DG(TI), RDSO)
Lucknow as per Indian Railway Standards in sizes of 210 mm x 297 mm or any
integral multiple thereof.
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(i) Outline general arrangement of the CT indicating plan, front elevation, side
elevation with all parts, fittings and accessories, electrical clearances, and
salient guaranteed particulars position of terminals and base mounting
channels.
(ii) Integral arrangement of the CT.
(iii) Cross sectional view clearly indicating core and windings with material
specifications, various clearances, supporting / clamping arrangement of
core, coil assembly and arrangement of primary and secondary side leads
inside the CT.
(iv) Untanking details.
(v) Porcelain bushing including cross sectional view, shed profile, creepage
distance, clamping arrangement and other salient electrical and mechanical
characteristics.
(vi) Rigid and flexible terminal connectors
(vii) Primary terminals and details of link and mounting arrangement.
(viii) Secondary terminals and secondary terminal box.
(ix) Rating and diagram plate, both in English and Hindi version.
(x) Detailed part drawings of the following
a) Oil level gauge

b) Nitrogen gas filling valve and oil filling port.
c) Oil drain pipe with plug.
d) Pressure relief device.
e) Cable gland.
f) Earthing terminals
(xi) Any other drawing considered necessary by the successful tenderer /

manufacturer and / or Purchaser.
A format of the title sheet to be adopted by the successful tenderer / manufacturer

for preparation of the drawings is attached at Annexure- VI.
The provisionally approved drawings shall be modified, if need be, as a result of

changes necessitated during type test or as desired by the Purchaser / DG(TI),
RDSO, Lucknow. The modification shall be first got approved from the Purchaser /
DG(TI), RDSO, Lucknow and then incorporated in the drawing. If there are no
modifications at all the provisionally approved drawings shall be finally approved.
After approval, six copies of each of the approved drawings alongwith two sets of
reproducible prints for each drawing shall be supplied to each consignee(s).
Besides two copies of drawings alongwith one set of reproducible prints shall be
supplied to DG (TI), RDSO, Lucknow (INDIA)
346
The successful tenderer / manufacturer shall supply at least two copies of
“operation / maintenance manual” for each CT to each consignee(s). Two copies of
the manual shall be supplied to DG (TI) RDSO, Lucknow.
14. TESTING OF TRANSFORMER
14.1 General
14.4.1 Once a purchase order is placed for supply of a CT the designs and drawings
together with the Quality Assurance Plan (QAP) shall be furnished to the
Purchaser/DG (TI), RDSO, Lucknow as the case may be within the period
stipulated in the order. Only after all the designs and drawings as well as the QAP
have been approved for prototype tests and a written advice given to that effect,
shall the successful tenderer/manufacturer take up manufacture of the prototype of
the CT. It is to be clearly understood that any change or modification required by
the above authorities to be done in the prototype shall be done expeditiously, not
withstanding approval having already been given for the designs and drawings.
Such change or modification shall be incorporated in the drawing as indicated in
Clause 13.3.
testing of the prototype, the successful tenderer/manufacturer shall submit a detailed
test schedule consisting of schematic circuit diagrams for each of the tests and the
number of days required to complete all the tests at one stretch. Once the schedule
is approved, the tests shall invariably be done accordingly. However, during the
process of type testing or even later, the Purchaser/ DG (TI), RDSO, Lucknow
reserves the right to conduct any additional test(s), besides those specified herein,
on any equipment / item so as to test the equipment / item to his satisfaction or for
gaining additional information and knowledge. In case any dispute or disagreement
arises between the successful tenderer / manufacturer and representative of the
Purchaser / DG (TI), RDSO, Lucknow, during the process of testing as regards the
procedure for type tests and/or the inspection and acceptability of the results of type
tests, it shall be brought to the notice of the Purchaser / DG (TI), RDSO, Lucknow,
as the case may be, whose decision shall be final and binding. Only after the
prototype CT is completed and ready in each and every respect, shall the successful
tenderer / manufacturer give the actual call for the inspection and testing with atleast 15 days
notice for the purpose.
14.4.3 In the event of the tests not being carried through to completion at one stretch for
any reason attributable to the successful tenderer / manufacturer and it is required
for the representative of the Purchaser / DG (TI) RDSO to go again or more number
of times to the works of the successful tenderer / manufacturer or other place(s) for
continuing and / or completing the tests on the prototype(s) of the equipment, the
successful tenderer / manufacturer shall reimburse to the Purchaser / DG (TI)
RDSO, Lucknow, shall be paid through a demand draft to the concerned accounts
officer of the Purchaser / DG (TI), RDSO, Lucknow, as shall be advised to the
successful tenderer / manufacturer.
14.5 Type Tests.
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The type tests shall be carried out on the prototype CT at the works of the
successful tenderer / manufacturer or at any reputed laboratory or testing house in
the presence of the representative of the Purchaser / DG (TI) RDSO, Lucknow, in
accordance with IS : 2705 and as altered, amended or supplemented by this
specifications. The following shall constitute the type tests :.
(i) Temperature rise test.

(ii) Lightening Impulse test.
(iii) Short time current test.
(iv) High voltage power frequency wet withstand voltage test.
(v) Determination of errors according to the requirement of the appropriate
accuracy class.
The temperature rise test shall be done in accordance with clause 7.2 and 9.7 of IS :
2705 (Part I) and shall be carried out for full load on the CT for the parallel
configuration of the winding i.e. 1000 / 5A or 1500 / 5Afor general and heavy haul
duties of the CT respectively and fitted with the approved terminal connectors. The
test shall be done continuously without any power supply interruption. In case
interruptions of power supply do take place for some reason, then the entire test
shall be repeated after steady state conditions are attained.
14.5.1.1 The points to be ensured during the temperature rise test, shall be:
(i) Only alcohol in glass thermometers shall be used for the measurement of the
ambient temperature.
(ii) The temperature of the winding shall be determined by the resistance

method only.
14.5.1.2 The temperature rise shall not exceed the limit laid down in clause 5.1(xv).
14.5.2 Lightning Impulse test
This test shall be done in accordance with Clause 9.1 of IS: 2705 (Part-I) on
the primary winding at a test voltage of 250 kV peak.
14.5.3 Short time current tests.
The short time thermal and dynamic (peak) current withstand tests shall be done in
accordance with clause 9.6 of IS : 2705 (Part I) to verify the ability of current
transformers and the fitted terminal connectors to withstand the rated short time
current specified in clause 5.1 (x) and (xi). The current transformer shall be deemed
to have passed the tests subject to satisfying the conditions laid down in clause 9.6.3
of IS : 2705 (Part I).
14.5.4 High voltage power frequency wet withstand voltage test
This test shall be done in accordance with Clause 9.9 of IS: 2705 (Part-I). The test
voltage applied shall have 95 kV.
348
14.5.5 Determination of errors according to the requirement of the appropriate accuracy
class.
The CT shall conform to accuracy class SP13. Test shall be done for current error,
phase displacement and composite error in accordance with Clause 7.1.1 and 7.1.2
of IS: 2705 (Part-3) to prove compliance with the requirements as indicated under
clause 5.1 (vi) and 5.1 (ix) of this specification.
14.6 Routine Tests

The routine tests shall be performed on each CT including prototype unit. The
following shall constitute the routine tests:
(i) Visual Examination

(ii) Insulation resistance test.
(iii) Over voltage inter turn test.
(iv) Determination of error according to the requirement of appropriate accuracy
class.
(v) Measurement of resistance of the windings.
(vi) Verification of terminal markings and polarity.
(vii) Power frequency (dry) withstand voltage test on primary winding.
(viii) Power frequency (dry) withstand voltage test on secondary winding
A general examination shall be made to check that the CT conforms to the

provisionally approved drawings, various items are accessible for maintenance, the
quality of workmanship and finish are of acceptable standards and all parts, fittings
and accessories are provided.
14.6.2 Insulation resistance
The insulation resistance of the primary windings and earth and between primary
windings and secondary winding shall be measured using 2.5 kV megger. The
insulation resistance between secondary winding and earth shall be measured using
500 V megger.
14.6.3 Over voltage inter turn test
The over voltage inter turn test shall be done in accordance with clause 9.5 of IS :
2705 (Part-I).
14.6.4 Accuracy test

The accuracy test shall comprise of:
a) current error and phase displacement at the rated primary current.
b) composite error at the rated accuracy limit of primary current.
349
The above tests shall be conducted in accordance with clause 7.2.1 and 7.2.2 of IS :
2705 (Part 3) to prove compliance with the requirements as indicated under clause
5.1 (viii) and 5.1 (ix) of this specification.
14.6.5 Measurement of resistance of the windings
The resistance of each of the windings shall be measured and computed at 75 C.

The secondary winding resistance shall not exceed 0.3 ohm.
14.6.5.1 Verification of terminal markings and polarity.
The terminal markings and polarity shall be verified in accordance with approved
drawing as per clause 9.2 of IS : 2705 (Part 1).
14.6.6 Power frequency (dry) withstand voltage test on primary winding
The test shall be conducted as per clause 9.3 of IS : 2705 (Part I). The test voltage
applied shall be as given below:
a) Between primary winding and earth 95 kV rms
b) Between two sections of the primary winding 2 kV rms
14.6.7 Power frequency (dry) withstand voltage test on secondary winding
The test shall be conducted as per clause 9.4 of IS : 2705 (Part I). The test voltage
applied shall be 3 kV rms.
14.7 Tests on parts, fittings and accessories.
14.7.1 Porcelain housing.
The porcelain housing shall be tested in accordance with IS : 5621 and the
certificate for compliance with the standard shall be furnished. The porcelain
housing shall also meet the requirement of clause 7.3 of this specification.
14.7.2 Terminal connector.
The terminal connector shall be tested in accordance with IS : 5561 and the
certificate for compliance with the standard shall be furnished.
14.7.3 Pressure relief device.
The pressure relief device (PRD) shall be subjected to air pressure test and leakage
test. The PRD should operate at a pressure between 0.4 and 0.45 kg/cm.
14.7.4 Insulating oil
The sample of insulating oil drawn from the prototype unit shall be tested in
accordance with IS : 1866.
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14.7.5 Failure of prototype
In the event of prototype CT failing in any one of the tests, further testing shall be
discontinued. The manufacturer after carrying out all the modifications as required
on the CT, shall offer a fresh prototype for carrying out all the tests indicated above.
14.8 Waiver of tests
If the prototype of the CT to this specification has already been approved in

connection with previous supplies to Indian Railways, fresh type testing may be
waived at the discretion of the Purchaser, provided that no changes whatsoever in
the design or materials used or the process of manufacture have been made.
However, the Purchaser reserves the right to conduct type tests if he deems it
necessary to do so in the light of experience gained from previous supplies.
14.9 Bulk manufacture

Only after approval of original tracings of drawings incorporating changes, if any,
as a result of the prototype tests and clear written approval of the results of the tests
on the prototype is communicated by the Purchaser / Director General (TI), RDSO,
Lucknow, to the successful tenderer / manufacturer, shall be taken up bulk
manufacture of the CT, which shall be strictly with the same materials and process
of manufacture as adopted for the prototype. In no circumstances shall materials
other than those approved in the design / drawings and/or during the prototype
testing be used for bulk manufacture on the plea that they had been obtained prior to
the approval of the prototype.
15.9 TECHNICAL DATA AND DRAWINGS.
The tenderer shall furnish along with his offer, in the proforma at Annexure-VII, the
Schedule of Guaranteed Performance, technical and other particulars (SOGP) for
the CT. The particulars shall be correct and complete in all respects. If there is any
entry like “shall be furnished later” or a blank against any item, the offer is not
likely to be considered as the evaluation of the offer is rendered difficult and can
not be compared with other offers, if any.
The tenderer shall specifically indicate in a “statement of compliance” attached with

reference to the clause(s) with the reasons / justification for the deviation. This shall
be in the form of a separate statement called the “statement of deviation”. If there is
no deviation at all, a separate “Nil” “statement of compliance” and “statement of
deviation” are not attached with the offer, it is not likely to be considered for the
reason that it is an incomplete offer which can not be properly evaluated and
compared with other offers, if any.
The tenderer shall furnish the following drawings as per Railways Standards in sizes
210 mm x 297 mm or any integral multiples thereof, along with his offer:
(i) Outline general arrangement drawing giving the overall dimensions of the
Transformer.
351
(ii) Rating and diagram plate.
(iii) Internal arrangement of the CT including cross-sectional views.
16. SPARES
16.1 The tenderer shall also quote separately for the following essential spares for every
lot of upto 5 CTs or part thereof:
(i) One primary bushing complete with parts and fittings.
(ii) Terminal connector for primary side bushing terminal.
16.2 A separate quotation shall be furnished for any other spares that the manufacturer
considers as necessary for maintenance of the CT.
17.1.1 The successful tenderer / manufacturer shall make necessary arrangements for
closely monitoring the performance of the CT through periodical (preferably once
in three months during the warranty period) visits to the location where they have
been erected for observations and interaction with the operating and maintenance
personnel of the Indian Railways. Arrangements shall also be made by the
successful tenderer / manufacturer for emergency / standby spare parts being kept
readily available to meet exigencies warranting replacement so as to keep the
equipment in service with least down time.
17.2 The successful tenderer / manufacturer shall respond promptly and in a workman like
manner to any call given by Indian Railways for any assistance by way of attending
to failures, investigation into the causes for failures including conducting of tests, if
any, to be done and such other items with a view to see that the CT serves the
purpose for which it is intended. Besides technical guidance to ensure proper
operation and maintenance of the CT shall be constantly rendered.
18. WARRANTY
18.1 The successful tenderer / manufacturer shall warrant that all equipment shall be free
from defects and faults in design, material, workmanship and manufacture and of
the highest grade consistent with the established and generally acceptable standards
for the equipment of the type ordered and in full conformity with the specifications
and shall operate properly.
18.2 This warranty shall survive inspection of, payment for and acceptance of the
destination or 18 (Eighteen) months from the date of commissioning and proving
test of the equipment at ultimate destination, whichever period expires earlier,
except in respect of complaints, defects and/or claims notified to the successful
352
tenderer / manufacturer within 3 (Three) months of the expiry of such date. Any
approval or acceptance of the Purchaser of the equipment shall not in any way limit
the successful tenderer / manufacturer’s liability.
18.3 The successful tenderer / manufacturer’s liability in respect of any complaints,

defects and/or claims shall be limited to the furnishing and installation of
replacement parts free of any charge or the repair of defective parts only to the
extent that such replacement or repairs are attributable to or arise from faulty
workmanship or material or design in the manufacture of the goods, provided that
the defects are brought to the notice of the successful tenderer / manufacture within
3 (Three) months of their being first discovered during the warranty period of 3
(Three) months from the date of expiry of warranty period, or at the option of the
Purchaser, to the payment of the value, expenditure and damage as hereafter
mentioned.
18.4 The successful tenderer / manufacture shall, if required, replace or repair the
ultimate destination or at the option of the Purchaser, successful tenderer /
manufacture shall pay to the Purchaser value thereof at the Contract Price or in the
absence of such price at a price decided by the Purchaser and such other
expenditure and damages as may arise by reason of the breach of the conditions
herein specified.
18.5 All replacement and repairs that the Purchaser shall call upon the successful tenderer
/ manufacture to deliver or perform under this warranty shall be delivered and
performed by the successful tenderer / manufacture, promptly and satisfactorily and
in any case within 2 (Two) months of the date of advice to this effect.
18.6 If the successful tenderer / manufacture so desires, the parts that are removed may
be taken over by him or his representative for disposal as he deems fit at the time of
of the successful tenderer / manufacture, so as to affect the strength, performance or
18.8 The decision of the Purchaser in regard to the successful tenderer / manufacture’s
conclusive.
19. TRANSPORTATION OF THE CT.

19.1 The CT may be transported according to the transport facilities available for the
route, viz. rail, road or sea. All parts, fittings and accessories which are liable to
damage during transit shall be removed and packed / crated separately. Detached
parts may be packed / crated and sent with CT along with the packing list, so that
all the parts are available at the destination with the unit. The packing has to be
done properly so that no damage occurs during transit.
19.2 The various components of each CT shall be securely packed in wooden crates
353
and boxes. General packing list, together with weight and overall dimensions of
packing cases shall be furnished for each CT indicating the following:
---------------------------------------------------------------------------------------------------
Crate No. Description of Approx. gross Approx. outside
Item / component weight in kg. dimensions
In the crate
---------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------
19.3 As far as possible, the gross weight of the crate / box shall be so kept that it can
be conveniently handled by two persons.
19.5 Necessary instructions for handling and storage of all items shall be included
along with the packing lists.
**************
354
Annexure VII to Specification No. ETI/PSI/90(6/95)
SCHEDULE OF GUARANTEED PERFORMANCE, TECHNICAL

AND OTHER PARTICULARS FOR 25 kV CURRENT
TRANSFORMER.
Note : Guaranteed particulars are to be established by actual test / test reports.

------------------------------------------------------------------------------------------------------------
measurement
------------------------------------------------------------------------------------------------------------
2. Country of manufacture
3. Reference to specification based on

which performance data is based
7. Rated system voltage
8. Highest voltage for equipment kV
9. Rated primary current A
10. Rated secondary current A
12. Rated burden VA
13. Rated transformation ratio
14. Accuracy class
15. Rated accuracy limit factor
16. Current error at rated primary current %
17. Phase displacement at rated primary current Minute
18. Composite error at rated accuracy limit %

primary current
19. Rated short time thermal current for 1 s. kA
20. Temperature rise over a maximum

ambient temperature of 50 C after
355
continuous full load operation
(i) of oil by thermometer
(ii) of winding by resistance
21. Core particulars
(i) Type of core
(ii) Maximum Flux density at T
(a) Rated primary current T
(b) 15 times rated primary current T
(iii) Thickness of steel stamping mm
(iv) Grade of core material and

conforming specification
(v) Watt loss / kg.
(vi) Minimum knee point (e.m.f) voltage V
(vii) Existing current at knee point (e.m.f)

voltage
22. Winding particulars
(i) Type of primary winding
(ii) Current density in primary winding A/mm2

at rated current
(iii) (a) Size and number of turns of mm

primary winding
(b) Size and number of turns of mm

secondary winding
(iv) Resistance of primary winding at 75 C Ohm
(v) Resistance of secondary winding at 75 C Ohm
(vi) Conformation to IS specification No.
(vii) Class of insulation
(a) Primary winding
356
(b) Secondary winding
(viii) Type of joints in the winding, if any.
(ix) Rated lightning impulse withstand voltage kV peak
(x) Rated short duration power frequency kV

(wet) withstand voltage of primary
23. Porcelain housing
(i) Name of manufacturer
(ii) Manufacturer’s type designation
(iii) Standard specification on which the

performance data are based
(iv) Voltage class kV
(v) Rated current
(vi) Minimum creepage distance mm
(vii) Weight kg.
24. Weights and dimensions :
a. Net weight of core kg
b. Net weight of copper in

(a) Primary winding kg
(b) Secondary winding kg
c. Net weight of steel enclosure fitting kg
d. Total weight of CT kg
e. Volume of oil l
f. Weight of oil kg
g. Overall dimensions of the CT
(a) Height mm
(b) Length mm
(c) Breadth mm
357
25. Name of suppliers and conforming IS
specification No.
(i) Terminal connector
(ii) Fasteners
(a) Stainless steel

(b) M.S. hot dip galvanized
(iii) Winding wire
(iv) Gaskets
(v) ‘O’ rings
(vi) Core material
Other particulars :
26. Is the CT fitted with lifting lugs? Yes / No
27. Is the porcelain housing of bushing of

single piece construction? Yes / No
28. Whether the CT is of sealed construction

with Nitrogen at top? Yes / No
29. Is the shed profile of porcelain housing free

from under ribs but has a lip ? Yes / No
30. Pressure relief device provided or not? Yes / No
31. Is clause by clause statement of Yes / No

compliance attached ?
32. Is the statement of deviation, if any, attached? Yes / No
33. Are fasteners of 12 mm dia and less exposed to Yes / No

atmosphere of stainless steel to grade 04 Cr
17 Ni 12 Mo 2 to IS 1570 (Part II)?
34. Are the fasteners of more than 12 mm Stainless steel /

Specification No. ETI/PSI/147 (04/92) dia
exposed to atmosphere stainless steel or Hot dip galvanized.
MS hot dip galvanized?
35. (i) Are all the parts, fittings and Yes / No

accessories from RDSO’s
approved manufacturer’s
358
(ii) If not, list the items which are
to be type tested in the presence
of RDSO representative.
36. Are all the drawings required as per Yes / No

Clause 15.3 (I, II & III) attached?
37. Is warranty as per Clause 18.0? Yes / No
38. Is the list of spares furnished? Yes / No
************
359
Addendum and Corrigendum Slip No. 1 (April 96) to the Technical Specification No.
ETI/PSI/90 (06/95) for 25 kV AC, 50 Hz, Single Phase, Oil filled Current Transformer
with CT ratio (i) 1000 – 500 / 5 A & (ii) 1500 – 750 / 5 A.
Sr. No Clause & Description As amended
1. 3.1 (i & ii) (page 4); Read the unit as ‘ºC’ instead of ‘C º’
Environmental Conditions
2. 5.1 (xv – a, b & c) (page 7); Read the units as ‘ºC’ instead of ‘C º’
Rating and general data.
3. 6.9 (page 9); The unit at the existing 2nd line may read as
Constructional feature. ‘mm2’ instead of ‘mm’.
4. 6.14 (page 9); The word ‘ct’ at the existing 5th line may be
Constructional features. read as ‘CT’.
5. 8.1 (page 10); The unit at the 4th line may be read as
Fasteners. ‘g/m2’, instead of ‘g/mo’.
6. 12.1 (iv) (page 11); The unit ‘mm’ may be read as ‘mm2’.
Parts, fittings and accessories.
7. 14.2.1 (page 14); The first sentence of the paragraph may be

Temperature rise test. replaced by the following:
“The temperature rise test shall be done for

the parallel configuration of the windings
i.e. 1000 / 5 A or 1500 / 5 A for general and
heavy haul duties of the CT respectively.
The test shall be in accordance with clause
7.2 & 9.7 of IS: 2705 (Part I) and shall be
carried out, fitted with the approved
terminal connectors, for rated current of
1000 A for general purpose CTs (ratio –
1000 / 5A) and for rated current of 1250 A
for heavy haul duties (ratio – 1500 / 5A).”
8. 14.4.3.1 (page 17); The existing unit at the third line may be
Pressure relief device read as ‘kg / cm2’
360
Add the following before the existing
9. SOGP Annexure VIII entries:
“18. Temperature rise”.
i) Item 18, (page 2);
Temperature rise. The unit ‘C’ may be read as ‘ºC’
The second line of the existing entries

ii) Item 18, 203,4 (page 2) “Specification no. ETI/PSI/14 (04/92) may
be deleted”.
iii) Item 32, (page 5)
Under the unit column the existing entries
may be read as,
361
Addendum and Corrigendum Slip No. 2 (June 97) to the Technical Specification no.
ETI/PSI/90 (06/95) for 25 kV AC, 50 Hz, Single Phase, Oil filled Current Transformer
with CT ratio (i) 1000 – 500 / 5 & (ii) 1500 – 750 / 5.
Sr. No Clause & Description As amended
1. 14.4.3.1 – Pressure relief The existing second sentence may be

device. replaced with the following :
“The PRD is designed to moperate at a

pressure between 2.5 to 4.5 kg / cm2”.
362
Addendum / Corrigendum Slip No.3 (October 2001) to the Technical Specification
No.ETI/PSI/90(06/95) for 25 kV, AC, 50 Hz,Single phase, Oil filled current
transformer with CT ratio (i) 1000-500/5, & (ii) 1500-750/5
S.No. Clause No. Description As amended
1.0 Clause 4.1.1 General scheme Replace the existing line from Board at 220
Page-5 kV/132 kV/110 kV/66 kV either “with” Board
/Tata Power at 220 kV/132 kV/110 kV/66 kV/22
kV, either” . Replace the existing term “step
down” with “step up step down”.
2.0 Clause 4.1.3 General scheme After the existing line “the attached sketch
Page-5 No.ETI/PSI/702-1 mod “C at annexure-I” add
“and sketch No.ETO/PSI/709” at Annexure-1A”.
3.0 Clause 4.2.(i) General scheme Replace the existing clause with following : “
Page-5 Protection of the 220/27 kV or 132/27 kV or
110/27 kV or 100/27 kV or 66/27 kV or 22/27 kV
traction transformer installed at the traction
substation.”
4.0 Clause 4.2. General scheme Replace the existing clause with following: “
(iii) Page-6 Protection of the 220/132/110/100/66/22 kV
transmission lines”.
5.0 Clause 5.1. Accuracy Class Add PS (for 1500-750 5 CT only) with the
(viii) Page-6 existing entry of SP i.e. the accuracy class will
become 5P and PS (FOR 1500-750 5ct only).
6.0 Clause 5.1. Minimum Knee Add a new clause as 5.1 (xvii) with following
(xvii) Page-7 point voltage entry 210 Volts for any of the winding taps
(for PS Class ) (1500-750 5).
7.0 Clause 5.1. Maximum Add a new clause as 5.1(xvii) with following
(xviii) Page-7 exciting current entry 500 mA at rated knee point voltage.
(for PS class)
8.0 Clause 14.2 Type Tests Add a new clause as 14.2.6 with following entry
Page - 15 :
“PS class CTs shall be subjected to additional
type tests as per clause 6.1 to 6.3 of IS : 2705 Pt-
IV.
9.0 Clause 14.3 Routine Test Add a new clause as 14.3.9 with following entry
Page - 17 :
“PS class CTs shall be subjected to additional
routine tests as per clause 6.1 to 6.3 of IS : 2705
Pt-IV.
(B.P. Singh)
363
Addendum / Corrigendum Slip No.4 (June 2003) to the Technical Page 1 of 2
Specification No. ETI /PSI/90 (6/95) for 25 kV, AC, 50 Hz,Single
phase, Oil filled current transformer with CT ratio
3000-1500/5A, to be used in Mumbai Area.

1. Covering Page of CT ratio of Add “(iii) 3000-1500/5A (for both sides of
the specification 22/25 kV, 30 MVA transformer to be used in
Page-1 Mumbai area )”
2. Clause 2.1 item Governing IS 2074 is to be replaced with ISO/EN 12944
10 of page 3 specification on protective paint system.
3. Clause No.4.1.3 General After the existing line “the attached sketch
Page -5 Scheme No.ETI/PSI/702-1 mod C at Annexure-I” add
“and sketch No.ETI/PSI/709 mob B” at
Annexure-I/A”.
4. Clause 5.1 Rating and general data
4.1 Clause 5.1 (vi) of Rated Add “iii) 3000-1500/5”
Page 6 transformation
ratio.
4.2 Clause 5.1 (viii) Accuracy Replace the existing entry with following :
of Page 6 Class i) 5P – for a) 1000-500/5 and
b) 1500-750/5
ii) PS – for a)1500-750/5 and – (For Mumbai
b) 3000-1500/5 area)
4.3 Clause 5.1 (xvii) Minimum Replace the existing entry with following :
of Page 7 Knee point a) 210 volts for any of the winding taps
voltage (for (1500- 750/5A)
PS class) b) 360 volts for any of the winding taps
(3000-1500/5A).
5. Clause 9.1 of Painting Replace the existing clause with following :
Page 10 “All steel surfaces exposed to weather shall be
properly descaled/grit blasted. The epoxy and
polyurethane protective paints as per ISO/EN
12944 have to be provided for proper protection
against corrosive and coastal environments and
give life of approx. 12-15 years. All the
external surfaces of the current Transformer
shall be given first coat of epoxy zinc
rich (having minimum 83% metallic zinc)
primer (50 micron thickness), intermediate coat
of epoxy chemical and corrosion resistant High
Build Epoxy Intermediate paint (100 micron
thickness) and
364
Addendum / Corrigendum Slip No.4 (June 2003) to the Technical Page 2 of 2
Specification No. ETI /PSI/90 (6/95) for 25 kV, AC, 50 Hz,Single
Phase, Oil filled current transformer with CT ratio
3000-1500/5A, to be used in Mumbai Area.
final coat of Glossy Aliphatic Acrylic

Polyurethane Coating paint ( 50 micron
thickness. ) The total dry film thickness of the
paints shall be minimum 200 micron. The shade
of paint shall be gray as shade 631 of IS: 5. Same
paints have to be applied at damaged surfaces, if
any, at site during erection / commissioning of
the transformer. One final coat of polyurethane
paint has to be applied to ensure proper
smoothness and finish.
365
RDSO Specification No. ETI / PSI / 90 (06/95) for 25 kV Current Transformer.
The following amendments are made in addition to the addendum and corrigendum
slips issued to the specification.
1. Para 3.1(i) Substitute 50°C with 45°C
2. Para 3.1 (ii) Substitute 4 0°C with 35°C
3. Para 3.1(viii) substitute 200 Kgf./.m2 with 112.5 kgf.m2
4. Para 4.1.4 Substitute the following in place of existing clause :
“The supply to the OHE can be switched on / off

through circuit breakers provided at SSP/SP/TSS and
any fault on OHE is cleared these”.
5. Para 4.2 (iii) Deleted
6. Para 4.2.1 (i) a) & b) Delete the word “(MHO)” in (a) & (b)
7. Para 5 (xv) In line 2, substitute 50°C with 45°C
8. Para 7.7 In line 1, add the word “preferably” after the word
“shall be”
9. Para 11.1 (xi) Substitute 50°C with 45°C
10. Para 12.2 In line 1, substitute the word “only” with “preferably
from”
11. Para 18.2 In line 2, substitute “24” with “36” & in line 3,
substitute “18” with “24”.
12. Scheduled of garanteed particulars Sl.No.18 : Substitute 50°C with 45°C
366
lR;eso t;rs
Specification No. TI/SPC/PSI/30/TRN/1050
for
30MVA, 110/27kV SINGLE -PHASE

TRACTION POWER TRANSFORMER
WITH ON LOAD TAP CHANGER
FOR USE IN MUMBAI SUB-URBAN AREA
DECEMBER 2005
ISSUED BY
___________________________________________________________
TRACTION INSTALLATION DIRECTORATE RESEARCH
DESIGNS AND STANDARDS ORGANISATION
(MINISTRY OF RAILWAYS)
MANAK NAGAR, LUCKNOW-226 011
367
Specification No. TI/SPC/PSI/30TRN/1050
For 30 MVA, 110 /27 kV Traction Transformer
SPECIFICATION FOR 30MVA, 110 /27kV single -phase traction power transformer
SPECIFICATION No. TI/SPC/PSI/30TRN/1050
Amendment Amendment /Revision Total pages Date of Issue

Number including drawings
0 NA 77 01.12.2005
PREPARED BY CHECKED BY APPROVED BY
SIGNATURES
DATE
DESIGNATION SE-I/TI Dir/TI-I Sr.EDTI
COPY NUMBER
ISSUED BY …………….. SIGNAGURE ……………..DATE …………………….
ISSUED TO …………………………………………………………………………….
368
INDEX
Clause No. Description
1.0 Scope
Duties of traction transformer in 25kV ac traction
Process for prototype /Vendor approval from RDSO
Pre bid meeting
Scope of supply
Accessories
2.0 Climatic, Environmental & Operating Conditions
3.0 Design and constructional features
Salient Design Features: Overall Dimensions, Tank, Marshalling Box,
Core and
Winding
Insulating Oil
Bushings and Terminal Connectors
Clearances
On Load Tap-Changer
Cooling Equipment
Corrosion prevention systems and Fasteners
4.0 List of related specifications
5.0 Rating, name plate details and other information
6.0 Inspection and testing
Inspection
Type tests
Routine tests
Revalidation of type tests
7.0 Maintenance Manual, tools gauges etc.
8.0 Training of Indian Railway’s personnel
9.0 Packing, Delivery, Commissioning etc.
10.0 Warranty
11.0 Spares, After sales-service & AMC
12.0 Technical Data and drawings to be furnished alongwith tender
13.0 Clause wise conformity, deviations etc.
14.0 Capitalization of transformer losses
15.0 List of appendices in the specifications
APPENDIX-A Schedule of Guaranteed Performance, Technical and Other Particulars-
Part- I
APPENDIX-B Schedule of Guaranteed Performance, Technical and Other Particulars-
Part- II
APPENDIX-C Formula for Calculation of Short Circuit Mechanical Forces
APPENDIX-D Capitalization of Transformer Losses
APPENDIX-E General Scheme for Traction Power Supply System
APPENDIX-F Overall Dimensions of the Transformer
APPENDIX-G Format of the Title Sheet to be adopted for Preparation of the Drawings
APPENDIX-H Nitrogen Injection Fire Prevention and Extinguishing System for
Oil Filled Transformer
APPENDIX-I List of RDSO’s Approved Sources for Parts, Fittings and Accessories
369
RDSO Specification No. TI/SPC/PSI/30TRN/1050
GOVERNMENT OF INDIA: MINISTRY OF RAILWAYS
Specification No. TI/SPC/PSI/30TRN/1050
30MVA, 110 /27kV SINGLE -PHASE

TRACTION TRANSFORMER
1.0 SCOPE
1.1 This specification applies to 30MVA, ONAN, 110 kV/27kV / 50 Hz single-phase

traction power transformer for installation in Indian Railway's 25 kV ac traction
substations, which may be manned or unattended type.
1.2 Duty of traction power transformer used in 25 kV AC traction.
Power is received from the grid network of the State Electricity Board or any other
power utility at 110 kV, either at individual traction sub-station (TSS) or at a single point of
supply from where it is transmitted through railway's own transmission lines, to the
traction substations, with line sectioning facilities provided as required. 25 kV power
supply for traction is drawn through a single phase step-down traction transformer. The
primary winding of this transformer is connected to any two nominated phases of the
incoming three phase lines. On the secondary side, one of the two terminals of the 25kV
winding is connected to the traction overhead equipment, while the other is solidly
earthed and also connected to the running traction rails. The power is tapped through the
secondary winding of the traction transformer and is fed to the over head equipment
(OHE) through the associated circuit breakers on the secondary sides, with a separate set of
25 kV circuit breakers called" Feeder Circuit Breakers" for feeding the traction
overhead equipment (OHE) lines. General power supply schematic diagram is given in
appendix-E. The transformer in one TSS may require to feed the power in the adjacent
OHE in case of failure of transformer of other TSS or failure in the OHE. Traction
transformers at two to three TSSs shall be operated in parallel by closing the sectioning
breaker on 25 kV OHE.
1.3 Process of approval by RDSO and prototype clearance.
Vendors applying to RDSO for registration should have ISO- 9000 series certification and
meet requirements of STR (schedule of technical requirement) no. TI/STR/014 rev. 0 for
which:
i) The manufacturer or his authorized representative shall purchase schedule of
technical requirement & specification against payment of amounts.
ii) After complying with above, manufacturer may apply for vendor approval form
No. TIF-0001 against payment of requisite amount.
iii) On TIF 0001 being found fit on scrutiny, inspection of the works shall be done by
RDSO’s representative to assess the capacity/ capability. The vendor shall offer
370
all facilities to RDSO for conducting the assessment of

manufacturer’s capacity/capability.
iv) Based on report of inspection for capacity/ capability assessment, the vendor will be
issued registration form TIF0002 for registration as a developmental source of the
equipment.
v) The vendor shall get the design/ drawings approved from RDSO and there after
offer the product for prototype testing.
vi) On successful prototype tests, approval shall be accorded in the form no.
TIF0003, the developmental status valid for a period of 2 years.
vii) Consideration for upgradation to a regular source will depend on quantity
supplied and service performance.
1.4 Pre-bid meeting shall be arranged by the purchaser, with eligible tenderers for
the particular requirements of traction transformers to this specification, site conditions,
mode of transport, availability of site, erection and commissioning etc.
1.5 Scope of supply, including accessories.

The transformer shall be supplied complete with all parts, fittings and accessories necessary
for its efficient operation. All such parts, fittings and accessories shall be deemed to
be with in the scope of this specification, whether or not specifically mentioned
herein.
1.5.1 Conservator tank: It shall be of adequate capacity and complete with supporting
bracket or structure, oil filling cap and drain valve of appropriate size, to be indicated in
the technical details. The cylindrical portion of the conservator tank shall be of single
piece construction without any gasketed joint. Suitable air cell arrangement of high
quality material shall be provided in the conservator to ensure that the transformer
insulating oil does not come in contact with air. The material of cell shall be coated fabric
consisting of – highly resistant polyamide fabric, externally coated with transformer oil
resisting coating (chemical), inner coating resisting ozone and weathering. Suitable
instructions may please be provided for installation / commissioning and future
maintenance of the air cell arrangement.
1.5.2 Oil level gauge: It shall be of magnetic type having a dial gauge with markings
corresponding to minimum oil level, maximum oil level and oil level corresponding to oil
temperature of 300C, 450C and 850C. The oil level indicator shall be so designed and
mounting that the oil level is clearly visible to an operator standing on the ground.
1.5.3 Silica gel breather: It shall be complete with oil seal and connecting pipes. The
connecting pipes shall be secured properly. The container of the silica gel breather shall be
of transparent material suitable for outdoor application. The connecting arrangement of
the silica gel breather shall be flange type.
1.5.4 Pressure relief device: It shall be designed to operate to release internal pressure at
preset value without endangering the equipment or operator and shall be of
instantaneous reset type.
371
1.5.5 Filter valves: The valves shall be flanged to seat 40 mm adopter threaded to
thread size P 1 - 1/2 for connection to oil filtration plant. The bottom and upper filter
valves shall be of appropriate size and suitably baffled to reduce aeration of oil.
1.5.6 Drain valve: It shall be of appropriate size fitted with an oil sampling device.
1.5.7 Equipment earthing terminals: Two earthing terminals shall be provided on the
tank for its earthing with the help of 3 mild steel flats, each of size 75 mm x 8 mm. The
terminals shall be clearly marked for earthing.
1.5.8 Buchholz relay: It shall be of double float type, with two shut - off valves of
appropriate size to be indicated in the technical details, one between the conservator tank
and the Buchholz relay and the other between the transformer tank and the Buchholz
relay. The relay shall have one alarm contact and one trip contact, none of the contacts
being earthed. The contacts shall be of mercury - switch type, electrically independent
and wired upto the marshalling box. A testing petcock shall be brought down through a
pipe for the purpose of sampling the gas, if any, collected in the Buchholz relay.
1.5.9 Oil temperature indicator (OTI): It shall have one alarm contact, one trip
contact and two normally open spare contacts, none of the contacts being earthed. The
contacts shall be electrically independent. The OTI shall have a local /remote indication
(in control panel) for oil temperature.
1.5.10 Winding temperature indicator (WTI): It shall have one alarm contact, one trip
contact and two normally open spare contacts, none of the contacts being earthed. The
contacts shall be electrically independent. The WTI shall have a local /remote indication
(in control panel) for oil temperature.
1.5.11 Thermometer pockets: A separate thermometer pocket with cap shall be

provided on the bell tank for measuring the top oil temperature in the tank.
1.5.12 Nitrogen injection fire prevention and extinguishing system: The complete
arrangement of Nitrogen injection fire prevention and extinguishing system has to be
provided with the transformer. The requirements of this system have to be as per details
given in the Appendix-H. The drawings/documents shall be furnished by the successful
tenderer for the approval of RDSO. The system shall be procured from manufacturer
having previous supply and performance experiences; credentials shall be furnished along
with the tender documents. Clause 10.0 & 11.0 of the specification shall be applicable for
warranty, after sale service and AMC respectively for the fire prevention and
extinguishing system.
1.5.13 Thermo Siphon Filter System is to be provided for absorbing the moisture
present in the insulating oil with the natural convection. The full details for installation
and subsequent maintenance have to be furnished to RDSO and the consignee.
372
1.5.14 All valves shall be of the double flange type and fitted with suitable blanking
plates on the outer face of the exposed flange.
1.5.15 The capillary tubes for temperature indicators shall be able to withstand normal
bending. They shall be supported properly without sharp or repeated bends or twists.
1.5.16 All parts, fittings and accessories for the transformer shall be only of those
manufacturers approved by RDSO, as given in the Appendix-I. If any item from unlisted
manufacturer / source is proposed to be used, it shall be got approved by RDSO.
2.0 Environmental & Operating Conditions
2.1 The transformer shall be suitable for outdoor use in dry arid and also tropical
climates and in areas having heavy rainfall, pollution due to industry and coastal
environment and severe lightning. The limiting weather conditions, which the equipment
has to withstand in service, are indicated below:
S. No. Parameters Value

1. Maximum ambient air temperature 50 0 C
2. Minimum ambient air temperature -20C
3. Maximum relative humidity 100%
4. Annual rainfall Between 1750 mm & 6250 mm
5. Number of thunderstorm days per annum 85 (Max)
6. Number of dust storm days per annum 35 (Max)
7. Number of rainy days per annum 120 (Max)
8. Maximum basic wind pressure 200 kgf/m2
9. Altitude above m.s.l. (max) 1000 m
10. Pollution level Very Heavy as per IEC 815-
1986& IS 13134-1992
2.2 The transformer installation would be subject to vibrations on account of passage of

trains on nearby tracks. The amplitudes of these vibrations which occur with rapidly
varying time periods in the range of 15 to 70 ms, lie in the range of 30 to 150 microns
with instantaneous peaks up to 350 microns.
2.3 The ac electric locomotives are fitted, for conversion of ac to dc, with single-
phase bridge- connected silicon rectifiers with smoothing reactor for feeding the dc
traction motors. The rectifiers introduce harmonic currents in the 25 kV power supply
system.On few of the electrified sections, locomotives fitted with phase controlled
asymmetrical thyristor bridge, in place of silicon rectifiers are also in use; these introduce
further harmonics in the system. The typical percentages of harmonics present in the
traction current with electric locomotives are as follows:
373
Harmonics With diode rectifier With thyristor

3 rd (150Hz) 15% 32%
5 th (250Hz) 6% 18%
7th (350Hz) 4% 8%
9 th (450Hz) - 4%
11th (550Hz) - 5%
3.0 Design and constructional features
3.1 Overall dimensions

3.1.1 The overall dimensions of the transformer shall be kept as low as possible and in
any case the transformer with all parts / fittings shall not occupy more space than
described below ( refer the sketch No. ETI/PSI/SK/340-1 at Appendix – F).
1. Length x Width ( in mm) 8000 x 7000

2. Height of the top most point of primary bushing terminal 7500 mm
3. Height of the topmost point of secondary bushing terminal 5500 mm
It shall be possible to transport the transformer in semi knocked down condition to the
railway traction sub-station site by rail / road.
3.2 Transformer Tank
3.2.1 The tank for the transformer shall be of bell type construction with flanges on the
outside and shall have a flat top. The flanges of the upper and lower tanks shall be jointed
by bolts, nuts and suitable plain/spring/belvelle washers. A suitable gasket and metallic
stoppers shall be provided between the flanges of upper and lower tank so as to prevent
leakage of insulating oil. The tank shall be so designed that the winding and core get fully
exposed when the bell tank cover is lifted.
3.2.2 The tank shall be constructed from mild steel of a quality that allows welding any
defect/flaw, with a single tier construction so shaped as to reduce welding to the
minimum. The welded joints shall be made using the latest welding techniques. The tank
shall be adequately strengthened for general rigidity to permit hoisting of the transformer
filled with oil by crane. The tank body shall be designed to withstand a vacuum of 760
mm of Hg.
3.2.3 The tank shall be fitted with four lifting pads at the lower and to enable lifting of
the transformer filled with oil by means of lifting jacks. The lifting jacks shall be supplied as
optional T&P.
3.2.4 The tank shall be fitted with an under carriage and mounted on four bi-directional
swiveling type flanged rollers for being rolled on 1676 mm (5' 6") gauge track on which it
shall also rest in the final position. The rollers shall be provided with detachable type
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locking arrangement to enable their locking after installing the transformer in the final
position to prevent any accidental movement of the transformer.
3.2.5 There shall be at least five inspection covers of suitable size on the tank to enable
inspection of the lower portions of bushings and the leads as well as various connections of
the on load tap - changer.
3.2.6 The rubberized cork / nitrile gaskets used in the transformer shall conform to IS:
4253 (Part - II). The tank rim should be nitrile rubber cord gasket sitting in semicircular
grove.
3.2.7 All valves used in the transformer shall conform to IS: 3639 and shall be of good
quality and leak proof. The manufacturer shall ensure that suitable anti - theft measures
are provided on these valves so as to prevent theft of oil during transit/service.
3.2.8 Suitable supports shall be provided on the tank for fixing of Aluminum ladder for
ease of maintenance at site. Removable aluminum ladder shall be a part of supply.
3.3 Marshalling box
3.3.1 A Vermin proof, weather proof and well ventilated marshalling box made of
thickness not less than 2 mm, strengthened with adequate stiffeners, shall be provided on
the left hand side of the transformer tank as viewed from the secondary terminals side. It
shall have a hinged door with provision for pad locking the door opening outward
horizontally.
3.3.2 The marshalling box shall have a sloping roof. The top of the marshalling box
shall be at a height of about 2 m from the rail level.
3.3.3 The marshalling box shall house the winding and oil temperature indicators and
terminal board .To prevent condensation of moisture in the marshalling box metal clad
space heater, controlled by an associated thermostat and switch, shall also be provided.
Cable glands shall be provided for the incoming and outgoing cables.
3.3.4 The temperature indicators shall be so mounted that their dials are at a height of
not more than 1.6 m from the rail level. Transparent windows of tough acrylic plastic or
similar non - fragile transparent material shall be provided on the marshalling box so as to
enable reading of the temperature indicators without opening the door of the
marshalling box.
3.3.5 All cables from the bushing current transformers, buchholz relay, magnetic oil
level gauge, pressure relief device and temperature indicators shall be run through
suitable conduits/perforated covered cable trays upto the marshalling box. The cables
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shall be of 1100 V grade, PVC insulated, PVC sheathed, steel wire armoured, stranded
copper conductor conforming to IS: 1554 (Part - I). The cables shall be adequately
insulated for heat from the tank surface and the sun.
3.3.6 All wiring in the marshalling box shall be clearly identified by lettered / figured
ferrules of the interlock type, preferably of yellow colour with black letters /figures. The ac
and dc circuits shall be clearly distinguished and well separated from each other.
3.3.7 Suitable legend and schematic diagram plates made of anodized aluminium with
black lettering and lines shall be fixed on the inside surface of the marshalling box door.
3.4 Core
3.4.1 The core shall be built from high permeability cold rolled grain oriented silicon
steel laminations MOH, Hi-B or ZDKH grade. The flux density in any part of the core
and yokes at the principal tapping with primary winding excited at the rated primary
voltage and frequency shall not exceed 1.55 T. The successful tenderer / manufacturer
shall furnish calculations to prove that this value shall not be exceeded. The core has to be
preferably of boltless design to avoid the possibility of local heating.
3.4.2 The laminations for the core shall be free from waves, deformations and signs of
rust. Both sides of the laminations shall be coated with suitable insulation capable of
withstanding stress relief annealing. In assembling the core, air gaps shall be avoided.
Necessary cooling ducts shall be provided, if required, in the core and yoke for heat
dissipation. The core-clamping frame shall be provided with the lifting eyes for the
purpose of tanking and untanking the core and winding of the transformer.
3.4.3 The core shall be electrically connected to the tank.
3.4.4 Yoke/core clamping bolts if provided shall have adequate threaded length beyond the
face of the nuts for tightening at a later stage, if need arises. Each of the core
clamping bolts and the core-clamping framework shall be insulated from the core
laminations and tested after completion of the core assembly to ensure that they
withstand a voltage of 2 kV r.m.s. with respect to core for a duration of 60 s.
3.4.5 The transformer is required to be continuously in service, preferably without

requiring any attention from the date of its energisation upto the periodical overhaul
(POH) which is generally done after 12 years of service. The need, therefore, for
tightening of core clamping bolts should not normally arise before the POH of the
transformer. The successful tenderer /manufacturer of the transformer shall take this
aspect into account during core assembly /manufacture.
3.4.5 Manufacturer shall, preferably have the core cutting facility in their works and
proper monitoring and quality control to avoid any mixing with defective /second grade
materials.
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3.4.6 Manufacturer shall offer the core for inspection and approval by the purchaser
during manufacturing stage. The following documents shall also be kept ready during
stage inspection of core as a proof towards use of core material as mentioned in SOGP and
used in the prototype.
a) Invoice of the supplier
b) Manufacturer’s test certificate c) Packing list
d) Bill of lading
e) Bill of entry certificate by customs.
3.5 Windings
3.5.1 The winding shall be of concentric disc construction with primary winding duly
intershielded /interleaved for better impulse voltage distribution. The configuration of the
windings on each leg after the core shall normally be -LV wdg, HV wdg, regulating wdg
(tap), unless approved by RDSO. For any other improved winding design to give better
performance, full details with drawing shall be furnished to RDSO for approval.
3.5.2 The windings shall be made of continuous electrolytic copper conductor, paper
insulated to class - A insulation. The conductor shall not have any sharp edges which may
damage the insulation.
3.5.3 Normally, no joint shall be used in the winding conductor. If a joint becomes
inescapable, it shall be brazed with high silver alloy grade BA Cu Ag6 conforming to IS:
2927 or electrically butt - welded.
3.5.4 The ratio of width to thickness of copper conductor used for winding shall be as
small as possible but shall not exceed 5:1 so as to avoid tilting of conductors when the
windings are subjected to axial and radial forces during short circuit.
3.5.5 A separate tapped winding shall be provided on the primary side for connection of the
on load tap - changer. The tapped winding shall be distributed in multi-sections in order
to reduce the imbalance in ampere turns to the minimum at any tap position.
3.5.6 The transformer windings shall be designed for the following rated withstand
following rated withstand voltages:
S.No. Item Secondary Primary

1. Highest voltage for equipment 52 123
Um, kV
2. Rated short duration powerfrequency 95 230
withstand voltage, kV
3. Rated lightning impulse withstand voltage, 250 550

kV peak
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3.5.7 The windings shall be so designed that the transfer of lightning switching surges
from primary to secondary windings and vice-versa is kept to the minimum level.
3.5.8 The windings shall be designed to withstand the magnetizing inrush currents due to
repeated switching on of the transformer.
3.5.9 The axial pre - compression on the windings shall preferably be double the
calculated axial thrust that may be set up under dead short - circuit condition so as to
ensure that the windings do not become loose due to frequent short circuits in service.
3.5.10 During short circuits, the stresses actually set up in conductors, spacers, end
blocks, clamping rings and such other parts of the transformer shall not exceed one third of
the maximum permissible values.
3.5.11 Pre-compressed spacers shall be used between disc shaped coils of the windings to
transmit the axial forces generated due to the short circuits.
3.5.12 Wood insulation, if used, on the core and winding shall be seasoned, dried and
well compressed and shall have adequate strength.
3.5.13 A uniform shrinkage shall be ensured during the drying of the individual coils or
assembly of coils by providing a uniform clamping force with the help of hydraulic jacks or
similar such devices.
3.5.14 In order to cater for shrinkages that may occur in service, substantial clamping
rings shall be provided at the tops of the windings, being pressed down upon them by
means of adjustable pressure screws or oil dash pots or any other suitable device, so as to
maintain a constant pressure and obviate the need for any retightening in between
successive periodical overhauls.
3.5.15 The coil and core assembly shall be retightened after oil impregnation. The
successful tenderer / manufacture shall ensure that there is no further shrinkage of the coil
assembly in any additional cycle after the final curing.
3.5.16 The successful tenderer / manufacturer shall furnish details of various stages of
drying of coils, coil assembly upto and including oil impregnation and final tightening of
the coil assembly. Values of pressure, duration, temperature and degree of vacuum
maintained at various stages of drying shall also be indicated.
3.5.17 The core and winding of the transformer have to be dried preferably using vapour
phase drying. To ensure the removal of moisture from the transformer the PI value after
drying has to be achieved equal to or more than 2 in the manufacturing at the works.
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3.5.18 In order to keep unbalanced axial forces due to non - uniform shrinkage/unequal
height of the coils to the minimum wedges of pre - compressed wood or similar such
material shall be used.
3.5.19 To prevent displacement of the radial spacers used in the outermost windings,
closed slots shall be provided and a vertical locking strip shall be passed through these
slots, wherever necessary.
3.5.20 The vertical locking strips and slots of the radial spacers shall be so designed as to
withstand the forces generated due to short circuits.
3.5.21 The vertical locking strips and radial shall be made of pre-compressed pressboard
conforming to grade PSP: 3052 of DIN: 7733.
3.5.22 To prevent end blocks from shifting, pre - compressed pressboard ring shall be
provided in between the two adjacent blocks. Coils clamping rings made of densified
wood or mild steel shall be located in position with pressure screws.
3.5.23 Leads from the windings to the terminals, from the tap switch to the tapings of the
primary windings and other interconnections shall be properly supported and secured.
3.5.24 The following particulars / documents in respect of the radial spacer blocks
(winding blocks), vertical locking strips (axial ribs), end blocks, insulating cylinder,
angle rings, paper insulation of the conductor and coil clamping plates used in the
manufacture of the windings shall be furnished.
1. Reference to specification and grade of material.

2. Source(s) of supply.
3. Test certificates.
3.6 INSULATING OIL
The transformer shall be supplied with new inhibited mineral insulating oil
conforming to IS: 12463 and the additional requirements stipulated under clause 6.3.8.9. In
addition 10% extra oil by volume shall be supplied in non-returnable barrels. The
characteristic of the insulating oil before energisation of the new transformer and during its
maintenance and supervision in service shall conform to IS: 1866.
3.7 BUSHINGS AND TERMINAL CONNECTORS
3.7.1 Both the primary and secondary side bushings shall conform to IS: 2099. On the
primary side, 145 kV class OIP condenser bushings shall be used. On the secondary side,
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sealed draw rod/ solid stem type oil impregnated paper OIP condenser bushings shall be
used. The dimensions of the bushings shall conform to IS: 12676.
3.7.2 The bushings on primary and secondary sides shall be designed for a rated current of
600A and 2500 A respectively. The temperature rise of any part of the bushing shall not
exceed 400 C over an ambient temperature of 500 C while carrying the rated current
continuously.
3.7.3 The porcelain housing of bushing shall be of a single piece construction i.e. there
shall be no joint in the porcelain. The shed profile shall have a lip at the extremities but
free from ribs on the underside so as to avoid accumulation of dust and pollutants and to
3.7.4 The bushings shall have a non- breathing oil expansion chamber. The expansion
chamber shall be provided with an oil level indicator, which shall be so designed and
dimensioned that oil level is clearly visible from ground level.
3.7.5 A test tap shall be provided for dielectric or power factor measurement for OIP
bushings.
3.7.6 The bushings shall be designed for the following insulation level:
S.No. Item Secondary Primary
1. Highest voltage for equipment Um, kV 52 145
2. Rated short duration powerfrequency 95 275

3. Rated lightning impulse withstand voltage, 250 650

kV peak
3.7.7 The design and construction of the bushing shall be such that stresses due to
expansion and contraction in any part of the bushings shall not lead to its deterioration/
breakage.
3.7.8 The condenser bushings on secondary side shall be free from corona and shall not
cause radio interference.
3.7.9 The bushing terminals shall be provided with terminal connectors of bimetallic
type and conform to the following:
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1. Primary side: For 110 kV:

Rigid type terminal type connector to suit 28.62 mm overall dia,
ACSR conductor (Zebra), size 54/7/3.18 mm,based on RDSO’s
standard drawing no. ETI/PSI/P/11010 and shall match with the
size of 110 kV side bushing stud on the other side.
2. Secondary For 27 kV:

side: Expansion type terminal connector to suit 50 mm overall
diameter Aluminium tubular busbar based on the RDSO's standard
drawing No. ETI/PSI/P/11220.
3.7.10 The terminal connectors shall conform to IS: 5561. The design shall be such as to
be connected to the equipment terminal stud with a minimum of four 12 mm diameter
bolt, nuts, spring and flat washers. The fasteners shall conform to clause 3.12 of this
specification.
3.8 BUSHING TYPE CURRENT TRANSFORMERS
3.8.1 The 145 kV and 52 kV bushings on primary and secondary shall be so arranged as
to accommodate bushing type current transformers (BCTs) for the biased differential
protection of the transformer. The BCTs shall conform to IS: 2705 and meet with the
stipulations in clause 5.3 (20) of this specification.
3.8.2 The BCTs shall be so designed as to withstand thermal and mechanical stresses
resulting from frequent short circuits experienced by the transformer on which these are
fitted.
3.8.3 Apart from the BCTs required for the biased differential protection, a BCT of
accuracy class 5 and conforming to IS: 2705, with suitable tappings, shall be mounted
inside one of the bushings of the secondary side of the transformer for use with the
winding temperature indicator (WTI).
3.8.4 The BCTs and the bushings shall be so mounted that removal of a bushing
without disturbing the current transformers, terminals and connections or pipe work is
easy and convenient.
3.8.5 The leads from the BCTs shall be terminated in terminal boxes provided on the
bushing turrets. Suitable links shall be provided in the terminal boxes for shorting the
secondary terminals of the BCTs, when not connected to the external measuring circuits.
3.8.6 The leads from the secondary winding of the BCTs terminated in the terminal box
on the bushing turret upto the marshalling box shall be of 1100 V grade, PVC insulated,
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PVC sheathed, armoured, stranded copper cable of cross-section not less than 4 mm2 to
IS: 1554 (Part-I).
3.8.7 Cable glands of proper size shall be provided in the terminal boxes to lead in/lead
out the cables.
3.9 CLEARANCES
The relative orientation in space of the bushings fitted with terminal connectors, the main
tank, radiators, conservator, pressure relief device, oil piping and other parts when
mounted on the transformer shall be such that the various clearances in air from bushing
live parts shall not be less than the appropriate values given hereunder:

2. Minimum clearance, mm 500 1100
The same distance shall apply for clearance phase - to - earth including oil piping work,
conservator, pressure relief device and such other parts), phase to phase, and towards
terminals of a lower voltage winding.
3.10 ON LOAD TAP-CHANGER
On load tap changer shall be sourced from reputed manufacturer and it should be type
tested as per relevant IEC 60214 and test methods shall be in conformance to the
procedures indicated in IEC 60214. The OLTC shall have proven field performance.
Voltage shall be substantially constant at the untapped windings (secondary windings)
and variable at the tapped winding (primary winding). The category of regulation applied
shall be constant –flux variable voltage type (CFVV).
The 17 taps on-load tap changer shall be in tank type, divertor - selector type, single –
phase enclosure type, installed in a separated oil tank. It shall have range from
118.75 kV to 98.75 kV (+ 7 taps to - 9 taps) with per tap voltage of 1.25 kV. The voltage
ratio shall be checked according to the guaranteed figures and the tolerances stipulated in
the standards. The principal tap shall be on tap no. 8. There shall be 7 Taps for higher
input voltage and 9 taps for lower input voltage variation. On load tap changer shall have
maximum rated through current of 600 A to meet the normal rated load as well as non
cumulative over load at all the taps as mentioned in clause 5.3. The OLTC shall have BIL
rating corresponding to 145 kV class and short circuit withstand current as per relevant
IEC standard but not less than 8 kA for 3 seconds.
The OLTC must be designed to ensure to the prescribed and expected harmonic levels of
the system. The design of transition resistance and contacts shall be adequately taken care.
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The OLTCs should also be suitable for paralleling of three transformer of different
loading. The loading pattern will be furnished during ordering stage.
The full technical description shall be given as regards power and auxiliary circuits;
periodicity for checking and overhauling the power circuit shall be indicated in the
transformer maintenance manual.
3.10.1 The transformer shall be provided with local OLTC control cabinet and RTCC
panel. The tap changer shall have the following characteristics:
i The power circuit of the on-load tap changer shall be connected to the primary
windings and shall enable the required voltage variations.
ii The oil volume of the on -load tap changer unit must be separated from the tank
for core and winding oil.
iii 50 000 operations without any attention.
iv Motor operated for local as well as remote operation and external handle for
manual hand operation.
v Tap position indicators
vi Commutation current compatible with the overload current of transformer.
Necessary provisions be available to ensure that OLTC will not operate during
overloading.
vii Diverter switches shall be designed for high speed operation and shall be
interlocked to ensure that there is no possibility of an operation stopping in mid-
position. Arcing contacts shall be of tungsten alloy material.
viii Operating mechanism for on load tap changer shall be designed to go through one
step of tap change per command. Subsequent tap changes shall be initiated
only by a new or repeat command.
ix Local OLTC control cabinet shall be mounted on the tank in accessible
position. It should be adequately ventilated and provided with anti- condensation
metal clad heaters. All contactors relay coils and other parts shall be protected
against corrosion, deterioration due to condensation, fungi etc.
x Limit switches shall be provided to prevent overrunning of the mechanism and
shall be directly connected in the circuit of the operating motor. In addition, a
mechanical stop shall be provided to prevent over-running of the mechanism under
any condition.
xi A five-digit non resetable type counter shall be fitted to the tap changing
equipment to indicate the number of operations completed.
xii It shall not be possible for any two controls to be in operation at the same time.
xiii A suitable protection relay shall be connected on the oil pipe between the on- load
tap changer and the expansion vessel.
xiv Devices for ease of extraction for maintenance purpose.
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3.10.2 OLTC Control of Transformers
The on load tap changer of the single-phase transformer shall be suitable for local and
remote control. It shall be provided with necessary interface for its remote control
through SCADA. The control feature shall provide the following:
i) Local Electrical Control

a. ‘Local-Remote’ selector switch mounted in the local OLTC control cabinet shall
switch control the load tap changers as follows:
(i)When the selector switch is in ‘local’ position, it shall be possible to operate the
‘raise-lower’ control switches specified below. Remote control of the raise- lower
functions shall be prevented.
(ii) When the selector switch is in ‘remote’ position the local OLTC control
cabinet mounted ‘raise-lower’ switch specified below shall be in-operative.
Remote control of the raise/lower function shall be possible from the remote
control panel.
b. A ‘raise-lower’ control switch/push button shall be provided in the local OLTC
control cabinet. This switch shall be operative only when ‘local remote’ selector
switch is in ‘local’ position.
c. An OFF-ON tap changer control switch shall be provided in the local OLTC
control cabinet of the transformer. The tap changer shall be in-operative in the
OFF position.
ii) Manual Control
The cranking device for manual operation of the OLTC gear shall be removable and
suitable for operation by a man standing at ground level. The mechanism shall be
complete with the following:
a. Mechanical tap position indicators that shall be clearly visible from near the
transformer.
b. A mechanical operation counter.
c. Mechanical stops to prevent over cranking of the mechanism beyond the extreme
tap positions.
d. The manual control considered as back up to the motor operated load tap changer
operation. The manual operating mechanism shall be labelled to show the direction
of operation for raising / lowering.
3.10.3 Remote Tap Changer Control Panel
The contractor shall supply a Remote Tap changer control (RTCC) panel suitable for
remote operation of on load tap changing gear.
The RTCC panel shall house actuating switch for electrical raise/lower control, tap
position indicator, signal lamps for “Tap change in progress” and “Tap changer out of step”
and all other auxiliary devices for remote electrical control of the OLTC.
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3.10.4 Voltage Regulation through Parallel Operation and AVR (Automatic voltage
regulator)
The traction power transformers at the traction sub stations shall be able to be
operated in Parallel. The approximate distance between such traction sub stations
may be in range of 10 - 20 kms. AVR (Automatic voltage regulator) shall be
provided to maintain the voltage in the desired range and also to ensure the desired
Transformers are at the same tapping point. It should have both automatic and
manual provisions. It should be possible to operate the OLTC through remote and
the required control panel shall be provided. The servo –mechanism settings shall
be designed and executed to avoid too many actuation .The manufacturers shall
provide technical and directional diagrams. The AVR shall have following
features/characteristics.
• Automatic voltage control shall be initiated by a voltage-regulating relay of

field proven make and suitable mounting. The AVR shall easily be
extendable with functions for monitoring and cooling of transformers.
• The nominal reference voltage derived from a circuit mounted 1 phase

Voltage transformer (VT)
• The AVR shall be microprocessor based numerical relay with illuminated

graphical LCD display
• The relay shall have 3 independent selectable reference voltage levels
• The following methods for voltage compensation shall be

adjustable
a) Active Current (Line Drop Compensation)
b) Reactive current (Z-Compensation)
• The bandwith shall be adjustable between 0.5% to 9.0% in steps of 0.1% of

the desired voltage level
• The time delay for regulation shall be selectable within limits of 1 - 600
seconds. Either linear or integral time behaviour shall be possible. Separate
setting of delay time T2 for deviation above 2 taps difference is required.
• The relay shall be equipped with undervoltage and overcurrent

blocking facility which shall make the control inoperative if voltage falls below the
respond threshold and can be adjusted by percentage value. Overvoltage detection
shall send periodic impuls signals without regard of the adjusted time delay.
• The standard LDC display of the relay shall have facility to indicate the
following integrated features:
a) display of OLTC tap position

b) Measurement Voltage
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c) Reference Voltage
d) Actual deviation (bandwidth)
e) Load current, Active power, Reactive power, Apparent power, phase
angle, Power factor, Frequency.
• The unit shall have the facility to compensate the VT and CT- errors.
• To provide easy and fast installation the AVR shall be equipped with
NORMSET functionality.
• The unit shall be equipped with measurement recorder for voltage, current and
tap position. Those data as well as power P, Q, S and Cos phi shall be stored up
to one year. The measurement is adjustable by 1, 2, 4, 10, 20 or 40 seconds. A
separate event recorder for over- and undervoltage records all measured values
every 300ms. The recorded values shall be presented in graphical format on the
device and on the connected computer.
• The Unit shall have facility to make selection of Auto / Manual and Local /
Remote either directly on the device or via remote signal.
• The Unit shall have different LEDs to indicate transformer protection alarms
(U<, U>, I<)
• The Unit shall in addition be equipped with at least 4 freely programmable LEDs
in different colors to indicate different Operations / Alarm / Faults conditions.
• The unit shall be able to take Tap position via BCD input (digital signal) from
OLTC
• without any additional transducers.
• The Unit shall be equipped with at least 12 free programmable binary in- and outputs
• The Unit shall have facility to monitor and control the following
transformer parameters:
a) Life time consumption of transformer
b) Recording of Hot spot temperature
c) Measurement and recording of Oil temperature
• The Unit shall be delivered with WIN-based visualisation software to make
the parameter settings of the device and it shall also be possible to do the
parameter setting through keyboard of relay.
• The Unit shall be able to communicate with higher level Computer Control
System either via fibre optical serial interface RS485 or RS232 and protocol
IEC60870-5-103
• The Unit shall be capable to be easily extended with additional functionalities
after several years in operation. This contains the extension of hardware for
additional
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signals and the extension of functionalities (e.g. parallel operation of transformers)

without replacement of the existing device.
3.10.5 Auxiliary power supply and control supply
Auxiliary supply of single phase AC 240 Volts (varying from 180 to 270 Volts) and
control supply of DC at 110 volts (varying from 77 to 121 Volts) are available at the
traction sub station for OLTC.
3.11 COOLING EQUIPMENT
3.11.1 The transformer shall be designed for ONAN type of cooling.
3.11.2 The radiators shall consist of a pressed steel plate assembly formed into elliptical
oil channels (as per IEEMA (Indian Electrical & Electronic Manufactures Association)'s
standard) or a series of separate elliptical tubes. The radiators shall be designed in such a
manner that the temperature - rise limits specified under Clause 5.3 (13) of this
specification are not exceeded. Collector/ header pipes in the radiators are to be ERW
pipes of thickness 4.5 mm. The external painting of the radiator has to be as per clause
3.13 of this specification. The radiators & accessories should be given external paint
coats - first coat of epoxy zinc rich (having minimum 83% metallic zinc) primer (50
micron thickness), intermediate coat of epoxy chemical and corrosion resistant High
Build Epoxy Intermediate paint (100 micron thickness) and final coat of Glossy Aliphatic
Acrylic Polyurethane Coating paint (50 micron thickness). The total dry film thickness of
the paints shall be minimum 200 micron. The shade of paint shall be gray as shade 631 of
IS: 5.
3.11.3 The radiators shall be removable (after isolating the same from the main tank) to
facilitate transportation of the transformer. A drain plug of size 19 mm and an air -
release plug of size 19 mm shall be provided at the bottom and at the top of each radiator
bank for draining and filling of oil respectively. Each radiator bank shall also be provided
with shut - off valves of size 80 mm shall be used between tank and headers.
3.11.4 The radiators shall preferably be supported directly on the transformer tank. Each
radiator bank shall be fitted with two hooks, one at the centre for lifting the radiator and
the other for tying the unit in service.
3.12 FASTENERS
All fasteners of 12 mm diameter and less exposed to atmosphere shall be of stainless

steel and those above 12 mm diameter shall preferably be of stainless steel or mild steel
hot dip galvanized to 610 g / m2 of zinc. The material of the stainless steel fasteners
shall conform to IS: 1570 (Part- V). Grade 04Cr17Ni12Mo2
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3.13 PAINTING
3.13.1 Shot blasting / sand blasting shall be done on the transformer tank to remove all
scales, rust and other residue before applying the paint inside the tank. All steel surfaces
which are in contact with insulating oil shall be painted with heat resistant oil - insoluble
insulating varnish.
3.13.2 All steel surfaces exposed to weather shall be descaled /grit blasted. The epoxy
and polyurethane protective paints as per ISO/EN 12944 have to be provided for proper
protection against corrosive and coastal environments and give life of approx. 12-15
years. All the external surfaces of the Transformer shall be given first coat of epoxy zinc
rich (having minimum 83% metallic zinc) primer (50 micron thickness), intermediate
coat of epoxy chemical and corrosion resistant High Build Epoxy Intermediate paint (100
micron thickness) and final coat of Glossy Aliphatic Acrylic Polyurethane Coating paint
(50 micron thickness). The total dry film thickness of the paints shall be minimum 200
micron. The shade of paint shall be gray as shade 631 of IS: 5. Same paints have to be
applied at damaged surfaces, if any, at site during erection /commissioning of the
transformer. One final coat of polyurethane paint has to be applied to ensure proper
smoothness and finish.
4.0 LIST OF RELATED SPECIFICATION
4.1 In the preparation of this specification, assistance has been derived from the
following standards and codes of practices (latest version), and Indian Electricity Rules
wherever applicable.
1 IS:5 Colours for ready mixed paints and enamels.

2 IS/EN 12944 Protective Paint Systems
3 IS: 12463 New insulating oils.
4 IS:1554 (part-I) PVC insulated (Heavy duty) electric cables for working
voltages up to and including 1100 volts.
5 IS:1570 (Part-V) Stainless and heat resisting steels.
6 IS:1576 Solid pressboard for electrical purposes.
7 IS:1866 Code of practice for maintenance and supervision of
mineral insulating oil in equipment.
8 IS:2026 Power transformers.
9 IS:2099 Bushing for alternating voltages above 1000 volts.
10 IS:2705 Current transformers.
11 IS:2927 Brazing alloys.
12 IS:3024 Electrical steel sheets (oriented).
13 IS:3637 Gas operated relays.
14 IS:3639 Fittings and accessories for power transformers.
15 IS:4253 Cork and rubber.
16 IS:5561 Electrical power connectors.
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17 IS:5621 Hollow insulators for use in electrical equipment.

18 IS:5728 Guide for shot- circuit calculations.
19 IS:6209 Methods for partial discharge measurements.
20 IS:6600 Guide for loading of oil - immersed transformers.
21 IS:8468 On load tap changers.
22 IS:10028 Code of practice for selection installation and maintenance of
transformers.
23 IS:10593 Method of evaluating the analysis of gases in oil- filled electrical
equipment in service.
24 IS:12676 Oil impregnatedpaperinsulatedcondenserbushings- dimensions and
requirements.
25 IEC:76 Power transformers.
26 IEC:137 Bushings for alternating voltages above 1000 volts.
27 IEC:185 Current transformers.
28 IEC 60214 On load tap changers
29 DIN:7733 Laminated products, pressboard for electrical engineering, types,
specification, the later shall prevail.
4.3 Any deviation from this specification, proposed by the tenderer, calculated to
improve the performance, utility and efficiency of the equipment, will be given due
consideration provided full particulars of the deviations with justification therefore, are
furnished. In such a case, the tenderer shall quote according to this specification and the
deviations, if any, proposed by him shall be quoted as an alternative/ alternatives.
5.0 Rating, name-plate details and other information
5.1 The rating plate shall indicate the ratings of the transformer, the connection
diagram of the windings, the particulars of the bushing current transformers and other
details as per IS: 2026. The rating plate shall be both in English and Hindi version.
5.2 The short- circuit apparent power at the transformer location for various system
voltages is as under:
Highest system voltage Three Phase Short - circuit apparent power

kVrms) (MVA)
123 10000
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5.3 Particulars of the System

The rating and general data of the transformer shall be as follows:
1. Type : ONAN cooled, single phase, step-down power

transformer, double limb wound, core -type for outdoor
installation.
2. Windings : Uniformly insulated concentric disc duly interleaved /

intershielded.
3. Rated frequency, Hz : 50 +/-3%
4. Rated primary voltage Un, kV : 110 (However there may be

voltage variation from 90 to 121 kV)
5. Highest Primary
system voltage Um, kV : 123
6. Rated secondary voltage : 27

(at no-load), kV
7. Rated power, MVA : 30
8. Rated current at the principal tapping

1. Rated primary current, A : 273
2. Rated secondary current, A : 1111
9. Maximum value of Percentage Impedance at the (16 +/- 0.5)% at principal tap &
principle and extreme tap positions at 30 MVA between 15 to 17 % at extreme tap
base. position
(Absolute value of transformer
impedance at all the taps shall be
within 15 to 17 % of the base
value at principal tap)
11. Non - cumulative over load capacity after the 1. 150% rated load for 15
transformer has reached steady temperature on min
continuous operation at rated load( i.e. at rated
power) 2. 200% rated load for 5
min
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Note: Non cumulative power load means overload which occur at sufficient interval of
time apart such that the temperature rise limits, both of oil and winding do not exceed the
values specified in clause 5.3 (13) of this specification .The interval of time between two
successive non cumulative overloads shall not be less than 3 hours.
11. Polarity : Subtractive
12. Tappings : A separate tapped winding on the primary

(On load tap changer) winding to give rated secondary voltage for
variation in primary voltage from 118.75
kV to 98.75 kV, in steps of 1.25 kV each.
7 Taps for higher input voltage and 9 taps
for lower input voltage variation.
(However the voltage variation on primary
may be from 90 to 121 kV)
OLTC shall be of 145 kV voltage class and
shall have maximum rated through current
not less than 600 A, short circuit withstand
current not less than 8 kA for 3 seconds.
13. Temperature rise The temperature rise over an ambient

temperature of 500C both at rated and
overload conditions shall not exceed the
value indicated below:
1. Winding: 50 0C at rated load, and 60 0C
for overloads as specified in Clause 5.1(10)
(temperature measured by resistance method).
2.Top oil:400C(temperature rise measured
by thermometer).
3. Current carrying parts in air: 40 0C
(temperature rise measured by thermometer).
14. Maximum permissible losses at rated frequency, voltage, current and at the
principal tapping
1. Max. No-load loss (kW) 15

2. Max Load loss (kW) 117
3. Total loss (kW) 132
15. Ability to withstand short circuit

1. Thermal ability : 5s
2. Dynamic ability : 0.25 s
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16. Flux density at rated voltage and : Shall not exceed 1.55 tesla
frequency at principal tapping (Flux density
has not to exceed 1.90 tesla at any of the
taps at extreme voltage condition)
17. Current density in the windings at : Shall preferably not exceed 2.5
rated current A/mm2
18. Acoustic sound level when energized at : Not more than 75 dB at a

rated voltage and at no-load distance of one meter.
19. Bushings:
Item Secondary Primary
1. Type OIP condenser OIP condenser 52 145

2. Highest voltage for equipment
Um, kV
3. Rated current, A 2500 600
4. Minimum creepage distance in air , 1600 3625
mm
20. Bushing type current transformers for differential protection

of transformer:
Item Secondary Primary
1. Highest voltage for equipment 52 123
Um, kV
2. CT ratio 3000/5 600/5
3. Frequency , Hz 50 +/- 3 %
4. Class of accuracy as per IS PS

2705 (Part IV)
5. Minimum knee -point emf , V 360 175
6. Maximum excitation current at

knee - point voltage , A 0.100 0.75
7. Maximum resistance of the

secondary winding , ohm 0.9 0.25
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6.0 Inspection and Testing
6.1 Inspection
The inspection of the transformer shall be carried out by an authorized representative of

the Indian Railways as per purchase order. Prototype inspection shall be done by
RDSO. After successful completion of all the type and routine tests as per this
specification, prototype approval shall be issued by RDSO. After approval of prototype,
inspection and routine tests on the balance quantity shall be done by the authorized
representative of the Indian Railways as per purchase order.
6.1.1 Only after all the designs and drawings have been approved and clearance given to
this effect by RDSO, the manufacturer shall take up manufacture of the prototype for
inspection/testing by RDSO. It is to be clearly understood that any changes to be done on
the prototype as required by RDSO, the same shall be done expeditiously.
6.1.2 Prior to giving a call for inspection and testing of the prototype, the successful
tenderer/manufacturer shall submit a detailed test schedule consisting of test procedures,
schematic circuit diagrams, items/parameters to be checked and values required as per
specification for each of the tests and the number of days required to complete all the
tests at one stretch. The schedule shall also indicate the venue of each of the tests.
Once the schedule is approved, the tests shall invariably be done accordingly. However,
during the process of type testing or even later, the DG/TI/RDSO, Lucknow reserves the
right to conduct any additional test(s), besides those specified herein, on any
equipment/item so as to test the equipment/item to his satisfaction or for gaining
additional information and knowledge. In case any dispute or disagreement arises
between the successful tenderer/manufacturer and the representative of the DG/TI/RDSO,
Lucknow during the process of testing as regards the procedure for type tests and/or the
interpretation and acceptability of the results of type tests, it shall be brought to the notice of
the DG/TI/RDSO, Lucknow as the case may be whose decision shall be final and
binding. Only after the prototype of the equipment is manufactured and ready in
all respects, shall the successful tenderer/manufacturer give the actual call for the
inspection and testing with at least 15 days notice for the purpose.
any reason attributable to the successful tenderer/manufacturer and it is required for the
representative of the DG/TI/RDSO, Lucknow to go again or more number of times to the
works of the successful tenderer/manufacturer or to any NABL approved testing
house/laboratory where tests are being done for continuing and/or completing the tests on
the prototype(s) of the equipment, the successful tenderer/manufacturer shall reimburse to
the DG/TI/RDSO the cost for the representative(s) having to visit the works or other
place(s) for the tests more than once. The cost as claimed by the DG(TI)/RDSO,
Lucknow shall be paid through a Demand Draft to the concerned Accounts Officer of the
DG/TI/RDSO Lucknow as shall be advised to the successful tenderer/manufacturer.
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6.1.4 The tests shall be conducted on the prototype of the transformer at the works of
the manufacturer or at any NABL approved testing house or laboratory in the presence of
DG (TI)/RDSO, Lucknow or his authorised representative. The prototype shall be
complete in all respects, including the terminal connectors as would be supplied if it had
passed the tests.The tests shall be conducted to the governing specification and as
modified or amplified herein.
6.1.5 For tests conducted in the laboratories of Central Power Research Institute,
Bhopal/ Bangalore, Electrical Research Development Association, Vadodara or any such
testing house or laboratory, a certificate to the effect that the equipment has passed the
tests as per specification shall be obtained by the manufacturer and submitted to the DG
(TI), RDSO, Lucknow. Full details of the tests and test parameters shall be furnished
along with the test reports.
6.1.6 The type tests may, at the discretion of the DG (TI)/RDSO, also be carried out on
one or more of the following equipments:
- Equipment completely manufactured at the manufacturer's works overseas.
- Equipment assembled in India using CKD if the tenderers so desire.
- Equipment indigenized by the Indian Manufacturer (stages/indigenization levels
at which the type tests will require to be carried out, will be settled mutually
between the Indian manufacturer and the Railways, in consultation with the
collaborator.)
6.1.7 All the testing /measuring equipments shall be duly calibrated by a master
traceable to National Standards.
6.1.8 Irrespective of the equipment being a standard/proven item of the manufacturer

for which type tests have already been conducted and the test results are available, the
type tests shall nevertheless, be conducted for the procurement against this specification.
The type tests and the routine tests to be carried out on the equipment, as part of above
inspection, are given below.
6.1.9 The type tests shall be carried out in accordance with TIQ 2001 Ver.1, Quality
Plan For Traction Power Transformer Prototype testing & with the relevant standards as
modified or amplified by the specification where ever applicable, at the works of the
successful tenderer /manufacturer, or at a reputed testing laboratory in the presence of the
authorized representative of the DG/TI/RDSO, Lucknow. Successful tenderer shall
furnish the type and routine test schedule based on the RDSO specification for approval
before commencement of tests.
6.2 Tests during manufacture
Though the tests described below shall form a part of the type tests, the
manufacture shall carry out these tests on each and every unit during the process of
manufacture and submit the test reports to the Purchaser's Inspector deputed for
witnessing the routine tests:
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1. Oil leakage test.

2. Vacuum test.
3. Pressure test.
4. Insulation test for core bolts.
5. Test for pressure relief device.
6.2.1 Oil leakage test: The transformer with its radiators, conservator tank and other
parts, fittings and accessories completely assembled shall be tested for oil leakage by
being filled with oil conforming to IS: 12463 at the ambient temperature and subjected to a
pressure corresponding to twice the normal static oil head or to the normal static oil
head plus 35 kN/m2 (0.35 kgf/cm2), whichever is lower, the static oil head being
measured at the base of the tank. This pressure shall be maintained for a period of not less
than 12 h, during which time no leakage shall occur.
6.2.2 Vacuum test: The transformer tank only shall be tested at a vacuum of 3.33
kN/m (0.0333 kgf/cm2) for 60 min. The permanent deflection of flat plates after release
2
of vacuum shall not exceed the values specified below:
Horizontal length of flat plate Permanent deflection, mm

Upto and including 750 mm 5.0
751 mm to 1250 mm 6.5
1251mm to 1750 mm 8.0
1751 mm to 2000 mm 9.5
2001 mm to 2250 mm 11.0
2251 mm to 2500 mm 12.5
2501 mm to 3000 mm 16.0
Above 3000 mm 19.0
6.2.3 Pressure test: Every transformer tank, radiator and conservator tank shall be
subjected to an air pressure corresponding to twice the normal static head of oil or to the
normal static oil head pressure plus 35 kN/m2 (0.35 kgf/cm2), which ever is lower, as
measured at the base of the tank. The pressure shall remain constant for 1 h to indicate
that there is no leakage.
6.2.4 Insulation test for core bolts: This test shall be done as described in Clause 3.4.4
of this specification.
6.2.5 Test for pressure relief device: Every pressure relief device shall be subjected to
gradually increasing oil pressure. It shall operate before the pressure reaches the test
pressure specified in Clause 6.2.3 hereof and the value at which it has operated shall be
recorded.
6.2.6 The purchaser may, if he so desires, carry out any checks or tests on the quality of
manufacture at any stage during coil winding, drying of coils, assembly of coils on core
and method of drying, vacuum impregnation, tightness of core clamping bolts, adequacy
of pressure on coils or any other aspects as deemed so as to ensure that proper quality is
maintained.
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6.3.1 Type tests
The type tests shall be carried out on the prototype transformer at the works of the
successful tenderer/manufacturer or at any NABL approved testing house or laboratory in
the presence of the representative of the purchaser /DG (TI), RDSO, Lucknow, and in
accordance with the relevant specifications and as altered, amended or supplemented by
this specification. The following shall constitute the type tests:
1. Temperature - rise test.
2. Lightning impulse test.
3. Test with lightning impulse, chopped on the tail.
4. Short - circuit test.
5. Measurement of acoustic sound level.
6. Measurement of partial discharge quantity.
7. Measurement of harmonics of no - load current.
6.3.1 Temperature - rise test
6.3.1.1 The temperature - rise test shall be done with the tap changer on the lowest tap
position (- 9 tap) with IS: 2026 ( Part II) except as modified hereunder:
1. At rated load.
2. At 150% rated load for 15 min after continuous operation at rated load for
1 h.
3. At 200% rated load for 5 min after continuous operation at rated load for
1 h.
The tests shall be done continuously without any power supply interruption. In case
interruptions of power supply do take place for some reason, then the entire test shall be
repeated after steady state conditions are attained.
6.3.1.2 The points to be ensured during the temperature - rise test shall be:
1. The ambient temperature shall be measured using alcohol in glass

thermometers only.
2. The winding temperature shall be determined by the resistance method only.
3. The temperature of the top oil shall be measured by an alcohol in
glass thermometer placed in an oil- filled thermometer pocket.
4. The average oil temperature shall be calculated as the difference between
the top oil temperature and half the temperature drop in the cooling
equipment (radiators).
396
5. The temperature of the hot - spot in the winding shall be the sum of
the temperature of the top oil and 1.1 times the temperature rise of the
winding above the average oil temperature.
6.3.1.3 The test shall be carried out as described below:
6.3.1.3.1 100% load
1. A quantum of power equal to the sum of the measured losses viz. No- load loss
and load losses measured at minus 9 tap position, corrected to 750C plus
10 % of such sum shall be fed to the primary winding of the transformer with the
secondary windings short- circuited.
2. The power so fed to the transformer shall be continuously maintained till such time
as the steady state temperature is reached i.e. the top oil temperature rise does not
vary by more than 10 C during four consecutive hourly readings.
3. On attaining the steady state temperature, the current in the primary winding of the
transformer shall be brought to the rated current which shall be maintained
for 1 h. At the end of the period the power supply to the transformer shall
be switched off and the time of switching off recorded.
4. The measurement of hot resistance shall commence as soon, as is possible after
switching off. The first reading of the resistance shall be taken before the expiry
of 90 s from the instant of switching off and the first ten readings shall be taken at
intervals of 15 s apart. Thereafter, another ten readings shall be taken at intervals of
30 s apart.
5. The time at which each of the resistance values is read shall also be recorded.
6. The temperature of the ambient, top oil, the top and bottom radiator header oils
shall also be recorded at half - hourly intervals through out the test starting
from the instant power supply is switched on to commence the test till it is
switched off.
7. The WTI and OTI readings shall also be recorded at half-hourly intervals right
from the instant the power supply is switched on to commence the test till it is
switched off.
8. After power supply is switched off, the readings of OTI and WTI shall be
recorded at intervals of 1 min apart for 30 min.
6.3.1.3.2 150% load
1. After completion of the test at 100 % load, the transformer shall be fed with
power, which shall be a value so as to cause circulation of the rated current in the
primary winding with secondary windings short - circuited. This current shall be
circulated for 1 h.
2. The current shall thereafter be increased to 150 % of the rated current and
maintained for a period of 15 min. At the end of the 15 min period, the power
supply shall be switched off and the time of switching off shall be recorded.
3. Thereafter the readings as indicated in Clauses 6.3.1.3.1(4 to 8) shall be
recorded.
397
4. The temperature of ambient, top oil, the top and bottom radiator header oils and
the temperatures indicated by OTI and WTI shall also be recorded at the time of
switching on 150% load as well as at the time of switching off the power supply.
6.3.1.3.3 200% load
1. After completion of the test at 150 % load, the transformer shall be fed with
power, which shall be a value so as to cause circulation of the rated current in the
primary winding with secondary windings short - circuited. This current shall be
circulated for 1 h.
2. The current shall thereafter be increased to 200% of the rated current and
maintained for a period of 5 min. At the end of the 5 min period, the power
supply shall be switched off and the time of switching off shall be recorded.
3. Thereafter the readings as indicated in Clauses 6.3.1.3.1 (4 to 8) shall be
recorded.
4. The temperature of ambient, top oil, the top and bottom radiator header oils and
the temperatures indicated by OTI and WTI shall also be recorded at the time of
switching on 200% load as well as at the time of switching off the power supply.
6.3.1.4 Determination of thermal time constant of the windings: The thermal time
constant of the primary and secondary windings under both rated and overloads
shall be verified during the temperature - rise tests.
6.3.1.5 The temperature rise of the oil, windings and current carrying parts in air under
both the overloads conditions stipulated in Clauses 6.3.1.3.2 and 6.3.1.3.3 above
shall not exceed the values stipulated in Clause 5.3 (13) of this specification. The
winding hot - spot temperature under the overload conditions shall not exceed 1150
C.
6.3.1.6 Testing and calibration of the temperature indicators: The functioning of the
OTI and WTI shall be verified during the tests described above. Both the OTI and
WTI shall be recalibrated, if necessary, to reflect the respective temperatures
correctly. In particular, the reading of the WTI shall be same as the calculated
value of the hot - spot temperature of the winding.
6.3.1.7 Determination of the thermal time constant of the WTI: The thermal time
constant of the WTI shall be determined for comparison with the thermal time
constant of the winding of the transformer with respect to the transformer oil. For
this purpose, the indications of the WTI and the OTI shall be recorded every 1 or 2
min during the first 1 h from the instant the transformer is loaded. From the slope
of the curve plotted with the time on the X - axis and the difference between the
readings of the WTI and OTI at the particular time on the Y - axis, the thermal time
constant of the WTI shall be determined. This value shall not vary appreciably
from the thermal time constant of the winding as calculated theoretically and as
ascertained from the slope of the cooling curves.
398
6.3.1.8 The Dissolved Gas Analysis shall be conducted on the sample of oil drawn from
the transformer tank before & after temperature rise test.
6.3.2 Lightning impulse test
6.3.2.1 This test shall be done in accordance with IS: 2026 (Part III). Each of the
terminals of the primary and secondary windings shall be tested with the
following voltages:
1. Highest voltage for equipment, Um, kV 52 123

2. Lightning impulse withstand voltage, kV peak 250 550
6.3.3 Test with lightning impulse, chopped on the tail
This test shall be done in accordance with IS: 2026 (Part III) with the appropriate
test voltage stipulated in Clause 6.3.2.1 above.
6.3.4 Short - circuit test
6.3.4.1 The short- circuit test shall be conducted in accordance with IS: 2026 (Part I) with
the following schedule:
6.3.4.2 Prior to commencement of the test, the following measurements/ tests shall be
made:
1. Insulation resistance of the windings with respect to the earth and between
the windings.
2. No- load current.
3. No- load loss.
4. Resistance of the windings.
5. Percentage impedance voltages.
6. Load loss.
7. Voltage ratio.
8. Di- electric tests comprising:
1) Separate - source voltage withstand test, and
2) Induced over-voltage withstand test.
9. Recording of recurrent surge oscillogram (RSO) at the highest (+ 7 tap),
lowest (- 9 tap) and principal tapping.
6.3.4.3 The test shall preferably be done by closing the breaker on the secondary side
after energizing the primary winding at its rated voltage.
6.3.4.4 The transformer shall be subjected to a total of seven shots in the following
sequence:
399
1 st shot - Symmetrical current at the highest tap (+ 7 tap).

2 nd shot - Asymmetrical current at the highest tap (+ 7 tap).
3 rd shot - Asymmetrical current at the principal tap.
4 th shot - Symmetrical current at the principal tap.
5 th shot - Symmetrical current at the lowest tap (- 9 tap).
6 th shot - Asymmetrical current at the lowest tap (- 9 tap).
7 th shot - Symmetrical current at the lowest tap (- 9 tap).
6.3.4.5 The operation of each shot shall be 0.25 s.
6.3.4.6 Measurements shall be done after each shot for the following:
1. Percentage impedance voltage.

2. No-load current.
3. No- load loss.
6.3.4.7 Further testing and inspection of the transformer subjected to the short-circuit test
shall be carried out as per IS: 2026 (Part-I) with the modification that:
1. The dielectric routine tests shall be at 100% of the original test value.
2. The percentage impedance voltages measured after the short-circuit test
shall not vary by more than 2% from those measured before the short-
circuit test.
6.3.4.8 On completion of the short-circuit test the transformer shall be untanked for
inspection of the core and windings. In case the inspection of the core and
windings do not reveal any apparent defects and the results of the short – circuit
test, the values of percentage impedance voltages as also the results of the routine
tests done after the short- circuit test are in order, the transformer shall be deemed
to have passed the short-circuit test. If any of the results of the tests are not in
order or the inspection of core and windings reveals any defect, then the
transformer shall necessarily have to be dismantled completely for detailed
inspection.
6.3.4.9 Frequency response analysis (FRA) of the prototype transformer is to be

preferably carried out before and after the short circuit test to judge the healthiness
of the transformer after short circuit and this can be kept as reference for
future. Similar Frequency response analysis (FRA) records for other transformer
units may preferably be furnished to be used for future reference.
6.3.5 Measurement of acoustic sound level
Measurement of acoustic sound level of the transformer, energised at rated

voltage and frequency shall be carried out either as per Indian Electrical &
Electronics Manufacturers Association (IEEMA) or as per National Electrical
Manufacturers Association (NEMA) procedure.
400
6.3.6 Measurement of Partial discharge quantity
Partial discharge quantity of the windings shall be measured in accordance with

IS: 6209 and IS: 2026 (Part – III).
6.3.7 Measurement of harmonics of no- load current
The magnitude of harmonics of no- load current, as expressed in percentage of the

fundamental, shall be measured by means of a harmonics analyzer, in accordance with
IS: 2026 ( Part- I ).
6.3.8 Type tests on parts, fittings and accessories
The tests on the various parts, fittings and accessories shall be conducted as described
below.
6.3.8.1 On load tap – changer
6.3.8.1.1 Tests shall be carried out thereon in accordance with relevant IEC 60214 / IS: 8468.
6.3.8.1.2 Test for temperature rise of contacts: the test shall be carried out at
rated current. The temperature rise shall not exceed the limit specified in IS: 8468.
6.3.8.1.3 Mechanical endurance test: With the tap-changer in oil, 100 operations
shall be done manually and 10,000 operations shall be done with the motor drive unit.
An operation shall comprise moving the tap-changer from one tap position to the next
higher or lower tap position. All the taps of the tap- changer i.e. + 7 tap position to the –
9 tap position shall be covered during the test. While testing with the motor drive unit
the applied voltage for the motor drive unit shall be adjusted to the values indicated
below, and the number of operations at each value of voltage shall be as indicated against
each.
1. At the minimum voltage 2500 operations

2. At the maximum voltage 2500 operations
3. At the rated voltage 5,000 operations.
6.3.8.1.4 Milli- volt test: The test shall be done both before and after the
mechanical endurance test to assess the condition of the contacts. The variation in the milli-
volt drop values shall be not more than 20 %.
6.3.8.1.5 Short- circuit current test: The test shall be done in accordance with
IEC 60214/ IS: 8468 with short –circuit currents as mentioned in clause 3.10.
401
6.3.8.1.6 Dielectric tests: The tests shall be done in accordance with IEC 60214/
IS:8468.
6.3.8.1.7 Auxiliary circuits insulation tests: Auxiliary circuits including the

motor and other auxiliary equipment shall be tested in accordance with IS: 8468.
6.3.8.2 Condenser bushings
6.3.8.2.1 The type tests shall be carried out in accordance with IS: 5621 on
porcelain housing of the condenser bushings. The following shall constitute the type tests:
1. Visual inspection.
2. Verification of dimensions.
3. Electrical routine test.
4. Porosity test
5. Temperature cycle test.
6. Bending test.
6.3.8.2.2 The type tests shall be carried out in accordance with IS: 2099 on
the prototype of the condenser bushings. The following shall constitute the type tests:
1. Wet power frequency withstand voltage test.

2. Dry lightning impulse voltage withstand test.
3. Thermal stability test.
4. Temperature rise test.
5. Thermal short time current withstand test.
6. Dynamic current withstand test.
7. Cantilever load withstand test.
8. Tightness test.
9. Test of tap insulation.
10. Tightness test at flange or other fixing device.
11. Measurement of partial discharge quantity.
6.3.8.3 Bushing type current transformers

The bushing type current transformers shall be tested in accordance with IS: 2705
(Part-I & IV).
6.3.8.4 Buchholz relay

The Buchholz relay shall be tested in accordance with IS: 3637.
6.3.8.5 Terminal connectors

The terminal connectors shall be tested in accordance with IS: 5561.
402
6.3.8.6 Temperature indicators
The following tests shall be conducted on prototypes of OTI and WTI.
1. Accuracy with reference to a standard instrument.

2. Calibration of the indicators to reflect the actual temperature of the
oil/winding.
3. Dielectric test at 2.5 kV for 60 s.
4. Vibration test.
5. Dust and water splash test to IP 55 degree of protection.
6.3.8.7 Pressure relief device
The following tests shall be conducted on the prototype of pressure relief device:
1. Air pressure test.

2. Leakage test.
3. Contact rating and operation test.
4. Dielectric test on contacts at 2.5 kV for 60 s.
6.3.8.8 Radiators
The radiators shall be tested for air leakage at a pressure of 2.5 kg/cm sq. The pressure
shall remain constant for 1 h to indicate that there is no leakage.
6.3.8.9 Insulating Oil
The tests shall be carried out in conformity with IS: 12463 on the sample of new inhibited
mineral insulating oil for use in the transformer. In addition to the requirement of IS:
12463, the insulating oil filled in the transformer shall also meet the following
characteristics-
(i) Oxidation Stability (test method as per IS: 12422)
a. Neutralization value after oxidation (max.):0.2mgKOH/g

b. Total sludge value after oxidation (Max.): 0.05% by mass
(ii) SK value: less than 8%
(iii) Oxidation inhibitor (DBPC) content: 0.25 to 0.3 % by mass.
403
6.4 Routine tests
The following routine tests shall be performed on each transformer including the prototype
unit in accordance with IS: 2026:
1. Visual examination
2. Insulation resistance test.
3. Measurement of no- load current.
4. Measurement of no- load loss.
5. Measurement of resistance of the windings.
6. Measurement of percentage impedance voltages.
7. Measurement of load loss.
8. Polarity test.
9. Voltage ratio test.
10. Dielectric tests comprising:
1)Separate- source voltage withstand test, and
2)Induced over voltage withstand test.
11. Recording of recurrent surge oscillogram (RSO).
12. Tests on on load tap- changer.
13. Measurement of capacitance and tan-delta values
6.4.1 Visual examination: A general examination shall be made to check that the
transformer conforms to the approved drawings. Various items are accessible for
maintenance, the quality of workmanship and finish are of acceptable standards and all
parts, fittings and accessories are provided.
6.4.2 Insulation resistance test: The insulation resistance of the windings with respect to
the earth and between the windings shall be measured using a 5 kV megger.
6.4.3 Measurement of no – load current: Measurement of no- load current referred to

the primary side shall be done at:
1. 90%, 100% and 110% of the rated voltage at the principal tapping, and
2. the appropriate tap voltage at the + 7 tap and – 9 tap positions.
6.4.4 Measurement of no- load loss: Measurement of no- load loss referred to the
primary side shall be done at:
1. 90 %, 100% and 110% of the rated voltage at the principal tapping, and
2. the appropriate tap voltage at the + 7 tap and – 9 tap positions.
6.4.5 Measurement of resistance of windings: The resistance of the windings shall be

measured at all tapings and computed at 750 C.
404
6.4.6 Measurement of percentage impedance voltages: The percentage impedance

voltages at principal, + 7 tap and – 9 tap positions shall be measured at rated current and at
ambient temperature and computed at 750 C.
6.4.7 Measurement of load loss: Load losses at rated current shall be measured at
principal, + 7 tap and – 9 tap positions at ambient temperature and computed at 750.
6.4.8 Polarity test: The polarity (subtractive) and marking of the terminals for the
polarity shall be verified.
6.4.9 Voltage ratio test: Voltage ratio shall be measured at all tap positions.
6.4.10 Dielectric tests
6.4.10.1 Induced over voltage withstand test: The test shall be done by applying the
test voltage across the entire secondary winding as per IS: 2026(Part III).
6.4.10.2 Separate-source voltage withstand test: The test voltage to be applied shall be as
under:

2. Rated short duration power frequency 95 230
6.4.11 Recording of recurrent surge oscillogram (RSO): The oscillograms shall be

taken at the + 7 tap, – 9 tap and principal tapping.
6.4.12 ests on on load tap changer: The tests shall be conducted in accordance with
IS: 8468.
6.4.13 Measurement of capacitance and tan-delta values: The measurement of

capacitance and tan-delta (dielectric loss factor) of the transformer windings shall be
made by Schering bridge.
6.5 During the routine tests on any unit if it is found that the sum of the measured
losses (i.e. no- load and load losses) measured at – 9 tap position (corrected to 750C)
exceeds the value defined in Clause 6.3.1.3.1(1), or if the no-load loss/ load loss at the
principal tapping exceeds the maximum guaranteed figures, then the transformer shall be
rejected.
6.6 The prototype approval shall be accorded after conducting all the type and routine
tests stipulated in this specification and TIQ 2001 ver 1. If the prototype of a transformer
conforming to this specification has already been approved in connection with previous
supplies to Indian Railways, fresh type testing may be waived at the discretion of the
Purchaser, provided that no changes what so ever in the design or material(s) used or the
process of manufacture have been made. However, the Purchaser reserves the right to
405
conduct type tests if he deems it necessary to do so in the light of experience gained from
previous supplies.
6.7 Only after approval of the original tracings of drawings incorporating changes, if any,
as a result of the prototype tests and clear written approval of the results of the tests on
the prototype is communicated by the Purchaser/DG (TI), RDSO, Lucknow, to the
successful tenderer/manufacturer, shall he take up bulk manufacture of the transformer -
which shall be adopted for the prototype. In no circumstances shall materials other than
those approved in the design/drawings and/or during the prototype testing be used for
bulk manufacture on the plea that they had been obtained prior to the approval of the
prototype.
6.8 The tenderer may quote separately his charges for short-circuit and temperature-rise
tests. No charges shall be payable for any other type and routine tests.
6.9 Revalidation of type tests

The type tests will be repeated at an interval every five years and / or considering the
changes in the design or material(s) used or the process of manufacture.
7.0 Maintenance Manual, tools gauges etc.

Five copies of the Erection, Commissioning, Operation and Maintenance Manual approved
by RDSO shall be supplied to each consignee, in case order is more than 10 nos. In case
order is less than 10 nos. 2 copies of manual shall be supplied. Two copies of manuals shall
be supplied to the Purchaser and DG (TI), RDSO, Lucknow (India) for record.
The successful tenderer/manufacturer shall list out the special tools, gauges and testing
instruments/kits that will be required for inspection, adjustment and maintenance of the
interrupter. Individual prices for the items included in the above list shall also be
furnished. The exact quantities of tools, gauges and testing instruments /kits to be
procured initially shall be decided at the time of contract for the interrupters based on the
above price list.
8.0 Training of Indian Railway’s personnel

The offer shall include the training of two personnel of the Indian Railways free of cost
at the manufacturer’s works in India or abroad and at the maintenance
depots/workshops on a Railway system or other public utility where transformers of
similar/identical design are in operation. The total duration of training for each personnel
shall be 2 weeks of which approximately one week will be at manufacturer’s works and
one week on a Railway system or other public utility. If the country of manufacturer
is not India, the cost of travel to that country and back will be borne by the Indian Railways.
Other details shall be settled at the time of finalizing the contract/Purchase Order.
9.0 Packing, Delivery, Commissioning etc.
9.1 The transformer shall be transported depending upon the transport facilities
available for the route i.e. by rail or truck or ship.
406
9.2 The transformer shall be dispatched with its core and windings along with the tap-
changer assembly in the transformer tank filled with oil and the space above the oil filled
with pure dry air or inert gas like nitrogen at a pressure slightly above atmospheric
pressure. However, if there are limitations on account of weight, the tank shall be filled
with nitrogen under pressure and the oil for the first filling shall be supplied separately in
steel drums. In case the tank is filled with inert gas the temperature and pressure at the
time of filling shall be marked conspicuously on the transformer.
9.3 All openings created on the tank by removal of any items shall be closed with
suitable blanking plates. All the parts, fittings and accessories such as conservator tank,
bushings, silica gel breather, radiator, Buchholz relay, temperature indicators and other
items shall be packed / crated separately along with a packing list/check list in each crate
containing the following particulars:
Crate No. Description of item/ Approx.gross Approx. outside

component in the crate weight in kgf dimensions in mm
All the matching parts shall be identical with the transformer Sl. No. or Work
Order No. to avoid any mismatching at site.
9.4 The packing shall be done properly so that no damage occurs during transit.
9.5 All the parts, fittings and accessories for each transformer shall be so dispatched
that they arrive at site together to enable erection of the complete without delay.
9.6 Necessary instructions for handling and storage of all items shall be included
along with the packing lists.
9.7 In case of overseas supply, packing shall be sea worthy.
9.8 The transformer shall be erected and commissioned by the Purchaser. The
successful tenderer/manufacturer shall invariably make available at site the services of an
engineer of his to ensure, by his continued presence, that the process of erection, testing
and commissioning of the transformer is in accordance with established practices. For
this purpose prior intimation regarding the dates/period and locations at which the
transformers are to be erected and testing / commissioning done shall be given by the
Purchaser to the successful tenderer/manufacturer. No charges shall be payable by the
purchaser to the successful tenderer/manufacturer for the services of his engineer in this
regard.
9.9 If any transformer has been received at site in a damaged condition and in the
opinion of the Railway's Engineer at site it is required to be repaired at the successful
tenderer/manufacturer's works, the transformer shall be taken back to the works promptly
and after repair, all necessary tests including the routine tests shall be done on the
407
complete transformer in the presence of and to the satisfaction of the Railway's Engineer
prior to returning the transformer to site. Such tests are necessary to ensure that the
quality of the workmanship during repairs is satisfactory and shall be done free of cost.
Any tests, as decided by the Railway's Engineer at site shall also be conducted on the
transformer at site free of cost.
10.0 Warranty
The successful tenderer/manufacturer shall warrant that all equipment be free from
defects and faults in design, material, workmanship and manufacture and of the highest
grade consistent with the established and generally accepted standards for the equipment
of the type ordered and in full conformity with the specifications and shall operate
properly.
This warranty shall cover inspection of, payment for and acceptance of the
equipment, but shall expire 30 (Thirty) months after the delivery at ultimate destination, or
24 (Twenty four) months from the date of commissioning and proving test of the
equipment at ultimate destination in India, whichever period expires earlier, except in
respect of complaints, defects and/or claims notified within 3(Three) months of the
expiry of such date. Any approval or acceptance by the Purchaser of the equipment shall
not in any way limit the successful tenderer/manufacturer’s liability.
The successful tenderer/manufacturer’s liability in respect of any complaint, defects

and/or claims shall not be limited to the furnishing and installation of replacement of parts
free of any charge or the repair of defective parts only to the extent that such
replacement or repairs are attributable to or arise from faulty workmanship or material or
design in the manufacture of the goods, provided that the defects are brought to the notice of
the successful tenderer/manufacturer within 3(Three) months of their being first
discovered during the warranty period of 3(Three) months from the date of expiry of
warranty period, or at the option of the Purchaser, to the payment of the value,
expenditure and damage as hereafter mentioned.
The successful tenderer/ manufacturer shall, if required, replace or repair the

ultimate destination or at the option of the Purchaser. Successful tenderer/manufacturer
shall pay to the Purchaser value there of at the contract price or in the absence of such
price at a price decided by the Purchaser and such other expenditure and damages as may
arise by reason of the breach of the conditions herein specified.
All replacement and repairs that the Purchaser shall call upon the successful
tenderer/manufacturer to deliver or perform under this warranty shall be delivered and
performed by the successful tenderer/manufacturer, promptly and satisfactorily and in
any case within 2(Two) months of the date of advice to this effect.
If the successful tenderer /manufacturer so desires, the parts that are removed may be taken
over by him or his representative for disposal as he deems fit at the time of
replacement with good parts. No claim whatsoever shall lie on the Purchaser thereafter
for the parts so removed.
408
The warranty herein contained shall not apply to any material which shall have been
of the successful tenderer/manufacturer, so as to affect the strength, performance or

The decision of the Purchaser in regard to successful tenderer/manufacturer’s liability
and the amount, if any, payable under this warranty shall be final and conclusive.
11.0 Spares & after sales-service & AMC
11.1 The Tenderer shall quote separately for the following essential spares for every lot of
upto 5 transformers or part thereof.
1. One set of primary coil, secondary coil and tapping coil.

2. One primary bushing complete with parts, fittings and bushing type current
transformer.
3. One secondary bushing complete with parts, fittings and bushing type current
transformer.
4. One complete set of gaskets of all sizes required for use in the transformer.
5. One breather unit with silica gel.
6. One set of radiator banks.
7. One Buchholz relay.
8. One complete on load tap -changer.
9. One each of terminal connectors for primary and secondary side bushing terminals.
10. One set of valves.
11. One pressure relief device.
11.2 The successful tenderer / manufacturer shall make necessary arrangements for
closely monitoring the performance of the transformer through periodical visit to the
locations where they are erected for observations and interactions with the operating and
maintenance personnel of Indian Railways. Arrangements shall also be made by the
successful tenderer / manufacturer for emergency / standby spare parts being kept readily
available to meet exigencies warranting replacement so as to keep the transformer in
service with list down time.
11.3 Successful tenderer / manufacturer shall respond promptly on call given by

RDSO/railway for any assistance by way of attending to failures, investigations into the
causes of failures including the tests, if any, to be done and such other items with a view to
seeing that the transformer serves the purpose for which it is procured. Besides,
technical guidance to ensure proper operation and maintenance of the transformer shall be
constantly rendered.
11.4 In the event of the purchaser requiring maintenance support through AMC, the
tenderer shall quote for this separately alongwith his offer, the annual rate of AMC for 10
years period. The tenderer shall take necessary measures to ensure that the downtime of
the equipment is the least.
409
Railway may incorporate clause in the tender documents for AMC such that
payments are based on the availability/ downtime of the equipment in slab rates. A fixed
period of time after communication of the failure, for which downtime shall be reckoned,
will be decided by the purchaser/ railway.
12.0 Technical Data and drawings to be furnished alongwith tender
12.1 The tenderer shall furnish along with his offer, in the proforma at Appendix-A,
the schedule of Guaranteed Performance, Technical and Other Particulars (SOGP, Part - I)
for the transformer. The particulars shall be complete in all respects. The values/
information given in this SOGP, Part-I, will be used for technical evaluation of the
tender.
12.2 Only the successful tenderer shall furnish the consolidated information as given in
the proforma at Appendix-B, the schedule of Guaranteed Performance, Technical and
Other Particulars (SOGP, Part - II) for the transformer.
12.3 The tenderer shall furnish the following information along with his offer:
12.3.1 Calculations for:
1. Temperature rise of winding at rated current.
2. Hot-spot temperature of the winding at 150% and 200% rated loads for 15
min and 5 min respectively.
3. Thermal withstand capacity of the windings for a short circuit of 5 s
duration.
4. Mechanical forces in respect of the following as per IEEMA (Indian
Electrical & Electronic Manufacturer's Association) formulae given ion
Appendix-C.
i) Asymmetrical short-circuit current.
ii) Hoop stress in primary and secondary windings.
410
iii) Compressive pressure in the radial spacers.
iv) Internal axial compressive force.
v) Axial imbalance force.
vi) Radial bursting force. vii) Resistance to collapse.
viii) Bending stress on clamping ring and densified wood.
ix) Maximum allowable torque on pressure screws for coil clamping
bolts at the time of tightening, if any.

5. Flux density with the characteristic curve.
6. Maximum value of inrush current.
411
12.3.2 Drawings for:
1. Outline general arrangement drawing giving complete details of the

transformer.
2. Arrangement of the core, windings and magnetic path.
3. Magnetizing characteristic of CRGO sheet steel.
4. Drawing showing elevation of the core and winding and other insulation materials.
5. A sectional view showing the position of core cylinders, winding blocks, vertical
ribs and other insulating materials.
6. Details of coil clamping arrangement.
7. General arrangement of the off-circuit tap - changer.
12.3.3 Other documents:
1. Quality assurance plan for the tendered transformer.

2. ISO certification regarding quality system manufacturing, testing facilities, R&D
facilities and reliability.
3. List of essential plant, machinery and testing facilities.
4. Up-dated calibration certificate for the testing equipment.
5. Type test reports for the relevant rating of the tendered transformer.
6. List of supplies & performance reports from the users for tendered
transformer.
12.4 The successful tenderer / manufacturer shall submit to DG(TI), RDSO, Lucknow
for approval the following detailed dimensioned drawings as per Indian Railways
standard in sizes of 210mm x 297mm or any integral multiples thereof:-
1. Outline general arrangement of the transformer indicating plan, front elevation,

side elevation with all parts, fittings and accessories, electrical clearances as well
as salient guaranteed particulars.
2. Internal arrangement of the transformer indicating primary and secondary bushing
lead connections, core to core- clamp earthing, core- clamp to tank earthing,
core- clamp to core-base bolting, and the locking
arrangement of the core & coil assembly with the tank.
3. Cross sectional view of the core and windings with material specifications and
makes.
4. Details of the pressure screws / oil dash-pot/ coil clamping bolts or other devices
and their location with materials specifications and makes.
5. Schematic view of the valves used on the transformer and the antitheft devices
as to diagram.
6. Transport outline dimensional diagram.
7. General arrangement of the on load tap-changer assembly with salient technical
parameters.
8. Tap-changer cubicle layout.
9. Schematic diagram for driving of on load tap-changer from remote control centre by
telecommand and corresponding telesignalling.
412
10. Name and rating plate of on load tap-changer.

11. General arrangement of marshalling box indicating protection control
equipment.
12. Wring diagram of protection and control circuits marshalling box.
13. Schematic diagram of protection and control circuits in marshalling box with
cable schedule.
14. Legend plate showing protection and control circuits for fitment in the
marshalling box.
15. Oil communicating type IS bushing for primary side including cross- sectional
view, shed profile and salient electrical and mechanical characteristics.
16. OIP condenser bushing for secondary side including cross-sectional view shed
profile and salient electrical and mechanical characteristics.
17. Dimensional drawing, V-I characteristic and rating plate for bushing types current
transformers.
18. Rigid type terminal connector for primary side bushing terminal.
19. Expansion type terminal connector for secondary side bushing terminal.
20. Rating plate diagram of connections, both in English and Hindi versions.
21. Details of radiators including the painting schedule.
22. Details of breather
23. External cables run with cable schedule.
24. Details of ‘O’ ring and different gaskets to be used in the transformer
25. Any other drawings considered necessary by the successful tendered/
manufacture and/ or purchaser.
12.4.1 The format of the title sheet to be adopted for preparation of the drawings is
attached at Appendix -G.
12.4.2 After approval, six copies of each of the approved drawings along with two sets of
reproducible prints for each drawing shall be supplied to each consignee(s). Besides,
two copies of drawings along with one set of reproducible prints and drawings on CD (in
AUTOCAD 2000) along with hard copy after final approval of the drawings shall be
supplied to DG, RDSO, and Lucknow.
12.4.3 Two copies of the "Operation / Maintenance Manual" for each transformer shall be
supplied to the consignee(s). Two copies of the manual shall be supplied to the DG
(TI), RDSO, Lucknow. While preparing the instruction and maintenance manual for
inspection/test schedule for traction transformer issued by RDSO shall be taken into
account.
13.0 Clause wise conformity, deviations etc.

compliance with each clause and sub-clause of this specification. A separate statement
shall be attached with the offer indicating references to the clauses where the tenderer
deviate there from together with detailed remarks/justification. If there are no deviations, a
‘NIL’ statement shall be attached.
413
13.2 Any deviation from this specification which the tenderer proposes to improve
consideration, provided full particulars of the deviation with justification thereof are
furnished, and are found acceptable by RDSO.
14.0 CAPITALISATION OF TRANSFORMER LOSSES
The capitalized valve of transformer losses shall be as low as possible and

commensurate with optimum no-load and load the losses. The capitalized value shall be
computed as detailed at Appendix D and furnished with offer. Capitalized value
calculated, as per Appendix D shall be added to the unit cost of the transformer for taking
into consideration the cost of losses during its service life.
14.0 List of appendices used in the specification.
Appendices enclosed with this specification are as follow.
S.No. Appendix Description
1. Appendix-A Schedule of Guaranteed Performance, Technical and

Other Particulars – Part – I
2. Appendix-B Schedule of Guaranteed Performance, Technical and
Other Particulars – Part – II
3. Appendix-C Formula for Calculation of Short Circuit Mechanical
Forces
4. Appendix-D Capitalization of Transformer Losses
5. Appendix-E General Scheme for Traction Power Supply System
6. Appendix-F Overall Dimensions of the Transformer
7. Appendix-G Format of the Title Sheet to be adopted for Preparation of
the Drawings
8. Appendix-H Nitrogen Injection Fire Prevention and Extinguishing
System for Oil Filled Transformer
9. Appendix-I List of RDSO’s Approved Sources for Parts, Fittings and
Accessories
*******
414
For 30 MVA, 110 / 27 kV Traction Transformer
APPENDIX-A
PARTICULARS, SOGP- Part-I (GURANTEED PARTICULARS ARE TO BE
ESTABILISHED BY INSPECTION, ACTUAL TESTS/TEST REPORTS) – Values /
Information are to be furnished by each of the tenderers and this will be used for
technical evaluation of the tenders.
.S.No. DESCRIPTION SPECIFIED VALUE/
VALUE/INFORMATION INFORMATION
to be
FURNISHED BY
TENDERER
1 2 3 4
A. RATINGS/PARTICULARS
3. Reference to specification based TI/SPC/PSI/30TRN/1050
on which performance data is & IS:2026 (Part I to IV)
prescribed
4. Rated power 30 MVA
5. i) Rated Primary current ii)Rated 273 A
Secondary current 1111 A
6. Rated voltage:
i) Primary 110 kV
ii) Secondary (at no-load) 27 kV
7. Rated frequency 50 +/- 3% Hz
8. Temperature rise above ambient
temperature of 500C:
1) Oil:
i)At rated load
ii)At 150% rated load for 15 min Maximum 400C
iii)At 200% rated load for 5 min
2) Winding:
i)At rated load Maximum 500C
ii)At 150% rated load for 15 min Maximum 600C
iii)At 200% rated load for 5 min Maximum 600C
9. Hot -spot temperature of winding over
ambient temperature of 50 0C:
i) At rated load
ii) at 150% rated load for 15min Maximum 1150C
iii) At 200% rated load for 5 min
10. Interval of time between two
successive overloads after continuous
working at full load ,at maximum
ambient temperature of 50 0C:
i)Between two consecutive
overloads of 50% for 15 min
ii)Between two consecutive overloads of which Maximum 180
one is of 50% for 15 min and the other of 100% minute
for 5 min
415
APPENDIX-A
S.No. Description SPECIFIED VALUE/
VALUE/INFORMATION INFORMATIO
N to be
FURNISHED
BY TENDERER
11. Losses:
i) No-load loss at rated frequency Maximum 15 kW
and at rated voltage at principal tap
ii) Load loss(at 750C ) with rated
current and frequency at principal tap Maximum 117 kW
iii) Total losses at rated current and
frequency at principal tapping
12. Impedance voltages (at 75 C) at rated current and

frequency
:i) Principal tapping
ii) - 9 tap 16 +/- 0.5) %
iii) + 7 tap 15 to 17 %
15 to 17 %
13. Ability to withstand short circuit:
i) Thermal 5 Sec
ii) Dynamic 0.5 Sec.
14. Details of core:
i) Type of core CRGO
ii) Grade of core material (viz. MOH/Hi- MOH, Hi-B or ZDKH
B/ZDKH) and conforming specification
iii) Flux density at principal tapping
at rated voltage and frequency. 1.55 Tesla Maximum
iv)Thickness of steel stampings
v)Core bolt Insulation withstand 0.27 mm max.
voltage 2 kVrms for 60 sec
15. Details of Windings :
i) Type of winding : Uniformly insulated
1) Primary concentric disc duly
2) Secondary interleaved
ii) Ratio of width to thickness of copper Uniformly insulated
conductor of winding. interleaved disc duly
iii) Max. Current density at rataed current interceed
1) Primary Shall not exceed 5:1
2)Secondary
iv) Dielectric strength for windings : 2.5 A/mm2
1) Full wave lightening Impulse withstand 2.5A/mm2
voltage:
a) Primary winding
b) Secondary winding 550 kV peak
2) Lightening impulse chopped on tail withstand 250 kV peak
voltage:
a) Primary winding
b) Secondary winding 550 kV peak
3) Separate source power frequency withstand 250 kV peak
voltagae :
---
416
APPENDIX-A
.S DESCRIPTION SPECIFIED VALUE/
oN VALUE/INFORMATION INFORMATION to be
. FURNISHED BY
TENDERER
a) Primary winding 230 kVrms

b) Secondary winding 95 kVrms
4) Induced over voltage withstand 2 x rated secondary voltage
value
16. On load tap-changer :
i) Name of the manufacturer ----
ii) Country of origin ------

TI/SPC/PSI/30TRN/1050,
iii) Governing specification IEC 60214 & IS: 8468
iv) Number of tappings: Seven

1) plus tappings Nine
2) minus tappings
+ 7 tap and – 9 tap with per tap
v) variation of voltages on different voltage of 1.25 kV
tappings
600 A
vi) Maximum rated through current
145 kV
x) Voltage class
8 kA for 3 seconds
xi) Short circuit withstand current
110Vdc
xi) Rated voltage of control circuit
17. Bushings:
i) Primary side: -----
1) Name of the manufacturer
-----
2) Country of origin
IS 2099 & IS 12676
3) Governing specification TI/SPC/PSI/30TRN/1050
OIP condenser bushing

4) Type designation
145 kV
5) Voltage class 600A
6) Rated current 3625 mm (Minimum)
7) Creepage distance
ii) Secondary side: ----

-----
IS 2099 & IS 12676
3) Governing specification TI/SPC/PSI/30TRN/1050
OIP condenser bushing

4) Type designation
417
APPENDIX-A
.S DESCRIPTION SPECIFIED VALUE/
oN VALUE/INFORMATION INFORMATION to be
. FURNISHED BY
TENDERER
5) Voltage class 52kV

6) Rated current 2500A
7) Creepage distance 1600 mm (Minimum)
18. Insulating oil:
i) Governing specification IS:12463
ii) Source of supply RDSO approved source
19. Type of transformer tank Bell type
20. Details of radiators:

i) Make and type
ii) Type of mounting

21. Acoustic sound level at a distance of 1 75 dB Maximum
m, when energised at rated voltage and
rated frequency without load.
22. Partial discharge value at 1.5 Um/ 3 As per IS 6209 &
kV rms IS:2026(Part-III)
23 Dimensions of the complete transformer
including all parts, fittings and
accessories:
1) Overall length 8000 mm (Maximum)
2) Overall breadth 7000mm (Maximum)
3) From rail level to the topmost 7500mm (Maximum)
point
24. Is warranty as per clause 10.0? Yes/No
25. Is the list of spares furnished or not? Yes/No.
26. Are the details of fire protection and Yes/No.

extinguishing system by nitrogen
injection method including layout
drawing and the equipment drawing with
complete bill of materials given in the
tender?
418
APPENDIX-B
PARTICULARS, SOGP- PART - II (GURANTEED PARTICULARS ARE TO BE ESTABILISHED
BY INSPECTION, ACTUAL TESTS/TEST REPORTS)
.
S DESCRIPTION UNIT OF
VALUE/
oN MEASUREMENT
INFORMATION
.
1 2 3 4
A. RATINGS/PARTICULARS
3. Reference to specification based on
which performance data is prescribed
4. Rated power MVA
5. Primary current at:
i) Rated load A
ii) 150% rated load for 15 min A
iii) 200% rated load for 5 min A
6. Secondary current at:
i) Rated load A
ii) 150% rated load for 15 min A
iii) 200% rated load for 5 min A
7. Rated voltage:
i) Primary kV
ii) Secondary (at no-load) kV
8. Rated frequency Hz
9. Max. Temperature rise above ambient
temperature of 500 C:
1) Oil:
i) At rated load 0
C
ii) At 150% rated load for 15 min 0
C
iii) At 200% rated load for 5 min 0
C
2) Winding:
i) At rated load 0
C
C
C
10. Max. Hot -spot temperature of winding
over ambient temperature of 50 0C:
i) At rated load 0
C
C
C
11. Interval of time between two successive
overloads after continuous working at
full load ,at maximum ambient
temperature of 500 C:
i) Between two consecutive Minute
overloads of 50% for 15 min
ii) Between two consecutive Minute
overloads of which one is of 50% for
15 min and the other of 100% for 5
min
419
APPENDIX-B
.S DESCRIPTION UNIT OF
oN MEASUREMENT VALUE/
. INFORMATION
12. No-load current referred to Primary
side at rated frequency and at :
i) 90% rated voltage A
ii) Rated voltage A
iii) 110% rated voltage A
iv) Appropriate voltage at - 9 tap A
v) Appropriate voltage at + 7 tap A
13. Power factor of no-load current at rated

voltage and rated frequency
14. Value of the inrush current at rated A
voltage on primary side ,the secondary
side being open circuited
15. Losses:
i) Max. No-load loss at rated
frequency and at:
1)90% rated voltage at the principal tapping kW
2)Rated voltage at the principal tapping kW
3) 110% rated voltage at the principal
tapping kW
4)Appropriate voltage at - 9 tap kW
5)Appropriate voltage at + 7 tap kW
ii) Max. Load loss(at 750C ) with rated

current and frequency :
1) Principal tapping kW
2) - 9 tap kW
3) +7 tap kW
iii) Max. Total losses at rated current

and frequency:
1) Principal tapping kW
2) - 9 tap kW
3) + 7 tap kW
16. Resistance voltage (at 750 C ) at rated
current at principal tapping:
i)Primary %
ii)Secondary %
17 Reactance voltage (at 75 C) at rated current %
and frequency at principal tapping
18. Impedance voltages (at 75 C) at rated
current and frequency:
i) Principal tapping %
ii) - 9 tap %
iii) +7 tap %
19. Resistance (at 75 C) of primary Ω
winding
420
APPENDIX-B
.S DESCRIPTION UNIT OF VALUE/
oN MEASUREMENT INFORMATION
.
20. Resistance (at 75 C ) of secondary
winding at:
i) Principal tapping &
ii) + 7 tap
iii) - 9 tap &
21. Reactance of winding:
&
i)Primary
ii)Secondary at:
1. Principal tapping H
2. + 7 tap H
3. - 9 tap H
22. Regulation (at 75 C) with rated current H
and at power factor of:
i) Unity
ii) 0.8 lagging %
%
23. Efficiencies:
i) Efficiency (at 75 0C) at unity power
factor:
1) 100% load
2) 75% load %
3) 50% load %
4) 25% load %
ii) Efficiency at (75 0C) at 0.8 power %
factor lagging at:
1) 100% load
2) 75% load %
3) 50% load %
4) 25% load %
%
iii) Percentage of rated load at which
maximum efficiency occurs. %
24. Ability to withstand short circuit:
i) Thermal ii)
Dynamic Sec
Sec
25. Thermal time constant (calculated):
i) for primary and secondary windings
with respect to oil at:
1) rated current Minute
2) 150 % rated current Minute
3) 200 % rated current Minute
ii) Complete transformer at rated Minute
current.
26. Temperature gradient between oil and
winding at:
i) rated current 0
C
ii) 150% rated current for 15 min. 0
C
iii) 200% rated current for 5 min. 0
C
421
APPENDIX-B
.
27. Temperature rise of oil:
i) Calculated average temperature rise
of oil at
0
1) Rated current C
0
2) 150% rated current for 15 min. C
0
3) 200% rated current for 5 min. C
ii) Estimated temperature rise of top oil

0
at: 1) Rated current C
0
2)150% rated current for 15 min. C
0
3)200% rated current for 5 min. C
28. Details of core:

i) Type of core
ii) Flux density at principal tapping at Tesla
rated voltage and frequency.
iii) Flux density at principal tapping at Tesla
110% rated voltage and frequency.
iv) Thickness of steel stampings Mm
v) Grade of core material (viz.
MOH/Hi-B/ZDKH) and conforming
specification
vi) Watt loss in watt/kg of the core Watt/Kg
lamination at 1.55 tesla and 50 Hz
vii) Exciting VA/kg for core stampings
at:
1) Flux density of 1.55 tesla VA/kg
2) Flux density at rated voltage VA/kg
3) Flux density at 110% rated voltage VA/kg
viii) Exciting VA/kg for assembled core
at:
1) Flux density of 1.55 Tesla
2) Flux density at rated voltage VA/kg
3) Flux density at 110% rated VA/kg
voltage. VA/kg
ix) Type of insulation between core
laminations
x) Type of joint between the core limbs
and yoke.
xi) Core bolt Insulation withstand
voltage kV
xii) Core bolt insulation flashover
voltage kV
422
For 30 MVA, 110 / 27 kV Traction Transformer VALUE/
INFORMATION
oN MEASUREMENT
.
APPENDIX-B
29. Details of windings:

i)Type of winding:
1) Primary
2) Secondary
3) Number of turns of primary
winding
4) Number of turns of sec. Winding
5) Number of parallel paths in

primary winding
6) Number of parallel paths in

secondary winding
7) Is inter leaving/interhielding of the Yes/No
winding adopted to ensure better
impulse voltage distribution in
primary winding?
8) Is inter leaving/inter shielding of Yes/No
the winding adopted to ensure
better impulse voltage distribution
in secondary winding?
9) Is the insulation of end turns of
primary winding reinforced? Yes/No
10) Is the insulation of end turns of
secondary winding reinforced? Yes/No
ii) Mode of connection ( i.e. in series or
in parallel of the portions of the primary
and secondary windings on the two limbs
of the core, if applicable:
1) Primary
2) Secondary
iii)Dimensions of the copper conductor

used in the winding:
1) Primary
2) Secondary mmxmm
3) Tapped primary mmxmm
mmxmm
iv)Current density at rated current:
1) Primary
2) Secondary A/mm2
v) Insulation used over the conductor A/mm2
(details of material and specification
there for)
vi)Type of joints , if any ,in the
windings
vii) Dielectric strength for windings :
1) Full wave lightening Impulse
withstand voltage:
a) Primary winding
b) Secondary winding kVpeak
kVpeak
423
APPENDIX-B
.
2) Lightening impulse chopped on tail

withstand voltage:
a) Primary winding kVpeak
b) Secondary winding kVpeak
3) Separate source power frequency
withstand voltage:
a) Primary winding kV
b) Secondary winding kV
4)Induced overvoltage withstand value kV
viii) Minimum flashover distance to
earth in oil of :
1) Secondary winding to core
2) Primary winding to yoke mm
3) Primary winding to tank mm
mm
ix) Material used for coil clamping
rings and specification therefor
x) Can either end of secondary winding

be connected directly to earth: Yes/No
xi) Magnitude of axial precompressive
force on the windings:
a) Primary
b) Secondary T
xii) Calculated maximum axial thrust in T
the windings due to dead short at the
terminals:
a) Primary
b) Secondary T
xiii) Calculated short circuit forces: T
1) Hoop stress in primary winding
2) Hoop stress in secondary winding Kgf/cm2
3) Compressive pressure in the radial Kgf/cm2
spacers Kgf/cm2
4) Internal axial compressive force
Kgf
5) Axial imbalance force
Kgf Kgf
6) Resistance to collapse
Kgf/cm2
7) Bending stress on clamping ring
Kgf
8) Radial bursting force
xiv) Arrangement to maintain constant

pressure on the windings
xv) Maximum permissible torque on
pressure screws for coil clamping at the
time of tightening, if any.
424
INFORMATION
oN MEASUREMENT
.
APPENDIX-B
30. On load tap-changer :

i) Name of the manufacturer
ii) Country of origin
iii) Type designation
iv) Governing specification
v) Is a separate tapped winding Yes/No

provided on primary
vi) Number of tappings:
1) plus tappings
2) minus tappings
vii) Percentage variation of voltages on %
different tappings
viii) Minimum contact pressure kg
between moving and stationary A
contacts kV
ix) Maximum rated through current kA
x) Voltage class
xi) Short circuit withstand current V(dc)
(thermal) for 3 seconds
xii) Rated voltage of control circuit
xiii) Tap changer motor particulars : V
1) Make and type A
2) Rated voltage KW
3) Rated current Rpm
4) Rated power
5) Speed
6) Class of insulation
31. Bushings:
i) Primary side:
3) Governing specification
4) Type designation
5) Voltage class KV
6) Rated current A
7) Visible power frequency discharge KV rms
voltage
8) Wet one minute power frequency KVrms

withstand voltage
9) Lightening impulse withstand KV peak
voltage
10) Creepage distance mm
425
APPENDIX-B
.
11) Weight of assembled bushing Kg
ii) Secondary side:

4) Type designation
5) Voltage class KV
6) Rated current A
7) Visible power frequency discharge KV

voltage
8) Wet one minute power frequency KV
withstand voltage
9) Lightening impulse withstand KV peak
voltage mm
10) Creepage distance Kg
11) Weight of assembled bushing
32. Bushing type current transformers:
i) Primary side:
3) Transformer ratio
4) Class of accuracy A
5) Rated current VA
6) Rated output mA
7) Exciting current at the rated knee
point voltage V
8) Rated knee point voltage Ohm
9) Secondary winding resistance
corrected to 750C KA, sec
10) Short time thermal current and
duration
ii) Secondary side:

3) Transformer ratio
4) Class of accuracy A
5) Rated current VA
6) Rated output mA
7) Exciting current at the rated knee
point voltage V
8) Rated knee point voltage
9) Secondary winding resistance Ohm
corrected to 750C
10) Short time thermal current and
SOGP – Part-II
426
RDSO Specification No. TI/SPC/PSI/30TRN/1050 APPENDIX-B
INFORMATION
oN MEASUREMENT
.
duration KA, sec
33. Insulating oil:

i) Governing specification
ii) Source of supply
34. Type of transformer tank
35. Details of radiators:
i) Make and type
ii) Type of mounting
iii) Overall dimensions ( LxWxH) mm
36. Details of Buchholz relay:

i) Make and type
ii) Governing specification
iii) Provision of shut-off values on either side of the relay

and sizes
iv) Provision of alarm contact
v) Provision of trip contact vi) Rated current of

contacts
Yes/No mm
Yes/No Yes/No A
427
37. Details of winding temperature indicator: 2.Governing
i) Make and type specification
ii) Governing specification 3.Type
iii) Number of contacts provided 4.Rated

iv) Rated current of contacts A current
v) Dielectric withstand value of kV 5.Temprature

contacts. rise over an
38. Details of oil temperature indicator: ambient
i) Make and type temperature
of 450 C
ii) Governing specification while
carrying rated
iii) Number of contacts provided current
iv) Rated current of contacts A 6.Short time

current and
v) Dielectric withstand value of KV duration
contacts
39. Details of magnetic oil level gauge: ii) Secondary
side:
i) Make and type
1.Source of
supply
2.Governing
specification
3.Type
APPENDIX-B 4.Rated
current
5.Temperatur
.S DESCRIPTION UNIT OF e rise over an
VALUE ambient
oN MEASUREMENT temperature
INFORMATION of 450 C
. while
ii) Governing specification carrying rated
current
iii) Diameter of dial mm 6.Short time

current and
iv) number of contacts provided durationA
v) Rated current of contacts A

0
C
vi) Dielectric withstand value of kV
contacts
40. Details of pressure relief device: kA, sec.
i) Make and type
ii) Governing specification
iii) Does it rest itself? Yes/No
41. Bimetallic terminal connectors: A

i) Primary side:
0
C
1.source of supply
428
KDSO Specification No. TI/SPC/PSI/30TRNFor 30 MVA, 110 / 27 kV Traction Transformer
oN MEASUREMENT
.
42. Acoustic sound level at a distance of
1 m, when energised at rated voltage
and rated frequency without load.
43 Partial discharge value at 1.5 Um/ 3
kV rms
44. Weights and dimensions:
i) Net weight of core
ii) Net weight of copper:

a) Primary winding
b) Secondary winding
iii) Net untanking weight of core, frame

and coils.
iv)Net weight of insulating oil
v) Volume of insulating oil
vii) Total weight of cooling equipmen

vii) Total weight of transformer without oil.
viii)Total shipping weight of complete
transformer including all detachable parts,
fittings and assemblies ix)Shipping weigh
of largest package
x) Crane lift ( excluding slings)

for untanking core and coils
x) Crane lift (excluding slings) for removal or primary

side bushings
xi) Crane lift (excluding slings) for
removal or primary side bushings.
xii) Dimensions of the complete transformer

including all parts, fittings and accessories:
1) Overall length
2) Overall breadth
3) From rail level to the topmost point
xiii) Minimum thickness of steel plate/

sheet used:
1) Bell tank
2) Tank bottom
3) Conservator\
4) Radiator
5) Marshalling box.
6) Tap changer cubicle.
xiv) Overall shipping dimensions of the larges package ( LxBxH)
429
RDSO Specification No. TI/SPC/PSI/30TRN/1050 VALUE/
For 30 MVA, 110 / 27 kV Traction Transformer INFORMATION
oN MEASUREMENT
.
APPENDIX-B
xv) Mode of transportation of
transformer unit ( filled with
Oil/nitrogen gas)
B. Other Particulars Nos.
45 Is the transformer tank fitted with lifting
pads? If yes what is the numbers of
pads? Nos.
46 What is the number of inspection
covers provided? Yes/No
47. Are conduits/trays provided for cable
run Yes/No
48. Is the core electrically connected with
the tank? Yes/No
49 Will the gaskets to be used in the
transformer give trouble free service for
at least 12 years? If not indicate the life.
50. Is the core construction without core Yes/No
bolts?
51. Are the core bolts grounded, and if so Yes/No
how ?
52. Are the magnetic shunt pockets of core Yes/No
lamination provided inside the tank
surface to absorb stray flux? If yes, the
material specification shall be furnished
53. What is the number of radial spaces
used in the ;
i) primary windings
ii) secondary windings.
54. What is the number of joints provided
in the :
i) primary windings
ii) secondary windings.
55. Are the spacers/blocks/angle rings of pre- Yes/No
compressed press boards? If no, indicate
the material with specification.
56. Are arrangements made for ensuring Yes/No
automatic constant pressure on the
coils? If no give the reasons.
57 Are the closed slots provided on the Yes/no
outer most winding for locking the
vertical strips.? If no give the reasons
58. What is the periodicity for tightening of Years
the coil clamping arrangement
59. What are the calculated short circuit currents for :
i)Symmetrical:
1) Primary winding AA
3) Secondary winding A
ii)Asymmetrical:
1) Primary winding
2) Secondary winding.
430
A
.S DESCRIPTION UNIT
A OF
oN MEASUREMENT
Tesla
.
60. What is the overflux withstand
capability of the transformer (max.
permissible limit of flux density)?
61. Are windings pre-shrunk? Yes/No
62. Have the details of drying cycles of the Yes/No
coils/coil assembly including final
tightening values of pressure, temperature
and degree of vacuum at various stages of
drying been furnished.
?
63. Is a test tap provided in each of the Yes/No
primary side and secondary side
bushings?
64. Are the porcelain housing of the Yes/No
bushings of single piece construction?
65. Is the shed profile of the porcelain of Yes/No
the bushing free from under ribs but
has a lip?
66. Is the bushing type current transformer Yes/No
of low reactance type?
67. Is clause by Clause" Statement of Yes/NO
compliance" attached?
68. Is “Statement of deviation" if any Yes/No
attached?
69. Does the tap changer have snap action? If Yes/No
not, give reasons.
70. Is the tap changer of the rotary type or Rotary/ sliding

the sliding type?
71. Is the Buchholz relay provided with Yes/No

two shut-off valves, one on either side ?
72. Is separate conservator tank and Yes/No

buchholz relay provided for tap
changing equipment?
73. Are fasteners of 12 mm diameter and Yes/No

less exposed to atmosphere of stainless
steel to grade 04 Cr 17 Ni 12 Mo to IS
1570 Part-V ?
74. Are the fasteners of more than 12 mm Stainless steel/hot dip galvanized
diameter exposed to atmosphere of
stainless steel or MS hot dip
galvanized?
75. Are test certificates for tests as per Yes/No

clause 16.0 attached?
431
RDSO Specification No.TI/SPC/PSI/30TRN/1050
For 30 MVA , 110/27 kV Traction Transformer
0
S DESCRIPTION UNIT OF APPENDIX-B
No MEASUREMENT VALUE/
INFORMATION
76. Are all the calculation required as per clause 17.3.1 Yes/No
attached?
77. Are all the drawings required as per clause 12.3.2 Yes/No
attached?
78. a) Are all the parts , fittings and accessories from Yes/No
RDSO’s approved manufactures?
b) If not, list the items, which are to be type tested
in the presence of the RDSO’s representative.
79. Is adequate space provided in the marshalling box Yes/No
for housing the wiring and components/
equipment?
80. Is warranty as per clause 23.0? Yes/No
81. Is the list of spares furnished or not? Yes/No
82. Are the details of fire protection and extinguishing Yes/No

system by nitrogen injection method including
layout drawing and the equipment drawing with the
equipment drawing with complete bill of materials
given in the tender?
432
APPENDIX-C
FORMULA FOR CALCULATION OF SHORT CIRCUIT MECHANICAL FORCES
Namenclature
Ai= Total supported area of the inner radial spacer in cm2.

Ao=Total area of the outer radial spacer in cm2
At=Area of tie rods in cm2
a=Per unit turns , out of circuit , in the winding.
bi=Thickness of inside winding conductor in cm
Dmi=Mean diameter of inside winding in cm.
di=Diameter of inner winding conductor in cm.
TM
=Current density in A/ cm2
E=Modulus of Elasticity of conductor in kg/ cm2
ez=per unit impedance
Fa=Axial imbalance force due to tapping within winding in
Kgf.Fc=Internal axial compression force in kgf.
Fr=Radial bursting force in kgf.
hw=Winding height in cm.
Iph=Rated phase current in A.
Isc=First peak value of asymmetrical short circuit current in A.
N=Number of turns per phase in the circuit.
Ns=Number of supports to be provided in the winding.
Nt=Number of the tie rods.
Pi=Compressive pressure in the inner redial spacers in kg/ cm2.
Po= Compressive pressure in the outer redial spacers in kg/ cm2.
Pt=Tensile stress in the rods in kg/cm2.
R=Sum of the resistance of the transformer and system in ohm.
Rdc=dc resistance of the phase at 75o cin ohm.
Sn=Rated kVA.
X=Sum of the reactance of the transformer and system in ohm.
m=Hoop or compressive stress in kg/cm2.
Scope
The calculation methods discussed below would be applicable to two winding transformers,
having core type construction and concentric winding with tappings placed within the body of the
outer winding.
1. Calculation of first peak value of Asymmetrical short circuit current.
Isc=k 2(Iph/e)A.
k 2 values are appended below (Ref.IS:2026 Part-I Clause 16.11.2)
X/R= 1 1.5 2 3 4 5 6 8 10 ɛ14
k 2= 1.51 1.64 1.76 1.95 2.09 2.19 2.27 2.38 2.46 2.55
Note: For other values of X/R between 1 and 14 , the factor k 2 may be determined by linear interpolation.
2. Calculation of Asymmetrical short circuit Ampere-turns
N x ISC
3. Hoop Stress
⌠m=(kxIph2xRdc) / (hwxez2 )
433
APPENDIX-C
k (Cu)=0.03(k 2)2 /(2.55)
k 2 as derived from item 1 above.

The figure so calculated shall be less than 1250kg/cm2 .
Note: The value of Iph2xRdc / hw referred to inner or outer winding shall be incorporated in the
formula depending upon whether inner or outer winding stress is required to be calculated.
4. Radial Bursting force
Fr=(2 x ⌠m x Iph x N)/ TM
5. Number of supports to be provided in winding (Flat conductor)
Ns=(Dmi x 12x ⌠m)/(bi x
E) Where,E=1.13x106
Kg/cm2.
6. Number of supports to be provided in winding (Round conductor)
Ns=(8x Dmi x ⌠m)/(dix E)
7. Calculation of internal axial compression
Fc-(-) (34Sn)/ (ez x hw)
Note: 1/3 Fc is acting on outer winding.

2/3 Fc is acting on inner winding.
(-) Indiactes that force is acting towards the centre.
8. Calculation of Axial imbalance force due to tapping within the windings

Fa=a x (Nisc)2x10-7kg.
Note 1 : If tapping are divided into two groups between the centre and the end of the windings, the force
will be reduced to 1/4th of the figure obtained by the above formula.
Note 2: If the compensating gap is provided in the untapped winding , the force will be half of that
calculated above.
Note 3 : For multi layer single coil design and other modes of Ampere –turns balancing actual unbalance
Ampere-turns can be determined by residual Ampere-turn diagram.
9. Calculation of Maximum compressive pressure in the radial spacers
Pi=(Fa+2/3Fc)/Ai kg/cm2
Po=(Fa+1/3Fc)/Ao kg/cm2
Note: Value calculated should not exceed 300 kg/cm2 for normal calendared press boards and 500kg/ cm2
for precompressed press boards.
10. Calculation of tensile stress in the tie rods
Pt=(Fa – 1/3Fc)(Nt x At) kg/ cm2.

Fa as derived from item – 8 above.
434
APPENDIX-C
Fc as derived from item – 7 above.
Note : The value calculated should be less than 2500kg/ cm2 for Mild steel tie rods.
11. Calculation of resistance to Collapse
(Applicable only to disc winding using rectangular conductor)

2
F(Crit)={ 1.5E(Iph)2 x (m) / box Dmo x TM x 108} + {(450xAoxTMxb3)/Iph } t
Where :
E = Modulus of Elasticity of conductor in kg/cm2.
m =Number of turns x number of Parallel Conductors per coil.
Iph =Rated phase current in A.
Bo =Thickness of outer winding conductor in cm.
Dmo =Mean diameter of outer winding in cm.
TM
=Current density in A/mm2
Ao =Total supported area of the outer radial spacer in cm2
12. Calculation kof most highly Stressed Coil
(Applicable for tapped winding only)
Fa=(0.733 Q x Fr x log10(2aNc+1)t
Where:
Q =Turns per coil adjacent to tapped out of coil, expressed as fraction of total turns in the
limb.
Fr =Radial force as derived from item – 4 above.
A =Per unit number of turns out of circuit.
Nc =Number of coils per limb.
13. Calculation of ‘W’ i.e. mechanical loading per centimeter of periphery
WI =(fa)( xDm) kg/cm
Where
Fa =Value as derived from item-12 above in kg
Dm =Mean diameter of tapped winding in cm.
Add 25 % extra for concentration of force and assume W = 1.25 WI.
⌠max= (WxL2xy)/(12xIo) kg/cm2

Where :
L = Span in cm = { xDm / ns) x bs}
ns =Number of spacers.
Bs =Width of spacer in cm
Y =Maximum distance from neutral axis for conductor in cm i.e. axial height of the winding
across the neutral axis divided by 2.
Io = Moment of inertia of the coil i.e. bd3/12
b =Radial depth of coil in cm.
d =Axial height of coil in cm.
Maximum permissible value for ⌠max is 1250 kg /cm2.
435
APPENDIX-C
14. Calculation of bending stress on claiming rings
The stress on circular ring is as below:
⌠max = {(6 x F x D) /(8 b x t2 x n2)} t/cm2

Where :
F =Total axial force (Fa-1/3Fc) in t.
Fa =Value as derived from item – 8 above.
Fc = Value as derived from item – 7 above.
D =Diameter of ring in cm.
b =Width of ring in cm.
t =Thickness of ring in cm.
n =Number of jacking points.
Maximum permissible value for max is 1100kg/cm, if circular permawood ring is used.
************
436
APPENDIX-D
CAPITALISATIN OF TRANSFORMER LOSSES
Following formula shall be used for the purpose of calculating the present worth of the transformer after
taking in account capitalization of its losses.
K=D(I+i)n-1} / i(l+i)n
Where
K =Present worth of transformer in Rupees.

D =Annual cost of combined no-load and load losses in Rupees.
I =Discount factor @ 12% per annum.
N =Life of transformer
Substituting value of D, which is:
D={(I+F2C)x365x24Xt}/1000
Where,
I =Maximum No-load loss in watt.
C = Maximum Load –loss in watt.
F =Load factor
T =Tariff in Rupees
Assuming values of n as 50 years, F as 50% and T as Rupees 4.25 per kWh, the value
Of K is , K = 37.23(I+0.25C){(1+0.12)50 -1} /0.12(1+0.12)50
=309(I+0.25C).
437
438
439
440
APPENDIX-H
NITROGEN INJECTION FIRE PREVENTION AND EXTINGUISHING SYSTEM FOR

OH.FILLED TRANSFORMER
1.0 GENERAL DESCRIPTION:
Fire protection system based on principle of nitrogen injection shall be designed to prevent
tank deformation, detect and fire in oil filled transformers and to extinguish fires in the oil filled
transformers. In accordance with provision of IE rule 64.2 ii and 64.2 f.i.
Electrical isolation of transformer is an essential pre-requisite for nitrogen injection and the
designed system shall have provision to verify the condition. The fire protection system shall get
activated under condition of coexistent transformer differential protection relay and pressure relief
valve. The system shall be designed to operate automatically. However it shall be designed for
manual operation and manual over rides shall be provided for. The system shall be procured from
manufacturer having effected similar supply. Performance experience and credentials of supplier
shall be furnished along with the tender documents including the description of the system proposed
to detect & extinguish fires and the type of sensors displayed.
2.0 SCOPE:
The fire prevention and extinguishing system shall be supplied complete with all parts,
fittings and accessories necessary for its efficient and reliable operation. All such parts, fittings
and accessories shall be deemed to be with in the scope of this specification, whether or not
specifically mentioned herein.
Fire survival mineral insulated cables, able to withstand 750 C, of appropriate size shall be
used for connection of fire sensors / detectors in parallel. Fire retardant los some (FRLS ) cable of
appropriate size shall be sued for connection between transformer signal box/ marshalling box to
control box and control box to fire extinguishing cubicle. The testr certificate for the cables shall
be submitted.
Laying of oil drain pipe, nitrogen pipe, electrical cables, control boxes, extinguishing
cubicle, nitrogen cylinder, PRV, fire dete4ctors and other equipments & accessories required for
erection, testing, commissioning and performance demonstration of the complete fire protection
system us inclined in the scope.
It shall be the responsibility of the tenderer, i.e. transformer supplied to coordinate with
supplier of the Fire Protection System for all arrangements for the complete erection, testing,
commissioning and performance tests. The successful tenderer shall be required to furnish the
detailed drawings and all technical particulars to RDSO through the pruchaser for
scrutiny/approval. Civil Engineering work of construction of oil soak-pit for the drained oil and
plinth for extinguishing cubicle is outside the scope of this specification.
3.0 INSPECTION AND TESTS:
The tenderer shall submit the test scheme to purchaser for approval of RDSO Inspection
and testing shall be done based on the test scheme firmed up and approved by
441
APPENDIX-H
RDSO. Proving test will be carried out on individual equipment of the system and the total system in
the supplier’s workshop in presence of RDSO purchaser’s representative.
Performance test of the complete system shall be arranged by the transformer manufactures
at his works. These tests shall include simulation of activating condition and verification of the
response of the complete fire protection system. In addition to above, additional tests as required
necessary shall be conducted.
RDSO representative shall witness the above tests on the prototype unit and after its
successful completion , prototype approval of fire prevention and extinguishing system shall be
issued by RDSO. The transformer manufacturer shall submit to the purchaser’s representative, along
with other document the RDSO approved test reports, drawings and document including bill of
material for balance quantity.
4.0 DRAWINGS AND MANUALS
Ten sets of approved drawings and ten sets of operation and maintenance manual, spare parts
catalogue shall be supplied with the equipment.
5.0 Warranty, Spares & after sales-service & AMC:
Clause 10.0 & 11.0 of the specification shall be applicable for warranty, after sale service and
AMC respectively.
Following spares shall be supplied along with the system.

1. One spare set of nitrogen filled cylinders.
2. 50 % of the complement of all typed of sensors employed for detection of fire.
3. One pre-stressed non return valve.
4. One oil release unit.
5. One gas release units.
The list of recommended spares is to be submitted along with the tender.
***
442
APPENDIX-I
LIST OF RDSO’S APPROVED SOURCES (VENDORS)- FOR PARTS, FITTINGS &

ACCESSORIES OF TRACTION POWER TRANSFORMERS.
S.No. Description of item Name of approved sources

1. Buchholz relay, gas operated double 1. M/s Instrument & Control, Vadodra
float type, conforming to IS-3637
2. M/s Atvus Industries, Calcutta
2. Pressure relief device (instantaneous M/s SukrutUdyog, Pune

reset type) with a trip contract.
3. Magnetic oil level gauge with an M/s SukrutUdyog, Pune
alarm contact (dial dia. 250mm)
4. OIP condenser bushings, 1. M/s ALSTOM Instrument Transformer

conforming to IS : 12676 & IS-2099. Pvt. Ltd. Bangalore (for 245kV, 145 kV &
52kV class).
2. M/s Crompton Greaves ltd. Nasik (for
245kV, 145kV & 52kV class).
3. M/s Bharat Heavy Electricals Ltd. Bhopal
(for 145kV & 52kV class).
4. M/s Transformers & Electricals, Kerala
Ltd., Angamaly (for 145kV & 52kV
class).
5. Pressed steel radiators, conforming 1. M/s CTR Manufacturing Industries, Pune

to IEEMA-9/1990
2. M/s PE Engineers Pvt. Ltd., Hyderabad
3. M/s Thermal transfer products Pvt. Ltd.
Bangalore.
4. M/s HI-TECH Switchgears Pvt. Ltd.,
Navi Mumbai.
5. M/s BHEL, Bhopal
6. Mineral Inhibited Insulting oil, 1. M/s Apar Pvt. Ltd. (Special oil refiner),
conforming to IS: 12463 & Railways Mumbai
required characteristics.
2. M/s Raj Lubricants (Madras) Pvt. Ltd.
Chennai.
3. M/s Savita Chemicals Ltd., Mumbai
4. M/s Gulf Oil India Ltd. Mumbai
5. M/s Raj Petroleum Products ltd. Mumbai
6. M/s MP Petrochem Ltd. Indore
7. M/s Tashkent Oil Company (P) Ltd.
Vadodara
8. M/s Power Oil Petroleum Products
443
APPENDIX-I
LIST OF RDSO’S APPROVED SOURCES (VENDORS)- FOR PARTS, FITTINGS &

ACCESSORIES OF TRACTION POWER TRANSFORMERS.
S.No. Description of item Name of approved sources

7. Bushing type current transformer, 1. M/s Transformers & Electricals, Kerala
PS class, conforming to IS: 2705 Ltd., Angamaly
(Part I & IV)
2. M/s Bharat Heavy Electricals Ltd., Jhansi
3. M/s AU Electro Machines, Allahabad
4. M/s Mahendra Electrical Works, Thane
5. M/s Proection & Control Engineers,
Thane
6. M/s Narayna Powertech Pvt. Ltd.
Vadodara
8. Silicagel breather (Dehydrating) 1. M/s Atvus Industries (M/s Suvida

Enterprises), Calcutta
2. M/s Yogya Enterprises, Jhansi
9. Wheel Valve, double flanged type 1. M/s Manixon Industrial Corporation, Agra
conforming to IS : 3639
2. M/s Girrnar Industries, Agra
3. M/s AUDCO India Ltd. Marinalal Nagar
4. M/s Petson Valves, Coimbatore
10. Temperature Indicators – WTI & 1. M/s Perfect Controls, Chennai

OTI, with four electrical contacts
2. M/s Precimeasure, Banglore
11. Remote tap position indicator, M/s Pradeep Sales & Service, Mumbai
winding temperature indicator, oil
temperature indicator & Annunciator
(digital type).
12. Terminal Connectors (Rigid & 1. M/s Vinayak & Transmission Products
expansion type) conforming to IS : (P) Ltd. Mumbai
5561.
2. M/s Nootan Engineering Industries,
Vadodara
3. M/s Sree Engg. Corporation, Chennai
4. M/s Best & Crompton, Chennai
****
444
ANNEXURE – 1
Addendum to RDSO Specification no. TI/SPC/PSI/30 TRN/1050 for 30MVA, 11/27kV Single
Phase traction Power Transformer only for the purpose of MRVC work of Design, Supply, Erection,
Testing and Commissioning of 110kV / 25kV Traction Substation at Jogeshwari & 9 switching stations
in Mumbai Division of Western Railway at Mumbai (India)
Sr. Reference Clause Page

No.
1. Clause no.12 “Technical Data and 411 In the title after the work
Drawing to be furnished…..” “furnished” delete the works “along
with the tender” and add “by
successful tenderer”.
2. Clause no.12.3 “Technical Data 411 (i) Add “successful” after “the”
and drawings to be furnished by and before “tenderer”
the successful Bidder”.
(ii) Delete “his offer” and add
“detailed design and drawing
for approval of MRVC” at the
end of the sentence.
445
SPECIFICATION
FOR
EARTHING OF POWER SUPPLY

INSTALLATIONS
FOR 25kV, ac, 50 Hz, SINGLE PHASE
TRACTION SYSTEM
No. ETI / PSI / 120 (2 / 91)
447
SPECIFICATION No. ETI / EST / 120 (2 / 91)
GOVERNMENT OF INDIA
SPECIFICATION
FOR
EARTHING OF POWER SUPPLY INSTALLATIONS

FOR 25 kV, AC, 50 Hz, SINGLE PHASE TRACTION SYSTEM
ISSUED BY
MANAK NAGAR, LUCKNOW 226011
448
FEBRUARY – 1991
GOVERNMENT OF INDIA – MINISTRY OF RAILWAYS

CODE No. ETI / PSI / 120 (2 / 91) with C.S. No. 1 (10/93)*
CODE OF PRACTICE
FOR EARTHING OF POWER SUPPLY INSTALLATIONS
FOR 25 kV, ac, 50 Hz, SINGLE PHASE TRACTION SYSTEM
1. SCOPE
1.1 This code of practice caters for general arrangements of system and equipment
earthing at 220 / 25 kV or 132 / 25 kV or 110 / 25 kV or 66 / 25 kV traction
substations, 25 kV switching stations, booster transformer stations and auxiliary
transformer stations. Low voltage (LT) electrical power distribution system, 25 kV
overhead equipment system as well as signal and tele-communication equipment do
not come within the purview of this code.
2. TERMINOLOGY
2.0 The following terms wherever occurring in this code shall, unless excluded or
repugnant to the context, have the meaning attributed thereto as follows :-
2.1 Combined Earth Resistance : The resistance of an earth electrode(s) with respect to
earth, with the earth electrode(s) connected to the metal work of electrical
equipment other than parts which are normally live or carry current and the masts /
structures but without connection with the traction rail(s).
2.2 Earth : The conductive mass of the earth, whose electrical potential at any point is
conventionally taken as zero.
2.3 Earth electrode : A conductor (mild steel (MS) pipe) for group of conductors in
intimate contact with and providing an electrical connection to earth.
2.4 Earthing grid : A system of a number of interconnected, horizontal bare conductors

buried in the earth, providing a common ground for electrical devices and metallic
structures, usually in one specific location.
2.5 Equipment earthing : Earthing of all metal work of electrical equipment other than
parts which are normally live or current carrying. This is done to ensure effective
operation of the protective gear in the event of leakage through such metal work,
449
the potential of which with respect to neighboring objects may attain a value which
would cause danger to life or risk of fire.
• C.S. No. 1: Para 2.1, 2.11 and 16. vii added.

• Para 2.3 and 11.1 modified.
2.6 System earthing : Earthing done to limit the potential of live conductors with
respect to earth to values which the insulation of the system is designed to
withstand and thus to ensure the security of the system.
2.7 Touch Voltage (E touch) : The potential difference between a grounded metallic
structure and a point on the earth’s surface separated by a distance equal to the
normal maximum horizontal reach of a person, approximately one metre.
2.8 Step Voltage (E step) : The potential difference between two points on the earth’s
surface separated by distance of one pace, that will be assumed to be one metre in
the direction of maximum potential gradient.
2.9 Mesh Voltage (E mesh) : The maximum touch voltage to be found within a mesh
of an earthing grid.
2.10 Power supply installation : The electrical equipments and associated structures
provided at a Railway Traction Substation or Switching Station, or Booster /
Auxiliary transformer Station on the 25 kV over head equipment.
2.11 Traction Rail means a non-track circuited rail of a wired track, not required for
signaling purposes and which may be earthed. In non-track circuited sections, both
the rails of a wired track are traction rails and in single rail track circuited sections,
the traction rail is the non-track circuited rail.
3. OBJECT OF EARTHING
The object of an earthing system is to provide as nearly as possible a surface under
and around a station which shall be at a uniform potential and as nearly zero or
absolute earth potential as possible. The purpose is to ensure that generally all
parts of the equipment, other than live parts are at earth potential and that attending
personnel are at earth potential at all times. Also by providing such an earth surface
of uniform potential under and surrounding the station, there can exist no difference
of potential in a short distance big enough to shock or injure an attendant when
short circuits or other abnormal occurrences take place. The primary requirements
of a good earthing system are :
i) It should stabilize circuit potentials with respect to ground and limit the
overall potential rise.
ii) It should protect men and materials from injury or damage due to over
voltage.
iii) It should provide low impedance path to fault current to ensure prompt and
consistent operation of protective devices during ground faults.
450
iv) It should keep the maximum voltage gradient along the surface inside and
around the substation within safe limits during earth faults.
4. GOVERNING SPECIFICATIONS
Assistance has been taken from the following standards / codes of practices in the
preparation of this code of practice :
i) IS : 3043 – 1987 code of practice for earthing (first revision).

ii) Indian electricity Rules – 1956 (latest edition).
iii) National Electrical Code – 1985 of Indian Standards Institution.
iv) IEEE Guide for safety in a.c. substation grounding, No. ANSI / IEEE
Standard 80 – 1986.
5. EARTH RESISTANCE
At each power supply installation, an earthing system as specified in this code shall
be provided. S The combined resistance of the earthing system shall be not more
than the following values :-
S. No. Name of the station The limit of combined earth

resistance in ohms
1. Traction substation 0.5

2. Switching station 2.0
3. Booster transformer station 2.0
4. Auxiliary transformer station 10.0
6. EARTH ELECTRODES
6.1 The earth electrode shall normally be of mild steel galvanized perforated pipe of not
less than 40 mm nominal bore, of about 4 m length provided with a spike at one end
and welded lug suitable for taking directly MS flat of required size at the other end.
The pipe shall be embedded as far as possible vertically into the ground, except
when hard rock is encountered, where it may be buried inclined to the vertical, the
inclination being limited to 30 degree from the vertical. The connection of MS flat
to each electrode shall be made through MS links by bolted joints to enable
isolation of the electrode for testing purposes. A typical sketch of an earthing
station with one earth electrode is shown in Fig. 1.
451
6.2 Earth electrodes shall be embedded as far apart as possible from each other. Mutual
separation between them shall usually be not less than 8.0 m (which is twice the
length of the electrode).
6.3 If the value of earth resistance specified in clause 5 can not be achieved with a
reasonable number of electrodes connected in parallel such as in rocky soil or soil
of high resistivity, the earth surrounding the electrodes shall be chemically treated.
The earth electrode shall be surrounded in an earth – pit by alternate layers of finely
divided coke, crushed coal or charcoal and salt at least 150 mm all-round. Though
substantial reduction in earth resistance can be achieved by coke treated electrode,
yet as this method results in rapid corrosion not only of electrode but also of steel
frame work to which it is bonded, coke treatment shall be used only where
absolutely necessary and such electrodes shall not be situated within 8.0 m of other
metal work.
6.4 In high embankments, it may be difficult to achieve earth resistance specified in

clause 5 even after chemical treatment of electrodes. In those locations, use of
electrodes longer than 4 m so as to reach the parent soil is recommended.
6.5 As far as possible, earth electrodes for traction sub-stations / switching stations
shall be installed within and adjacent to perimeter fence. At large sites, apart from
securing a sufficiently low resistance and adequate current carrying capacity a
reasonable distribution of electrodes is also necessary.
7. EARTHING ARRANGEMENT AT TRACTION SUBSTATION

7.1 Earthing grid.
7.1.1 An earthing grid is formed by means of bare mild steel rod of appropriate size as
indicated in clause 7.1.2 buried at a depth of about 600 mm below the ground level
and connected to earth electrodes. The connection between the earth electrode and
the grid shall be by means of two separate and distinct connections made with 75
mm X 8 mm MS flat. The connection between the MS flat and the MS rod shall be
made by welding, while that between the earth electrode and the MS flats through
MS links by bolted joints. The earth electrodes shall be provided at the outer
periphery of the grid as shown in Fig. 2. As far as possible the earthing grid
conductors shall not pass through the foundation block of the equipments. All
crossings between longitudinal conductors and transverse conductors shall be
jointed by welding. The transverse and longitudinal conductors of the earthing grid
shall be suitably spaced so as to keep the step and touch potentials within
acceptable limits; the overall length of the earthing grid conductors shall not be less
than the calculated length (refer Annexure–I).
7.1.2 The size of the earthing grid conductor shall be decided based on the incoming
system voltage and fault level (refer Annexure I). The fault level considered shall
take into account the anticipated increase in fault current during the lifespan of the
station. The size shall be as given below :
452
S. No. System voltage Fault level Diameter of the grid
(kV) (MVA) Conductor (MS rod)
in mm
1. 66 up to 4000 32
above 4000 up to 5000 36
above 5000 up to 6000 40
2. 110 Upto 6000 32
above 6000 upto 8000 36
above 8000 upto 10000 40
3. 132 Upto 7000 32

above 7000 upto 10000 36
4. 220 Upto 12000 32

above 12000 upto 16000 36
above 16000 upto 2000 40
7.2 Buried rail.

7.2.1 A steel rail of section 52 kg / m (the one used for the railway track) and length
about 13 m shall be buried near the track at the traction substation at a depth of
about one metre to form part of the earthing system. Two separate and distinct
connections shall be made by means of 75 mm X 8 mm MS flat between the
earthing grid and the buried rail. The buried rail shall also be connected by means
of two separate and distinct connections made with 75 mm X 8 mm MS flat to the
non-track circuited rail (s) in a single-rail track circuited section and to the neutral
point (s) of the impedance bond (s) in a double – rail track circuited section.
7.2.2 In case where the feeding post is located separately away from the traction
substation, the buried shall be provided at the feeding post (where one terminal of
the secondary winding of the traction power transformer of the substation is
grounded).
7.3 System earthing.

7.3.1 One terminal of the secondary winding (25 kV winding) of each traction power
transformer shall be earthed directly by connecting it to the earthing grid by means
of one 75 mm x 8 mm MS flat, and to the buried rail by means of another 75 mm x
8 mm MS flat.
7.3.2 One designated terminal of the secondary of each potential, current and auxiliary
transformer shall be connected to the earthing grid by means of two separate and
distinct earth connections made with 50 mm x 6 mm MS flat.
7.4 Equipment earthing.

The metallic frame work of all outdoor equipments such as transformers, circuit
breakers, interruptors and isolators, as well as steel structures shall be connected to
453
the earthing grid by means of two separate and distinct connections made with MS
flat of size as indicated below; one connection shall be made with the nearest
longitudinal conductor, while the other shall be made to the nearest transverse
conductor of the grid :
S. No. Equipment System voltage and fault level Ground conductor

size
1. Equipments on the 66 kV, upto 3000 MVA
primary side of 110 kV, upto 5000 MVA 50 mm X 6 mm
traction power 132 kV, upto 6000 MVA
transformer. 220 kv, upto 10000 MVA
66 kV, above 3000 upto 6000 MVA

110 kV, above 5000 upto 10000 MVA 75 mm X 8 mm
2. Equipments on the 50 mm X 6 mm
secondary side of
traction power
transformer.
3. Fencing uprights/ 50 mm X 6 mm
steel structures.
4. Doors / fencing 6 SWG G.I. wire

panels.
7.5 Earthing inside control room.

An earthing ring shall be provided inside the control room by means of 50 mm x 6
mm MS flat which shall be run along the wall on teak wood blocks fixed to the wall
at a height of about 300 mm from the floor level. The earthing ring shall be
connected to the main earthing grid by means of two separate and distinct
connections made with 50 mm x 6 mm MS flat. The earthing ring shall also be
connected to an independent earth electrode by means of two separate and distinct
connections made with 50 mm x 6 mm MS flat. The metallic framework of control
and relay panels, LT a.c. and d.c. distribution boards, battery chargers, remote
control equipment cabinets and such other equipments shall be connected to the
earthing ring by means of two separate and distinct connections made with 8 SWG
galvanized Iron wire. The connection shall be taken along the wall and in recesses
in the floor. All recesses shall be covered with cement plaster after finishing the
work. Connections between the MS flats shall be made by welding.
7.6 Earthing of lightning arrester.
454
In addition to the earth electrodes provided for the main earthing grid, an
independent earth electrode shall be provided for each lightning arrester. This earth
electrode shall be connected to the ground terminal of the lightning arrester as well
as to the main earthing grid by means of two separate and distinct connections made
with 50 mm X 6 mm MS flat for the 25 kV side lightning arresters, and with 75 mm
X 8 mm MS flat for the primary side lightning arresters, and with 75 mm X 8 mm
MS flat for the primary side lightning arresters. The earth electrode shall be
provided as close as possible to the lightning arrester and the connections shall be
as short and straight as possible avoiding unnecessary bends. For lightning
arresters provided for the traction power transformers, there shall also be a
connection as direct as possible from the ground terminal of the lightning arrester to
the frame of the transformer being protected; this connection shall also be made by
means of two separate and distinct connections made with 50 mm X 6 mm MS flat
for 25 kV side arresters, and with 75 mm X 8 mm MS flats for primary side
lightning arrester.
7.7 Earth screen.

The area covered by outdoor substation equipments shall be shielded against direct
strokes of lightning by an overhead earth screen comprising 19 / 2.5 mm galvanized
steel stranded wire strung across the pinnacles of the metallic structures. The earth
screen wires shall be strung at a height as indicated in the approved traction
substation layouts (not less than 2.5 m above the live conducters) and shall be
solidly connected to the traction substation earthing grid at each termination by
means of 50 mm x 6 mm MS flat.
7.8 Earthing of fencing uprights and panels.

Each metallic fancing upright shall be connected to the traction substation main
earthing grid by means of two separate and distinct connections made with 50 mm x
6 mm MS flat. In addition, all the metallic fencing panels shall be connected to the
uprights by means of two separate and disktinct connections made with 6 SWG G.I.
wire. Al the metallic door panels shall also be connected to the supporting uprights
by means of two separate and distinct connections made with 6 SWG G.I. wire.
7.9 Earthing at the point of 240 V ac 50 Hz supply for oil filtration plant.
The 240 V ac 50 Hz distribution board for power supply to oil filtration plant shall
be connected to the main earthing grid by means of two separate and distinct
connections made with 50 mm x 6 mm MS flat.
8. EARTHING ARRANGEMENT AT SWITCHING STATION

8.1 A minimum number of three earth electrodes (excluding the one to be provided
separately for the remote control cubicle earthing – refer clause 8.4) shall be
provided at each switching station, and they shall be interconnected by means of 50
mm X 6 mm MS flat forming a closed loop main earthing ring. This ring shall be
connected by two separate and distinct connections made with 50 mm X 6 mm MS
flat, to the non-track circuited rail in a single-rail track circuited section and to the
neutral point of the impedance bond in a double – rail track circuited section of the
455
nearest track, so as to limit the potential gradient developing in the vicinity of the
switching station in the event of a fault.
8.2 System earthing.

One designated terminal of the secondary of each potential, current and auxiliary
transformer shall be connected to the main earthing ring by means of two separate
and distinct connections made with 50 mm X 60 mm MS flat.
8.3 Equipment earthing.

8.3.1 All masts, structures, fencing uprights, and all outdoor equipment pedestals
including auxiliary transformer tank shall be connected to the earthing ring by
means of two separate and distinct connections made with 50 mm X 6 mm MS flat.
All fencing panels shall be connected to the supporting uprights by menas of two
separate and distinct connections made with 6 SWG G.I. wire. All the metallic
door panels shall be connected to the supporting uprights by means of two separate
and distinct connections made with 6 SWG G.I. wire.
8.3.2 The metal casing of potential and current transformers shall be connected to the
mast / structures by means of two separate and distinct connections made with 50
mm x 6 mm MS flat.
8.3.3 The ground terminal of lightning arrester shall be connected directly to the earth
electrode by means of two separate and distinct connections made with 50 mm X 6
mm MS flat. The earth electrode shall be so placed that the earthing leads from the
lightning arrester may be brought to the earth electrode by as short and straight a
path as possible.
8.4 Earthing inside remote control cubicle.

An earthing ring shall be provided inside the remote control cubicle by means of 50
mm X 6 mm MS flat; the earthing ring shall be run along the wall on teak wood
blocks fixed to the wall at a height of 300 mm from the floor level. The earthing
ring shall be connected to the main earthing ring as well as to an independent earth
electrode by means of two separate and distinct connections made with 50 mm x 6
mm MS flat. The metal casing of LT a.c. and d.c. distribution borad, battery
chargers, terminal board, remote control equipment cabinets and other such
equipments shall be connected to the earthing ring by means of two separate and
distinct connections made with 8 SWG G.I. wire. The connections shall be taken
along the wall and in recesses in the floor. All recesses shall be covered with
cement plaster after finishing the work. Connections of earth strips to each other
shall be made by welding.
9. EARTHING OF NEUTRAL OF LOCAL POWER SUPPLY SYSTEM

At traction substations and switching stations where power supply at 415 V / 240 V,
ac, 50 Hz, is taken from the local supply authority and having neutral earth at some
distant point in the premises of the supply authority, the neutral of such supply shall
456
also be earthed by means of two separate and distinct connections made with 6
SWG G.I. wire by connecting to an independent earth electrode.
10. EARTHING ARRANGEMENT AT BOOSTER TRANSFORMER STATION

10.1 The minimum number of earth electrodes to be provided at each booster
transformer station shall be two. They shall be interconnected by means of 50 mm
x 6 mm MS flat to form an earthing ring. The ring shall be connected by means of
two separate and distinct connections made with 50 mm x 6 mm MS flat to the non-
track circuited rail in a single-rail track circuited section or to the neutral point of
the impedance bond in a double – rail track circuited section.
10.2 Each mast of the supporting gantry shall be connected at the bottom to the earthing
ring by means of two separate and distinct connections made with 50 mm x 6 mm
MS flat. The booster transformer tank shall be connected to the gantry mast by
means of two separate and distinct connections made with 50 mm x 6 mm MS flat.
11. EARTHING ARRANGEMENT AT AUXILIARY TRANSFORMER STATION

11.1 The combined earth resistance at an auxiliary transformer station shall be not more
than 10 ohm. Normally, one earth electrode is sufficient at each auxiliary
transformer section. The earth electrode shall be connected to the transformer mast
by means of two separate and distinct connections made with 50 mm x 6 mm MS
flat. In addition, both the mast and the earth electrode shall be connected to the
non-track circuited rail in a single-rail track circuited section or, to the neutral point
of the impedance bond in a double-rail track – circuited section by means of 50
mm x 6 mm MS flat.
11.2 The earthing terminal on the transformer tank shall be connected to the mast on
which the transformer is mounted by means of two separate and distinct
connections made with 50 mm x 6 mm MS flat. One terminal of the secondary
winding of the auxiliary transformer shall be connected to the earthing terminal on
the transformer tank and as well as to the mast by means of 50 mm x 6 mm MS flat.
These connections shall be as short and straight as possible and avoiding
unnecessary bends.
12. METHOD OF JOINTING

All the joints between the MS flats, MS rods or between MS flat and MS rod shall
be made by welding only. No soldering shall be permitted. For protection against
corrosion, all the welded joints shall be treated with red lead and afterwards thickly
coated with bitumen compound.
13. PAINTING OF MS FLATS

For protection against corrosion, all the exposed surfaces of earthing connections
(MS flats) above ground level shall be give all around two coats of painting to
colour grass green, shade – 218 of IS : 5.
14. CRUSHED ROCK SURFACE LAYER
457
At the traction substations and switching stations, a surface layer of crushed rock
shall be provided to a thickness of about 100 mm. If considered necessary from the
point of view of containing the step and touch voltages within the acceptable limits,
higher thicknesses may be provided depending on calculation based on site
conditions.
15. STEP AND TOUCH VOLTAGES

15.1 The formulae for calculating the tolerable touch and step voltages, estimated mesh
and step voltages, earth resistance, earth potential rise, size of earthing grid
conductor and length of buried grid conductor are given in Annexure – I
15.2 The design for earthing grid shall be done separately for each location depending on
the conditions obtaining and those foreseen.
16. DRAWINGS
The following drawings (latest versions) issued by RDSO in connection with this
code my be used for reference :
i) Typical earthing layout of

Traction substation. ETI / PSI / 224 – 1
ii) Typical return current connection
of buried rail at traction ETI / PSI / 0212 – 1
substation.
iii) Typical earthing layout of
subsectioning and paralleling station. ETI / PSI / 201 – 1
iv) Typical earthing layout of sectioning
and paralleling station. ETI / PSI / 202 – 1
v) Typical earthing layout of
booster transformer station. ETI / PSI / 211 – 1
vi) Typical arrangement of an earth
electrode at a traction substation. ETI / PSI / 222 – 1
vii) Typical earthing arrangement for ETI / PSI / 708

An auxiliary transformer station.
**********************
458
ANNEXURE – 1
FORMULAE FOR CALCULATION OF EARTHING GRID
BASED ON IEEE GUIDE FOR SAFETY IN AC SUBSTATION
GROUNDING, No. ANSI / IEEE Std 80 – 1986
1.0 Tolerable touch and step voltage
0.116 { 1000 + 1.5 Cs (hs, K) Ps}

1.1 E touch = ----------------------------------------- V (for 50 kg body)
ts
0.116 {1000 + 6 Cs (hs, K) Ps}

1.2 E step = -------------------------------------- V (for 50 kg body)
√ ts
where,
Cs (hs,K) = 1 for crushed rock having resistivity equal to that of soil. If
crushed rock resistivity is higher than that of soil, reference
may be made to Fig. 3 for obtaining the value of Cs.
Ps = Resistivity of surface material (crushed rock) in ohm-metre.
P = Resistivity of earth in ohm-metre.
P - Ps
K = -----------
P + Ps
ts = Duration of sock current in seconds.
hs = Thickness of the crushed rock surface layer in metres.
2.0 Estimated mesh and step voltageIG
2.1 E mesh = P x Km x Ki x ----- V
L
IG
2.2 E step = P x Ks x Ki x ----- V
L
Where,
Ki = Corrective factor for grid geometry, which accounts for the increase
in current density in the grid extremities.
= 0.656 + 0.172 n
IG
---- = Average Current per unit length of
L buried conductor in amperes / metre.
1 D2 (D + 2h)2 h Kii 8
Km = ----- {1n ( -------- + ------------- -- ------ ) + ------ 1n ---------- }
2∏ 16 h.d 8 D.d 4d Kh ∏ (2n-1)
Kii = 1 for grids with earth electrodes along the perimeter, or for grids
with earth electrodes in the grid corners, as well as both along the
perimeter and throughout the grid area.
1
459
= ------------ for grids without earth electrodes or grids with only a
2/n few earth electrodes none located in the corners or on
(2n) the perimeter.
Kh = √1 + h / ho
1 1 1 1 n-2
Ks = ------ [ ------- + --------- + ------- ( 1 -- 0.5 ) ]
∏ 2h D+h D for value of h between
0.25 and 2.5 m.
ho = 1 metre (reference depth of grid).
D = Spacing between parallel conductors of grid in metres (same
spacing in both directions).
n = √nA . nB for calculating E mesh.
= nA or nB, whichever is greater, for calculating E step.
nA = Number of parallel conductors of grid in transverse direction.
nB = Number of parallel conductors of grid in longitudinal direction.
h = Depth of earthing grid conductors in metres.
d = Diameter of earthing grid conductor in metres.
L = Total length of earthing system conductor.
= Lc + Lr for grids without earth electrodes or with only a few
electrodes located within the grid but away
from the perimeter.
Lc = Total grid conductor length in metres.
Lr = Total earth electrode length in metres.
IG = As defined in para 4.1 below.
Note : The estimated values of mesh and step voltage should be less than
the tolerable touch and step voltages respectively.
3.0 Earth resistance :
P ∏ P
3.1 Rg = -------- --------- + ---------
4 Ag L
where,
L = Total length of buried conductors in metres.
Ag = Area occupied by the earthing grid in square metres.
Rg = Station ground resistance in ohms.
4.0 Earth Potential rise :
4.1 Earth potential rise = Rg x IG
where,
Rg = Station Earth resistance in ohms.
IG = Cp x Dr x Ig
460
Cp = Corrective projection factor accounting for the relative increase of
Fault currents during the station lifespan; for a zero future system
Growth Cp = 1.
Ig = r.m.s. value of symmetrical grid fault current in amperes.
Df = Decrement factor for the entire duration of fault (to allow for the
effects of asyrmetry of the current wave).
= 1.0 for fault current duration of 0.5 second or more.
5.0 Size of earthing grid conductor
5.1 A = I √ t / 80
where,
A = Cross – sectional area of earthing grid conductor in square
millimeters.
I = r.m.s value of fault current in amperes.
t = Duration of fault current in second (taken as one second )
Note : To allow for the effects of corrosion, the size of the grid conductor selected
shall be such that its cross-section area is nearly twice that calculated above.
6.0 Minimum length of buried grid conductor
Km x Ki x P x IG √ ts
6.1 L > ------------------------------------------------------- for E mesh < E touch
116 + 0.174 Cs (hs, K) Ps
where,
L = Minimum length of buried grid conductor including earth
electrodes in Metres.
Ts = 0.5 second (assumed maximum duration of shock).
Cs (hs, K), Km, Ki, P, IG and Ps have been defined earlier.
461
SPECIFICATION
FOR
LOW MAINTENANCE LEAD ACID 40 AH
AND 200 AH CELLS FOR TRACTION
DISTRIBUTION SYSTEM.
No. RDSO/PE/SPEC/TL/0040-2003(Rev-0)
462
Material SPECIFICATION No. RDSO/PE/SPEC/TL/0040-2003(Rev-0)
GOVERNMENT OF INDIA
RESEARCH, DESIGN AND STANDARD ORGANISATION
MANAK NAGAR LUCKNOW-226011
SPECIFICATION FOR LOW MAINTENANCE LEAD ACID 40 AH AND 200 AH

CELLS FOR TRACTION DISTRIBUTION SYSTEM.
0.0 FOREWORD
0.1 In Traction Distribution System, 40Ah and 200Ah capacity cell is used for
installations in the control rooms at unattended switching stations and traction sub stations.
0.2.1 The batteries for traction sub-stations and switching stations shall be of single cell
construction and 55 cells constitute one set.
0.2.2 All types of traction sub-stations and switching stations shall be provided with
single set of cell.
0.2.3 The rated capacity of cell shall be 2V, 40Ah for switching stations & 2 V, 200 Ah
for traction sub-stations at 27 degree centigrade.
0.3 In the preparation of this specification assistance has been drawn from the
following publications.
(1) IS: 1146-1981

(2) IS: 6848-1979 (latest)
(3) IS: 266-1993
(4) IS: 1069-1993
(5) IS: 6071-1986
(6) IS: 3116-1965
(7) IS: 8320-2000
(8) IS: 4905-1998
(9) IS: 1651-91(latest)
(10) IS: 1652-91(latest)
(11) RDSO Spec. No. ELPS/SPEC/TL/09 (Dec , 1996) with Amendment No.2
(12) RDSO Spec. No. ETI / PSI/21(6/81) with A& C Slip No. 1
(13) RDSO Spec. No. ETI / PSI/25(6/81) with A& C Slip No. 1
463
1. SCOPE
1.1 This specification covers the design, manufacture, method of test and other
requirements of low maintenance stationery lead acid batteries for installation in the control
room at un - attended 132/25kV or 220/25kV traction sub stations (TTS) and at un-attended
sectioning and paralleling posts (SPs) and sub-sectioning and paralleling posts (SSPs). The
battery shall be of low maintenance design such that it requires very less topping up in the
actual service. Frequency of topping up shall be not earlier than 9 months. However,
attempt should be made to increase this period to 12 months.
1.2 The batteries shall be complete with all parts and accessories, which are necessary
for their efficient operation including the supporting stands. All such parts and accessories
shall be deemed to be with in the scope of this specification.
1.3 The batteries shall be delivered in the dry uncharged condition ready for filling
electrolyte and use at site. Sufficient quantity of electrolyte required for first filling with
10% extra shall be supplied separately in non-returnable containers.
2.0 TERMINOLOGY
2.1 TYPE TESTS:-. These are intended to prove the general quality and design of a
given type of battery.
2.2 ACCEPTANCE TESTS:- Tests carried out on samples selected from a lot for the
purpose of verifying the acceptability of the lot.
2.2.1 LOT:- All batteries of the same type, design and rating manufactured by the same
factory during the same period using the same process and materials, offered for inspection
at a time, shall constitute a lot.
2.3 ELECTROLYTE:- Aqueous solution of sulphuric acid for ionic conduction and
Electro-chemical reaction during passage of current through a cell.
2.4 TERMINAL POST (lug): - A post (lug) of a cell or battery to which an internal
electrical circuit is connected. Positive and negative terminal post shall be clearly and
unmistakably identifiable. The positive terminal shall be marked with red colour in
addition to '+' marking.
2.5 FLOAT:- A device for indicating the level of electrolyte in the cell container.
2.6 FLOAT GUIDE:- A removable bush of anti-splash and sealed type to facilitate
easy vertical movement of float stem.
2.7 VENT-CUM-FILLING PLUG:-A removable plug for fitting into the vent hole.
464
3.0 MATERIAL AND CONSTRUCTION
3.1 The cells shall be similar in type and shape. Lifting handle either moulded or
rope type shall be provided with suitable strength.
3.2 The maximum overall dimensions of the cells up to terminal shall not exceed
the values given in the table 1 of clause 7.1 of IS:1651-1991.The dimensions do not
include the projection of float.
3.3 The weight of cells with the electrolyte shall not exceed to the value 31 Kg
and 10 Kg for 200Ah and 40 Ah cell respectively.
3.3.1 The cell shall be so designed that the initial charging of the cell shall be
completed within 75 hours as per the charging method to be prescribed by the
manufacturers to the type testing authority as well as in the Maintenance Manual.
Subsequent charging for conducting various tests shall be restricted to 15 hours.
3.3.2 All the positive or negative plates shall be insulated at edges to avoid side
shorting.
3.4 CONTAINER AND LID
3.4.1 HARD RUBBER CONTAINER/LIDS:
The cells shall be supplied in containers, which shall conform to IS:1146-1981 with
latest amendment. The minimum height from the ball, as defined in the IS:1146-1981,
when dropped which causes the fracture, shall not be less than 400mm (min. single
time drop) for each side. However for 40 Ah cell the height which causes the fracture
shall not be less than 200 mm. The design will provide for adequate safety margins
for achieving the required strength.
Cell lids shall be either drop-on type together with suitable gasket or of the deep
sealing type suitable for use of bituminous sealing compound, with close-fitting
terminal post outlets and with vent- holes suitable for accommodating the float guide
and filling plug -cum-vent plugs.
3.4.2 PLASTIC CONTAINER/CELL LIDS:
3.4.2.1 The individual cells may be supplied with plastic containers / lids. The
container/lid shall have adequate strength with design margins to meet the actual field
conditions as prevalent over Indian Railways for which battery manufacturers shall
wholly be responsible notwithstanding the approval given by the RDSO . Adequate
measures shall also be taken by Manufacturers to avoid bulging of cells along shorter /
longer sides of the cells. Despite of the above design measures having been taken by
the manufacturers, if failures of cells on account of the container/lid
material/inadequate design are reported from the field, the manufacturers shall
465
replace these cells with new cells having improved design with plastic/hard
rubber container/lid as approved by the RDSO free of cost within the warranty period.
If design of the container/lid is with strengthening member/rib, it may be provided inside or

out side of the container/lid. In this case wall thickness refers to the base(web) thickness
only and does not include thickness of rib or strengthening members. However the overall
outer dimension shall not exceed the values specified as per clause 3.2.The design of
container and lid shall generally conform to the following specifications.
(1) Material Specification for PP-CP (Polypropylene Co polymer)

Container/lid Fire retardant (V2 Grade)
(2) Wall thickness of container 3.5 mm to 6.5 mm
The outer wall thickness shall be measured on all sides of the container i.e longer side,
shorter side, and base. However, the minimum wall thickness of container/lids shall not be
less than3.0 mm if design of the container/lid is with strengthening member/rib.
(3) Tests: These PP-CP containers shall be subjected to the tests as per Clause 7 of the
IS:1146-81 and the following tests shall be conducted during prototype testing
1. Verification of constructional requirements

2. Verification of marking and packing
3. High Voltage test
4. Drop Ball test
5. Plastic Yield test
6. Acid resistance test.
In addition, a test for checking the proper sealing of the container with the lid as per 5.13
shall be conducted during prototype test as well as acceptance test, if the lifting handle is
provided on the lid.
3.4.2.2 In order to have standardization of float guides, it should conform to drawing no.
RDSO/PE/SK/TL/0031-02 (Rev 0 ). Float guides of dimensions different than above
drawing may be accepted in special circumstances to be explained by the vendor.
3.4.3 MICRO POROUS VENT PLUG: Each cell shall be provided with adequate means,
both for venting and for servicing of the electrolyte. The vent -cum-filling plug shall
generally conform to RDSO drawing No. 4020/A Alt. 3 with the dome /filter made of
ceramic or any other suitable fire retardant material. For smaller battery i.e. 40Ah size of
vent plug can be smaller. The vent-cum-filling plug shall allow free escape of gases
evolved during service and shall not permit electrolyte to come out on the surface of the
lid. On removal of vent-cum -filling plug, drawing of the electrolyte sample, servicing and
checking of electrolyte shall be possible.
466
3.4.3.1 The material used for micro -porous vent plug shall have uniform porosity. It shall
also be free from abnormalities such as crack, breakage, foreign matter, dent and shall
conform to the following. The following tests shall be applicable on Micro -porous dome
of the vent plug only and dome shall be taken out for this purpose.
a) Porosity : 35 ± 5%
Porosity of micro-porous filter shall be calculated as given below:-

Weigh the sample in air (W1). Keep the sample in boiling water with few
drops of wetting agent (Teepol ) for 30 mts. Weigh the sample in water (W2). Next weigh
the wet sample outside water (W3). Calculate porosity as under:
a) Porosity % = (W3-W2)-(W1-W2)
------------------------------X 100
(W3-W2)
b) Breaking Strength: Shall not be brittle. To test this, a steel ball of 200 gm shall be
dropped two times from the height of 400mm on the top and
side of micro-porous dome.
c) Acid resistance: Dry and weigh the (micro-porous body) dome (W1), Keep the
dome in sulphuric acid of Sp. Gr. 1.3 at 40 Degree centigrade
for 100 hours. Remove it from acid, wash free of acid, dry and
weight (W2) . Calculate the percentage loss as follows
W1- W2
-----------X100
W1
The loss of weight shall not be more than 0.5%
d) Permeability : The full charge cell shall be fitted with vent plug and charged
at 2.5 times of C10 rate for 4 hours. All sealed Float guides
shall be in position properly except the one where manometer
with water is fitted. The cell shall not develop positive pressure
more than 2 mm of water column inside the cell.
e) Dimension : Shall generally conform to RDSO's drg. No. SKEL-4020/A

Alt. 3 or as approved by RDSO
f) Plastic Component : Plastic component to which the micro -porous top is bonded
shall be free from crack, flash, pin hole, air bubble, uneven
shrinkage foreign particles etc. and shall conform to the
following (Ref. Drg. SKEL-4020 Alt. 3)
: ABS Fire retardant or superior quality

Acid Resistance : No perceptible change
Heat : NO deformation at 70 deg. C
467
3.4.3.2 DIA AND PITCH THREAD:- The micro-porous vent cum- filling plug and
sealed float guide dia shall be 27 mm and pitch of thread shall be 3 mm as per
Drawing No. SKEL-4020/A Alt. 3 (sheet no.2 )
3.4.3.3 Each cell shall have one micro porous vent -cum -sealed float guide type for 40Ah
and having dome /filter made of ceramic or any other suitable fire retardant material and
meeting the requirements specified in clause 3.4.3
3.4.3.4 For 200 Ah each cell shall have one float guide sealed type and one vent-cum-
filling plug as mentioned above.
3.4.3.5 Each cells (i.e. 40Ah/200Ah) shall be provided with two terminal lugs made of lead
alloys, one negative and one positive according to fig. 1 of IS: 6848 except the thickness of
lug which shall be 5 mm minimum for 40Ah and 12 mm for 200Ah . The positive terminal
lugs shall have rounded edges and the negative terminal lugs shall have pointed edges, so
to be easily distinguishable ( fig. 1 of IS:6848-79)
3.5 INTER -CELL AND END -CELL CONNECTORS:
3.5.1 Inter -cell connectors for one set consisting of 55 cells of 40Ah and 200 Ah shall be
provided. The quantity to be supplied is given below.
i) Inter cell connector = 52 numbers
ii) Inter row connector = 2 numbers (Cell No. 14-15 and 42-43)
iii) Take off terminal = 2 numbers (End cells)
iv) Inter tier connector = 2 numbers (Cell No. 28 & 29)
v) Fasteners = 220 numbers
The fasteners M6X30for 40 Ah and M8x30 for 200 Ah shall be used.
3.5.1.1 Connector:
(i) The cable connectors should have lead coating to withstand any corrosive attack.
The thickness of the lead coating of lugs shall not be less than 25 microns. The lead
coating thickness shall be measured in accordance with Appendix 'F' of IS: 6848-79
with Amendment No 1,2 & 3.
(ii) The cables shall be of elastomeric type with composition class -6 of Table no. 1 of
RDSO approved make conforming to RDSO Specification NO. Spec./E-14/01 Part
I (Rev. II)-1993.
(iii) The design shall be such that the voltage drop across the cell cable connector in the
battery bank, shall not be more than 15mV per connector at C10 rate. However,
efforts shall be made to keep this voltage drop as minimum as possible. Cable
connector shall be of size 18 Sq. mm for 40Ah and 40sq. mm for 200 Ah.
respectively.
(iv) In the design, adequacy of contact pressure leading to low contact resistance shall
be considered and accordingly suitable fastening arrangements shall be suggested
468
/provided by the manufacturers. The details of recommended testing procedures and
its frequency to ensure low voltage drop etc. shall be laid down by the
manufacturers with consultation of RDSO.
3.5.2 Nut and Bolts for connecting the cells shall be made of copper, brass, stainless
steel or any other suitable alloy and effectively lead coated to prevent corrosion. However
acid resistance stainless steel bolts and nuts need not be provided with lead coating.
3.6 ELECTROLYTE: It shall be prepared from battery grade sulphuric acid conforming
to IS: 266-1993 with latest amendment.
3.6.1 A suitable electrolyte level indicator indicating lower and upper limits shall be
fitted to facilitate checking of electrolyte level in opaque containers. The materials used
shall be acid proof and shall not deteriorate during service.
3.6.2 The specific gravity of electrolyte when the cells are in fully charged condition at
27 degree Centigrade shall be between 1.210 to 1.220. The specific gravity shall be
corrected to 27 degree Centigrade using the formula given under cl. 3.2.2 of IS:8320 1982.
3.6.3 WATER: - The water used for topping up and preparing electrolyte shall conform
to IS:1069-1993
3.7 SEPARATOR:- Separator shall be Micro porous rubber, PVC or any other
material conforming to IS:6071-1986. The volume porosity shall be not less then 35%
3.8 SEALING COMPOUND: Sealing compound, if bitumen based shall conform to

IS:3116-1965 with latest amendment.
3.9 BATTERY STAND: Supply of battery stand is optional and should be supplied if
asked by the purchaser with each battery set. The battery stand shall be of double row
double tier construction made of 4.0 mm thick M.S to accommodate the battery. (3 mm
thick MS can be used for 40 AH cells) The battery stand shall be painted all over with three
coats of acid resisting varnish conforming to IS:342-1976. The battery stand shall be
provided with cell number plates and shall be manufactured as per drawings approved by
the purchaser.
3.9.1 Electrical insulating grade and acid resistsant PVC sheet, not less than 3mm thick,
for supporting the cells on the battery stand and necessary support insulators shall be
supplied to suit the battery stand.
4.0 SERVICE CONDITION
4.1 The batteries are intended for use in moist tropical climate in India where the
maximum ambient temperature may reach 45 deg. C in shade, the daily average maximum
ambient reaching 35 deg. C, with a relative humidity reaching up to 100%
469
4.2 40Ah batteries are required as a reliable power source for operation of the
interrupter and the various control/indication circuits at the unattended 25KV switching
stations, located along side Railway track for controlling power supply to the traction
overhead equipment. 200Ah batteries are required as a reliable power source for operation
of switchgear and various control /indication circuits at the unattended traction sub-station.
4.3 The batteries will be normally kept on trickle charge by suitable battery charger.
During AC supply failure or battery charger failure the battery will be called upon to
delivery the full load for operation of the interrupters and the various control/indication
circuits.
5.0 RATING:
5.1 RATED CAPACITY: The rating assigned to the battery shall be capacity (C10) in
ampere hour (after correction at 27 degree centigrade temperature) when the cell/ battery is
discharged at 10 hr rate to the end voltage of 1.85V per cell.
5.2 DECLARED CAPACITY: Since the declared C10 capacity of the battery is
generally higher then rated C10 capacity, the manufacturer will advice the declared C10
capacity of the battery.
5.3 OBTAINED CAPACITY: Obtained capacity is the capacity obtained during the
discharge of cell upto 1.85 V at 10 hours rate of the rated capacity of the battery. The
variation between declared capacity and obtained capacity shall not be more than ±3
percent.
5.4 TESTS AND PERFORMANCE:
5.4.1 Classification of tests
5.4.2 Type tests- The following shall constitute the type tests. All these tests shall be
started after 3 cycles of charge/discharge at 10 hour rate. All these tests shall be conducted
at 27±3 degree Centigrade unless and otherwise specifically mentioned.
a. Capacity at 10 hrs. rate (Obtained Capacity) according to cl. 5.6 of this spec.
b. Watt hour and Ampere hour efficency tests according to Clause 5.7 of this spec.
Watt hour efficency shall not be less than 80 percent and Ampere hour efficency shall not
be less than 95 percent. While conducting this test a minimum rest of 12 to 24 hours shall
be given between each charge/discharge.
c. Retention of charge according to clause 5.8 of this spec. Loss of capacity shall not
be more than 3 percent of the initial capacity (OTC) after 14 days. For this battery can be
stored at room temp. but not less than 22 degree centigrade. Charge/Discharge for this test
shall be conducted at 27±3degree centigrade.
470
d. Life test shall be conducted according to clause 5.9 of this specification. After
completion of life cycle test the cell shall be cut opened and examined to arrive at
the reason for reduction in capacity.
e. Storage test according to clause 5.10 of this spec.
f. Air pressure test according to clause 5.14 of this spec.
g. Checking of dimensions, mass, marking and workmanship according to clause 3

and 6.0 of this spec.
h. Material and component specification verification test according to clause 7.0 of

this spec.
i. Loss of water as per clause 5.11 of this spec.
j. Test of Micro- porous vent plug as per Clause 3.4.3 of this spec.
k. Equilibrium float current test as per Clause 5.12 of this spec.
l. Sealing of container with lid as per clause 5.13
5.5.0 SEQUENCE OF TYPE TESTS: The sequence of type tests and the number of
samples required shall be in accordance with Appendix "C".
5.5.1 If any of the samples fails in the relevant type tests, the testing authority may call
for fresh samples not exceeding twice the original number of cells tested in that particular
test and subject them again to test(s) in which failure occurred. If there is any failure in the
retest(s), the type shall be considered as not having passed the requirements of this
standard.
5.5.2 DURATION OF TYPE TEST:
Type tests as per clause 5.4.2 shall be completed within six months (Maximum) from the
date of starting the type test. Except storage test which shall be completed in two years
from the date of starting the test.
5.5.3 INSPECTING AUTHORITY : The type test as per clause 5.4.2 of cells shall be
conducted by the representative of RDSO/Lucknow, India at the works of manufacturers at
their cost.
5.5.4 ACCEPTANCE TESTS:
5.5.4.1 The following tests shall be conducted as acceptance tests:-
471
a. Capacity test at 10hrs. rate according to clause 5.6 of this spec. The capacity obtained shall not
have variation of more than ± 5 percent of the capacity obtained (as approved by RDSO
on the capacity obtained) during prototype testing. The weight of dry cell shall not vary more than
± 5 percent of the weight obtained during prototype testing.
b. Checking of dimensions, mass, markings and workmanship as per clause 3 & 6.
c. Checking of container strength on assembled cell shall be done by dropping a ball from a
height of 400 mm for 200Ah cell and 200 mm for 40Ah cell as per clause 7.8 of IS:1146-
1981. The container should not crack. For verification of crack, air pressure test shall be
done. This test shall be conducted on five No. of assembled cell for each lot.
5.5.5 SAMPLING SCHEME AND CRITERIA FOR ACCEPTANCE:
A recommended sampling scheme and criteria for the acceptance of the lot for various lot
sizes is given in Appendix 'D'.
5.6 TEST FOR CAPACITY AT 10HRS. RATE
5.6.1 After standing on open circuit condition for not less than 12hrs. and not more than
24 hrs. form the completion of a full charge, the battery shall be discharged through a
suitable resistance at a constant current I= 0.1X C10 amperes, and discharge shall be
stopped when the closed circuit voltage across the battery terminals falls to 1.85 volts per
cell.
5.6.2 At this rate of discharge, hourly voltage readings may be taken until the battery
voltage approach 1.90 volts per cell after which the readings shall be taken every 15
minutes until the voltage falls to 1.85v/cell.
5.6.3 On the first discharge the battery or cell shall give ±3 percent of declared capacity.
5.6.4 The battery shall be charged at normal charging rate immediately after discharge.
The charging of batteries may be carried out for test purposes using constant potential
charging method or constant current charging method as recommended by the
manufacturer.
5.6.5 The capacity in Ampere hour shall be obtained by multiplying the discharge current
by the total time of discharge in hours and the product so obtained shall be corrected to a
temperature of 27 degree cerntigrade by the following formula:-
The capacity at 27 deg. C. = CT

--------------
1+ K(t-27)
472
Where CT is the observed capacity at t degree Centigrade. K is the variation factor 0.0043.
t is the average room temperature in degree Centigrade.
5.6.6 The capacity at 10 hrs. rate shall within ± 3 percent of declared capacity .
5.6.7 After 10 hrs discharge the cells/battery should be charged at normal charging period
within 15 hrs.
5.7 TEST FOR AMPERE HOUR & WATT HOUR EFFICENCY
5.7.1 The following method shall be used for determining the maximum ampere hour and
watt-hour efficiencies.
5.7.2 Ampere hour efficiency: A fully charged battery shall be discharged at I=0.1xC10
amperes to a end voltage of 1.85 volts/cell, care full measurements being made of exact
number of ampere hours delivered. On the recharge the same number of ampere- hours are
put back at the same current. A second discharge shall then be made to the same cut off
voltage as before. The efficiency of the battery is then calculated as the ratio of the ampere-
hour delivered during the second discharge to the ampere hour put on the charge.
5.7.3 Watt hour efficiency. The watt hour efficiency shall be calculated by multiplying the
ampere - hour efficiency by the ratio of average discharge and recharge voltages. The
values of discharge and recharge voltages shall be calculated from the log sheets for
ampere hour efficiency.
5.8 TEST FOR RETENTION OF CHARGE
The object of this test is to determine the loss of capacity of a battery unit on open circuit
during a specified period.
5.8.1 The battery unit shall be fully charged at the normal charging rate specified by the
manufacturer and it shall then be subjected to two consecutive capacity test discharges in
accordance with clause 5.6, the value of the initial capacity, C being calculated as the mean
of the two results thus obtained.
5.8.2 After a complete recharge and after cleaning the surface, the battery unit shall be left
on open circuit for a period of 14 days without disturbance at ambient temperature.
5.8.3 After14 days of storage of the battery unit shall be discharged in accordance with
clause 5.6. The value of the capacity measured after storage shall be denoted by C1.
5.8.4 After the discharge the battery unit shall be fully charged at the normal charging rate
recommended by the manufacturer.
5.8.5 The loss of capacity's expressed as a percentage, shall be calculated from the
formulae.
473
S= C- C1
----------- X100
C
5.8.6 Requirement: The loss of capacity calculated as in 5.8.5 shall not be more than 3
percent over 14 days storage period.
5.9 LIFE TEST
It should be conducted as per clause 12.8(endurance test ) of IS1651-1991

applicable to normal cells.
5.9.1 REQUIREMENT: The cell shall give not less than 9 hour of discharge at 10 hour
rate, till end voltage of 1.85 volt.
5.10 STORAGE TESTS
5.10.1 The cell/battery unit shall be capable of being stored unfilled for a period of 24
months from the date of sealing by inspecting authority. After storage for the specified
period, the battery unit shall be tested as per clause 5.6
5.10.2 The capacity after 24 months, when tested as above shall be not less than ± 3 of the
obtained capacity.
5.11 LOSS OF WATER TEST:
5.11.1 After fully charging the cell it should be cleaned and dried. It should be weighed
immediately but not exceeding one hour after drying with an accuracy of 0.05 percent or
maximum least count of 50gm for the balance used. Then all vent cum-filling plugs should
be closed tightly and connected to constant voltage charger keeping the voltage 2.4 ±0.05
volts per cell for 21 days in water bath at the temperature of 50± 2 degree centigrade.
Thereafter cell is removed from circuit and dried. After this it is weighed accurately.
5.11.2 The water loss shall not exceed 0.8gm/Ah/cell of the obtained capacity.
5.12 EQUILIBRIUM FLOAT CURRENT TEST :
5.12.1 This test shall be conducted during the initial three days (72 hours) of water loss
test. The cell under test shall be kept in water bath at 50± 2 degree Centigrade. Charging
voltage shall be 2.4 ±0.05 V per cell. The float current shall be measured and recorded. It
shall not be more than 3mA/AH of the obtained test capacity.
5.13 TEST FOR SEALING OF CONTAINER WITH THE LEAD
The test shall be conducted after filling the cell with the electrolyte up-to-the maximum
permissible level. The filled battery shall be kept in water bath of temp. 50 ± deg. C for 2
hours. A jig shall hold the battery container alongwith a dead weight equal to the weight of
474
fully topped up battery. The battery shall be lifted by the lifting handle provided on the
battery lid. The same shall hold for 5 minutes. The cell lid shall not show any visible sign
of movement at the sealing joint.
5.14 TEST FOR AIR PRESSURE
The sealing of each cell of the battery shall be checked by compressed air at a pressure
equal to 700 mm of water. The volume of tubes and auxiliary parts in connection with the
cell under pressure shall not exceed 0.5 liter. Air pressure in the cell shall be noted 15
seconds after the supply has been disconnected and it shall not fall below 670 mm of
water.
5.15 TEST EQUIPMENTS:
5.15.1 The voltmeters, Ammeters, Thermometer and Hydrometer etc. required the tests
specified in this standard shall meet the requirements given in Clause 10.2 of IS: 8320.
Where digital ammeter /voltmeter are used, the meter shall be capable of displaying up to
two decimal in the range 0 to 99 volts and one decimal in 100 and above volts range. Use
of digital ammeter/voltmeter is preferable for testing capable of displaying at least upto one
decimal of the current to be measured data recorders shall be used for C10, Ah and Wh
efficiency, ROC I & II and life cycle testing with continuous logging facility of voltage,
current , AH input/output with reference to time. Manual recording is not permitted.
5.16 TEMPERATURE FOR TEST:-
Unless otherwise specified the temperature for test shall be between 20 degree and 32
degree centigrade, unless it is unavoidable.
6.0 MARKING & WORKMANSHIP
6.1 For Hard Rubber Container:-
Marking -Both the shorter or longer sides of such container shall have the following details
embossed on the container:-
a) Manufacturer's name or trade mark and place of manufacturing,

b) Rating at 10hrs. discharge rate, and
c) Specific gravity of the electrolyte in the fully charged condition at 27 deg. C.
Note: STICKER not permitted on cells.
6.1.1 For plastic container:
Marking - On the top lid or container wall such details embossed are required:
475
a) Manufacturer's name or trade mark of manufacturing
Both the shorter or longer sides of such container shall have the following detail stencil on
the container,
a) Manufacturer's name or trade mark

b) Rating at 10 hrs. discharge rate and
c) Specific gravity of the electrolyte in the fully charged condition at 27±2 deg. C
d) Place of manufacturing
Note: STICKER not permitted on cells
6.1.2 The year and month of manufacture shall be punched on the terminal lug base.
6.1.3 Manufacture name or trademark and rating of battery will be stenciled or embossed
on the connector.or on lid in ppcp container if marking are not embossed in container
Workmanship: The container shall be from any cracking or chipping or distortion and any
sign of leakage or spillage
6.1.4 A yellow band of 25mm width shall be provided on both sides along the width of the
cell for easy identification of low maintenance batteries.
6.2 Cells should be suitably packed to avoid damage due to rough handling in transit
7. MATERIAL AND COMPONENT SPECIFICATION VERIFICATION TEST:
7.1 The battery shall be examined in the dismantled condition to see that the manufacturing
is to the approved outline and assembly drawing and the various components are
conforming to the specification as detailed above. The samples of sealing compound,
separator, container and electrolyte shall be taken at random from the manufacturing line
and tested to see that they meet requirements of the relevant specifications.
8. MAINTENANCE TOOLS AND INSTRUCTIONS:
A wall mounting type " Tool Board" of suitable material and protected against acid fumes
shall be supplied along with each battery bank. The tool Board shall comprise:-
i. One Syringe for adding or taking out electrolyte from the cells.
ii. One syringe type hydrometer of requisite range for measuring the specific gravity
of electrolyte in the cells. This shall be provided with a graduated scale, one division of
which representing at the most 0.005 unit of specific gravity with accuracy of calibration
not less than 0.005 units of specific gravity.
iii. One cell-testing-voltmeter 0-3 volts of accuracy class 0.5 in accordance with
IS: 1248-1968. The resistance of the Voltmeter shall be 1000 Ohms per Volt.
476
iv. One thermometer with an appropriate scale for measuring temperature of
electrolyte. One division of the graduated scale of the thermometer shall represent at
the most 1deg. C, the accuracy of calibration being not less than 0.5 deg. C.
9. DRAWING
9.1 The manufacturer shall supply two sets of drawing in A4 size listed a below for
approval while offering the cell for type testing.
(a) Detail drawing with dimensions of front, top and side view of the cell.
(b) Detail drawing of the container showing different sections with dimensions.
(c) Part drawings with sectional details of -
(1) Terminal Post (positive and negative)
(2) Container lid
(3) Pole + and -
(4) Plates (+ve and -ve groups assembly)
(5) Separator
(6) Sealed float guide
(7) Micro porous vent plug
(8) Inter cell / unit and end cell connectors
(9) General arrangements of drgs. of 56 cells set indicating connections from cell to
cell.
(10) Any other drgs. Considered relevant
10.0 For the purpose of the cells supplied against this approval, approval means the
approval of general design features. Not with standing the approval, manufacture is
wholly and completely responsible for performance, life and reliability of battery
during service.
10.1 Before offering the battery for prototype testing, all relevant drawings as
considered by the RDSO, shall have the approval of competent authority. The
manufacturer shall produce only drawings approved by competent authority during
the prototype inspection and shall not undertake any modification until such time
battery under prototype testing is completed and the observations of RDSO are
recorded.
10.1.1 After the prototype approval by RDSO of a batteries design etc, no design
change shall be undertaken by manufacturer on prototype cells/ batteries without
prior approval of RDSO, failing which the prototype approval may be with drawn by
RDSO at any time.
10.2 Not withstanding the above recommendations , manufacturer is wholly and

completely responsible for performance, life and reliability of battery during service,
It is also subject to satisfactory compliance to the various requirements like
477
satisfactory online performance, quality assurance plan as approved by RDSO,
successful completion of contracts/ Purchase orders placed by Railway
Board/Production Units/Railways etc.
10.3 All manufacturer are advised to ensure that the batteries mentioned in these
recommendations, have valid type approval certificate failing which no further
extension of approval may be granted by this office. The entire responsibility of the
offering the batteries timely in advance to RDSO for type testing lies wholly on the
manufacturer which may be noted. RDSO in no case shall be held responsible for
reminding the firm in this connection.
Application for revalidation of type approval certificate shall be made at least six
months in advance prior to expiry of validity of earlier approval granted.
10.4 If considered necessary, RDSO may undertake re-testing of some or al prototype

tests as per specifications at any time to ensure proper effective quality control being
exercised by the manufacturer at different stages of manufacturing.
10.5 RDSO may, also, undertake some special tests associating manufacturers to
validate the design changes for which all the necessary testing equipment /
instruments etc. shall be arranged by the manufacturer free of cost.
10.6 DESIGN DOCUMENTS AND INSTRUCTIONS MANUAL:
Following documents in the spiral bound form will be submitted to the RDSO.
a) Two set of drgs. As per clause 9.0 of this specification before offering for type test
for approval and one set for records (bound form) after completion of type tests.
b) (i) In house test results as per appendix 'A' and 'B' shall be sent to RDSO before
offering for type test.
(ii) Type tests results obtained by testing authority.
c) Instructions manual -Two copy of instruction manual with each lot to consignee
and one copy to RDSO
11.0 Alternative superior designs can be considered provided necessary technical

justifications with benefits is furnished for scrutiny.
12 AFTER SALES SERVICE
12.1 The successful tenderer shall make necessary arrangements for closely
monitoring the performance of equipments through periodical (preferably once in two
erected / installed for observations and interaction with the operating and
maintenance personnel of the Indian Railways. Arrangements shall also be made by
the successful tenderer for emergency / standby spare parts being kept readily
478
available to meet exigencies warranting replacement so as to keep the equipment in
service with least down time.
12.2 The successful tenderer shall respond promptly and in a workman like manner to any
call given by Indian Railways for any assistance by way of attending to failures.
Investigation into the causes of failure including tests, if any, to be done and for such other
items with a view to seeing that the equipment serves the purpose for which it is intended.
Technical guidance to ensure proper operation and maintenance of the equipment shall be
constantly rendered.
13. INFRA-STRUCTURE FOR QUALITY ASSURANCE
13.1 The firm/manufacturer shall have the infrastructure facilities like machinery and
plants and testing equipment as per Appendix " E" of the Specification. The requirements
are considered essential before considering a firm for approval for manufacture and supply
of the battery to the Indian Railways. In addition to the above, the firms having valid ISO
9000 certificate accreditation or equivalent for ensuring conformance to the laid down
Quality System requirements for design, manufacturing process, testing , quality control at
different stages of manufacturing etc. shall only be considered.
14. INFRINGEMENT OF PATENT RIGHTS
Indian Railways/RDSO shall not be responsible for infringement of patent rights arising
due to similarity in design, manufacture process, use of components, use in design ,
development and manufacture of batteries and any other factor, which may cause such
dispute. The responsibility to settle any dispute lies with the manufacturer.
479
APPENDIX -'A'
(Clause0.4)
SCHEDULE OF DESIGN PARTICULARS
The following particulars are required to be supplied by the manufacturer with the
quotation:
S. No. DESCRIPTION PARTICULARS TO BE FILLED IN
1. Make …………………….
2. Type of unit …………………….
3. Manufacturers nomenclature …………………….
4. Overall dimensions of unit …………………….
(length x width x height)
5. Mass per unit with acid …………………….
6. Cell container material …………………….
7. Type of positive plates …………………….
8. Type of negative plates …………………….
9. Separators …………………….
10. Maximum electrolyte temp. …………………….
That the cell / battery withstand
Without any damage
a) Continuously …………………….deg C
b) For a short period …………………….deg C
11. Electrolyte height above …………………….mm
the top of separators
12. Electrolyte height below …………………….mm
the bottom plates
13. Quantity of electrolyte …………………….
Liters per cell
14. Sp. Gr. of electrolyte for initial …………………….
filling at 27 deg. C
15. Details of initial treatment …………………….
Recommended
16. Material of terminal and …………………….
inter - cell connectors
17. Normal Charging Rate …………………….Amps
18. Frequency of topping up …………………….months
19. Inter cell connector size …………………….sq., mm.
480
APPENDIX 'B'
(Clause 0.4)
SCHEDULE OF PERFORMANCE
S. No. DESCRIPTION PARTICULARS TO BE FILLED IN
Batteries offered according to this

standard shall be covered by a type
approval certificate from an appropriate
authority. All variations in the design
shall be covered by a separate type
approval certificate. Following particulars
regarding the type tests shall be supplied
by the manufacturer along with the certificate
against any quotation or tender.
1. C-10 Ampere -hour capacity (actual /declared) …………………….Ah
2. Ampere hour efficency …………………….percent
3. Watt hour efficieny …………………….percent
4. Retention of charge …………………….percent
5. Life …………………….units
6. torage …………………….Ah
7. Rise in electrolyte temp above the ……………….deg. Cent

ambient air temp. when charged
from dully discharged to fully charged
conditions at normal rate.
8. Charge and discharge curves with voltage …………………….

Versus time showing the performance of the
Cell for discharge at 10 hours rate and charge at
Normal rate
9. Loss of water ………………..gm/Ah
481
APPENDIX"C"
SEQUENCE OF TYPE TESTING
--------------------------------------------------------------------------------------------------------
TEST SAMPLE NUMBER
1 2 3 4 5 6 7 8 9
--------------------------------------------------------------------------------------------------------
a(*) Checking of dimensions, x x x x x x x x x
mass, markings and workmanship
b. Capacity at 10hrs. rate x x x x x x - - -
c. Material and component - - - - - - - - x

specification verification test
d. Air Pressure - - - - - - x x -
e Storage - - - - - - x x -
f. Life - - x x - - - - -
g. Watt hour and Ampere - - - - x x - - -

hour efficiency
h. Retention of Charge - - - - x x - - -
i. Equilibrium float current x x - - - - - - -
j. Water loss x x - - - - - - -
k. Sealing of container x x
with lid
(*) Mass to be checked for sample numbers 1 to 6

(x) Samples to be subjected for tests
NOTE: The cell of new design shall be prototype tested for which samples offered by the
manufacturer shall be accepted. The cells shall be re-type tested every 5 year for
revalidation and the samples shall be drawn from mass production at random. In case of
unsatisfactory performance of cells in field, re-type testing can also be done earlier at the
discretion of the approving authority.
482
APPENDIX "D"
(Clause 5.5.5)
SAMPLING PROCEDURE FOR ACCEPTANCE TESTS
D.1 LOT
D.1.1 In the consignment, all the cells of the same rating manufactured from the same
material under similar conditions of production shall be grouped together to constitute a lot.
D.1.2 These cells in the sample shall be drawn from the lot at random. For the purpose of
random selection, reference may be made to IS: 4905- 1968
D.2 SAMPLE SIZE AND CRITERIA FOR CONFORMITY
D.2.1 The acceptance tests shall be conducted on minimum two samples upto a maximum
of 1 percent of each type in a lot, the samples being drawn at random by the purchasing or
inspecting authority as specified in clause 5.1.3.1 Appendix 'G' in Amendment NO. 1 of
IS:6848-79 latest
D.2.2 Criteria for Acceptance if any of the samples cells fail in any of the acceptance test,
twice the original number of samples shall be taken and subjected to all the acceptance
tests. If there is failure in re-test, the lot may be rejected.
483
APPENDIX "E"
LSIT OF MACHINERIES AND PLANTS FOR MANUFACTURE OF LOW

MAINTENANCE LEAD ACID STORAGE CELL
ESSENTIAL MANUFACTURING FACILITIES
1. Lead antimony alloying plant to have alloy with different antimony percentages
2. Lead oxide manufacturing mill
(a) Lead Peroxide manufacturing Plant.
3. Pressure die-casting machines for Positive /Negative grids (Hand molding process
not permitted)
(a) Die- casting machines for terminal post, inter cell connectors , poles etc,.
(Hand molding process not permitted)
4. Automatic pasting plant for negative plates (Hand pasting process not permitted)
(a) Automatic paste mixing plant (Manually not permitted)
5 Vibration plant for filling of positive tubular plates
6 . Positive tube bag manufacturing plant
7. Separator manufacturing plant
8. Container manufacturing plant with computer controlled rubber mixing for making
container
9 Plate formation plant
10. Jigs and fixtures to make groups of positive and negative plates
11. Bitumen compound sealing plant with thermostat
12. Chemical Laboratory to test various chemical ingredients.
13 Gas burners set for assembly of positive and negative group plates for battery .
14. Distilled water manufacturing plant
15 Container top lid- manufacturing plant
16 Container and top lid manufacturing plant for PPCP material
17. Heat sealing plant for PPCP cells
18. Compressor with dryer
19. Humidity chamber
20. ISO 9000 certificate
ADDITIONAL PLANT AND MACHINERY
(a) Air pollution control system

(b) Water effluent plant
(c) Water sera beer for formation room
(d) Fork lift
(e) Pallet truck
(f) Formation rectifier
(g) DG Sets
484
ESSENTIAL LIST OF TEST EQUIPMENT
1. C10 test conducted by computerized control battery charging /discharging equipment

with monitoring and recording system (Manually not permitted)
2 Fully computerized control life cycle testers with logging , monitoring and recording
system (Recording time, voltage, min. 6 channels , current m, temp , Ah, Wh, mode
and cycle step)
3. Temperature controlled test room
4 Carbon pile loads of different capacity
5. Container testing facilities as per IS -1146
(i.e. High Voltage tester, Plastic yield test apparatus, Electro magnetic ball drop test
apparatus Izod impact tester, tensile testing machine, digital and chemical testing
arrangements etc. )
6. Digital ammeter, voltmeter and thermometer of different ranges
7. Measurement facility for pore size of separators
8. Battery/cell internal resistance meter
9. Sulphuric acid and distilled water testing facilities as per IS specifications
10. Multimeter digital (Min. DCV 1000 V, ACV -750 V DC 10A, R- 2 mega Ohm)
ADDITIONAL LIST OF TEST EQUIPMENT
1. Thermostatically control rolled tank for life cycle units.

2. Separator testing apparatus as per IS 6071
3. Bitumen sealing compound testing apparatus as per IS 3116
4. Distilled water testing arrangements as per IS 1069
5. Microporous vent plug testing arrangement (i.e. Electromagnetic ball drop apparatus,
weighting digital top pan balance capacity 100 gms +- 0.05 gms, fire retardant test
apparatus, permeability test apparatus etc. )
6. Heating apparatus
7. Electronic Balances(capacity 50gms with decimal second digit)
8. Shore hardness meter
9. Manometer
10. Air pressure tests arrangements
11. Polarity testing arrangements
12. Short circuit testing arrangements.
485
SPECIFICATION
FOR
CHARGER FOR 110 V, 40 Ah AND 110
V, 200 Ah MAINTENANCE FREE,
SEALED, LEAD ACID BATTERY.
No. ETI / PSI / 158 (08 / 96)
486
GOVERNMENT OF INDIA
SPECIFICATION
FOR
CHARGER FOR 110 V, 40 Ah AND 110 V, 200 Ah
MAINTENANCE FREE, SEALED, LEAD ACID BATTERY.
ISSUED BY

LUCKNOW – 226011 .
487
GOVERNMENT OF INDIA
RESEARCH, DESIGN & STANDARDS ORGANISATION
SPECIFICATION FOR CHARGER FOR 110 V, 40 Ah AND 110 V, 200 Ah

MAINTENANCE FREE, SEALED, LEAD ACID BATTERY.
1.0 SCOPE
1.1 This specification applies to battery chargers for charging (i) 110 V, 40 Ah and (ii)
110 V, 200 Ah maintenance free, sealed type lead acid battery installed at
unattended 25 kV traction switching stations (SPs and SSPs), traction substations
(TSSs) and at remote control centre (RCC). The remote control centres are,
however, attended.
1.2 The battery charger shall be complete with all parts and accessories necessary for
their efficient operation. All such parts and accessories shall be deemed to be within
the scope of this specification, whether specifically mentioned or not.
1.3 This specification has been updated incorporating the corrections / additions as
circulated under A/C slip – 1 (Sep. 95) and – 2 (Feb. 96).
2.1 The battery charger are intended for use in moist tropical climate in India, where
the maximum temperature may reach 45 deg. Celsius in shade, the daily maximum
average ambient reaching 35 deg. Celsius, with a relative humidity reaching up to
100 %.
2.2 The battery chargers shall be suitable for operation of 240 V, 50 Hz. Single phase
power supply obtained from a 25 kV / 240 V LT supply transformer at the TSS / SP
/ SSP. The primary of the LT supply transformer is connected to 25 kV bus bar at
one end and to earth at the other. The 240 V supply at the TSS / SP / SSP is subject
to fluctuations of voltage between 180 and 265 V.
2.3 The battery charger is required for installation in control cubicles of unattended 25
kV switching stations / TSS or in equipment room at RCC to charge the
maintenance free battery at a constant voltage of 121.5 V for 54 cells configuration
@ 2.25 V / cell. A provision has also to be made to charge the battery at a constant
voltage of 124.2 V. under boost charging mode at the rate of 2.30 V / cell.
2.4 The battery charger shall be subjected to vibrations on account of trains running on
nearby tracks. The amplitude of these vibrations which occur with rapidly varying
488
time periods in the range of 30 to 70 ms lies in the range of 30 to 150 microns at
present, with the instantaneous peak going upto 350 microns. These vibrations may
become more severe as the speeds and loads of trains increase in future.
3.1 The battery charger and its parts and accessories shall, unless otherwise specified,
conform to the following standards (latest version) which shall be applied in the
manner, altered, amended or supplemented by this specification and the Indian
Electricity Rules, where applicable:
I) Mono-crystalline semiconductor IS : 4540 – 1968

rectifier assemblies and equipment. IS : 6619 – 1972
II) Rectifier transformer IS : 2026 – 1977
III) Mono-crystalline semiconductor IS : 3895 – 1966

rectifier cells and stacks.
IV) Electrical indicating instruments IS : 1248 – 1968
V) Miniature air break circuit breaker IS : 8828 – 1978
3.2 Any deviation from this specification calculated to improve the performance, utility
and efficiency of the equipment, proposed by the tenderer, will be given due
consideration, provided full particulars with justification thereof, are furnished. In
such a case, the tenderer shall quote according to this specification and the
deviations proposed by him shall be quoted as an alternative(s).
4. RATING AND OTHER PARTICULARS:
4.1 BATTERY CHARGER FOR 40 Ah BATTERY:
4.1.1 The battery charger shall be designed for following rating and other particulars:
4.1.2 Type Constant voltage current limiting type,

preferably with half controlled SCR diode
bridge, suitable for floor mounting.
4.1.3 Input voltage 240 V, 50 Hz. ac, subject to variation from

180 to 260 V.
4.1.4 Output voltage to battery (a) Float Mode : 121.5 V for 54 cell for
battery charging. configuration @ 2.25 V / Cell.
(b) Boost Mode : 124.2 V for 54 cell
489
configuration @ 2.30 V / Cell.
Under both float and boost mode the voltage

shall be manually adjustable between 115 V to
127 V.
4.1.5 Output voltage regulation +/- 1% for 0-110 % load on the charger and
simultaneous variation in ac input from 180
V to 265 V and frequency variation of +/- 3%.
4.1.6 Output current “ At SP / SSP : 9A (max), including 5A for

load and 4A for charging battery”.
4.1.7 Charging characteristics Constant voltage current limited charger,

current dropping on charging of batteries.
4.2 BATTERY CHARGER FOR 200 Ah BATTERY:
4.2.1 The battery charger shall be designed for following rating and other particulars:
4.2.2 Type Constant voltage type, suitable for floor

mounting.
4.2.3 Input voltage 240 V, 50 Hz. ac, subject to variation from

180 to 265 V.
4.2.4 Output voltage to battery 124 and 136 V

for battery charging. ( to be adjusted manually )
4.2.5 Output voltage regulation +/- 1% for 0-110 % load on the charger and
simultaneous variation in ac input from 180
V to 265 V and frequency variation of +/- 3%.
4.2.6 Output current At RCC / TSS : 40A (max), including 20A

for load and 20A for charging the batteries.
4.2.7 Charging characteristics Constant voltage, Current dropping on

charging of battery.
4.3 RIPPLE CONTENT:
4.3.1 The battery charger shall be equipped with suitable filter circuits on the output side
to reduce the ripple factor of output voltage to less than 3 % at full load, when
measured across a resistance load. The ripple factor is defined as the ratio of
superimposed ac rms voltage to average dc voltage.
490
4.3.2 The chokes and magnetic components wherever used, shall have copper winding
and shall be vacuum impregnated.
4.4 The battery charger shall be provided with a suitable control circuit to limit the
charging current. The charger should have provision to run in auto mode where it
automatically go to boost mode when battery draws more than 6 % Ah capacity
current for more than 30 S. Similarly if the battery current falls below 3 % Ah
capacity for more than 30 S, the battery charger should automatically work in the
float mode.
4.5 ANNUNCIATIONS AND INDICATIONS AND CONTROLS:
4.5.1 The following annunciations, indications, indicating instruments and controls along
with appropriate inscription labels shall be provided on the front panel of the
charger:
A) INDICATIONS:
i) AC ON Red LED
ii) OUTPUT ON Red LED
iii) BATTERY ON FLOAT CHARGE Amber LED
iv) BATTERY ON BOOST CHARGE Red LED
B) CONTROLS:
i) Input ON miniature circuit breaker (MCB).

ii) Output ON miniature circuit breaker (MCB).
iii) Charge selection adjuster 115 / 127 V.
iv) A selector switch may be provided to read either charger output
current or battery charging / discharging current, on a centre zero
Ammeter.
C) INDICATING INSTRUMENTS:
i) ac input Voltmeter 0-300 V
ii) dc output Voltmeter 0-150 V
iii) Charger output Ammeter (a) 10-0-10 A (for 40 Ah

Battery charger)
(b) 50-0-50A (for 200 Ah

Battery charger)
iv) Battery input / output Ammeter (a) 0-5A/10 A (for 40 Ah
491
Battery charger)
(b) 0-20 A/ 40 A (for 200

Ah Battery charger)
D) PROTECTIONS:
i) Fuse for ac input supply.

ii) Fuse for dc output to battery.
iii) Fuse for dc output to load.
iv) Protection against Reserve Polarity.
v) Battery over voltage protection (electronic control preferred)
NOTE : A separate battery input / output ammeter as asked for against C (iv) may
not be provided, in case a selector switch for the purpose, as mentioned under 4.5.1
(B) (iv) have been provided.
5. CONSTRUCTION:
5.1 All the parts and accessories of the battery charger shall be housed a suitable
cubical fabricated from angle iron frame work fitted with mild steel sheet panels of
thickness not less than 1.6 mm. The side and rear panel shall be provided with
louvers to provide adequate ventilation. Wire mesh with opening not more than 3
mm shall be provided on the inner side of the louvers for protection against entry of
lizards, vermin.
5.2 The battery charger cubical shall be treated with a suitable rust resisting primer
paint applied on the interior and exterior surfaces followed by an application of two
coats of enamel paint evenly sprayed to present a fine appearance. The colour of the
enamel paint applied on exterior surfaces shall be “Dark Admiralty Grey”, shade
632 of IS: 5 – 1961, and the interior surface shall be finished with white shade.
5.3 The charger shall be of robust construction. The components of the battery charger
shall be appropriately mounted and identified with identification labels. The layout
of major components shall permit easy access for maintenance. The assembly shall
be such that it will not be affected adversely by the vibrations induced from nearby
railway tracks. The clearances and the creepage distances shall be in accordance
with clause 4 of IS: 6619 – 1972. The noise level shall be kept to the minimum.
5.4 The rectifier shall be of full wave half controlled bridge connection, using silicon
diodes along with SCRs of liberal rating. The rectifier shall be suitably protected
against overloading due to short time heavy currents drawn during closing of the
circuit breakers, short circuits, over voltages and against inrush currents when
charging fully discharged batteries and also protected against reverse polarity of
battery.
492
5.5 The switches, meters and fuses shall be flush mounted on the front panel and shall
be of reputed make. These shall conform to relevant Indian Standard specifications.
5.6 The volt meters and ammeters shall be of flush mounted type of accuracy class 1.5
as per IS: 1248 – 1968 and shall have scale length of not less than 72 mm.
5.7 Wiring
5.7.1 The wiring inside the charger shall be with 1100 V grade PVC insulated single
core, tinned annealed stranded copper conductor for service in extremely tropical
climate. The PVC wires shall conform to IS: 694. The wiring shall also not be
prone to attack by vermin. For wiring, PVC insulated copper wires of adequate
cross section shall be used, having rated current carrying capacity of not less than 3
times the current it is designed to carry at full load.
5.7.2 The terminal ends of all wires shall be provided with numbered interlock type
ferrules which shall be of PVC or other durable material with markings either
engraved or punched so to be indelible. The ferrules shall be of white colour with
black lettering thereon.
5.8 The ac input and the dc output terminals shall be of robust design and shall be
suitable for PVC copper cable connections. The polarity of output dc terminals for
battery connections and load connections shall be clearly marked.
6. ACCESSORIES
The following fittings and accessories shall be provided on the battery charger:
6.1 Rating and diagram plate
6.2 Two earthing terminal suitable for taking 8 SWG GI wires.
6.3 PVC insulated PVC sheathed 1100 V grade 3 core cable with copper conductors
having a minimum cross section of 2.5 and conforming to IS: 694 – 1977 of 2 meter
length fitted with suitable 3 pin plug of 15 A rating for connection to 240 V ac
supply for 40 Ah battery. In case of the chargers for 200 Ah battery, a suitable
terminal block shall be provided to connect 240 V ac supply, with suitable 3 core
cable with copper conductors having minimum 6 sq.mm. cross section of 3 meter
length.
7. DRAWINGS
7.1 The successful tenderer shall submit the following detailed dimensioned drawings
along with three prints of each as per Railway standards in size of 210 mm x 297
mm or any integral multiple thereof for approval. A format of title sheet to be
493
adopted by the successful tenderer / manufacturer for preparation of the drawings is
attached at Annexure 2.
1. Outline general arrangement drawing (in three views) along with

mounting dimensions.
2. Schematic diagram of connections along with technical details of

components.
3. Cross-section views (showing location of major components).
4. Schedule of guaranteed and other technical particulars.
After approval six copies of approved drawings along with 2 sets of

reproducible copies shall be supplied to the purchaser.
7.2 Successful tenderer shall also be required to furnish the design calculations for
the rectifier transformer ratings, rectifier ratings and filter circuits for approval
by the purchaser.
7.3 The provisionally approved drawings shall be modified, if need be, as a result
of changes necessitated during type testing or as desired by the purchaser. The
modification shall be first got approved by the purchaser / Director General
(Traction Installation), Research Designs and Standards Organisation,
(DG/TI/RDSO), Lucknow and then incorporated in the drawing and each such
modification shall be got signed by the authority concerned on the drawings.
If there are no modifications at all, the provisionally approved drawings shall
be finally approved.
7.4 Six copies of approved drawings along with two sets of reproducibles shall be
sent to each consignee(s), as indicated in the purchase order. Besides two
copies of drawings along with one set of reproducibles shall be supplied to
DG (TI), RDSO, Lucknow.
7.5 The successful tenderer shall also be required to supply atleast 6 copies of the
Installation and Maintenance manuals for battery charger to each consignee
and two copies to DG (TI), RDSO, Lucknow.
8. TESTING OF BATTERY CHARGER
8.0 General
In the event of the tests not being carried through to completion at one stretch
for any reason attributable to the successful tenderer / manufacturer and it is
required for the representative of the Purchaser / Director General (Traction
Installation), Research Designs & Standards Organisation, (DG/TI/RDSO),
Manak Nagar, Lucknow, to go again or more number of times to the works of
494
the successful tenderer / manufacturer or other place(s) for continuing and/or
completing the tests on the prototype(s) of the equipment, the successful
tenderer / manufacturer shall reimburse to the Purchaser / DG (TI), RDSO,
Lucknow, the costs for the representative having to visit the works or other
place(s) for the tests more than once. The costs as claimed by the Purchaser /
DG (TI), RDSO, Lucknow, shall be paid through a demand draft to the
concerned Accounts Officer of the Purchaser / DG (TI), RDSO, Lucknow, as
shall be advised to the successful tenderer / manufacturer.
8.1 Type Tests
The following type tests shall be carried out on the prototype at the works of
the successful tenderer / manufacturer or at any reputed laboratory in the
presence of the representatives of the Purchaser / DG (TI), RDSO, Lucknow,
and in accordance with the relevant specifications – altered, amended or
supplemented by this specification.
8.1.1 Tests on complete charger.
8.1.2 Visual Inspection
The proper layout, component mounting, identification labels, connections

and construction shall be checked.
8.1.3 No load test
8.1.4 The test shall be carried out by applying input voltage varying from 180 V to
265 V (in steps of 180 V, 210 V, 240 V & 265 V). The dc output voltage shall
be manually adjusted between 115 V and 127 V, (in steps of 115 V, 120 V,
124 V & 127 V) at each step of ac input voltage (indicated above). The no
load ac input current shall be recorded in each case.
8.1.5 Load test with resistive load
The test shall be carried out at different ac input voltages from 180 V to 265 V
in steps of 180 V, 210 V, 240 V and 265 V. For each of these input voltages,
the output voltage shall be set at 115 V, 120 V, 124 V and 127 V. then for
each case, the load shall varied from 0% to 100% of rated load with the help
of resistance. The dc output voltage shall not decrease by more than 1% from
the set value, by variation of load from 0% to 100%.
8.1.6 Measurement of ripple content
Ripple voltage on d.c. side shall be measured during the load test (Cl.8.2.2.3)
and the percentage ripple content shall be calculated which shall not exceed as
specified in clause 4.
495
Efficiency test
This test can be combined with no load test and load test for which details have
been indicated in clause 8.2.2.2 and 8.2.2.3 respectively. For this test, input current,
voltage and power on the ac side shall be recorded at the minimum and maximum
output voltages. The efficiency and the power factor shall then be computed from
the test results.
The test shall be carried out at output voltage set to maximum. A suitable resistive
load shall be connected across the output and load current shall be adjusted to the
maximum rated current. The ambient temperature, surface temperature of
transformer, winding chokes and diode base etc. shall be recorded every half an
hour till such time the temperature is stabilised (i.e. the temperature do not rise by
more than 1 degree celcius between consecutive hourly readings). The temperature
rise of the transformer winding and choke measured by resistance method shall not
exceed 50 Deg. C. for class A and 90 Deg. C. for class F insulation. The SCR and
diode base temperature rise shall be within the prescribed values recommended by
the manufacturer.
8.2. Insulation Resistance Test

Insulation resistance shall be measured by using 1000 V dc megger between:
a) ac line lead to earth
b) dc output terminals to earth
c) ac line lead and output terminals.
The values shall be measured before and after the high voltage withstand test and
there shall not be any appreciable change in the measured values.
8.2.1 Power frequency voltage withstand test

The charger shall successfully withstand the test voltage of 2000 V ac rms 50 Hz
applied for one minute between:
1) dc output terminals and earth

2) ac input terminals and earth
3) dc output terminals and ac line load
8.2.2 Test on rectifier transformer
8.2.3 Measurement of resistance

Resistance of primary and secondary windings, shall be measured, preferably with a
bridge instrument, at ambient temperature and recorded.
496
8.2.3.1 Open circuit test
Rated primary voltage shall be applied to the primary of the transformer and the
primary and the secondary voltages and power drawn at no load shall be recorded.
8.2.3.2 Short circuit test

With the secondary winding short circuited, suitable voltage shall be applied to the
primary to pass the maximum rated current in the primary and the primary voltage,
current and power shall be recorded and the full load losses calculated.
8.2.3.3 Insulation resistance test

With the secondary winding short circuited, suitable voltage shall be applied to the
primary to pass the maximum rated current in the primary and the primary voltage,
current and power shall be recorded and the full load losses calculated.
8.2.3.4 Insulation resistance test

Insulation resistance shall be measured by using 1000 V dc megger between:
a) Primary winding and earth
b) Secondary winding and earth
c) Primary winding and Secondary winding (s).
The values shall be measured before and after the high voltage withstand test and
there shall not be any appreciable change in the measured values.
8.2.3.5 Power frequency voltage withstand test

The rectifier transformer shall successfully withstand the test voltage of 2000 V ac
rms 50 Hz applied for one minute between primary and secondary windings
combined together and core.
8.2.4 If prototype of a battery charger conforming to this specification has already been
approved in connection with the previous supplies to the Indian Railways, fresh
prototype testing may be waived, if it has passed the prototype test earlier and no
changes in the design or material used, have been made.
8.3 Routine Tests

The following routine tests shall be carried out on the battery charger:
8.3.1 Visual inspection

The proper layout, component mounting, identification labels, wiring, connections,
workmanship, quality of painting, surface finish and construction shall be checked.
8.3.2 No load test

The test shall be carried out in accordance with the clause 8.2.2.2 except that the
tests shall be carried out only at the rated input voltage of 240 V ac.
8.3.3 Load test with resistive load

The test shall be carried out in accordance with the clause 8.2.2.3 except that the
tests shall be carried out only at the rated input voltage of 240 V ac.
497
8.3.4 Insulation resistance test
The test shall be carried out in accordance with the clause 8.2.3.4.
8.3.5 Power frequency voltage withstand test

The test shall be carried out in accordance with the clause 8.2.3.5.
9. INFORMATION TO BE GIVEN BY THE TENDERER
9.1 The tenderer shall furnish along with his offer, in the proforma at Annexure-1, the
“schedule of guaranteed performance, technical and other particulars” (SOGP) for
the battery charger. The particulars shall be correct and complete in all respects. If
there is any entry like “shall be furnished later” or a blank against any item, the
offer is not likely to be considered as the evaluation of the offer is rendered difficult
and can not be compared with other offers, if any.
9.2 The tenderer shall specifically indicate in a “statement of compliance” attached

with the offer his compliance with each and every clause of this specification, in
case the tenderer wishes to deviate from any clause of this specification he may do
so giving reference to the clause(s) with the reason / justification for the deviation.
This shall be in the form of a separate statement called the “statement of deviation”.
If there is no deviation at all, a separate “Nil” “statement of deviation” shall be
attached with the offer. If the “statement of compliance” and not likely to be
considered for the reason that it is incomplete offer which can not be properly
evaluated and compared with other offers, if any.
10.1 The successful tenderer shall make necessary arrangements for closely monitoring
the performance of the equipment through periodical (preferably once in two
erected / installed for observations and interaction with the operating and
maintenance personnel of the Indian Railways. Arrangements shall also be made by
the successful tenderer for emergency / standby spare parts being kept readily
available to meet exigencies warranting replacement so as to keep the equipment in
service with least down time.
10.2 The successful tenderer shall respond promptly and in a workman like manner to
any call given by Indian Railways for any assistance by way of attending to
failures, investigation into the causes of failures including tests, if any, to be done
and such other items with a view to seeing that the equipment serves the purpose
for which it is intended. Besides technical guidance to ensure proper operation and
maintenance of the equipment shall be constantly rendered.
498
11 WARRANTY
11.1 The successful tenderer / manufacturer shall warrant that all equipment shall be ree
from defects and faults in design, material, workmanship and manufacture and of
the highest grade consistent with the established and generally acceptable standards
for the equipment of the type ordered and in full conformity with the specifications
and shall operate properly.
11.2 This warranty shall survive inspection of, payment for the acceptance of the
destination, or 18 (Eighteen) months from the date of commissioning and proving
test of the equipment at ultimate destination, whichever period expires first except
of complaints, defects and/or claims months of the expiry of such date. Any
approval or acceptance of the Purchaser of the equipment shall not in any way limit
the successful tenderer / manufacturer’s liability.
11.3 The successful tenderer / manufacturer’s liability in respect of any complaint,

defects and/or claims shall be limited to the furnishing and installation of
replacement parts free of any charge or the repair of the defective parts only to the
extent that such replacement of repairs attributable to or arise from faulty
workmanship or material or design in the manufacture of the goods, provided that
the defects are brought to the notice of the successful tenderer / manufacture within
3 (Three) months of their being first discovered during the warranty period or at the
option of the Purchaser, to the payment of the value, expenditure and damage as
hereafter mentioned.
11.4 The successful tenderer / manufacture shall, if required, replace or repair the
equipment of such portion thereof as is rejected by the Purhaser free of cost at the
ultimate tenderer / manufacture shall pay to the Purchaser value thereof at the
Contract Price or in the absence of such price at a price decided by the purchaser
and such other expenditure and damages as may arise by reason of the breach of the
conditions herein specified.
11.5 All replacements and repairs that the Purchaser shall call upon the successful
tenderer / manufacture to deliver to perform under this warranty shall be delivered
and performed by the successful tenderer / manufacture, promptly and satisfactorily
and in any case within 2 (Two) months of the date of advice to this effect.
11.6 If the successful tenderer / manufacture so desires, the parts that are removed may
be taken over by him or his representative for disposal as he deems fit at the time of
499
11.7 The warranty therein contained shall not apply to any material which shall have
been repaired or altered by the Purchaser or on his behalf in any way without the
consent of the successful tenderer / manufacture, so as to affect the strength,
performance or reliability or to any defects to any part due to misuse, negligence or
accident.
11.8 The decision of the Purchaser in regard to successful tenderer / manufacture’s

conclusive.
500
ANNEXURE –I
SCHEDULE OF GUARANTEED PERFORMANCE, TECHNICAL

S. Description Unit of measurement

No
3. Standard Governing Specification.
5. Designed capacity of charger for charging Ah.

battery of.
6. Rated input voltage V ac
7. Output voltage.
I) To battery: V dc
II) To load: V dc
8. Output voltage regulation from 0-110% load:

a) To battery: % +/-
b) To load: % +/-
9. Maximum output current of charger A
10. Declared values.

a) No load loss of complete charger mA
b) Full load loss of complete charger on A
c) Overall efficiency of charger at full load
d) Variation in maximum charging current to
battery with 10% increase in supply
voltage
e) Percentage ripple content in output
voltage at full load with resistance load
connected.
501
11. Size and type of 240 V ac incoming lead.
12. Thickness of sheet steel for charger cubicle. “mm”
13. Overall dimensions:

i) Height mm
ii) Width mm
iii) Depth mm
14. Total weight. kg
15. Rectifier transformer particulars:

a) Name of manufacturer
b) Governing specification
i) Rated input voltage V ac
ii) Taps provided for variation in
input voltage.
iii) Rated kVA kVA
c) Type of winding.
d) Type of impregnation of.
e) Class of insulation.
502
RDSO Specification No.ETI / PSI /158 (08/96) for Battery Charger
issued to the specification :
1. 7.4 Delete the second sentence in the para.
2. 7.5 Delete the words “Two copies to DG(TI),RDSO,

Lucknow “at the end of para.
3. 11.2 The para is modified as given below :
“The warranty shall be 36 (Thirty six) months from the date

of delivery of the equipment at the ultimate destination or 24
(twenty four) month from the date of commissioning of the
equipment at the ultimate destination, whichever occurs
first”.
4. 11.3 In Line 8, delete the words at the end of the para starting with
“Or at the option ……………..as hereafter mentioned”
503
SPECIFICATION
FOR
OUTDOOR CIRCUIT BREAKER
FOR
RAILWAY AC TRACTION
SUB - STATIONS
No. TI / SPC / PSI / CB / 0000
504
Specification No. TI/SPC/PSI/CB/0000
GOVERNMENT OF INDIA
SPECIFICATION
FOR
OUTDOOR CIRCUIT BREAKER
FOR RAILWAY ac TRACTION
SUB - STATIONS
ISSUED BY

LUCKNOW – 226011 .
505
CIRCUIT BREAKER
for
Railway ac Traction Sub-Station
1. Scope
1.1 This specification applies to outdoor type single pole, double pole & triple pole SF6
and vacuum circuit breaker for use in unattended / attended Railway Traction Sub-
Stations in any part of India for controlling power supply to the 25 kV ac 50 Hz.
single phase traction overhead equipment (OHE). This specification supersedes
Specification No. ETI/PSI/93 (5/94), ETI/PSI46 (9/94), ETI/PSI/131 (8/89) and
ETI/PSI/116 (4/88) . This specification shall also apply for primary side 22 kV and
100 kV two pole vacuum and SF6 circuit breaker to be used in Mumbai area of
Central and Western railway ac traction system.
1.2 The CB shall be complete with all parts, fittings SF6 gas for the first filling, Vacuum
bottle as the case may be and accessories necessary for its efficient operation,
including mounting frame work of steel. All such parts, fittings and accessories
shall be deemed to be within the scope of this specification, whether specifically
mentioned or not. The CB shall be of proven design.
1.3 The CB shall be erected by the Purchaser / Indian Railways. However, in case a
defect / deficiency is noticed, the manufacturer/ successful tenderer will have to
depute his engineer for necessary remedial action without any cost to the Railways.
In all the cases in which an order is placed either on new manufacturer or for a new
type /design of the CB, the services of manufacturer’s engineer shall be made
available free of cost during the erection and proving /pre-commissioning test for
the first order or for the first order of their CB. For this purpose, prior intimation
regarding the date and the location shall be given by the purchaser to the successful
tenderer / manufacturer.
2.0 Governing Specification
2.1 The CB shall unless otherwise specified therein, conform to the “IEC 60056 / 1987,
High voltage ac circuit breaker” and the Indian Electricity Rules, wherever
applicable.
2.1.1 In the preparation of this specification, assistance has been derived from the
following Standards :
(1) IEC : 60056 (1987) : High voltage alternating current circuit breakers
(2) IEC : 376 (1971) : Specification and acceptance of new sulphur

hexafluride gas.
506
(3) IEC : 694 (1980) : Common clauses for high voltage Switchgear and
Control gear standards.
(4) IS : 456 (1978) : Code of Practice for plain and reinforced concrete.
(5) IS : 996 (1979) : Specification for single phase small ac and

universal electric motors.
(6) IS : 2099 (1973) : Specification for bushing for alternating voltages

above 1000 V.
(7) IS : 2544 (1979) : Specification for porcelain post insulators for

systems with nominal voltages greater than 1000 V.
(8) IS : 5561 (1978) : Specification for electric power connectors.
(9) IS : 5621 (1980) : Specification for hollow insulators for use in

electric equipment.
(10) IS : 6875
(Pt. 1-1973) : Specification for control switches ( switching
device for control and auxiliary circuits including
contactor relays) –
for voltages up to and including 1000 V ac and 1200
V dc – General requirements and tests.
(11) IS : 7906
(Pt. I-1976) : Specification for helical compression springs.
(12) IS : 7907
(Pt. I-1976) : Specification for helical extension springs.
(13) IS : 13118 (1991) : Specification for high voltage alternating current

circuit breakers.
(14) IS : 1554
( Pt. V – 1988) : Specification for PVC insulated (heavy duty )
electrical cables for working voltage up to &
including 1100 V.
(15) IS : 808 (1989) : Dimensions for hot rolled steel beam, column,
channel & angle sections.
(16) IS : 2147 (1962) : Degree of protection provided by enclosures for low

voltage switchgear.
507
(17) RDSO Specification No. ETI/OHE/13 (4/84) : For hot dip galvanization.
(18) RDSO Specification No. ETI/OHE/18 (4/84) : For steel and stainless steel bolts,
nuts and washers.
(19) RDSO Specification No. M&C/PCN -102/86 : For Epoxy bases zinc phosphate
primer ( two pack).
(20) RDSO Specification No. M&C/CPN -110/88 : For Aluminium paints based on
Polyurethane.
(21) AC Traction manual (Issued in 1994)
2.2 Any deviation from this specification as proposed by the tenderer to improve upon
the performance, utility and efficiency of the equipment will be given due
consideration, provided full particulars of deviation with justification thereof are
furnished, subject to approval of RDSO. In case of any contradiction between the
provisions of the Indian Standards Specification/IEC standard and this
2.3 This specification is framed merging the four RDSO Specification Nos.(i)
ETI/PSI/93(5/94), (ii) ETI/PSI/46 (9/94), (iii) ETI/PSI/131 (8/89) and (iv)
ETI/PSI/116 (4/98) for 25 kV ac 50Hz single pole SF6 circuit breaker, 25 kV ac
50Hz single pole vacuum circuit breaker, 25 kV ac 50Hz double pole SF6 gas
circuit breaker for 2 x 25 kV AT feeding system and 220 kV/132 kV / 110 kV / 66
kV ac 50 Hz double pole and triple pole outdoor SF6 circuit breaker respectively.
Hence the firms approved as per any of the above specifications (four), shall be
considered as approved as per this specification also. The changes are only in
respect of operating sequence for 25kV CB which has been changed from O-0. 3s-
CO-30s-CO to O-0.3s-CO-15s-CO, ground clearances and supervision of erection
and commissioning which shall be incorporated in their design at the time of
offering the equipment as per this specification. Apart from above, his specification
also includes technical details and others for 22 kV and 100kV two pole vacuum
and SF6 circuit breaker to be used in ac traction system of Mumbai area.
3.0 Traction Power Supply
3.1 General Scheme
3.1.1 The single phase 50Hz power supply for railway traction at 25 kV is obtained from
220/132/110/100/66/22 kV three phase grid system through step down / step up
single phase power transformer, the primary winding of which is connected to two
of the phases of the three phase effectively earthed transmission line network of the
State Electricity Board. The primary voltage of the traction transformer being 220
kV or 132 kV or 110 kV or 100 kV or 66kV or 22 kV and no load secondary
voltage being 27 kV. In order to reduce the imbalance on the three-phase grid
system, the two phases of the three phase transmission line are tapped in a cyclic
508
order for feeding the successive traction sub-stations (TSS). The distance between
adjacent TSS is normally between 50 km and 80 km depending upon density of
traffic gradients in the section and other factors.
3.1.2 One terminal of the 25 kV secondary winding of the traction transformer is

connected to the OHE through circuit breaker / interrupters and the other terminal is
solidly earthed and connected to the appropriate traction rail (s). The current flows
through the OHE, to the locomotives and returns through the rail(s) and earth to the
TSS. In sections where booster transformers and return conductor are provided the
current returns through booster transformer ; the traction rail(s) and partly through
earth in the vicinity of TSS. Approximately midway between two adjacent TSS a
dead zone known as ‘neutral section’ or ‘phase break’ is provided to separate the
two sections of OHE fed by different phases. The power fed to the OHE on one side
of the TSS is controlled by a feeder circuit breaker while the power fed to the OHE
of each track is controlled by an interrupter. In case of fault on the OHE, the feeder
circuit breaker trips to isolate the faulty OHE. A schematic diagram No.
ETI/PSI/702-1 showing the general arrangement at a TSS is at APPENDIX – I
3.2 Nature of faults on the OHE
3.2.1 OHE is prone to frequent earth faults caused by failure of insulation or by OHE
snapping and touching the rail/earth or by a piece of wire dropped by birds which
connects the OHE to earth at over line structures/supports or by miscreant activities.
3.2.2 The two sections of OHE fed by different phases are sometimes inadvertently
bridged causing wrong phase coupling.
3.3 Protection Scheme
3.3.1 The faults in the OHE are isolated by the feeder circuit breakers which operates
through either one or more of the following relays ;
Distance mho relay
(i) Instantaneous over-current relay
(ii) Wrong phase coupling relay and
(iii) High speed inter tripping relay
3.3.2 The faults in the traction transformer are isolated by one of the following relays :
(i) Differential relay

(ii) IDMT over current relays for the primary (HV) as well as for the secondary
(LV) side.
(iii) Instantaneous earth leakage relays on the primary (HV) side as well as on
the secondary (LV) side,
(iv) Auxiliary relays for transformer faults i.e. Buchholz, excessive winding and
oil temperature trip and alarm and low oil level alarm.
509
3.3.3 The faults in the shunt capacitor bank are isolated by one of the following relays :
(i) Over current relay

(ii) Over voltage relay
(iii) Under voltage relay
(iv) Neutral current relay
3.3.4 In the event of the 25 kV feeder as well as transformer circuit

breakers failings to operate under fault conditions, the circuit breakers on the
primary side of the transformer operates to isolate the fault.
3.4 Short circuit level
3.4.1 The fault level for different grid supply voltages based on a three phase
symmetrical short circuit fault is between 1000 MVA and 10,000 MVA depending
upon the proximity of the traction sub-station to the generating station. The fault
level for various system voltage in the vicinity of traction sub-station is as under :
NOMINAL SYSTEM VOLTAGE ( k V )

22 25 66 100/110 132 220
Item
Fault 1000 550 3500 6000 10,000 20,000
MVA
3.5 Nature of load on the 25 kV system
3.5.1 The traction load is of frequent and rapidly varying nature and fluctuates between
no load and overloads. The load cycle varies from day due to non-uniform pattern
of traffic.
3.5.2 An ac electric locomotive is fitted with single phase bridge connected silicon
rectifier with smothering reactor for conversion of ac to dc for feeding the dc
traction motors. The ripple content is in region of 25 to 40%which introduces
harmonics in the 25 kV power supply. The typical percentages of harmonics present
in the traction current are as follows :
Width diode With With

Rectifier Thyristor GTO’s
3rd harmonic (150 Hz) 15% 23% 3%

5th harmonic (250 Hz) 6% 14% 2%
7th harmonic (350 Hz) 4% 10% 0.5%
9th harmonics (450 Hz) - 4% 0.35%
11th harmonic (550 Hz) - 3% 0.40%
Total harmonic distortion 16.64% 29.15% 3.68%
510
3.5.3 The average power factor of electric locomotive and multiple unit train generally
varies between 0.7 and 0.8 lagging without compensation.
3.5.4 In big yards and loco sheds, large number of locomotives / Electrical multiple units
(EMUs) stand idle with only the load of their auxiliaries drawing higher reactive
power. Therefore these are drawing power at low power factor.
3.5.5 For improving power factor, fixed shunt capacitor bank with 13% series reactor are
also installed at some traction sub-stations, the net kVAR rating of which is
generally in the range of 2000 – 3500 kVAR
3.6 Electrical parameters

3.6.1 OHE is made up of a stranded cadmium copper catenary of 65 mm2 cross section or
a stranded aluminum alloy catenary of 116 mm2 cross section and a grooved copper
contact wire of 107 mm2 cross section, making up a total of 150 mm2 copper
equivalent. For 2 x 25 kV AT feeding system, as a feeder wire, a stranded
aluminum alloy catenary of 240 mm2 is used. The calculated OHE impedance value
of AT feeding circuit (OHE : Al 116 or Cu 107 mm2 & feeder wire : Al, 240 mm2 )
for single track line is 0.0601 + J 0.1419 Ohm/Km ( at 25 kV system impedance).
The OHE impedance values for conventional 25kV system are generally taken as
under :
(i) Single track OHE without BT & return conductor 0.41 70º Ohm/km
(ii) Double track OHE without BT & return conductor 0.24 70º Ohm/km
(iii) Single track OHE with BT & return conductor 0.70 70º Ohm/km
(iv) Double track OHE with BT & return conductor 0.43 70º Ohm/km
(v) Add booster transformer impedance @ 0.15 Ohms per booster transformer
where these are provided.
(vi) Percentage impedance of traction transformer (12+/ -0.5 ) for 21.6 MVA at
27 kV.
3.7 Duties of the Circuit breaker
3.7.1 The circuit breaker is used at the following locations in the 25 kV ac, 50 Hz single
phase traction system.
(i) As transformer circuit breaker on the primary side of traction transformer

for voltage of 22kV, 66 kV, 100 kV, 110 kV, 132 kV and 220 kV and also
for incoming and outgoing transmission line at substation.
511
(ii) As transformer circuit breaker on the secondary side of the traction
transformer for voltage of 25 kV.
(iii) As feeder circuit breaker for controlling power supply to OHE through
interrupters for voltage of 25 kV.
(iv) As Shunt Capacitor Bank circuit breaker for controlling power supply to
shunt capacitor bank for foliage of 25 kV.
(v) For controlling power supply to major yard/loco sheds for voltage of 25
kV
3.7.2 Special Duty to be performed by 25 kV CB
3.7.2.1 The 25 kV circuit breaker shall be called upon to trip under short-circuit
conditions. On an average, the number of fault trippings seen by the feeder
circuit breaker per month are about 40 nos. but in exceptional cases the
number of fault trippings per month may go as high as 120 numbers. The
magnitude of short current interrupted generally ranges from 2 kA to 8 kA.
The circuit breaker shall also be called upon to clear wrong phase coupling
on the OHE when two sections of the OHE fed by different phases from
adjacent sub-stations are accidentally shorted.
3.7.2.2 The design and construction of the 25 kV circuit breaker shall be such that it
is capable of a cumulative duty (n I2 where ‘n’ is the number of C-O
operations at a current of I kA rms ) of 20,000 kA2 in service without
adjustment /change of any part/contacts or SF6 gas/vacuum bottle
lubrications and tightening of moving parts in the operating mechanism and
cleaning of porcelain insulators can however be done as per manufacturer
recommendations
3.7.2.3 The manufacturer shall supply graphs in support of suitability of offered

circuit breaker to perform above duties at the tender stage, indicating the
cumulative duty which can be performed by offered CB without any
maintenance /replacement of an components.
3.7.2.4 The 25 kV circuit breaker is also required to interrupt line charging and
magnetizing current of locomotive transformers without restrike. Values
line charging current is of the order of 10A and values of magnetizing
current for locomotive / EMU are likely to be as under :
(a) Locomotive - 6.38 A.

(b) EMU - 6.0 A
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3.7.2.5 The 25 kV circuit breakers are normally operated through remote control. A
single shot auto reclosing scheme provided the remote control system to
facilitate the reclosing of the circuit breakers automatically once within the
preset “dead time” after the tripping of the circuit breaker on an OHE fault.
This failure helps in quick restoration of power supply to the OHE if the
fault is of a transient nature. The “dead time” is the period taken by the auto
reclose mechanism to close the circuit breaker after the same has tripped on
fault is set at 0.5 sec.
4.0 Environmental Conditions
4.1 The CB shall be suitable for outdoor use in moist tropical climate and in
areas subject to heavy rainfall, pollution due to industry and saline
atmosphere and severe lightning. The limiting weather conditions for which
the equipment has to withstand in service are indicated below :
(i) Maximum ambient air temperature 50ºC

(ii) Minimum ambient air temperature 0ºC
(iii) Average ambient air temperature over a period of 24 h 40ºC
(iv) Maximum relative humidity 100ºC
(v) Annual rainfall Ranging between
1750 mm & 6250 mm
(vi) Number of thunderstorm days per annum 85 (Max)

(vii) Number of dust storm days per annum 35 (Max)
(viii) Number of rainy days per annum 120 (Max)
(ix) Maximum basic wind pressure 200 kgf/m2
(x) Altitude Not exceeding 1000 m
(xi) Pollution level Heavily polluted
4.2 The CB would be subjected to vibrations on account of trains running on

nearby railway tracks. The amplitude of these vibrations which occur with
rapidly varying time periods in the range of 15 ms to 70 ms lies in the
range of 30 to 150 micron at present, with the instantaneous peak going upto
350 micron.
5.0 Technical Specification
513
5.1 The rating and other particulars
The circuit breakers shall be designed for the following rating and other particulars :
S. Particulars RATED SYSTEM VOLTAGE (kV)

No. 22 25 66 100/110 132 220
1 2 3 4 5 6 7 8
(i) Number of 2 1 or 2 ---------- 2 or 3 as required---------------
poles
(ii) Nominal 22 25kV 66 100/110 132 220
system subject to
voltage (kV) variation

from 19
kV to
27.5 kV
occasiona
lly
touching
30 kV.
(iii) Rated voltage 24 52 72.5 110/123 145 245
(kV)
(iv) Rated 460 kv
insulation (rms)
level
(a) Rated 50 kv 95 kv 160 kv 230 kv 275 460 kV

1 minute (rms) (rms) ( rms) (rms) kv (rms)
wet (rms)
power
frequency
withstand
voltage
(b) Rated 125 kV 250 kV 350 kV 550 kV 650 kV 1050 kV

impulse (peak) (peak) (peak) (peak) (peak) (peak)
(1.2/50µs)
withstand
voltage
(v) Rated -------------------------- 50 Hz ± 3% ------------------------
frequency
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(vi) Rated normal 2000 A 1600 A 1250A 1250 A 1250 A 1250 A
current
(vii) Rated short 40 20 31.5 31.5 31.5 31.5 kA
circuit kA kA kA kA kA
breaking
current
(viii) Rated
breaking
capacity
(symmetrical)
- 550 MVA - - - -
(i) Single
pole 1000 550 MVA 2283.75 3874.5 4567.5 7717.5
MVA MVA MVA MVA MVA
(ii) Two pole - - 3955.5 6710.8 7911.1 13367.1

(iii) Three MVA MVA MVA MVA
pole
(ix) Out of phase 10 5 7.9 7.9 7.9 7.9
breaking kA kA kA kA kA kA
current (rms) (rms) (rms) (rms) (rms) (rms)
(x) Rated single 150 A 150 A 500 A 500 A 500 A 400 A

capacitor
bank
breaking
current
(xi) Rated line 10 A 10A 10A 31.5A 50A 125A
charging
breaking
current
(xii) Rated small
inductive ------------------------------------ 10 A -------------------------------
breaking
current
(xiii) Rated making 100 kA 50 kA -------------------- 78.8 kA (peak)-----
current (peak) (peak) --
(xiv) Rated
operating O-0.3s-CO-15s -CO -----O – 0.3s – CO – 3 min - CO ---
sequence -
(xv) Total break --------------------- Not more than 60 ms --------------------------
time
(xvi) Rated short 40 kA for 20 kA for -------------- 31.5 kA for 1 s -----------
time current 3s 3s -
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(xvii) First pole to ---------- 1.5 for 2 parameters ------------- 1.3 for 4
clear factor parameters
(xviii) Corona - - 53 kV 88 kV 106 kV 176
extinction kV
voltage
(xix) Rating of
auxiliary
switch
contacts --------------------------- 110 V dc ---------------------------------
(a) Rated
voltage
(b) Rated --------------------------- 10 A -------------------------------------
current
(continuous)
(c) Rated -------- 2A at 220 V dc with 20 ms circuit time constant ------
breaking
current
5.2 Clearances
The design of the CB shall be such that when it is erected on the supporting structure,
the following clearances / distance of lowest live part of the circuit breaker from the
ground level / earth are achieved :
S. Clearance/ distance 22 kV 25 kV 66 kV 100 /110 132 220 kV

No kV kV
1 2 3 4 5 6 7 8
1. Minimum height of 3800 3800 4600 4600 4600 5500
lowest live part of the mm mm mm mm mm mm
CB from ground
level
2. From a point where a 3000 3000 3500 3500 4000 5000
man may be required mm mm mm mm mm mm
to stand for operation
or for attending the
breaker (sectional
clearance)
3. Minimum height of
the bottom most part ----------------------- 2500 mm ------------------
of any insulator from
the ground level.
4. Minimum clearance 500 500 630 900 1300 2100
between live part & mm mm mm mm mm mm
earth part.
5. Distance between 1500 1500 2000 3000 3000 4000
pole centers for 2/3 mm mm mm mm mm mm
poles
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6.0 Type and General Construction
6.1 The CB shall be of outdoor type suitable for mounting on steel structure. The 25 kV
CB shall be of a single pole or double pole identical to single pole unit operated
through a common shaft by operating mechanism, where as the CB of 22kV & higher
voltage class covered by this specification shall consist of two or three (as required )
separate but identical single pole units operated through a common shaft by the
operating mechanism. The CB shall comprise of -
(i) The pole (interrupting chamber and support insulators )

(ii) Operating mechanism cubicle and
(iii) Mounting steel frame.
6.1.1 Interrupting chamber
6.1.1.1 SF6 Circuit Breaker
The operating mechanism, pole assembly and supporting structure shall be separate
and capable of being packed and handled individually and erected in a given
sequence. The interrupting chamber comprising fixed and moving contacts with an
insulating enclosure shall be filled with SF6 gas and mounted on a supporting
insulator. The design and construction of the CB shall be such that the SF6 gas
leakage rate per year shall be limited to less than 1% by mass of the first filling. No
condensation of SF6 gas shall take place on internal insulating surfaces. Inside the
interrupting chamber there shall be an absorbent to absorb products of decomposition
of SF6 gas and moisture if any. It shall be convenient to enable the pole being
dismantled and removed from the operating mechanism with out SF6 gas escaping.
The material used in the construction of the interrupting chamber shall be fully
compatible with SF6 gas. The position of vents, diaphragms and pressure relief
devices, if used, shall be so arranged as to minimize danger to the operator in the
vicinity of the CB in the event of SF6 gas escaping under pressure.
SF6 gas used in the CB shall conform to IEC-376 (1971) or the latest. The gas for the
first filling shall be supplied with the CB.
6.1.1.2 Vacuum Circuit Breaker
The operating mechanism, the pole assembly and supporting structure of vacuum
CB shall be separate and capable of being packed and handled individually and
erected in sequence. The pole shall comprise the interrupting chamber and the
support insulator. The interrupting chamber shall consist of vacuum bottle
contained in porcelain hollow insulator. The vacuum bottle shall comprise a
vessel sealed for lifetime with insulating walls and metal ends containing the fixed
and moving contacts. The movement of the Moving contact in the vacuum
enclosure shall be guided means of metal bellows.Suitable metallic shields shall be
guided by means of metal bellows. Suitable metallic shields shall be provided for
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preventing heat and metal vapour from arcing zone affecting the insulating
envelope. These shields will also control the electric field when contacts are
open and voltage is appearing across the CB contacts. This will mask high internal
stress points and produce an almost linear axial grading of the external insulating
surfaces. A shield shall also be provided to protect the bellows. The design and
construction of vacuum bottle of the CB shall be such that the current chopping
level is kept to the minimum and shall not produce any appreciable switching over
voltages.
6.1.2 Porcelain hollow insulator and terminal connector
6.1.2.1 Porcelain hollow insulator
The porcelain hollow insulators used as the support insulator and interrupting
chamber insulator for the CB shall be of out door type conforming to IS:5621 (1980)
The porcelain hollow insulator shall be of single piece construction i.e. there shall be
no joint within the porcelain. To reduce joints for leakage of SF6 gas (in case of SF6
gas CB), more than one porcelain hollow insulator shall be used for interrupting
chamber insulator or support insulator. The shed profile shall have a lip at the
extremity but free from ribs on the underside so as to avoid accumulation of dust and
pollutants and permit easy cleaning. These insulators shall be procured from RDSO’s
approved sources only.
The porcelain insulators for the support and interrupting chamber shall have
minimum creepage distance as given in the table below :
Rated voltage (kV) 22 25 66 100/110 132 220

Minimum creepage distance
(mm)
i) Support insulator 600 1300 1813 3075 3625 6125
ii) Interrupting 600 1300 1450 2460 2900 4900

chamber insulator
6.1.2.2 Terminal Connectors
6.1.2.2.1 The CB shall have aluminium terminal pads and shall be supplied with the
flexible terminal connectors as per RDSO Drawing No. ETI/PSI/11060
(Appendix – II), suitable for connection to 50 mm outside diameter
aluminium tubular bus bars for 22kV & 25 kV CB and for 66kV, 100/110
kV, 132 kV and 220 kV CB the terminal connector shall be as per RDSO
drawing No. ETI/PSI/11030 (mod G) (Appendix – III), suitable for
connecting to “ZEBRA” 28.62 mm ACSR conductors. The connectors shall
be procured only from manufacturers approved by DG/TI/RDSO/Lucknow.
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6.1.2.2.2 The connectors shall conform to IS :5561 (1978 ) and design shall be such,
so as to be connected to the equipment terminal pads with minimum four
12mm diameter bolts, nuts, lock-nuts of stainless steel conforming to
IS:1570 (PtV) (1978) grade 04Cr, 17Ni and Mo2 each of these bolts shall
have two flat washers.
6.1.3 Contacts for both Vacuum & SF6 CB
6.1.3.1 Main contacts
The main, fixed and moving contacts of the CB shall have ample cross-
section and contact pressure for carrying the rated current and short time
current without excessive temperature rise, pitting and welding.
Arcing tips shall be made up of cupro-tungsten alloy or any other suitable
material. The nozzle, main contacts & arcing contacts or parts thereof
which are liable to wear shall be replaceable (in case of SF6 gas CB)
Indication for contact wear condition shall be provided.
6.1.3.2 Auxiliary Switch Contacts
Apart from the auxiliary switch contacts required exclusively by the

manufacturer for the functioning of the CB at least 6 pairs of normally open
(NO) contacts and 6 pairs of normally closed (NC) contacts shall be
provided additionally for the exclusive use of the Purchaser. The auxiliary
contacts which are operated in conjunction with the main contacts shall be
positively driven in both the directions.
6.1.4 Operating Mechanism
6.1.4.1 The CB shall be operated by a motor charged spring stored energy

mechanism. Both opening and closing operations shall be done by the stored
energy of spring(s). The motor shall be so rated that the time required for
fully charging the closing spring is not more than 15 seconds. The closing
action of the CB shall charge the opening spring so that the CB is ready for
opening anytime thereafter. The spring shall be of robust design using tested
steel as per IS : 7906 or IS : 7907 (1976). The ends of the compression
springs if used shall be flattened to enable proper fixing and shall be
flattened to enable proper fixing and shall minimize the possibility
misalignment.
6.1.4.2 The motor for spring charging shall be suitable for operation from a 110V
dc power from a battery. The voltage at motor terminals is likely to vary
between 110% and 85% of the normal value. The carbon brushes provided
shall have cooper pigtails for carrying motor current. A miniature circuit
breaker of adequate ratings and of reputed make shall be provided in the
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motor circuit for protection of the motor against over current and earth
faults.
6.1.4.3 The operating mechanism shall be designed so that the CB can be operated
from the operating mechanism cubicle itself as well as remotely from the
control panel in the TSS and also from the Remote Control Centre (RCC)
which is situated away from the CB. For this purpose “LOCAL / REMOTE”
two way selector switch shall be provided in the operating mechanism
cubicle. When the switch is in the “LOCAL” position, the CB can be
operated locally and when it is in the “REMOTE” position, the CB can be
operated from the control panel or from the RCC. The selector switch shall
be spring loaded in order that it automatically returns to the
“REMOTE” position. For closing and opening the CB from the operating
mechanism cubicle itself, the switch shall be of push button type or knob
type.
6.1.4.4 The operating mechanism shall also be provided with a suitable emergency
device to manually open the CB in the event of failure of any part of dc
control circuit including the opening coil in the operating mechanism.
6.1.4.5 The operating mechanism shall also be provided with a suitable device to
manually close the CB (mainly for maintenance purposes ). In addition, a
detachable handle/crank shall be provided for manually charging the closing
spring. The height from ground/platform level at which the handle/crank is
to be inserted in the operating mechanism shall be between 1500 mm and
2000 mm so as to enable its operation conveniently by the operator standing
on the ground / platform. The height of other devices like interlock, ON-
OFF switches, selector etc. to be operated from ground / platform shall also
be at a height between 1500mm and 2000mm.
6.1.4.6 In addition to the manually operated local mechanical opening and closing
devices as indicated in Clause 6.1.4.4 & 6.1.4.5 above, provision shall also
be made by means of a suitable crank or handle for slow closing slow
opening of the circuit breaker for maintenance purposes.
6.1.4.7 The closing coil and the opening coil in the operating mechanism shall be
suitable for operation from 110V dc power supply from a battery. The
closing coil shall be suitable for operating at a voltage variation of +10% to
–15%, while the opening coil shall be suitable for operating at a voltage
variation of +10% to –30%
6.1.4.8 The circuit breakers shall be fitted with an electrical anti-pumping device, to
give priority to tripping command in case of a persisting closing command
being simultaneously present.
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6.1.4.9 The circuit breaker shall be trip-free.
6.1.4.10 Facility for trip circuit supervision shall be provided with indication to
remote locations (RCC)
6.1.4.11 An operation counter having five digit recording mechanism for the number
of tripping operations shall be provided at a suitable location so as to be
conveniently read by the operator standing on the ground. The operation
counter shall be of lock type and shall not be of resetable type.
6.1.4.12 Mechanical indicators clearly visible from ground, shall be provided for
‘CLOSED’ and ‘OPEN’ conditions of the CB.
6.1.4.13 All working parts of the operating mechanism shall be of corrosion resisting
material bearings, if any, shall be sealed type. Bearing, pins, bolts nuts and
other parts shall be adequately locked to prevent loosening.
6.1.4.14 In case of drop in pressure of SF6 gas below the set value the temperature
compensated alarm pressure switch shall get actuated for generating an
alarm. If the drop in the pressure continues, the temperature compensated
lock out pressure switch shall get actuated to cause the circuit breaker to trip
and get locked in the tripped condition. Separate auxiliary contact from
pressure switches shall be made available for tele-signalling the alarm
condition from the alarm pressure switch and the trip and lock out condition
from the lock out pressure switch. The maximum pressure, normal pressure,
alarm actuating pressure and tripping & lock out pressure of the circuit
breaker shall be furnished by the manufacturer on the schematic drawing of
the CB. Maximum and minimum permissible pressure of SF6 shall be
indicated on the rating plate also.
6.1.4.15 The operation of closing device when CB is already in “CLOSED”

condition shall not cause damage to any part of the CB or endanger the
operator standing near the CB. The power requirement for tripping coil or
closing coil shall not exceed 200W and power requirement at any time
including spring charging shall not exceed 1000W.
6.1.4.16 In the event of 110V battery supply voltage dropping below 77V which is
minimum voltage prescribed for operation of tripping coil to trip the circuit
breaker, the circuit breaker should trip automatically by means of a suitable
arrangement / device (CTD).
6.1.4.17 Shock absorbers used (if any) shall not require any maintenance during the
entire life of the CB.
6.1.4.18 The operating mechanism and associated accessories shall be enclosed in a

weather, dust and vermin proof cabinet or cubicle. The cubicle made of at
521
least 2mm thick sheet steel (of tested quality) with provision for padlocking.
The cubicle shall be tested for dust and water proofing as per IP 55 as per
IS:2147 (1962) from any national laboratory.
6.1.4.19 Suitable heater(s) shall be provided in operating mechanism cubicle to

operate at 240V ac, 50 Hz single phase supply to prevent condensation of
moisture during monsoon/winter. A 240V ac. 5A, 3 pin socket outlet for an
inspection lamp shall also be provided. Miniature circuit breaker of reputed
make & of
adequate rating shall be used for protection of the heater circuit
for overload and earth fault.
6.1.4.20 The entry of all cables into operating mechanism cubicle shall be only
through suitable cable glands which shall not allow ingress of vermin,
insects etc. into cubicle. The cable glands shall be supplied with the CB.
Five cable glands shall be provided of which three shall be for cable of 16.5
mm outside diameter while the balance two glands shall be for cable of 14
mm outside diameter.
6.1.4.21 The wiring inside the operating mechanism cubicle shall be with 1100V
grade PVC insulated single core cable conforming to IS:1554 (Pt. I-
1988), with stranded copper conductors of adequate cross-section (with min
2.5 Sq strand copper) so proportioned as to reduce voltage drop and I2 R
losses to the minimum. The ends of wires shall be terminated with crimped
eye type lugs. The wiring for 110V dc control circuit and 240V ac circuit
shall be segregated and properly identified. The positive and negative wires
of dc circuits shall also be segregated. The length of the cables used shall be
kept to the minimum. Wire inside the cubicle shall be properly laid on trays
and anchored to avoid breakage during vibration.
6.1.4.22 The terminal end of all wires shall be provided with numbered interlock
type ferrules which shall be of PVC or other durable material with markings
(numbers) either engraved or punched so as to be indelible. The ferrules
shall be of white colour with lettering thereon in black. All wiring shall be
properly supported and suitably protected to avoid rubbing against any
metallic part.
6.1.4.23 Terminal blocks of standard make shall be provided in the operating

mechanism cubicle. There shall be insulating barriers between
adjacent terminals. The terminals shall be of stud type with spring
washers. Suitable dust proof shrouds of unbreakable transparent
material shall be provided on each terminal block. The terminal blocks
used for dc and ac circuits shall be clearly distinguished and separated
from each other. Similarly positive and negative terminations of the
wiring of the dc circuit shall be segregated and separated by insulting
barriers.
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6.1.4.24 The following gauges/switches shall be provided for monitoring the
pressure / density of SF6 gas ( in case of SF6 CB). The pressure gauge
shall have no oil to avoid leakage. The gauges shall be so positioned
as to clearly and conveniently readable from ground/platform
(1500mm to 2000mm from ground/platform). The density pressure
switch(es) monitor and pressure gauges shall be common for all the
poles of the breaker and these shall indicate and actuate for any loss of
pressure in the CB.
(i) An accurate pressure gauge of adequate range.
(ii) Gas density temperature compensated pressure switch(es).
6.1.4.25 For earthing of the operating mechanism cubicle, two earthing

terminals of adequate capacity to carry the rated short circuit current
shall be provided. The earthing terminal shall be provided with 17.5 +
0.5/ - 0.0 mm diameter stud/hole for fixing the earthing flat.
7.0 Steel supporting frame

7.1 The steel supporting frame for CB shall be designed with a factor of
safety of not less than 2.5 with respect to the yield point under
conditions of maximum loading for a basic wind pressure of 200
kg/m2 on 1.5 times the projected area of each member of one face and
taking into account the dead and impact loads of CB. Only tested
quality steel shall be used confirming to IS : 808 (1989) and test
certificate shall be furnished to RDSO. The fixing distance for steel
supporting frame on the foundation to RDSO. The fixing distance for
steel supporting frame on the foundation for single pole 25kV CB
shall be 650x725 mm
7.2 Typical design calculations for the steel supporting frame shall be
furnished by the manufacturer to the RDSO during design approval
stage for checking the safety of the supporting frame proposed to be
used.
7.3 For earthing at least 2 legs of the steel supporting frame shall be
provided with stud/hole type earthing terminals of adequate capacity to
carry the rated short circuit current safely. The earthing shall be
provided with 50 x 8 mm MS flat. The terminal shall be provided with
17.5 + 0.5 / -0.0 mm diameter stud/hole for fixing the earthing flat.
8.0 Foundations
Gravity foundation of plan mass concrete to M 10 mix as per IS: 456
(1978) shall be designed considering the normal and impact loading in
opening / closing operations. The basic wind pressure shall be taken as 200
kgf/m2 . Two alternative design of foundations one for a normal soil of
523
bearing capacity 5500 kgf/m2 and other for black-cotton soil of bearing
capacity 16500 kgf/m2 shall be furnished by the manufacturer. The
foundation block design shall give complete details of its size of pockets
provided for grouting the fixing bolts. Detailed design calculation for
proposed foundation shall be submitted to DG (TI) RDSO for scrutiny and
approval.
9.0 Corrosion prevention system

9.1 Galvanising
The operating mechanism cubicle and steel supporting frame shall be hot
dip galvanized in accordance with RDSO Specification No.
ETI/OHE13/(4/84) and the weight of zinc coating shall be not less than
1000 gm/m2.
9.2 Painting
If the successful tenderer / manufacturer is not able to hot dip galvanize the
operating mechanism cubicle and these steel supporting frame as per Clause
9.1, it shall be painted conforming to RDSO’s specification No. M&C/PCN-
102/86 AND M&C/PCN-110/88
10.0 Fasteners
All fasteners of 12 mm diameter and less exposed to atmosphere shall be of

stainless steel and those above 12mm diameter shall be of preferably
stainless steel or of mild steel hot dip galvanized, to RDSO’s specification
No. ETI/OHE/18(4/84).
11.0 Interlocking arrangements
11.1 The CB shall be provided with a suitable interlocking device for electrical
and mechanical interlocking with its associated isolator(s), such that (i) the
isolator(s) can be operated only when the CB is locked in ‘open’ condition
and (ii) the CB can not be operated both manually and electrically either on
LOCAL or on REMOTE unless the isolator(s) is locked in the CLOSE or
OPEN condition.
11.2 Interlocking Scheme for 25 kV CB
11.2.1 Three types of isolator interlocking schemes shall be utilized. The details of
these schemes are indicated below.
(a) Single isolator interlocking (SI)
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Under this scheme, the circuit breaker shall be interlocked with its single
associated isolator. This interlocking scheme shall be provided on the circuit
breaker to be installed as transformer breakers and circuit breaker for
controlling feed to the shunt capacitor.
In this scheme the key shall be trapped in the lock mounted on the circuit
breaker mechanism when the circuit breaker is in closed position. The key can
be released from the operating mechanism when the circuit breaker is in the
‘open’ position only. Any attempt to forcibly withdraw the key when the
circuit breaker is in the closed position shall result in tripping of the circuit
breaker. The key thus released from circuit breaker shall be utilized to operate
the lock mounted on the isolator. It shall be possible to release this key from
the isolator lock only when the isolator is locked in ‘open’ or ‘closed’
position. Once the key has been removed from the circuit breaker operating
mechanism, it shall not be possible to operate the circuit breaker either
manually or electrically by local / remote control.
(b) Double isolator interlocking (DI)
The scheme is identical to the SI scheme but in this the circuit breaker shall be
interlocked with its two numbers associated isolators. The interlocking shall
be provided on circuit breaker to be installed as feeder breakers.
(c) Bus coupler isolator interlocking (BCI)
Under this scheme the circuit breakers of adjacent bay shall be interlocked
with the bus coupler isolator / interrupter. The operation of the bus coupler
isolator/interrupter shall not be possible unless both the circuit breakers of
adjacent circuit are locked in open position. In this scheme the two keys so
released from the circuit breakers shall be inserted in a key exchange box
(which shall be supplied loose) for releasing a third key which shall be used
for operating the bus coupler isolator /interrupter. The details of all these
schemes indicated above are given in drawing no.ETI/PSI/SK/5214 enclosed
as Appendix (IV)
11.2.2 SI interlocking scheme shall include supply of 2 locks alongwith the common
interlocking key, out of which one lock shall be duly mounted on the circuit
breaker operating mechanism and the other shall be supplied loose for
mounting by Purchaser on the associated isolator.
11.2.3 DI interlocking scheme shall include supply of 3 locks along with the common
interlocking key, out of which one lock shall be duly mounted on the circuit
breaker operating mechanism and 2 locks shall be supplied loose for mounting
by Purchaser on the associated isolators.
525
11.2.4 BCI interlocking scheme shall include supply of a key exchange box which can
be operated by the two keys released from the circuit breakers of adjacent
circuits and one loose lock operated by the key released from the key exchange
box. The loose lock shall be suitable for directly mounting on the bus coupler
isolator (supply of locks fitted on the circuit breakers operating mechanism shall
be covered under SI/DI interlocking schemes.
11.2.5 The interlocks provided on the circuit breakers installed at a traction sub-station
shall have non-interchangeable key codes to safeguard against any mal-
operation.
11.2.6 The lock meant for mounting on the associated isolator(s) and bus coupler
isolator shall be bolt type lock of approved design. The internal mechanism of
the lock shall be made of non-ferrous metal and the outer housing shall be of
steel hot dip galvanized. RDSO drawing No. ETI/PSI/SK/344 showing the
interlocks is attached with this specification as Appendix VI. The key when
trapped inside the lock shall remain properly secured so as to safeguard against
its working loose due to vibrations.
11.2.7 One spare duplicate key shall be supplied with each of the three types of
interlocking schemes.
11.2.8 In order to facilitate the ordering of interlocks, the tenderer shall separately
furnish prices for SI, DI and BCI interlocking schemes. The requirements of
interlocks and the key codes to be adopted shall be ascertained by the successful
tenderer from the respective consignee.
11.3 Interlocking scheme for 22 kV, 66 kV, 110kV, 132 kV and 220 kV CB
11.3.1 Two types of interlocking arrangement designated as type-I and Type-II may be
used. In Type-I, the circuit breaker is interlocked only with its associated double
pole or triple pole isolator. In Type-II CB is interlocked with associated line
isolator and bus coupler isolator. The operation of the line isolators and bus-
coupler isolator should not be possible unless both the circuit breakers of the
two adjacent circuit are locked in the open condition.
11.3.2 Type_I inter locking scheme shall include supply of two locks and a common
key, out of these two locks, one lock shall be mounted by the manufacturer on
the circuit breaker operating mechanism and the other supplied loose for
mounting by the purchaser on the associated isolator. The design of the lock
shall be approved by RDSO.
11.3.3 Type-II interlocking scheme shall include supply of 3 Nos. loose locks for
mounting on associated isolators by the purchaser. These locks shall be
operated through the common key being supplied under Type-I inter locking
526
scheme. Details of interlocking scheme indicated above are given in
Drawing No.ETI/PSI/5212 (MOD B) at Annexure (V).
11.3.4 When both Type I and II inter locking schemes are ordered for a circuit
breaker, in all 5 Nos. locks and a common key shall be supplied with each
circuit breaker. Out of these 5 locks, one lock along with the key shall be
mounted on the operating mechanism of the circuit breaker by the
manufacturer of the circuit breaker and other 4 blocks shall be supplied
loose for mounting on associated isolator(s), line isolators and bus coupler
isolator by the purchasers.
11.3.5 Requirement of inter locks under Type-I and Type-II interlocking scheme at
a Traction substation having double circuit incoming line and provided with
two nos. Traction transformers shall be as follows :
Type - I Scheme - 2 sets.

Type - II Scheme - 2 sets.
11.3.6 The inter locks provided on the circuit breaker installed at a particular
traction substation shall have non-interchangeable key codes to safeguard
against any mal-operation.
11.3.7 The lock for mounting on the isolators shall be a castle type lock of
approved design. However, the lock for mounting on the circuit breaker may
be a bolt type lock, with adopter. The internal mechanism of the lock shall
be of non-ferrous material and the outer housing shall preferably be of mild
steel hot dip galvanized. The key, when trapped inside the lock, shall remain
properly secured and it shall not become loose due to vibration.
11.3.8 One spare (duplicate) key shall be supplied for each type of the interlocking
arrangements.
11.3.9 In order to facilitate the ordering of interlocks, the tenderer shall separately
furnish prices for Type-I and Type-II interlocking arrangements. The scope
of supply for inter locks shall include locks (and keys) to be fitted on the
circuit breaker(s) and also on the associated isolator(s). The requirements of
interlocking and the key codes to be
adopted shall be ascertained by the successful tenderer from the consignee.
11.3.10 The electrical and mechanical interlocks shall be procured only from
RDSO’s approved manufacturers. Approved supplier for electrical and
mechanical interlocks are :
(i) M/s. Enterprising Engineers, Bhopal.
(ii) M/s. PS Power Controls, Chennai.
12.0 Parts, fittings and accessories
527
12.1 The following parts, fittings and accessories shall be provided for each CB :
(i) SF6 gas pressure gauge (in case of SF6 CB)
(ii) Temperature compensated gas density pressure switch(es) (in case of

SF6 CB)
(iii) Provision for replenishment of SF6 gas, preferably in the operating

mechanism cubicle (in case of SF6 CB)
(iv) Contact wear indication.
(v) Operating mechanism cubicle door padlocking arrangement with

padlock.
(vi) Local operated mechanical opening and closing device.
(vii) Spring loaded local/remote selector switch.
(viii) Local operated electrical closing and opening device (push or knob)
(ix) Operation counter.
(x) Interlocking device (as required)
(xi) Terminal connectors.
(xii) Earthing terminals.
(xiii) Name / rating plate.
(xiv) Mechanical ‘ON’ and ‘OFF’ position indicators.
(xv) Handle / crank for slow closing and slow opening of CB.
(xvi) Supporting frame work.
(xvii) Lock out device.
(xviii) Tripping device in case of 110V dc failure (CTD).
(xix) Anti-pumping device.
(xx) Foundation Bolts.
528
(xxi) Handle/crank for charging the closing spring manually.
12.2 The name / rating plate shall contain the following particulars
Each CB shall be provided with a rating plates (both Hindi & English
weather proof material, fitted in a visible position showing the items
indicated below. The letters/numbers on the plate shall be indelibly marked
by etching/engraving.
(i) Manufacturer’s name and country of origin.
(ii) Type designation and No. of pole.
(iii) Serial number.
(iv) Rated voltage.
(v) Rated normal current.
(vi) Rated frequency.
(vii) Rated short circuit breaking current.
(viii) Rated short circuit peak making current.
(ix) Rated single capacitor bank breaking current.
(x) Rated out of phase breaking current.
(xi) Rated short time withstand current and it’s duration.
(xii) Rated insulation level.
(xiii) Rated operating sequence.
(xiv) Control circuit voltage with permissible variation for

(a) Closing coil
(b) Opening coil
(c) Motor voltage
(xv) Total weight of CB
(xvi) Specification conforming to IEC / RDSO
(xvii) Quantity of SF6 gas ( by mass )
529
(xviii) SF6 Gas pressure
(a) Maximum
(b) Normal
(c) Alarm
(d) Lock out
(xix) Vacuum level in Torr (for vacuum CB)
(xx) Order reference
(xxi) Month / Year of manufacture
13.0 Testing
13.1 General
13.1.1 After all the designs and drawings have been approved and clearance given to this
effect by RDSO, the manufacturer shall take up manufacture of the prototype for
inspection / testing by RDSO. It is to be clearly understood that any changes to be
done on the prototype as required by RDSO, the same shall be done
expeditiously.
13.1.2 Prior to giving a call to the Purchaser / Director General Traction Installations,
Research Designs and Standards Organisation, Lucknow ( DG/TI/RDSO,
Lucknow) for inspection and testing of the prototype, the successful tenderer
/manufacturer shall submit a detailed test schedule consisting of test procedures,
schematic circuit diagrams, items / parameters to be checked and values required
as per specification for each of the tests and the number of days required to
complete all the tests at one stretch. The schedule shall also indicate the venue of
each of the tests. Once the schedule is approved, the tests shall invariably be done
accordingly. However, during the process of type testing or even later, the
Purchaser / DG/TI/RDSO, Lucknow reserves the right to conduct any additional
test(s), besides those specified herein, on any equipment / item so as to test the
equipment / item to his satisfaction or for gaining additional information and
tenderer / manufacturer and the representative of the purchaser/DG/TI/RDSO,
Lucknow during the process of testing as regards the procedure for type tests
and/or the interpretation and acceptability of the results of type tests, it shall be
brought to the notice of the Purchaser/DG/TI/RDSO, Lucknow as the case may be
whose decision shall be final and binding. Only after the prototype of the
equipment is manufactured and ready in all respects, shall the successful tenderer
/ manufacturer give the actual call for the inspection and testing with at least 15
days notice for the purpose.
any reason attributable to the successful tenderer / manufacturer and it is required
530
for the representative of the Purchaser/DG/TI/RDSO, Lucknow to go again or
more number of times to the works of the successful tenderer/manufacturer or to
any reputed testing house/laboratory where tests are being done for continuing
and/or completing the tests on the prototype(s) of the equipment, the successful
tenderer / manufacturer shall reimburse to the Purchaser/DG/TI/RDSO, the cost
for the representative(s) having to visit the works or other place(s) for the tests
more than once. The cost as claimed by the Purchaser/DG/TI/RDSO Lucknow
shall be paid through a Demand Draft to the concerned Accounts Officer of the
Purchaser/DG/TI/RDSO Lucknow as shall be advised to the successful tenderer /
manufacturer.
13.1.4 The tests shall be conducted on the prototype of the CB at the works of the
successful tenderer / manufacturer or at an reputed testing house or laboratory in
the presence of Purchaser/DG(TI)/RDSO, Lucknow or his authorized
representative. The prototype shall be complete in all respects, including the
terminal connectors as would be supplied if it had passed the tests. The tests shall
be conducted as per relevant Governing Specification and as modified or
amplified herein. In case of test being conducted at Government test house, the
presence of Purchaser’s representative for witnessing the tests may be waived off
subject to the discretion of Purchaser/DG(TI)/RDSO, Lucknow.
13.1.5 For the tests which are conducted in the laboratories of Central Power Research
Institute, Bhopal/Bangalore, Electrical Research Development Association,
Vadodra or any such testing house or laboratory a clear certificate to the effect
that the equipment has passed the tests as per specification shall be obtained by
the manufacturer and submitted to the Purchaser/DG (TI) RDSO, Lucknow. Full
details of the tests and test parameters shall be furnished along with the test
reports.
13.2 Type tests
The type tests comprises of :

(i) Mechanical operation tests as per clause 13.2.1
(ii) Temperature rise tests as per clause 13.2.2
(iii) Dielectric tests as per clause 13.2.3

(a) Rated lightning impulse voltage withstand test as per
clause 13.2.3.1
(b) Rated one minute power frequency wet withstand voltage test
as per clause 13.2.3.2
(iv) Rated short circuit making and breaking capacity test (basic short
circuit test duties) as per clause 13.2.4
(v) Rated short time withstand current & peak withstand current test as
per clause 13.2.5
531
(vi) Line charging breaking current test as per clause 13.2.6
(vii) Test to prove the rate transient recovery voltage (TRV) and rate of
rise of recovery voltage (RRRV) as per clause 13.2.7
(viii) Short line fault test (kilometers faults) as per clause 13.2.8
applicable only for 66 kV and above.
(ix) Out of phase making & breaking test as per clause 13.2.9
(x) Capacitor current switching test as per clause 13.2.10
(xi) Measurement of RIV level as per clause 13.2.11 – (Applicable for 110
kV & above CB).
(xii) Special electrical test – applicable for 25kV circuit breaker only as per
clause 13.2.12
13.2.1 Mechanical operation test

13.2.1.1 The test shall be conducted in accordance with clause 6.101of IEC 60056(1987)
but the number of operations shall be 10,000 in case of 22kV & 25 kV CB and
5000 in case of 66, 100/110, 132 and 220 kV instead of 2000 specified therein.
For this purpose, CB shall be tested in accordance with Table XII of IEC 60056
(1987). However, the sequence shall be repeated 5 times to complete 10,000
operations in case of 22 kV & 25kV CB and 2.5 time in case of 66kV, 100/110
kV, 132 kV and 220 kV CB.
13.2.1.2 Following checks/ tests shall be done before commencement of mechanical

operation test.
(i) General visual inspection of the equipment to check its conformity with the
approved drawings.
(ii) Operation of various circuits and devices of the CB.
(iii) Measurement of dimensions of components liable to wear, dimension of

opening, closing and wipe springs, lift of tripping and closing coil plunger, and
clearances of opening and closing coil armatures.
(iv) Measurement of insulation resistance of auxiliary and motor circuits with 500V
meter.
(v) Measurement of contact resistance of main circuit by dc voltage drop.
(vi) Mechanical operation comprising 5 closing and 5 opening operations at the

specified normal, minimum and maximum control voltages.
532
(vii) Closing and opening travel characteristics of contacts to record the following at
the specified normal, minimum and maximum control voltages (at minimum &
maximum SF6 gas pressure in case of SF6 CB.
Opening speed & time

Closing making speed.
Closing speed & time
Contact bounce and
Contact level
13.2.1.3 The measurements of items (v) & (vii) above shall be repeated after every
5000 operations for 22 kV & 25 kV CB and 2500 operation in case for 66,
100/110, 132 & 220 kV CB and observations made/results obtained shall be
evaluated by comparing with the figures and the tolerances given by the
successful tenderer / manufacturer in the SOGP.
13.2.1.4 After completion of 10,000 operations in case of 22kV & 25 kV CB and

5000 operation in case of 66kV, 100/110kV, 132 kV and 220 kV CB and
before dismantling the CB for internal inspection, the following checks/tests
shall be performed.
(i) Gas pressure at ambient temperature (in case of SF6 CB). The same
shall be within 99% of pressure recorded at the beginning of the
operation.
(ii) Dielectric tests on control and auxiliary circuit (110V dc) by

applying 2 kV (rms) for 1 min. after disconnecting the motor.
(iii) Spring charging motor shall be tested at 1 kV (rms) for 1 mm.
(iv) Power frequency dry withstand voltage test on complete CB for 1

minute.
(v) Temperature rise test on opening and closing coils as 13.2.2.2
(vi) Closing and opening travel characteristics of contacts to record the

following at the specified normal, minimum and maximum control
voltages (at minimum & maximum SF6 gas pressure in case of SF6
CB.
Closing speed
Opening speed.
Closing making speed
Contact bounce and
Contact level
533
The above parameters shall be within the specified limits declared by
the manufacturer in SOGP.
(vii) For SF6 gas CB the tightness of gas sealing arrangement shall be
measured by tests conducted on either a complete CB or on sub-
assemblies in combination with tightness co-ordination chart as
provided in the Appendix ‘EE’ of IEC 60056(1987) to ascertain total
system leakage rate and time between refilling of SF6 gas pressure.
Drop in pressure shall not be used to detect the leakage rate of the
SF6 gas as it will not indicate the correct readings.
13.2.2.1 On main contact

The temperature rise test on the main circuit ( contacts )and terminal
connectors shall be carried out as per clause 6.3 IEC 694(1980). Contact
resistance of the main circuit shall be determined by dc voltage drop
recorded before and after this test.
13.2.2.1.1 Procedure
Unless otherwise specified, temperature rise on the main circuit be made on

a new CB in closed position with clean contacts. The test shall be made
with rated normal current.
The test shall be done in indoor environment substantially free from

currents, except those generated by heat from the CB being tested.
Temporary connections to the CB terminals shall be such that no significant
amount of heat is conducted away from, or conveyed to the CB during the
test. The temperature rise at the terminal of main circuit and the temperature
connections at a distance of 1 m from the terminal shall be measured as a
difference of temperature rise shall not exceed 5° C. The type and sizes of
temporary connections shall be recorded in the test report.
13.2.2.1.2 The maximum temperature rise of contacts, terminals for connection to

external conductors by bolts, material used as insulation and metal parts
contact with insulation shall not exceed the values given in Table below
when carrying rated normal current continuously. These values shall be
conforming to IEC 694 (1980).
TABLE
Sl. Nature of faults / components Maximum temperature rise

No. at an ambient temperature
not exceeding 50° C
1. CONTACTS
i) Bare copper and bare copper 25° C
534
alloy in SF6 gas
ii) Silver contacts in SF6 gas 55° C
2. Terminal for external connection by 40° C
bolts.
3. Insulator (Porcelain). 130° C
13.2.2.1.3 In case a layer of coating of silver over the contact area is not maintained at
the end of any tests the contacts shall be regarded as bare for the purpose of
temperature rise limits.
13.2.2.2 On Auxiliary equipment (Closing & opening coils)

The temperature rise test on the coils shall be carried out a per clause 6.3 of
IEC 694 (1980).
13.2.2.2.1 Procedure
Temperature rise on auxiliary equipment (closing and opening coils) shall
be made by the method of measuring variation of resistance before and after
energisation at 110V dc. For this purpose the coil (s) shall be energized 10
times for 1s, the interval between the instant of each energizing being 2s.
The resistance of the coil shall be measured immediately before and after
such energisation. The value of temperature rise, over the ambient, shall be
computed.
13.2.2.2.2 The maximum temperature rise shall be as per table V of IEC 694(1980)
considering the insulating material of the coil. The temperature rise shall not
exceed the value a guaranteed by the manufacturer in SOGP.
13.2.3 Dielectric tests
Dielectric tests shall be carried out generally in accordance with Clause 6.1
of IEC 694(1980). Humidity and air density correction factor if less than 1.0
shall not be applied. The tests shall be done at a minimum SF6 gas pressure
( in case SF6 CB). The test shall comprises of :
13.2.3.1 Rated impulse withstand voltage test
The CB shall withstand rated impulse voltage of 1.2/50 µs wave shape as

per table below :
NOMINAL SYSTEM VOLTAGE OF CB (kV)

22 25 66 100/110 132 220
APPLIED
535
VOLTAGE 125 250 350 550 650 1050
(kVp)
13.2.3.2 Rated one minute wet power frequency voltage withstand test
The CB shall withstand rated one minute wet power frequency withstand
voltage as per table below.

22 25 66 100/110 132 220
APPLIED
VOLTAGE 50 95 160 230 275 460
(kV rms)
13.2.4 Basic short circuit test duties
The basic short circuit test duties 1 to 5 shall be in accordance to clause

6.106 of IEC – 60056 (1987). The power frequency recovery voltage shall
be as per clause 6.104.7 of IEC 60056 (1987).
13.2.5 Rated short time withstand current & peak current withstand test
This test shall be conducted as per clause 6.5 of IEC 694(1980) and the
values shall be as under

22 25 66 100/110 132 220
Value of 40KArms 20
current for 3s KArms -------- 31.5 kArms for 1s, 78.75kAp---
& 100kAp for 3s -
duration 50kAp
13.2.6 Line charging current switching test

This test shall be conducted as per clause 6.111.5.1 of IEC 56 (1987) test
values shall conform as given in SOGP.
13.2.7 Test to prove rated transient recovery voltage (TRV)
The measurement shall be done as per clause 6.104.5 of IEC 60056(1987).
13.2.8 Short line fault test
This test shall be conducted as per clause 6.109 of IEC 60056(1987)
13.2.9 Out of Phase making and Breaking test
536
This test shall be conducted as per clause 6.110 of IEC 60056 (1987) at its
rated out of phase breaking current. The applied voltage and power
frequency recovery voltage shall be set as per table below :

22 25 66 100/110 132 220
Current 10KA 5 KA
rms rms -------- 7.9 kA rms ----------
Recovery 48 60 144 246 290 490

voltage kVrms kVrms kV rms kV rms kV rms kV rms
13.2.10 Capacitor bank breaking current test
The test shall be carried out at its rated single capacitor bank breaking current
generally as per Clause 6.111 of IEC 60056 (1989). No restrike shall occur
during the test. The breaking current shall conform to the guaranteed value.
13.2.11 Measurement of RIV level
The test shall be conducted as per Clause 6.2 of IEC 694 (1980).
13.2.12 Special electrical test (applicable for 25 kV CB only)

CB shall be subjected to short circuit making and breaking capacity test at a
current of 6.25 kA for duty cycle of CO-15s-CO for 200 close-open
operations. During this test no part of CB shall require any inspection /
maintenance, change of SF6 gas or vacuum bottle or any other part. The
standard value of prospective TRV shall be taken as 64kV. Other conditions
shall be similar to short circuit test duties specified in IEC 56 (1987).
Test may be interrupted once after every 10 CO operations if need arises to
enable the components to cool down to ambient temperature.
13.3 Condition of CB during the tests conducted as per clause no. 13.2.4, 13.2.5,
13.2.6, 13.2.7, 13.2.8, 13.2.9, 13.2.10, 13.2.11 and 13.2.12 of this
specification shall conform as under :
13.3.1 During these tests the CB shall neither show signs of excessive distress nor
endanger the operator. No disruptive discharge between energized parts and
earth, shall occur during the tests. There shall be no indication of significant
leakage current to the earthed structure or screens whenever fitted during the
test. The earthed parts shall be connected to earth through a fuse consisting of
a copper wire of 0.1 mm diameter and 5 cm length. The fuse wire shall be
intact after the tests.
13.4 Condition of CB after the tests conducted as per clause no. 13.2.4, 13.2.5,
13.2.6, 13.2.7, 13.2.8, 13.2.9, 13.2.10, 13.2.11 and 13.2.12 of this
specification shall conform as under :
537
13.4.1 The mechanical functions and insulation of the CB shall be essentially in the
same condition as before the tests. The wear of the contacts shall not be
disproportionate to its original size and shape. The CB shall be capable of
carrying its rated normal current and also capable of performing its assigned
duty provided in Clause 3.7 of the specification. The CB shall withstand for 1
min dry power frequency withstand voltage condition as per table below :

22 25 66 100/110 132 220
Power
frequency 50 95 160 230 275 460
withstand kV rms kV rms kV rms kV rms kV rms kV rms
voltage
13.5 The tenderer may quote separately the charges for short circuit test duties, short
time withstand current and peak current withstand test, line charging breaking
current tests, tests to prove rated TRV, short line fault test, out of phase making &
breaking test, capacitor bank breaking current test, measurement of RIV level &
special electrical test a per clause no. 13.2.4, 13.2.5, 13.2.6, 13.2.7,13.2.8, 13.2.9,
13.2.10, 13.2.11 and 13.2.1 No test charge shall be payable for any other tests.
13.6 If the prototype of the CB conforming to this specification has been approved for
earlier supplies to Indian Railways, testing of prototype again may be waived
provided that no changes in the design and / or material used have been made. For
this purpose the successful tenderer/ manufacturer shall approach Purchaser / DG
(TI), RDSO, Lucknow with complete document to ascertain whether he
equipment is identical to the prototype approved earlier. Once prototype approval
is accorded after conducting all or part of the type tests by RDSO, the prototype
approved earlier. Once prototype approval is accorded after conducting all or part
of the type tests by RDSO, the prototype approval shall normally be valid for 5
years subject to the no change of design, material and process adopted prototype.
13.7 Only after clear written approval of the prototype is communicated by

Purchaser/DG/TI/RDSO/Lucknow to the successful tenderer / manufacturer, they
shall take up bulk manufacture of the CB which shall be strictly with the same
design, material and process as adopted for the prototype. In no circumstances the
material from sources other than those approved in the designs / drawings and / or
the prototype shall be used for bulk manufacture.
13.8 The successful tenderer / manufacturer shall furnish copies type test reports as per
relevant IS/IEC for all the important items including items listed at Annexure ‘B’.
Suitable monogram in the form of engraving /embossing or other similar means
shall be provided for each of these items to identify their manufacturer / source
and shall be verified during the prototype inspection.
538
13.9 Details of the important parts and sub-assemblies listed at Annexure –B shall be
furnished by the successful tenderer /Manufacturer to DG(TI)/RDSO/Lucknow
for record.
13.10 Routine tests
Every CB shall be subjected to the routine tests at the manufacturers’ works

as per clause 7 of IEC 60056(1987). Routine test reports of items /
components used shall be made available to the testing authority. The
routine tests comprise
(i) Rated one minute Power frequency dry withstand voltage test on the
main circuit as per clause no 13.10.1
(ii) Dielectric test on control and auxiliary circuits as per clause no
13.10.2
(iii) Measurement of contact resistance of main circuit as per clause no
13.10.3
(iv) Mechanical operation tests as per clause no 13.10.4
(v) Design and visual checks as per clause no 13.10.5
13.10.1 Rated one-minute power frequency dry withstand voltage test
The CB shall withstand dry power frequency voltage for one minute as per
table below –

22 25 66 100/110 132 220
Power
frequency 50 kV 95 kV 160 230 275 460
withstand rms rms kV rms kV rms kV rms kV rms
voltage
13.10.2 Dielectric tests on control and auxiliary circuits
The control and auxiliary circuits shall withstand 2000 V ac for one minute
after disconnecting spring charging motor. The spring charging motor shall
withstand 1500 V ac for 1 minute.
13.10.3 Measurement of contact resistance of the main circuit
The resistance shall be measured by dc voltage drop. The measured value

shall not exceed 1.2 times the value of resistance recorded before temperature
rise test during type test approved by DG (TI), RDSO.
539
13.10.4 Mechanical operation test
The test comprising five opening and five closing operations at each of the
rated, maximum and minimum control voltages i.e. at 110 V dc, +10% and –
15% for closing operations and at 110V dc –30% for openings shall be
performed . The contact travel characteristics shall be recorded for each
closing and opening operation. The characteristics shall be within the tolerances
specified in SOGP / type test values approved by DG(TI), RDSO.
13.10.5 Design & visual check

The CB shall be checked to verify its compliance with this specification. In
particular following items shall be checked.
(i) Verification of dimension of equipment and assembly as per

drawings / data sheets approved by RDSO
(ii) Verification of operation under local and remote.
(iii) Verification of clearance as per approved drawing.
(iv) Quality of painting / galvanizing of cubicles and mounting structure.
(v) Cubicle shall be dust and vermin proof conforming to IP 55 of IS

: 2147 (1962)
(vi) Fasteners used in various assemblies shall be of stainless steel for

12mm dia or below and those above 12mm may be hot dip
galvanized or stainless steel.
(vii) Verification of behavior under local electrical command while on

Local / Remote selector switch is in remote and vice versa. The CB
should not operate.
(viii) Verification of manual opening and closing operation.
(ix) Verification of emergency device for opening of CB in the event of

failure as per clause 6.1.4.4.
(x) Verification of rated operating sequence.
(xi) Verification of interlocking.
The CB should not close either on remote or on local

(mechanical or electrical) if key of the interlocking key is removed
from the CB operating mechanism
540
(xii) Measurement of spring charging time.
(xiii) Verification of contact wear indicator position.
(xiv) Measurement of current drawn by the motor.
(xv) Verification of function of tripping device in the event of 110V dc

supply failure (CTD)
(xvi) Verification of function of anti pumping device.
(xvii) Measurement of resistance of operating coils.
(xviii) Verification of SF6 gas alarm and lockout setting.
(xix) Verification of wiring and numbering of cable.
(xx) Verification of signal positions for close/trip and spring charged /

spring discharged.
(xxi) Verification of make, type designation and rating of

parts/components.
(xxii) Verification of name plate details.
(xxiii) Verification of type and routine test reports of parts/components

used.
(xxiv) Verification of tightness of sealed SF6 gas pressure system using

halogen detector. For this purpose polythene bags of appropriate size
shall be tied enveloping the leakage points. after 24 hours the
halogen detectors nozzle shall be pierced at the bottom of the bag to
sniff any SF6 gas which might have leaked (in case SF6 gas CB).
There shall not be any leakage of SF6 gas.
(xxv) Checking of proper fixing and support of springs, gas pipes, relays
gauges and tripping/closing coils.
(xxvi) Checking of free movement of armature of opening and closing

coils.
(xxvii) Visual check of painting and galvanisation.
(xxviii) Checking of valve and pipe coupling.
541
14.0 The tenderer shall specifically indicate in a statement attached with his
offer, his compliance with each clause and sub-clause of this specification.
A separate statement shall be attached with the offer indicating references to
the clauses where the tenderer deviate there from together with detailed
remarks/justification. If either the statement of compliance or statement of
deviations is not attached with the offer, it is not likely to be considered. For
the reason that it is an incomplete offer which can not be properly evaluated
and compared with other offers, if any. If there are no deviations, a ‘NIL’
statement shall be attached.
15.0 Following drawings / documents to be furnished along with the tender :
(i) Full dimensioned General Arrangement drawing indicating

clearances, fixing arrangement of the mounting structure on the
foundation.
(ii) Schematic drawing.
(iii) QAP for the equipment
(iv) ISO certification.
(v) List of essential plant, machinery and testing facilities.
(vi) Type test report for relevant rating as per RDSO / IEC specification.
(vii) List of supplies and performance report for the tendered equipment
from user railway /other customer.
(viii) The information furnished in the schedule of guaranteed technical

performance, data and other particulars (Annexure –A) shall be
complete in all respects. If there is any entry like ‘shall be furnished
later’ or blanks are left against any item, the tender is not likely to be
considered as such omissions cause delays in finalizing the tender.
16.0 Technical data and drawing to be furnished by successful tenderer/

manufacturer.
16.1 Details of the important parts and sub-assemblies listed at Annexure – B

shall be furnished by the successful tenderer / manufacturer to RDSO after
award of contract
542
16.2 The successful tenderer shall submit following details / dimensioned
drawings as per Indian Railways’ standard in sizes of 210 mm x 297
mm or any integral multiples thereof for approval.
(i) Name / Rating plate.
(ii) General assembly showing mounting arrangement and overall

dimensions.
(iii) Schematic and wiring diagram with explanation sheet.
(iv) Cross-section of interrupting chamber indicating the arcing/main

contacts and nozzle(s) or of the vacuum bottle as the case may be.
(v) Details of main, fixed and moving contacts and arcing contacts.
(vi) Operating and coupling mechanism of complete CB along with

schematic diagram showing the mechanical linkages with
explanation sheet.
(vii) Detailed drawings of spring for closing and opening.
(viii) SF6 gas circuit showing location of all gauges, pressure switches,
feed port, valves, interrupting chamber, piping coupling etc. with
explanation sheet.
(ix) Full details of all sealing points with details of O-rings and gaskets.
(x) Details of Terminal Connector.
(xi) Details of Porcelain hollow insulators for support and interrupting

chamber.
(xii) Plain mass concrete foundation drawing and design calculations.
(xiii) Design calculation for structural safety along with details of

supporting structure.
(xiv) Erection, commissioning, operation and maintenance manual.
(xv) Details of main parts / sub-assembly as per annexure B.
(xvi) Any other drawing considered necessary by the successful tenderer

/manufacturer and / or Purchaser.
16.3 Numbering of drawings shall be so structured as to give information about

total number of drawings, data sheets/instructions sheets relating to the
543
contract for example a drawing designated as “D307 [4-12] sheet 2 of 5”
denotes that :
(i) D 307 is the drawing No – the choice of which is left to the

successful tenderer.
(ii) It is the 4th drawing out of a total set of 12 drawings/data sheet for
the contract.
(iii) It is the 2nd sheet out of total 5 sheets and
16.4 Cross reference of identical drawing if approved for earlier contract shall be
given in the drawing. Information required during erection, commissioning
and maintenance of equipment shall be shown in greater detail.
16.5 After approval, six copies of approved drawings along with two set of
reproducible prints shall be supplied to each consignee. Drawings shall
made in Auto CAD R 14, which is Window based for approval to RDSO.
Two sets of approved drawings of hard copies, one copy of RTF and one set
of floppies in Auto CAD R 14 shall be sent to RDSO for record.
16.6 Space earmarked for assigning RDSO’s drawing no. shall be available on
the right hand top side of each drawing. Numbering shall be allotted by
RDSO after approval of the drawing.
16.7 Five copies of the approved Erection, Commissioning, Operation and

Maintenance Manual shall be supplied to each consignee, in case order is
more than 10 nos. In case order is less than nos. 2 copies of manual shall be
supplied. Two copies of manuals shall be supplied to the Purchaser /DG
(TI), RDSO, Lucknow (India) for record.
16.8 Drawings approved by RDSO after prototype approval shall be submitted

for the future contracts also till the validity of prototype approval, with a
clear certification on the drawing that design, process and material have not
been changed in the design of the subject equipment from the prototype
already approved by RDSO.
17.0 Erection, Testing and Commissioning
The CB shall be erected and commissioned by the purchaser / manufacturer.

However, in case a defect / deficiency is noticed, the manufacturer /
successful tenderer will have to depute his engineer for necessary remedial
action without any cost to the Railways. In all the cases in which an order is
placed either on new manufacturer of for a new type/design of the CB, the
544
services of manufacturer’s engineer shall be made available during the
erection and proving/pre-commissioning test for the first order of their CB
free of cost. For this purpose, prior intimation regarding the date and the
location shall be given by the purchaser to the successful
tenderer/manufacturer.
18.0 Spares
18.1 The tenderer shall furnish alongwith his offer, a list of spares (with cost)
recommended by him for maintenance of the CB for a period of ten years.
The list should include gaskets/O-rings, parts which are likely to wear and
items requiring replacement /replenishment, besides other items
recommended by the manufacturer. The successful tenderer shall give an
undertaking to the effect that he shall supply the required spares for the total
life of the equipment (i.e. 25 years approx).
18.2 The tenderer shall furnish along with his offer, the cost of gas filling
arrangement, evacuation plant for SF6 gas and cost of SF6 in 10kg cylinder.
19.0 Training of Indian Railway’s engineers
The offer shall include the training of two engineers of the Indian Railways
free of cost at the manufacturer’s works in India or abroad and at the
maintenance depots /workshops on a Railway system or other public utility
where circuit breakers of similar /identical design are in operation. The total
duration of training for each engineer shall be 4 weeks of which
approximately two weeks will beat manufacturer’s works and two weeks on
a Railway system or other public utility. If the country of manufacturer is
not India, the cost of travel to that country and back will be borne by the
Indian Railways. Other details shall be settled at the time of finalizing the
contract/Purchase Order.
20.0 After sales-service

20.1 The successful tenderer shall make necessary arrangements for closely
monitoring the performance of the CB through periodical (preferably once in
two months during warranty period) visit to the locations where they are
erected for observations and interactions with the operating and maintenance
personnel of Indian Railways. Arrangements shall also be made by the
successful tenderer / manufacturer for emergency / standby spare parts being
kept readily available to meet exigencies warranting replacement so as to keep
the CB in service with least down time.
20.2 Successful tenderer / manufacturer shall respond promptly and in a work man
like manner to any call given by Indian Railway for any assistance by way of
attending to failures, investigations into the causes of failures including the
tests, if any, to be done and such other items with a view to seeing that the CB
serves the purpose for which it is procured. Besides, technical guidance to
545
ensure proper operation and maintenance of the CB shall be constantly
rendered.
21.0 Warranty
21.1 The successful tenderer/manufacturer shall warrant that all equipment shall be
free from defects and faults in design, material, workmanship and manufacture
and of the highest grade consistent with the established and generally accepted
standards for the equipment of the type ordered and in full conformity with the
specifications and shall operate properly.
21.2 This warranty shall cover inspection of, payment for and acceptance of the
equipment, but shall expire 30 (Thirty ) months after the delivery at ultimate
destination, or 24(Twenty four) months from the date of commissioning and
proving test of the equipment at ultimate destination in India, whichever period
expires earlier, except in respect of complaints, defects and/or claims notified to
the successful tenderer/manufacturer within 3 (Three) months of the expiry of
such date. Any approval or acceptance by the Purchaser of the equipment shall
not in any way limit the successful tenderer /manufacturer’s liability.
21.3 The successful tenderer/manufacturer’s liability in respect of any complaint,

defects and /or claims shall not be limited to the furnishing and installation of
replacement of parts free of any charge of the repair of defective parts only to
the extent that such replacement or repairs are attributable to or arise from
faulty workmanship or material or design in the manufacture of the goods,
provided that the defects are brought to the notice of the successful
tenderer/manufacturer within 3 (Three) months of their being first discovered
during the warranty period of 3 (Three) months from the date of expiry of
warranty period, or at the option of the Purchaser, to the payment of the value,
expenditure and damages as hereafter mentioned.
21.4 The successful tenderer / manufacturer’s shall, if required, replace or repair the
equipment of such portion thereof as is rejected by the Purchaser free of cost at
the ultimate destination or at the option of the Purchaser. Successful tenderer /
manufacturer shall pay to the Purchaser value thereof at the contract price or in
the absence of such price at a price decided by the Purchaser and such other
expenditure and damage as may arise by reason of the breach of the conditions
herein specified.
21.5 All replacement and repairs that the Purchaser shall call upon the successful
tenderer / manufacturer to deliver or perform under this warranty shall be
delivered and performed by the successful tenderer / manufacturer, promptly
and satisfactorily and in any case within 2 (Two) months of the date of advice to
this effect.
21.6 If the successful tenderer/manufacturer so desires the parts that are removed
may be taken over by him or his representative for disposal as he deems fit at
546
the time of replacement with good parts. No claim whatsoever shall lie on the
Purchaser thereafter for the parts so removed.
21.7 The warranty herein contained shall not apply to any material which shall have
been repaired or altered by the Purchaser or on his behalf in any way without
the consent of the successful tenderer/manufacturer, so as to affect the strength,
performance or reliability or to any defects to any part due to misuse,
negligence or accident.
21.8 The decision of the Purchaser in regard to successful tenderer/manufacturer’s

conclusive.
22.0 Packing and dispatch
22.1 The various components of each CB shall be securely packed in wooden
crates/boxes. General packing list, together with weight and overall
dimensions of each packing case shall be furnished for each CB indicating
the following :
Crate/Box No. Description of Gross weight Approximate
item/component in kg outside
in the crate /box dimensions.
22.2 As far as possible, the gross weight of a crate/box shall be so kept that it
shall be possible to manually handle it by two persons.
22.4 Necessary instructions for handling and storage shall also be furnished for
use at receiving end.
22.5 Porcelain housing/support insulator shall be supplied securely packed in

wooden crates. Not more than two porcelain housing/support insulators shall
be packed in a crate in order to facilitate manual loading and un-loading.
547
Annexure – ‘A’
Schedule of guaranteed performance technical and other particulars for 220 kV, 132 kV,
100kV, 110kV, 66 kV, 22kV and 25 kV and 25kV TP/DP/SP outdoor type SF6 gas and
vacuum circuit breakers, Guaranteed particulars are to be established by test reports actual
tests.
Sl. Description Unit of Data

No. measurement
1. Maker’s Name
(i) Circuit breaker pole

(ii) Operating mechanism
A. RATING
4. Number of poles No.

5. Rated voltage KV
6. Voltage rating class as per standard KV
7. Rated normal current A
8. Rated frequency Hz
9. Rated insulation level of the circuit
breaker
(i) One minute dry and wet power KV (rms)
frequency withstand voltage
(ii) Switching surge withstand KV (p)

voltage
(iii) Standard lightning impulse KV (p)

withstand voltage 1.2/50 µS
wave form (full wave)
(iv) Corona extension voltage KV (rms)

10. Rated circuit breaking current
(i) Symmetrical at a recovery KA

voltage of not less than the
highest system voltage
(ii) Asymmetrical at a recovery KA
voltage of not less than the
highest system voltage.
(iii) Breaking capacity MVA
548
(symmetrical)
11. Rated making current KA peak

12. Rated line charging breaking current A
13. Rated cable charging breaking current A
14. Rated small inductive breaking current A
15. Rated capacitor bank breaking current A
16. Rated short time current
(i) for 1 s. kA
(ii) for 3 s. kA
17. Rated operating sequence
18. Rated transient recovery voltage kV
19. Breakage current on out of phase KA (rms)
condition
B. CONSTRUCTIONAL FEATURES
20. Number of breaks per pole
22. Contact travel characteristics
(i) Length of contact travel Mm
(ii) Closing speed m/s
(iii) Opening speed m/s
(iv) Initial opening speed m/s
(v) Closing making speed m/s
(vi) Contact bounce mm (max)
(vii) Bounce duration s(max.)
( Please furnish a graph showing

contact travel characteristics )
23. Type of main contacts
24. Type of arcing contact
25. SF6 gas pressure
(i) Normal kg/cm2

(ii) Minimum kg/cm2
(iii) Maximum kg/cm2
26. SF6 gas pressure at alarm kg/cm2

27. SF6 gas pressure at trip and lock out kg/cm2
28. SF6 gas leakage rate (by weight) per year %
549
29. (i) If absorbent for decomposed Yes / No
SF6 gas product provided
(ii) Minimum quantity of Kg
absorbent per pole/
30. Net weight of SF6 gas per pole/circuit Kg
breaker
31. Details of vacuum bottle (for Vac. CB)
(i) Make
(ii) Type designation
(iii) Voltage class kV
(iv) Total weight kg
32. Weight of pole assembly
(i) per pole kg

(ii) per circuit breaker kg
33. Weight of operating mechanism kg

34. Total weight of the circuit breaker kg
35. Minimum electrical clearance
(i) between poles mm
(ii) between live part and earth mm
36. Minimum sectional clearance between mm
lowest live part and any part where a
person may stand.
37. Minimum height of bottom most part of mm
any insulator from ground level
38. Distance between centers of pole for TP & mm
DP CB
39. Overall dimensions of the circuit breaker
complete with insulators, operating
mechanism cubicle etc. mounted on the
supporting structure.
(i) Length mm
(ii) Width mm
(iii) Height mm
Please furnish the General
Arrangement drawing with overall
dimension.
C. OPERATING PARTICULARS
40 Closing time from the instant of closing ms
coil energisation (max.)
41. Opening time from the instant of trip coil ms
energisation (max.)
42 Make Time (max.) ms
550
43. Arcing Time
(i) At rated normal current ms

(ii) At rated short circuit breaking ms
current
(iii) At 60% of short circuit ms
breaking current
(iv) At 30% of short circuit ms
breaking current
(v) At 10% of short circuit ms
breaking current
44. Critical current kA

45. Total break time from the instant of trip
coil energisation to the final extinction of
arc
(i) At rated normal current ms
(ii) At short circuit breaking ms
current
46. Rated restriking voltage KV
(i) Amplitude factor
(ii) Rate of rise at natural
frequency
(iii) Type and device used to limit
rate of rise of restriking
voltage
47. Minimum time interval (t) permissible s
between successive “CO” operation after
first auto reclosure.
48. Number of operations (close and open) No

the circuit breaker can perform with the
available stored energy
49. Number of operations permissible without

change of SF6 gas / vacuum bottle (min)
(i) At 50% of rated current No.

(ii) At 100% of rated current No.
(iii) At 50% of short circuit No.
breaking current
(iv) At 100% of short circuit
breaking current
50. Number of operations permissible without

replacement / inspection of contacts (min)
551
(i) At 50% of rated current No.
(ii) At 100% of rated current No.
(iii) At 50% of short circuit No.
breaking current
(iv) At 100% of short circuit No.
breaking current
(A graph establishing the above two

parameters at SN 49 and 50 should be
enclosed)
51. First pole to clear factor (In case of TP

and DP CBs)
D. OTHER TECHNICAL
PARTICULARS
52. Maximum rise at temperature over an
ambient of 50ºC when carrying its normal
rated current continuously.
(i) Main contacts in SF6 gas ºC

(ii) Terminal when connected with ºC
external connectors
(iii) Metal parts acting as springs ºC
(iv) Metal parts in contact with ºC
insulators
(v) Auxiliary contacts ºC
(vi) Operating coils ºC
53. Power required for tripping /closing (max) W
54. Control circuit voltage with permissible

voltage variation
(i) Closing coil V.dc + % / -%

(ii) Tripping coil V.dc + % / -%
(iii) Contactors (if any) V.dc + % / -%
(iv) Any other item (for which the
tenderer feels that the voltage
is to be maintained within
certain limits)
55. Type of tripping / closing mechanism
552
56. Manual tripping / closing mechanism
(lever push button or any other device)
57. Spring Charging Motor

(i) Make and type designation
(ii) Rating KW
(iii) Voltage with permissible V
variation
(iv) Power frequency withstand KV(rms)
voltage
(vi) Time required by the motor S
to charge the spring(s) fully
(vii) Power required at normal W
controlled voltage to charge
the spring
(viii) Mode of protection IS / IEC
(ix) Specification for design and
testing
58. Springs – Closing / Opening
(i) No. of springs

(ii) Type (compression / tension)
(iii) Specification for design and IS / IEC
testing
59. Porcelain Insulators Support

Insulator
(i) Makers name and type Interrupting

designation Chamber
(ii) Minimum creepage distance Insulator
60. Insulation grade of PVC control wiring V
cable
61. Approximate height of the close/trip mm

switch and socket for spring from ground
level
62. Details of Operation counter :

(i) Make and type
(ii) No. of digits
63. Auxiliary Switch (contacts)
553
(i) Make and type
(ii) Normally open contacts Total Spare
(iii) Normally closed contacts Total Spare
(iv) Continuous rating of contacts A
(v) Breaking capacity of contacts A
at 220 V dc with inductive
load No.
(vi) Life (No. of operations)
64. Limit switch (for spring charging motors)
(i) Make and type

(ii) Continuous rating of contacts A
(iii) Breaking capacity of contacts A
at 220 V dc with inductive
load
(iv) Life (No. of operations) No.
65. Gas pressure indicator and pressure switch
(i) Make and type designation

(ii) Range and list count
(iii) Governing specification
66. Sulphur Hexa Fluoride gas (SF6) IS/IEC

Governing specification
E. OTHER DETAILS
67. Is the circuit breaker having a common Yes/No

drive (for TP and DP CB) ?
68. Are the main and arcing contacts easily Yes/No
replaceable ? (for SF6 CBs)
69. Is signal provided (audible/visible) in the Yes/No

event of drop of SF6 gas to a pre-
determined value ?
70. Is a device for tripping the circuit breaker, CTD/No volt

in the event of 110 V dc supply failure, relay
provided
(Indicate the type of device) ?
71. Does provision of trip circuit supervision Yes/ No

exist ?
72. Is electrical anti-pumping device Yes / No
554
provided ?
73. Is mechanical closing device provided ? Yes / No
74. Is local electrical closing & tripping Yes / No
device provided ?
75. Is manual closing & tripping device Yes / No
provided ?
76. If terminal connector for CB provided ? Yes / No
77. Is mechanical tripping device provided ? Yes / No
78. Is handle/crank for manual charging of the Yes / No
closing spring provided ?
79. Is operating counter visible without Yes / No
opening the mechanism door ?
80. Are the mechanical close and open Yes / No
indicator provided ?
81. Is two position LOCAL/REMOTE switch Yes / No
provided ?
Indicate type – (Spring loaded)
82. Is the CB trip free ? Yes / No
83. Are electrical and mechanical interlocks Yes / No
with keys provided ?
84. Is the operating mechanism housed in a Yes / No
dust, weather and vermin proof cabinet of
2 mm thick sheet steel construction ?
(indicate the protection)
85. Is a heater provided for prevention of Yes / No
condensation of moisture in the operating
mechanism box ?
86. Is three pin socket and inspection lamp Yes / No
provided ?
87. The size and number of cable glands Dia No
provided Dia No
88. What is the insulation grade of PVC cable V
used ?
89. Are the cables terminated with crimped Yes / No
lugs ?
90. Is ac & dc and +ve & -ve wiring Yes / No
completely segregated ?
91. Are the terminal blocks for wiring dust Yes / No
proof and provided with unbreakable
transparent shrouds ?
92. Are the two distinct earthing terminals
provided with indication for earth ?
(i) Support structure Yes/No
(ii) Operating mechanism cubicle Yes/No
93. Are fasteners of 12 mm dia and less Yes / No
555
exposed to atmosphere of stainless steel ?
94. Are the fasteners of more than 12mm dia Yes / No
of stainless steel or mild steel hot dip
galvanized ?
95. If supervision for erection testing and Yes / No
commissioning is provided ?
96. If training of two IR engineers be Yes / No
arranged for a total period of 4 weeks ?
97. Is warranty provided as per clause Yes / No
No. 21 ?
98. Has list of spares been furnished ? Yes / No
99. Has list of special maintenance tools Yes / No
furnished ?
100. Has erection, operation and maintenance Yes / No

manual furnished ?
101 Does provision for slow opening and slow Yes / No

closing exists ?
102. Have closing/tripping springs properly Yes / No

fixed to prevent their misalignment ?
103. If any deviations asked ? Give number of Yes / No

clauses where deviation has been asked
for .
104. Is any external indicator for contact wear Yes / No

provided ?
105. What are the test certificate attached ?

please list out.
106. If painting of steel surfaces exposed to Yes / No

weather, done to RDSO’s specification ?
107. If the support structure and operating Yes / No

mechanism cubicle hot dip galvanized ?
108. Quantity of zinc for galvanization Kg/m2
556
Annexure – ‘B’
The following information shall be furnished by the manufacturer / supplier
Sr.No. Description Unit of measurement Data

1. Fixed main contact :
(i) Description and type
designation
(ii) Make
(iii) Identification mark
(iv) Item drawing No.
(v) Material and specification No.
2. Moving main contact
designation
(ii) Make
(iii)Identification mark
(v) Material and specification No.
3. Fixed arcing contact :

(i)Description and type
designation
(ii) Make
(iii)Identification mark
(v)Material and specification No.
4. Moving arcing contact :

designation
(ii) Make
(v)Material and specification No.
5. Nozzle – Main and auxiliary (if any):

designation
(ii) Make
(v) Material and specification No
6. Vacuum Bottle
557
designation
(ii) Make
(iii) Rating
(iv) Identification mark
(v) Item drawing No.
(vi) Geometry of contact
(vii) Governing specification
No.
(viii) Weight
(ix) Level of vacuum adopted
(x) Level of current chopping
(xi) Shelf life
7. Auxiliary contact

designation
(ii) Make
(v) Governing specification
No.
(vi) Rating :
(a) Voltage
(b) Continuous current
(c) Breaking and making
current
(d) Electrical &
Mechanical life (No.
of operations)
8. Motor limit switch :

(iii) Make
No.
(vi) Rating :
(a) Voltage
(c) Breaking and making
current
(d) Electrical &
558
Mechanical life
(No. of operations)
9. MCB’s
(iii) Make
No.
(vi) Rating :
(a) Voltage
(c) Breaking and
making current
(d) Electrical &
Mechanical life (No.
of operations)
10. Spring charging motor

(iii) Make
No.
(vi) Rating :
(a) Voltage (with

permissible
variation)
(b) Wattage
(c) Power frequency
voltage withstand
(e) Time required by
the motor to charge
the spring fully
(max.)
(f) Power required at

normal control
voltage
to charge the spring
(g) mode of protection
559
11. Spring Closing Tripping Other

(iii) Make
(iv) Identification Mark
(vi) Drawing No.
(vii) Rating
(a) No. of springs
(b) Type (compression/tension/spiral
(c )No. of turns
(d) Gauge
(e) External diameter
(f) Stiffness
(g) Material
(h) Force developed in Fully charged position
12. Operating Coil :

Closing Tripping

(iii) Make
(vi) Rating :
(a) Operating voltage
(with permissible
variation )
(b) Power
(c) Resistance at 20ºC
13. Operation Counter :

(iii) Make
(vi) Number of digits
14. Gas pressure indication and Pressure Pressure

pressure switch indicator switch
560
(iii) Make
(vi) Range and least count
15. Heater :
(iii) Make
Rating :
(a) Voltage V – ac
(b) Power W
(vi) Make and type designation of

thermostat
16. Interlock :
(iii) Make
(vi) Electrical rating of switch used
V dc A
17. Terminal connector :

(iii) Make
(vi) Rating
(a) Voltage V ac
(b) Current / Power A
18. Resisters :
(iii) Make
(vi) Rating :
(a) Voltage V
561
(b) Current / Power A/W
19. Relays and contactors (please furnish details for
all the type of relays / contactors used ) :
(iii) Make
(vi) Rating :
(a) Operating voltage range
(b) Pick up voltage
(c) Drop out voltage V±
(d) Burden V
(e) Auxiliary contact rating V
(f) Guaranteed life VA
1. Electrical No. of
2. Mechanical operations
(g) Wiring details (drawing No.) No. of
operations
20. ‘O’ Ring and Gasket (please furnish details for
all the varieties )
(i) Description and make
(ii) Dimension / drawing No.
(iii) Material and specification
21. Valves and couplings :
(iii) Governing specification
22. Shock absorber :

(iv) Governing specification
(v) Type brand and specification of fluid
used (if any)
562
Addendum / Corrigendum Slip No.1 of August 2001 for specification No. TI /SPC /
PSI /CB / 0000 for out door circuit breaker for Railway Traction substation.
1. Page No. 3 Clause No. 2.3

Please read the line 8 - “The change are only – this specification” as follows.
“The changes are in respect of following . (i) Line charging breaking current test
has been included. (ii) Operating sequence of 25 kV CB has been changed from O-
0.3s – CO – 30s- CO to O-0.3s – CO-15s –CO (iii) Ground clearances has been
revised. (iv) Supervision of erection and commissioning of CB has been revised.”
2. Page No. 10 & 11 Clause No. 5.1 Rating and other particulars.
The table under this clause be changed as given below.
S. Particulars RATED SYSTEM VOLTAGE (kV)

No. 22 25 66 100/110 132 220
1 2 3 4 5 6 7 8
(vi) Rated normal 2000 A 1600 A 1250A 1600 A 1600 A 2000 A
current
(vii) Rated short 25 kA 20 kA 31.5 40 kA 40 kA 50 kA
circuit kA
breaking
current
(viii) Rated breaking
capacity
(symmetrical)
(i) Single - 550 MVA - - - -

pole
(ii) Two pole 600 550 MVA 2284 4920 5800 12250
MVA MVA MVA MVA MVA
(iii) Three - - 3956 8522 10046 21218

pole MVA MVA MVA MVA
(ix) Out of phase 6.25 5 7.9 10 10 12.5

breaking kA kA kA kA kA kA
current (rms) (rms) (rms) (rms) (rms) (rms)
(xiii) Rated making 62.5 50 kA 78.8 100 kA 100 kA 125 kA
current kA (peak) kA (peak) (peak) (peak)
(peak) (peak)
(xvi) Rated short 25 kA 20 kA 31.5 40 kA 40 kA 50 kA
time withstand (rms) (rms) for kA (rms) for (rms) for (rms)
current for 3 s 3s (rms) 1s 1s for 1s
for 1s
563
3. Page No. 33 Clause No. 13.2.5 -Rated short time withstand current and peak
withstand current test.
The table under this clause be changed as given below.
NOMINAL SYSTEM VOLTAGE OF CB (KV)

22 25 66 100/110 132 220
Value of
current &
duration
rms 25 kA for 20 kA for 31.5 kA 40 kA for 40 kA 50 kA for
3s 3s for 1s 1s for 1s 1s
peak 62.5 kA 50 kA 78.75 kA 100 kA 100 kA 125 kA
4. Page No. 33 Clause No. 13.2.9 Out of phase making and breaking test. The table
under this clause be changed as given below :
NOMINAL SYSTEM VOLTAGE OF CB (KV)

22 25 66 100/110 132 220
Current
rms 6.25 5 kA 7.9 kA 10 kA 10 kA 12.5 kA

Recovery ----------------------------NO CHANGE -----------------------------------
Voltage
564
Addendum / Corrigendum Slip No.2 (July 2003) to specification No.TI /SPC / PSI
/CB / 0000 for out door circuit breaker for Railway Traction substation.
This is to be read with A&C Slip No.1 of August 2001. The Items given below are to be
changed as indicated :-
0.0 The following changes are made on Page No.12, 13 and 14 viz.
Clause No.5.1 – Rating and other particulars :-
S. Clause RATED SYSTEM VOLTAGE (kV)

No. No./Page No./ 22 25 66 100/11 132 220
Particulars 0
1. 5.1-vi, page 13 2000A 1600A 1250A 1600A 1600A 2000A
Rated normal or
current. 2000A**
2. 5.1-vii, page 25 kA 20 kA 31.5 kA 40 kA 40 kA 40 kA
13 Rated short
circuit
breaking
current.
3. 5.1-viii, page
13 Rated
Breaking
Capacity
(MVA)
i) Single Pole -- 550 -- -- -- --

ii)Double Pole 600 550 2284 4920 5800 9800
iii)Triple Pole -- -- 3956 8522 10046 16974
4. 5.1-ix, page 13 6.25 5 kA 7.9 kA 10 kA 10 kA 10 kA

Out of Phase kA rms rms rms rms rms
breaking rms
current.
5. 5.1-xiii, page 62.5 50 kA 78.8 kA 100 100 kA 100

13 Rated kA (Peak) (Peak) kA (Peak) kA
making (Peak) (Peak) (Peak)
current.
565
RDSO Specification No. TI / SPC / PSI / CB / 0000 for Circuit Breaker for Railway
Traction substation
issued to the specification by RDSO :
1. Para 1.3 The para is modified as under :

“ When pre-commissioning and commissioning tests on CB
are being conducted, the manufacturer’s engineer shall be
available at site. For this purpose, prior intimation regarding
the date and the location of the tests shall be given by the
successful bidder to the manufacturer.
2. Para 3.1.1 In line 10, substitute 50 km & 80 km with 6.5 km & 25 kms
respectively.
3. Para 3.1.2 In line 2, delete the word “Interrupter”

In line 10, delete the word “feeder”
In line 11, substitute “Interrupter” with “feeder circuit
breaker”
4. 3.7.1 (iii) Delete the words “through interrupter for voltage of

25 kV” after OHE in line 1 and add “of each track” after
OHE in line 1.
5. 4.1 (i) Substitute 50°C with 45°C

(ii) Substitute 0°C with 5°C
(iii) Substitute 40°C with 35°C
6. 4.1 (ix) Substitute 200 kgf/m2 with 112.5 kgf/m2
7. 6.1.2.1 delete the last sentence in para 1
8. 7.1 In line 3, substitute “200 kg/ m2”

with “112.5 kg/m2”
In line 7, substitute “RDSO” with “Purchaser”
9. 7.2 In line 2, substitute “RDSO” with “Purchaser”.
10. 8.0 In line 4, substitute 200 kg/ m2 with 112.5 kg / m2

In line 9, substitute DG (TI) RDSO with Purchaser.
566
11. 11.2.2 In line 4, delete the words “Supplied loose ”
In line 3, substitute the word “ for mounting by Purchaser”
with “mounted”
12. 11.2.3 In line 4, delete the words “Supplied loose”

In line 4, substitute the word “ for mounting by Purchaser”
with “mounted”
13. 11.2.8 Deleted
14. 11.3.2 In line 4, delete the words “supplied loose ”

In line 4, substitute the word “for mounting by the
Purchaser” with “mounted”
In line 5, Add “ / Purchaser” at the end after RDSO.
15. 11.3.3 In line 1, substitute the word “loose” with the word “of”
In line 2, Delete the word “by the Purchaser”
16. 11.3.4 In line 7, delete the word “by the Purchaser”
17. 11.3.9 Delete the 1st sentence in the para.
18. 11.3.10 In line 1, substitute the word “only” with the word
“preferably”
19. 13.1.1 In line 2, 3 & 4 add “Purchaser /” before the word RDSO.
20. 13.5 Delete the words starting with “The tenderer may
quote……….… upto 13.2.11 and 13.2.12.
Delete the word “other” in the last sentence.
21. 13.6 In line 2, delete the word “Indian”
22. 13.9 In line 3, add “Purchaser /” before DG (TI) / RDSO
23. 13.10.3 In line 3, add the word Purchaser /” before the word DG
(TI) / RDSO
24. 13.10.4 In line 7, add the word “Purchaser /” before the word DG
(TI) / RDSO
25. 13.10.5 (i) Add “Purchaser /” before the word “RDSO”
26. 16.1 In line 2, add “Purchaser/” before the word “RDSO”
567
27. 16.5 In line 3 & 5 add the word “Purchaser/” before the word
“RDSO”
28. 16.6 Delete the para.
29. 17.0 In line 1, substitute the word “Purchaser”

with“Contractor”
30. 21.1 Para 2 of the clause is modified as follows :
“The warranty period shall be 36 (Thirty six) months from

the date of delivery of the equipment at the ultimate
destination or 24 (Twenty four) months from the date of
commissioning of the equipment whichever period expires
earlier.”
In para 3, of the clause delete, from the line, 8, 9 & 10 the

words “of 3 (three) months…….. mentioned.
In para 4, in line 1, delete the words “if required”
In line 3, 4, 5, 6 & 7 delete the words “or at the

option…………….herein specified”
568
569
lR;eso t;rs
GOVERNMENT OF INDIA
M I N I S T R Y O F R A I LWAY S
Specification No. TI/SPC/PSI/PROTCT/4050
FOR
C ONTROL AND R ELAY PANEL
FOR
P ROTECTION S YSTEM
OF MUMBAI SUBURBAN AREA
FOR
50 H Z AC T R A CT IO N P OWER S UP PLY S YSTEM
INCLUDING
PA R AL LE L O PE R ATI O N O N 25 KV S I D E
OCTOBER 2005
ISSUED BY
RESEARCH DESIGNS & STANDARDS ORGANISATION,
M A N A K N A G A R , L U C K N O W -22601 1.
570
Index
ITEM HEADING PAGE

NO
1. SPECIAL REQUIREMENT FOR MU MBAI SUBURBAN AREA
2. SCOPE
3. TRACTION PO WER SUPP LY SYS TEM
5. DESIGN FEATURES
6. SCHEME OF PROTECTION
7. DETAILS ON PROTECTION OF INCOMING H.V. LINES
8. DETAILS OF PROTECTION SCHEME FO R TRACTION

TRANSFORMER
9. DETAILS OF SCHEME OF PROTECTION FOR 25 KV

OVERHEAD EQUIPMENT
10. INSPECTION AND TESTING
11. ERECTION, COMMISSIONING AND PROOVING

TESTS.
12. TECHNICAL DATA AND DRA WINGS
13. OPERATION & MAINTENANCE, INSTRUCTIONS &
TRAINING
14. WARRANTY
15. SERV ICE SUPPORT AFTER WARRANT Y AND AMC
16. SPEC IFIC AT ION CONFIR MATION
17. TENDER’S CREDENTIALS
18. IMPORTED RELAYS
571
ANNEXURES
ANNEXURE 1 ABBREVIATIONS USED. 50

ANNEXURE 2 DEFINITIONS 51
ANNEXURE 3 GOVERNING SPECIFICATIONS 53
ANNEXURE 4 SCHEDULE OF GUARANTEED PARTICULARS 55
ANNEXURE 5 MATERIAL SCHEDULE 67
ANNEXURE 6 MU MBA I A REA PO WER SU PP LY S CH EMA TIC 71
ANNEXURE 7 PR OTEC TION SCHEME FOR TSS, SSP 72
AND SP
572
1. 0 SPECIAL REQUIREMENT FOR MUMBAI SUBURBAN AREA
Electric traction in suburban areas of Mumbai presently employs 1500 Volts D.C. and the
network is being converted to utilize 25 kV AC for the railway traction system. In the
existing D.C system, the overhead equipment (OHE) is supplied power at 1500 volts from
rectifier fed traction sub-stations (TSS) with normally no sectioning; the sub-stations thus
are connected in parallel. In an event of failure of one of the TSSs the supply is maintained
from adjacent TSSs. Total supply interruption for sub-urban trains (EMUs) and the D.C.
locomotive hauled main line trains is rare.
The conventional 25 kV AC 50 Hz traction system on Indian Railways draws power from

two of the three phases of the incoming E.H.V. lines and transforms it to 25 kV, earthing
one of the secondary terminals of the transformer. Power is drawn from different phases at
adjacent TSSs, cyclically, to balance the load. The separation of phases is carried out on the
OHE contact wire system by provision of “neutral sections” which do not draw power and
mechanical continuity for passage of the pantograph of the motive power unit is ensured.
The drivers of trains are instructed to switch off the on-board 25 kV circuit breakers to
prevent flashovers while the pantographs negotiate the neutral sections. Tripping of the
feeder circuit breakers (CB) is associated with supply interruption over the feed zone.
The train movement (traffic density) in the sub-urban area of Mumbai is very high and the
requirements are therefore different from those of the conventional system with emphasis
on a protection system offers a reliable OHE supply, is capable of isolating the shortest
possible section in the fastest possible manner and localize a fault with minimal human
intervention. The spacing of signals and stations at short intervals and the short headway
between trains does not lend itself to the adoption of the conventional 25 kV AC supply
scheme, drawing power from different phases and the electrical separation on 25 kV side
through neutral sections.
This specification is prepared on the basis of earlier specification

No.TI/SPC/PSI/PROTCT/3003 and considering the suggestions / recommendations of
consultant to MRVC (Frischmann Prabhu (India) Pvt. Ltd. EPD Consultants, UK and DE-
Consultant, Germany) along with latest developments in protection relays and experience
of abroad railways.
1.1 Salient requirements for the Mumbai area summarized below.
a) Traction supply for Mumbai area at different traction substation shall be taken
at 110 kV from power supply authority and up to three adjacent traction
substations which draw power from one supply authority and from the same
phase may be operated in parallel on the 25 kV side of the traction transformers.
In service, the “neutral sections” separating the sectors shall be kept live, there-
by avoiding the operational and safety implications with the conventional
neutral sections, during exigencies, however, the neutral sections can be
activated by operating the specific switches/ interrupters/ CBs.
573
b) TSSs are spaced at distances of 6.5 to 20 kms.
c) Some of the sub-sectors are short, about 1 km.
d) SP/SSP shall be provided with CB’s in lieu of interrupters so that the smallest
possible section can be isolated & faults localized automatically, with minimal
intervention by the personnel on duty in the control room.
e) The motive power employed on trains, including EMUs, shall be with drives
based on IGBT or GTO based 3 phase converters or silicon rectifier based D.C.
Traction motor locos. The 3 phase drive motive powers are capable of
regeneration during braking operation. There is possibility of the regenerative
currents being fed back into the grid.
f) The starting currents in case of a number of EMUs starting together at times

may exceed the fault current in event of high impedance faults.
g) OHE System in Mumbai area is of 4 to 6 lines with arrangement at SSP/SP of

bus type as given in the enclosed drawing at Annexure-6.
h) OHE is of varying configuration and its line parameters are expected to be

different for different sections. Values of R and X may undergo change with
replacement with different size of wires or addition of new tracks. As
parameters of some of the sections may not be available, the successful tenderer
will be required to determine/measure the critical parameters needed for the
protection scheme as may be necessary.
i) In the Railway traction substation HV circuit breakers shall be provided on the

incoming feeder lines along with bus coupling breaker with associated
protection as different from the conventional 25 kV Traction sub-stations.
1.2 PRE -BID MEETING
A pre-bid meeting shall be arranged by the purchaser, with eligible tenderers and
associating RDSO & Rlys. for clarification on particular requirements of protection to this
specification, parameters of OHE (per km. resistance, reactance values) required for its
functioning, site conditions, erection and commissioning and field proving etc.
It is advised that tenderers visit the sites/sections and familiarize themselves with the local
conditions and understand the requirements of the system in detail, before tendering their
bids. Clarifications as may be necessary shall be obtained from the purchaser. After the
award of the contract the tenderer shall be fully responsible for successful integration of the
protection scheme with the associated scheme of equipment in the switchyard (TSS, SP,
SSP) and the RTUs and any items later considered as essential for successful integration,
shall be within the scope of the supply and work of the tenderer. In case of any consultancy
574
required by the tenderer for successful commissioning, tenderer shall arrange it within his
scope.
2.0 SCOPE
2.1 This specification applies to the design, development, manufacture, supply,

erection and field proving & monitoring of “numeric/processor based control and relay
panel” complete with numeric/ micro processor/ static protective relays, for use in the
traction substations and SSP/SPs for control of 110 kV and 25 kV circuit breakers, 25 kV
interrupters and protection of 220 or 132 or 110 kV single phase transformers with 25 kV
nominal secondary voltage, all substation equipment, 25 kV over head equipment (OHE)
feeders and capacitor bank (if asked for by the purchaser in the tender).
2.2 Accordingly, control & relay panels will be required at supply control posts as
follow.
(i) Traction substation to protect and control incoming HV lines*, traction

transformers, 25 kV feeders and 25 kV capacitor banks (if required by the
purchaser).
*NB: Protection of HV incoming lines shall be supplied by the concerned supply
authority in a separate panel giving all the necessary control, indication and
alarm contacts on the terminal junction inside the panel. However HV bus
bar protection and the connections from the protection panel of supply
authority to the C&R panel for Railways shall be within scope of the
tenderer.
(ii) SSPs to protect and control 25 kV feeders.
(iii) SPs to protect and control 25 kV feeders.
2.3 Scope of supply shall include all parts, fittings and accessories of the control &
relay panel required for normal functioning of the protection system. The panel shall be
complete with numeric-processor based protection package for traction transformers,
feeders and for capacitor banks (optional). The protection relays shall have communication
features and necessary interface equipments are to be provided for its normal functioning
and to ensure sending the fault waveform data stored in the relays at TSS/SSP/SP to remote
control centre through SCADA.
2.4 The control panel have been classified into four categories for the purpose of this
specification, viz.,
TYPE –I: Required at 220/25 kV or 132/25 kV or 110/25 kV traction substations with

single or double ended feeding with line tripping and line sectioning facilities.
(with or without capacitor banks as required by the purchaser)
575
TYPE-II: Required at 25 kV SP with CB and/or with line tripping and line sectioning
facilities suitable for single ended or double ended feeding.
TYPE-III: Required at 25 kV SSP with CB and/or with line tripping and line sectioning
facilities.
TYPE –IV: For yards, car shed or other areas not covered in the above types.
2.5 The control panels offered shall be an integrated one complete with relays, meters,
control switches, wiring and all accessories and materials necessary for efficient
control and protection of equipment and feeders. All accessories and materials shall
be deemed to be within the scope of this specification whether specifically
mentioned or not.
2.6 The specification covers the protection of TSS, SP & SSP and the related substation
equipment and the OHE. Protection of incoming feeder to the TSS from reverse
feeding the faults in the incoming line is included. The specification excludes the
protections for HV incoming lines provided by the electric supply authority as part
of the service connection scheme, however, necessary control/indication/alarm
connections/terminations, inter-tripping and inter-locking is required to be ensured
as specified in clauses 5.1.1.
2.7 Purchaser may consider any proposal for an improvement in the protection scheme.
However for all such proposals the tenderer shall be required to furnish full
technical detail, drawings etc. to satisfy the purchaser.
2.8 Any changes required in relays and C&R panel during or arising as a result of
commissioning /field proving tests shall be continued to be governed by this
specification and within the scope of supply by the tenderer.
3.0 TRACTION POWER SUPPLY SYSTEM
3.1 General scheme of traction power supply.
Power in Mumbai area shall be received from the grid network of the supply
authority at 110 kV at individual traction substation (TSS) with two Nos. traction
power transformer 25 kV power supply for traction is drawn through a single phase
step-down traction power transformer, the primary winding of which is connected
to any two nominated phases of the incoming three phase lines. On the secondary
side, one of the two terminals of the 25kV winding is connected to the traction
overhead equipment, while the other is solidly earthed and also connected to the
running traction rails. The method of connection to the running traction rails
depends on type of signaling track circuit used, and as follows.
576
a) Through an impedance bond offering negligible impedance for power frequency
AC current in case of AFTC.
b) In case of DC track circuiting it shall be directly connected to the traction return
rail.
3.1.1 Each transformer shall have its associated circuit breakers on the primary and 25
kV sides, with a separate set of 25 kV circuit breakers called “Feeder Circuit
Breakers” for the traction OHE lines; refer Annexure 6. These CB’s can be of
outdoor or indoor type, and employ SF6, vacuum or may be gas insulated type
switchgear.
3.1.2 On some sections (single ended supply), adjacent TSS shall be fed from different
phases of the three-phase system in rotation. Neutral sections in front of sectioning and
paralleling post (SP) shall be provided on the 25 kV OHE for segregating the different
phases. In between the TSS and SP, sub-sectioning posts (SSP) are provided for
sectionalizing and fault localization. The purchaser shall enclose their detailed general
supply diagram for the detailed understanding of the tenderer.
3.1.3 On other sections the adjacent TSSs are fed from the grid on the same phase and
shall feed the OHE in parallel. In such an arrangement, at SPs, bridging circuit breakers
shall normally be kept closed. In the event of a fault, the fault would be simultaneously fed
from adjacent TSS, which are in parallel operation. Refer Annexure 6 for details.
3.1.4 The supply to the OHE can be switched ON/OFF through circuit breakers which
can open or close automatically on fault. The circuit breaker provided at the TSS, SSP, SP
can clear the fault in their sub-sector. The other CBs of the adjacent sub-sectors shall not
trip normally in case of such faults.
3.1.5 Normally power supply from a TSS extends up to the SP on either side of the
substation. But in case of an emergency necessitating total shut down of the substation,
power supply from adjacent TSS on either side of the failed substation can be extended up
to the failed substation by closing the bridging CB of the 2 SPs. Also under certain
emergency conditions the supply can also be extended beyond the failed TSS up to the next
SP.
3.1.6 The sectioning posts may be provided with conventional overlap type, PTFE type
or any suitable type including automatic switched neutral sections. Neutral Section at the
SP between the TSSs proposed to be operated in parallel shall be of such type to facilitate
parallel operation and without tripling / closing of the loco/EMU circuit breakers during its
negotiation.
577
3.2 Nature of traction load and faults on the system.
3.2.1 The traction load is frequently and rapidly varying between no load and overload.
The TSS equipment is subject to a number of earth faults/short circuits.
3.2.2 The AC electric rolling stock/ AC-DC electric locos / EMUs are fitted with, for
conversion of AC to DC, single phase bridge-connected silicon rectifiers with smoothing
reactor for feeding the dc traction motors. The rectifiers introduce harmonic currents on the
25 kV Power supply. Also there are EMU’s / locomotives with GTO Pulse width
modulation devices, in place of silicon rectifiers. Typical percentages of the current
harmonics present in the traction current with electric rolling stock are as follows:
TABLE NUMBER - 1:
Harmonic currents Generated by IR Locomotives / 3 phase EMU’s

S. Harmonic order With Diode Three Phase EMU’s with
No Rectifier GTO’s*/ IGBTs.
1. 3rd harmonic(150 Hz) 15% The maximum harmonic
th
2. 5 harmonic(250 Hz) 6% current of the individual
3. 7th harmonic (350 Hz) 4% harmonics at no time shall
th exceed 0.5 Amps except for
4. 9 harmonic(450 Hz) -
th
5. 11 harmonic (550 Hz) - 3rd harmonic which shall have
THD’s 16.64% maximum value of 5 Amp.
*The GTO type of EMU’s / locomotives produce substantial 2nd harmonic currents which
may go up to 10 % of fundamental current at times.
The average power factor of an electric locomotive and electric multiple units
generally varies between 0.7 lagging to unity.
3.2.3 The EMUs rakes are generally formed of 9, 12 and 15 coaches. One three coach
unit can take starting currents of up to 70 amps on 25 kV side. Under normal running
condition such a 3 car rake draws 40 amps. Such rakes are also capable of producing
regeneration current up to 40 Amps per unit of 3 coaches.
3.2.4 In case of locomotive hauled trains, a 3-phase electrical locomotive, at full power,
draws up to 270 amps of current from the OHE; the current produced during regenerative
braking is of the order of 150 amps. Normally one such locomotive hauls one train but if
gradients are high and loads are more a maximum of 2 locomotives in multiple operation
may be employed.
578
3.2.5 The number of faults/short circuits, per TSS, in the conventional 25 kV AC system
vary between 10 to 25 per month.
3.2.6 Generally magnitude of fault current may vary between 40% and 100% of the dead
short circuit value. However at times the fault current may be much less in case of high
impedance faults; bird faults or bond open earth faults shall fall under the category of high
impedance earth faults of the order of around 200 Amps fault current.
3.3 Short circuit apparent power of the system
The normal short- circuit apparent power for various system voltages for primary
side of traction transformer is as under: -
TABLE NUMBER - 2: Short Circuit Level
Highest system Short circuit

voltage kV apparent power MVA
24 1000
72.5 3500
123 6000
145 10000
245 20000
Fault levels at 110 kV grid sub stations of M/s Tata Power Co, at the respective 110 kV
buses are indicated as follow.
TABLE NUMBER- 3 Fault level at the GSS of M/s Tata Power Co.
Grid Substation Three Phase Fault Single Phase Fault

Levels, MVA Levels, MVA
Mahalaxmi 3776 3324
Dharavi 5631 5808
Malad 2922 2747
Carnac 2307 2050
Parel 4048 3539
Salsette 6163 6544
Borivli 4644 4744
A fault on the incoming bus bar of power supply authority can be fed for a period of 500
ms before the protective trippings take place.
579
3.4 Power supplies at traction substation
The following power supplies are available at a traction substation.

i.) 110 V (+15 % & -30 %) dc from a battery.
ii.) 240V+20% A.C 50 Hz + 5% single phase from a 22/0.24 kV auxiliary
transformer.
3.5 OHE impedance
Configuration of OHE in Mumbai are combination of contact wire of size 193 mm2
/ 107 mm2 and catenary wire of size 240 mm2 / 322 & 129 mm2 (twin) / 65 mm2. Tenderer
shall carry out measurements of the OHE impedance in association with purchaser for the
correct setting and operation of the relays within its designed accuracy. The measurement
of impedance (R and X values) shall be done by injecting current of order of 800 A in each
OHE in each sub-sector i.e. TSS to SSP, SSP to SSP and SSP to SP using suitable 50 Hz,
AC voltage source. The likely range of voltage source may be from 100 to 800 Volts.
This shall be demonstrated and verified by correct operation during commissioning and
proving tests in the field.
The existing OHE may be replaced by conventional OHE gradually in a phased manner.
3.6 Booster Transformers
In order to reduce inductive interference on the nearby telecommunication circuits,

booster transformers on certain sections of electrified track are installed in series with the
25 kV traction overhead equipment. The primary winding of the booster transformer is
connected to the 25 kV overhead equipment and the secondary winding is in series with a
return conductor (RC) which is strung close to the 25 kV overhead equipment. Booster
transformers of 150 or 100 kVA rating force the traction return current from the rail/earth
to flow through the return conductor. The Booster transformers have leakage impedance of
about 0.15 ohm each and are spaced about 2.67 kms intervals. The BTs may be installed in
a complete sub-sector or in part of a sub-sector.
3.7 Connection of mast to traction rail and traction return.
The track circuiting being provided in AC sections of Mumbai area shall be of 2 types.
(a) DC track circuiting (DCTC)
(b) Audio Frequency track circuiting (AFTC)
580
DCTC is the conventional track circuiting generally available in all conventional
system where the traction transformer neutral point is connected to one or both the traction
rails near the TSS. The masts are connected to the traction rail and on the track circuit
portion only one rail is available for traction returns and in the non-track circuit regions
both rails are available for the purpose of traction return currents.
In AFTC type of track circuit Audio Frequencies in the range of 1500 Hz to 10000
Hz are used. The traction return current is ensured as per ACTM provisions and existing
practice on Western Railway. Traction mast shall be connected to the designated traction
rail.
The Masts in both the cases shall be connected to the traction rail as per the guidelines
prevailing / issued for DCTC/AFTC.
3.8 Traction Power Transformer
The primaries of the single phase traction transformers shall be of 220 kV or 132 or
110 kV and the secondary voltage of 27 kV. Transformers of 21.6 MVA will be with 11 to
13 % impedance and / or of 30 MVA with 15 to 17% impedance. The 30 MVA
transformers shall be provided with on load tap changer with taps to take care the input
voltage variation and maintain the no load voltage of 27 kV on secondary side. On load
tap changer can be operated from local and remote through SCADA. At one TSS,
transformers of either 21.6 MVA or 30 MVA ratings are provided. Traction transformers of
two or three adjacent TSSs may be effectively operated in parallel when the incoming HV
supply shall be from same phases and the SPs are bridged, as described in clause 1.1.
The traction transformers shall be designed to carry short time overloads as the traction
loads may exceed the rating for short periods.
TABLE NUMBER - 6: Rating of the power transformer

Short time duration Rated secondary current of the Transformer
21.6 MVA 30MVA
Continuous 800 1111
15 Min 1200 1667
5 Min 1600 2222
3.9 Current rating of the OHE.
The Current rating of the OHE is generally as follows. The tenderer shall use these values
for considering suitable relay and advice to the purchaser on the setting of the relays.
581
TABLE NUMBER - 7: Current handling capabilities of the OHE
Type of conductor Current handling limits of
the conductor (Amps)
Continuous 15 Minute
65 mm2 Catenary 212 265
2
240 mm Catenary 789 986
322 & 129 mm2 Catenaries, together 1471 1839
107 mm2 Contact 416 520
193 mm2 Contact 629 787
OHE with 65 mm2 catenary and 107mm2 Contact 628 785
2 2
OHE with 240 mm catenary and 193 mm Contact 1536 1920
OHE with 322 mm2 & 129 mm2 catenary & 193 2221 2777
mm2 contact wire
4.1 The control panels shall be designed for use in arid and also in humid tropical
climate with adverse atmospheric conditions as indicated below, and installed in track side
installations:
TABLE NUMBER – 8: Service Conditions

1. Max. ambient temperature. 55 ° C
2. Min. ambient temperature 0°C
3. Max. temp attainable by an object exposed to Sun 70° C
4. Max. & Minimum relative humidity 100% & 22%
5. Max. (Basic) wind pressure 150 kg/m2
6. Elevation above the mean sea level max. 1000 m above MSL
7. Average annual rainfall 1750 to 6250 mm.
8. Number of thunderstorm days per annum. 85 days.
9. No. of rainy days per annum 120 days (Max.)
10. Max no of dust storm days/annum 35 days
11. Vibrations Max: 350 micron
Average : 30 – 150 micron
Time duration: rapidly varying time duration 15 – 70 ms.
12. Seismic data Zone Zone-III
Coefficient of Seismic 0.04
acceleration
Importance factor (I) 2.5 for electrical
Equipment & 1.5 for others
13. Pollution level Very heavy, as in IEC 815-1986 & IS 13134-1992
582
4.2 The control and relay panel shall be installed at the traction substations, SSPs &
SPs which are normally unattended. The panels are situated close to the Railway tracks and
hence the Panels are subjected to vibrations due to running trains.
5.0 DESIGN FEATURES
5.1 Constructional Features
5.1.1 The C&R panel shall have modular construction to facilitate expansion and
replacement of the C&R panel components. The relays used for protection of HV bus bars,
traction transformers, OHE feeder and 25 kV capacitor banks (optional) shall be numeric-
processor type with modular construction.
There shall be numeric relay for HV bus bar protection. Transformer protection
shall include following protective relays.
a) Numeric type transformer differential protection

b) IDMT over current relay for primary as well as for secondary side. The IDMT
relay on HV side with an instantaneous over current element.
c) Instantaneous earth leakage relay on primary as well as secondary side.
d) High speed inter tripping relay.
e) Auziliary relays for transformer faults i.e.Buchholz, excessive winding and oil
temperature trip and alarm.
f) Reverse power flow relay.
g) All relay shall be draw out type.
At least two relays shall comprise of above transformer protections.
Protection of HV incoming lines shall be supplied by the concerned supply authority in a

separate panel giving all the necessary control, indication and alarm contacts on the
terminal junction inside the panel. However HV bus bar protection and the connections
from the protection panel of supply authority to the C&R panel for Railways portion is
under scope of this tender. C& R panel shall include the control of all HV breakers
including incoming breaker, bus coupling breaker and transformer breakers.
All CT and PT termination shall be provided to the HV line protection panel of supply
authority installed in the Railway traction substation. Separate 110 V DC and 240 V single
phase AC supply shall be extended to the HV line protection panel of supply authority with
appropriate rating of MCB.
The distance, WPC, OCR and Delta-I relays used for 25 kV feeder protection shall be of
numeric type. The auto reclose scheme for 25 kV feeder circuit shall be realized using
intelligent logic based relay of suitable design.
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In case of current operated relays facility shall be provided for automatic shorting of CT
terminals when the relays are withdrawn from the respective cases. All the relays shall
have flashing LED flags with external reset facility. Contact multiplication for
telesignalling to RCC shall be provided wherever required.
Note: - The tenderer is advised to refer Annexure –5 “Material Schedule”
5.1.2 The protection relays shall have facility to record 20 cycles of fault wave form (5
pre fault and 45 post faults both for current as well as the voltage). At a time minimum 8
such wave forms for voltage and currents shall be storable and shall be retrieved through
RS 232 serial connection port through a note book laptop computer and or a suitable
external printer. Such waveforms shall also be retrievable at RCC through SCADA.
Suitable software shall be available to interpret the fault waveform data by the tenderer.
The software shall be capable of analyzing the peak, RMS and average values of voltages
and currents, D.C. component of currents, harmonic analysis, s and determination of R, X,
Z, and φ of the fault voltage, current waveform. The accuracy of measurements shall be
1ms for time, 0.1 KV for voltages and 0.1 KA for currents.
5.1.3 The relay shall be equipped with a serial communication port so as to provide a
means of access to the relay menu structure from a remote terminal. The tenderer shall
supply the support software for the relay, which shall be used for communicating with the
relay and shall allow fault record retrieval, settings/setting groups to be viewed and
changed.
5.1.4 The protective relay shall be immune to all even and odd harmonic currents. They
shall be tuned for the fundamental frequency or shall work on the principle of fundamental
waveform extraction. The relay shall be immune to electrical / electro-magnetic
interference.
5.1.5 The relay shall provide date and time stamping up to 1 ms level for each fault.
Relay shall have facility for clock synchronization through SCADA or any other similar
synchronization facility.
5.1.6 A relay operation counter shall also be provided for each relay with resetting
facility.
This shall have facility to put date and time stamp for each tripping. Provision shall
be made to store the tripping information in a serial order with a separate data logger. This
data shall be retrievable through an external PC.
5.1.7 Suitable transducers or IED shall be employed for converting signals of the CT &
PT to desired levels for analog to digital conversion.. The status of switchgears,
occurrences of alarm events shall be continuously monitored/ scanned by the concerned
relays.
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5.1.8 The protection relays shall be compact in nature. There shall be separate protection
relays for H.V bus bar protection, transformer protection, OHE feeder protection and
capacitor bank protection (optional). Suitable contact multiplication shall be done as far
as possible through software. For this purpose only one set of NO/NC auxiliary contact
from each switchgear shall be terminated on C&R panel terminal block.
5.1.9 As the NO/NC signals from the switchgear are used for one of the functions namely
alarm, relay operation or in internal logic for interlocking, the burden in some case may be
more than what could be met by simple software multiplication. Interposing relays may
therefore be used at such places. The over all design however, shall be such as to minimize
the wiring.
5.1.10 In case of the feeder protection relay adequate redundancy shall be provided in
various elements to ensure that the protection is not disabled and in emergency cases of
mal-functioning of a protection unit/ relay, associated circuit breaker is automatically
tripped along with corresponding telesignal of the alarm regarding mal-functioning of the
protection element. The design shall be fail safe.
5.1.11 The feeder protection modules shall have self-diagnostic feature. Displays for
confirming the module healthiness or defects shall be displayed with alarms for speedy
trouble shooting by the operator.
5.1.12 The system shall have provision for extension to accommodate the protection for
capacitor banks, in addition of OHE circuit breakers of additional lines to cover the future
requirements up to 6 tracks normally.
5.1.13 C & R panel are to be of IP 52 to avoid ingress of vermin, insects, rats and dust and
suitable for use in tropical humid climate. Protection relays are to be of IP-42 class.
5.1.14 Each feeder protection relay shall have backlit LCD display of appropriate size
LCD characters for display of relay status, settings etc. Bright LEDs shall be used for
display of power ON conditions and trip indications of the relays. The parameters of the
relay shall be settable through a membrane keypad.
5.1.15 As the traction sub-stations are normally unattended, so there shall be a provision
for power down mode for the system when the substation is not being manned. In this case
all the protection elements shall function as usual but the alarm, annunciation/display and
local acknowledgement features will remain out of circuit till the system is activated again.
5.1.16 All the protection relays, D.C. and A.C. supply, equipment in yard, annunciator
windows and other peripheral equipment, measuring instruments required for the control
panel shall be hard wired to form a control and relay panel. For all the external connections
there shall be terminal blocks for terminating the connections.
5.1.17 The panel shall be of the vertical self supporting closed type steel construction, low
voltage, back to back duplex corridor type with central roofed in access. The central access
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corridor shall be provided with lockable doors at either end. The control board shall be
fabricated from sheet steel of thickness not less than 3.25 mm (10 SWG) for front and rear
panels, base frame, door frame, vermin proof fitments and not less than 2 mm (14 SWG)
for side panels , roof and doors. The bottom portion of the panel shall be provided with
detachable type sheet steel covers (over trench portion) with suitable cable glands to
facilitate entries of control cable from trenches to control board, the bottom of central
access corridor shall be provided with removable wooden planks of hard wood of adequate
thickness to facilitate free movement of working staff. The panel shall be suitable for
erection flush with the concrete floor by evenly spaced grouting bolts projecting through
the base channels of its frame. The panel shall be made in suitable sections to facilitate
easy transport, handling and assembly at site.
5.1.18 All control and supply cables shall be laid in a distribution trench running under the
control panel. The cables shall enter the board from the trench through suitable glands.
Detailed dimensions of the trench work required will be furnished. Provision shall be made
to seal the points of entry of cables to prevent access of rats, insects and lizards into the
board.
5.1.19 The sheet steel as well as other steel works shall be properly treated and then an
undercoat suitable to serve as base and binder for the finishing coat applied. The exterior
and interior surface and the base frame of the panels shall be epoxy powder coated in a
shade to be mutually decided later by manufacturer and purchaser.
If any painted surface gets damaged during transit the surface finish shall be
restored at site after erection.
5.2 Termination for the purpose of interfacing of C&R panel with SCADA.
5.2.1 Suitable termination for measurands and telesignalling, CT (with shifting link), PT
and AT out put for each CT, PT and AT shall be provided in C&R panel.
5.2.2 One set of NO/NC auxiliary contacts for each relay/indicator, CB, interrupter and
motor operated isolator shall be suitably wired up and terminated in the C&R panels at TSS
for the purpose of telesignalling and issue telecommands for the SCADA.
5.2.3 One set of NO/NC contacts for telesignalling failure condition to be transmitted
/reported to SCADA shall be suitably wired up and terminated in C&R panels with
identification level at terminals as described in Clause 5.4.4, 5.5.1, 5.6.1, 10.0.
5.2.4 One set of NO/NC auxiliary contacts for telesignalling and to reset each relay after
relay has been operated, shall be wired up and terminated in C&R panel.
5.2.5 One set of NO/NC contacts for telesignalling auto reclosure locked out in first cycle
and in second cycle and contacts for issue of telecommand for release of locked out.
5.2.6 Over and above, a provision of 30 % spare NO/NC contacts shall be made in the C
& R panel wiring which shall be decided at the time of finalization of C & R panel
drawings.
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5.2.7 The C&R panel shall have option for setting of relays & retrieving status locally.
Appropriate interface equipments shall be provided for exchange of information through
SCADA for retrieving the status of relay, waveforms and changing the relay settings by
remote through SCADA.
5.3 Control Panel
5.3.1 The scheme of connections at the TSS, SSP and SP showing the circuit breakers,
transformers, isolators and interrupters shall be represented by a single line mimic diagram
on the control panel. The colour of the bus bar shall be signal red to shade 537 of IS:5 for
220/132/100kV/22KV, golden yellow to shade 356 of IS:5 for 25 kV and black for 240V.
The mimic diagram shall be spray painted on the panel with the width of mimic strip of 8
mm. The successful tenderer shall get his designs for layout of equipment and wiring of the
control panel approved by RDSO.
5.3.2 Suitable spring loaded push-button switches shall be on the control panels in
conjunction with red and green indication LED’s for control and indication of circuit
breakers and interrupters. Automatic semaphore relays shall also be incorporated in the
mimic diagram to indicate the position of circuit breakers and interrupters. The semaphore
relay shall have the feature of disc coming to the neutral position in the event of failure of
supply.
5.3.3 A local/remote change-over switch shall be provided for each remote controlled
apparatus viz. circuit breaker/interrupter for changing over the control from local to remote
and vice versa. The auto-trip circuit operated by the protective relays shall, however, trip
the circuit breakers directly irrespective of the position of the change-over switch.
5.3.4 Back lit or bright segmented LED type digital ammeters and voltmeter shall be
provided for measuring currents and voltages through the CT, PT’s The accuracy of the
displayed parameter shall be 1 Amp and voltage up to 500 Volts. Suitable optocouplers and
transient surge suppression / limiter circuits shall be provided to avoid damages to the
digital measuring circuits. The meters shall be provided for measuring the following.
i) HV side voltage and current for each of two incoming lines at TSS.
ii) Voltage and total load current on 25 kV side each of the two transformers at
TSS.
iii) Power factor meter at 25 kV side of each transformer
iv) Current of each feeder at TSS
v) Voltage at 25 kV bus of SSP
vi) Voltage at 25 kV buses of either side of bridging CB at SP
vii) Current through bridging CB at SP.
5.3.5 The position of 220 or 132 or 110 kV and 25 kV isolators shall be represented on the
mimic diagram by manually operated semaphore switches. The size of the panel shall be
large enough to facilitate ease of maintenance. The inside of the panel shall be properly
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illuminated and provided with roof mounted fan to facilitate ease of maintenance. Suitable
plug points of 240 V AC for connecting maintenance equipment, test equipment and hand
lamps shall be provided inside the C&R panel.
The C&R panel may be either duplex or simplex type with sizes 1100x1900x2300 mm or
1100x600x2300 mm. Sizes of the panels are only indicative. The actual size and quantities
shall be decided at the time of drawing approval.
5.3.6 Facility shall also be provided on all control panels to verify the availability of 110
V dc supply and continuity of trip circuit for each breaker separately by means of push
buttons alongside the control switches and yellow indication LEDs.
5.4 Annunciation
5.4.1 The annunciator shall be provided as a digital LED/LCD type of displays with date
and time stamps. Electronic digital sound type alarms of selectable sound shall be
provided for the purpose of warning to any staff who may be available locally where an
incidence occurs. The LED/LCD shall be of sufficient size and shall be provided at eye
level to permit the operator to see and read the occurrence of the incidence clearly. The
alarm shall be loud enough be heard from a distance of 20 meters.
5.4.2 Red LEDs shall be provided on the control panel for giving individual visual and
audible alarm whenever any of the protective devices or other relays operates. The visual
alarm shall be of flasher type which continue to flicker and become stable till, the alarm is
accepted. The annunciation LEDs shall be provided on the control panel at the top in
suitable number of rows and concerned transformer/circuit-breaker/PT etc. symbol on the
mimic diagram, as approved by the purchaser. The alarm accepting, visual resetting and
annunciation testing buttons shall be mounted on the control panel at a convenient place &
height. The alarm bell shall be mounted inside the control board.
5.4.3 The tenderer shall clearly specify in his offer detailed technical description of the
annuniciator clearly bringing out the type of annunciator being provided by him with
detailed technical description of the annunciator.
5.4.4 Annunciation shall be arranged for the following fault conditions as are applicable
for each circuit. There shall be 30 % spare windows available at the annunciator window to
cater for future provisions.
Type I control panel
a) HV breaker trip at the supply authority end ( for each circuit)

b) Incoming HV breaker trip at railway TSS (for each circuit)
c) Primary transformer breaker trip (for each transformer CB)
d) 25 kV transformer breaker trip (for each transformer CB)
e) 25 kV feeder breaker trip (for each Feeder CB)
f) Transformer Buchholz trip (for each transformer)
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g) Transformer oil temperature trip (for each transformer)
h) Transformer winding temperature trip (for each transformer)
i) Transformer pressure relief device trip (for each transformer)
j) Tap changer pressure relief device trip (for each transformer)
k) 25 kV OHE supply /PT fuse fail (for each feeder CB)
l) 240 V single phase supply fail (only one No.).
m) 220 or 132 or 110 kV line breaker auto trip.
n) 220 or 132 or 110 line PT fuse fail
o) Communication circuit failed. (If communication based relay is provided)
p) Pantoflashover relay bypassed.
q) High fault current autorecloser bypassed.
r) Main feeder CB stuck (for each feeder CB).
s) Tri circuit of CB healthy
t) 110 V DC fail supervision
u) Low air/gas pressure alarm for each CB
v) Trip and lock out on low air/gas pressure for each CB
Type II Control Panel
a) 25 kV line breaker trip for each CB

b) 25 kV line PT fuse fail.
c) Communication circuit failed. (If communication based relay is provided)
d) Pantoflashover relay bypassed.
e) High fault current auto recloser bypassed.
f) Main feeder CB stuck.
g) 25 kV bridging CB trip.
h) 25 kV bridging CB close.
i) Tri circuit of CB healthy
j) 110 V DC fail supervision
k) Low air/gas pressure alarm for each CB
l) Trip and lock out on low air/gas pressure for each CB
Type III Control Panel
a) 25 kV line breaker trip for each CB

b) 25 kV line PT fuse fail.
c) Communication circuit failed.(If communication based relay is provided)
d) Pantoflashover relay bypassed.
e) High fault current auto recloser bypassed.
f) Main feeder CB stuck.
g) Trip circuit of CB healthy
h) 110 V DC fail supervision
i) Low air/gas pressure alarm for each CB
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j) Trip and lock out on low air/gas pressure for each CB
Type IV Control Panel
This shall be tailor made as per the specific requirement of the purchaser. The
annunciation to be brought out shall be discussed and decided mutually between the
purchaser and the tenderer.
5.4.5 For monitoring the OHE supply or 240 V supply, suitable relays operated off the
OHE PT or 240 V supply respectively shall be provided in the control panel by the
successful tenderer. A push - button, in series with each of these supply monitoring
circuits, shall be provided by the side of the corresponding supply fail indication LED to
test the healthiness of the monitoring and annunciation circuit.
5.4.6 A hooter or high audio level alarm for detecting the low D.C. or High D.C. voltages
shall be provided. The alarm shall sound in case the D.C. control voltage goes beyond the
limits as specified in this specification. (High or low)
5.5 DC supply supervision and annunciation
5.5.1 A provision shall be made for annunciation and supervision of 110 V d.c. supply to
various control and alarm and indication circuits. 110 V d.c. supply to control and relay
panel is normally made available from 110V battery chargers/batteries through distribution
panel provided in the control room, in six separate circuits as under:
Type – I Control panel
a) Control circuit for HV incoming line and bus coupling breaker.

b) Control circuit for H.V. and L.V. breakers of traction transformer - 1.
c) Control circuit for H.V and L.V. breakers of traction transformer - 2.
d) Control circuit for 25 kV feeder breakers.(One control circuit for two track)
e) A common circuit for alarm and indication purposes.
f) D.C. control voltage from battery low.
Type – II & III Control panel
a) Control circuit for 25 kV feeder breakers.

b) A common circuit for alarm and indication purposes.
c) D.C. control voltage from battery low.
Type – IV Control panel
(The design & specification for this type of control panels shall be as mutually
agreed to between the Purchaser and the tenderer)
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5.5.2 Provision for supervision of d.c. supply to each of the above circuits shall be
ensured. On failure of d.c. supply to any circuit, a yellow LED (provided individually for
each of the circuits) and horn / siren / electronic sound , operating both from 240 V A.C.
single phase supply and separate battery supply (tenderer’s scope) shall come up. The side
of the corresponding D.C. fail indication LED shall provide a push button, in series with
each supervision circuit, in order to test the healthiness of the supervision and annunciation
circuit. In addition, a common miniature type push button for the cancellation of horn shall
also be provided.
5.5.3 The control/common circuits mentioned in Clause-5.5.1 above, being common for
all the panels, are segregated suitably at the control panel for each panel through links
etc. so that D.C. supply is available to other panels when any one is taken out of service for
maintenance purpose.
5.5.4 Low control voltage alarm
A definite time under voltage relay shall be provided to detect the dropping of the
D.C. control voltage below the level as specified in this specification. Alarm / Hooter shall
be sounded if the low voltage condition persists for more than 10 sec.
5.6 Trip circuit supervision
5.6.1 The continuity and the availability of DC supply to the trip circuit of each circuit
breaker shall be monitored independently by an auxiliary relay connected in series with the
trip coil of the breaker. The current taken by the auxiliary relay shall not exceed 10 mA.
Whenever the auxiliary relay de-energizes (while the breaker is in the closed position)
either due to discontinuity in the trip circuit or d.c. supply failure, a yellow LED (provided
individually to the trip circuit of each breaker) and horn, both operated off 240 V , single
phase supply, shall come up. The side of the corresponding trip-circuit fail indication LED
to test the healthiness of the supervision and annunciation circuit shall provide a push
button, in series with each of these auxiliary relays.
5.6.2 Since the substation is un-attended, necessary cut-off switches shall be provided on
each control panel for disconnection of the audio-visual alarm and annunciation and
indication circuits to avoid un-necessary drainage of the battery.
5.7 Indication LED’s

5.7.1 Low consumption, extra bright, 5 mm dia, light emitting diodes (LEDs) shall be
used wherever required. The LEDs shall be suitably wired to glow off at 110 V d.c. supply.
LEDs shall be housed in suitable metallic holders with glazed/polished surface to act as
reflector. The holders shall be screwed to the panel from inside.
5.7.2 The following colour scheme shall be adopted for indication LED’s.
TABLE NUMBER – 10 Colour scheme for wiring

S.No Signal for Colour of light
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1. Circuit breaker closed Red
2. Circuit breaker open Green
3. Trip circuit healthy *Yellow
4. Circuit Breaker auto trip *Amber
5. 110 V D.C. fail supervision *Amber
6. Line potential *Red
7. Blower fan working *Blue
* These LED’s shall normally remain extinguished and shall light on

occurrence of the alarm / fault.
5.8 Test terminal blocks
5.8.1 Suitable test blocks shall be mounted conveniently inside the control panel so as to
be easily accessible. The current rating of the contact shall be 10 A continuous and 150 A
for at least one second at 240 V a.c. or 110 V d.c. The current terminals shall be provided
with short circuiting links or other suitable devices:
a) To short circuit the current transformer leads before interrupting the normal circuit
for injection from external source for testing (applicable for secondary injection
tests of relays).
b) To complete the current transformer circuit through a testing instrument in which

case the testing instrument shall be connected to the current terminals and the
intermediate link opened out (applicable for checking indicating instruments with
sub-standard meters at site).
5.8.2 The potential testing terminals shall be preferably housed in narrow recesses of the
moulded insulation block to prevent accidental short circuits. The arrangement of the
terminals shall be made such that either portable type energy and maximum demand
meters, or trivector meters with printo-maxigraph for recording kW, kVA and kVAR can be
connected when required.
5.8.3 Vertical or horizontal pillar stack type terminal blocks suitable for 1100 V service
and not less than 30 A rating shall be provided for terminating outgoing ends of control
panel wiring and the corresponding incoming tail ends of the control cables. Provision shall
be made on each pillar for holding 20% extra connections. The terminal blocks have
individual identification markings which shall be either engraved or made indelible by any
other means. Pillars of terminal blocks meant for connections of incoming control and
indication cables shall be specially provided with identification labels indicating
function(s) of each terminal block.
5.8.4 The terminals on the terminal blocks shall be of stud type suitable for terminating
the ends of control wiring and outgoing cable ends through crimped terminal spade/lugs,
which shall be securely tightened with nuts and spring washers. Suitable shrouds of
unbreakable transparent material shall also be provided on each terminal block.
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5.8.5 Terminal blocks connected to potential circuits and current circuits shall not be
placed adjacent to each other in a pillar. Where such segregation is not convenient due to
any reason, a dummy spacer of insulating material of adequate thickness or a space
terminal block shall be provided in between two such circuits.
5.9 Wiring of the C&R Panel
5.9.1 All panel wiring shall be done with switch board type 1100 V grade PVC insulated
single core, tinned annealed stranded copper conductors for service in extremely tropical
climate. The PVC wires shall conform to latest version/revision of IS:694 and duly tested
for flammability test as per IS:10810 (Part 53)-1984. The wiring shall also not be prone to
attack by vermin, i.e. mice, white ants, cockroaches etc.
5.9.2 The size of wires in the meter and relay circuits connected to the current
transformers shall not be less than 4 mm2 copper and in potential and other circuits not less
than 2.5 mm2 copper. The wires shall be stranded, composed of strands of not less than
0.91 mm (20 SWG).
5.9.3 The numbering and scheme of wiring for various circuits in the control and relay
panel shall be in accordance with latest version of IS: 375. The following colour scheme
shall be adopted for the wiring in order to facilitate identification of circuits:
TABLE NUMBER – 11 Colour schemes for wiring
S.No Circuit Colour of wire

1. 220 or 132 or 110 kV current Blue
transformer circuit.
2. 220 or 132 or 110 kV PT circuit. White
3. 25 kV potential transformer circuit Yellow
4. 25 kV current transformer circuit. Violet
5. 240 V A.C. auxiliary phase Red
neutral Black
6. DC control circuits Grey
7. Earth circuit Green
PVC sleeves of colours, red for trip circuit, blue for indication circuit, yellow for
alarm circuit, green for relay and other inter connections to be provided.
5.9.4 A suitable plaque of durable material and description giving the colour scheme of
wiring shall be provided inside the control board to facilitate quick identification of circuits
for maintenance purpose.
5.9.5 All potential bus wiring, D.C control supply bus wiring and other such other wiring
which runs from panel to panel within the control panel shall be suitable supported and
clipped to the frame work. The wiring for interconnection between control and relay panels
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shall be fixed under the roof of the corridor. All wiring shall be neatly bunched with PVC
tape or laced by thread.
5.9.6 Where a bunch of wire is clamped by metal clips, the wires shall be taped together
by one or two layers of PVC tape to protect them against mechanical injury. Wiring
connected to the space heaters in the panels shall be provided with porcelain beaded
insulation for a short distance from the heater terminals and heat resistant bushes of
insulating materials shall be provided at the terminal housing outlets. No joints shall be
permitted in the wiring.
5.9.7 The terminal ends of all wires shall be provided with numbered interlock type
ferrules, which are of PVC, or other durable material with marking either engraved or
punched so as to be indelible. The ferrules shall be of white colour with black lettering
thereon. However, for trip circuits ferrules of red colour shall be used. At a point of inter-
section where a change of number is necessary, duplicate ferrules shall be provided and
marked with proper numbers.
5.9.8 Ends of all wires shall be provided with terminal spades (tinned) which shall be
crimped to the wires. At terminal connections, washers shall be interposed between wire
terminals and holding nuts. The connection studs project at least 3 mm from the lock-nut
surface. Wire ends so connected at the terminal studs that no terminal ferrule gets masked
due to the succeeding connections. The wire ends shall be suitably bent to meet the
terminal stud at right angles with the stud axis; skew connections shall not be permitted.
5.10 Fuses and Links
5.10.1 HRC fuses of adequate current rating shall be provided in all potential circuits. Fuse
bases and carriers shall be mounted in the interior of the control board and at easily
accessible places. The fuse rating and the identification number, as assigned in the
schematic diagram shall be indicated on the fuse carriers. Suitable labels with engraved
markings indicating the rating, identification number and the circuit in which used, shall
also be provided below the fuse bases.
5.10.2 The links provided in the circuits either on negative/neutral side or for branching
purposes, shall also be similar to fuses mentioned above, except that these shall be
provided with tinned copper strip of suitable size in place of HRC fuse. The link
identification number as assigned in the schematic diagram shall be indicated on the link
carrier. The link base shall also be identified in the similar manner as the fuse base
mentioned in Clause 5.9.1.
5.11 Space Heaters & Control panel lighting
5.11.1 Suitable space heaters to operate off 240 V single-phase ac supply with `ON’
switches shall be provided inside the control board to prevent condensation of moisture in
humid weather.
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5.11.2 The interior of control panel enclosure shall be adequately lighted by incandescent
lamps/ florescent tube light connected to 240 V single phase ac supply. The central corridor
shall be illuminated by a lamp controlled by the door switches provided on the doors on
either side of the corridor. Each section of the control and relay panel shall also be
illuminated, controlled by separate switches.
5.11.3 Two sets, one each for relay panels and control panels, of 5 Amps, single phase, 3
pin plug sockets with switches shall be provided inside the control board at convenient
points for use of portable lamps.
5.12 Earthing
5.12.1 All current free metallic bodies of equipments/ relays etc. on the control board shall
be earthed properly. Main earth circuit shall be of 25 x 3 mm tinned copper strip and
individual connections of equipment/relays with main earth circuit shall be by means of
2.64 mm (12 SWG) tinned annealed copper bare conductor/strips, using tinned copper
spade terminals/lugs. Some times as an alternate, PVC insulated stranded tinned copper
wire of size equivalent to 2.64 mm (12 SWG) shall also be provided. Joints shall be
avoided as far as possible.
5.12.2 In order to facilitate the earthing of secondaries of CTs and PTs inside the control
board, suitable earth links of adequate size made of tinned copper/brass shall be provided
inside the control board at the appropriate points.
5.12.3 Multiple earthing of current/potential transformer circuits shall be avoided. Main

earth connection for each panel shall be brought out to two terminals for connection to the
general earthing system.
5.13 Name plate and Identification labels
5.13.1 All relays, instruments and other electrical devices mounted on the board shall have
name plates with rating data, serial number and manufacturer’s name.
5.13.2 Identification labels of size 65 x 13 mm bearing identification marks indicating

functions of respective equipments shall be provided on the exterior of control and relay
panels under all the relays, instruments and test blocks etc. Similar labels shall also be
provided under the switches where necessary.
5.13.3 Identification labels of size 25 x 25 mm bearing identification marks indicating

numbering of respective equipments shall be provided beside the semaphores, power
transformer and auxiliary transformer positions on control panels. The control and
local/remote selector toggle switches shall be provided with suitable labels duly inserted in
their pockets available for the purpose. The scheme of numbering of various equipments in
traction substations shall be supplied by the purchaser.
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5.13.4 All push buttons on the control panel shall have suitable inscription on their collars
indicating the functions of each push button. Where such collars are not available, separate
indicating labels of PVC sheet of suitable width and length not more than the overall
outside dimensions of the push buttons shall be provided. Similarly, the function of each
indication and annunciation LED shall be indicated by a label of elegant design and
appropriate size shall also be provided alongside/along with the concerned LED holders.
The inscription shall clearly convey the function of each indication LED.
5.13.5 Plastic plates about 50 mm wide, bearing suitable captions to identify the
transformer bay and corresponding outgoing 25 kV feeder, shall be provided on the top of
each relay and control panel.
5.13.6 All the identification labels on the exterior of control and relay panels shall be
secured with the help of chromium plated metallic screws.
5.13.7 Identification labels shall also be provided in the interior of the control panel. For
such of the equipments and fittings, which are exclusively mounted inside the control
panel, the labels of suitable size indicating function of respective equipment shall be
provided. Whereas the labels inside the control board for the equipments mounted
flush/semi-flush outside the control and relay panels, bear reference index code
corresponding to the schematic diagrams.
5.13.8 The labels inside the panels shall be secured with the help of adhesive of good
quality (wherever necessary). The labels in the interior of the board under the
equipments/relays shall be so provided that they are not obscured due to bunches of wire
runs and any other obstructions. Painting of inscriptions shall not be permitted.
5.13.9 All inscriptions on the labels to be fixed on the control and relay panels shall be
made on the PVC sheet strip of black background with white engraved letters/figures.
However, the labels to be fixed inside the panels shall be either of engraved lettering or of
aluminium anodized screen printed type.
5.13.10 The lettering for inscriptions on the labels shall be generally of the following sizes:
TABLE NUMBER –12 Label Sizes
S. Label description Size of label Height of

No. letters/figures
1. Main labels to be provided on the top 50 mm x length to 15 mm (two
Panels. suit rows)
2. Circuit labels to be provided at the 13 mm x 65 mm 5 mm (single
bottom of the panels row)
3. Function label under the equipments 13 mm x 65 mm 4 mm
4. Push button and indication LED labels - 4 mm (single
row) 3mm(double
row)
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5. Equipment numbering labels. 25mm x 25 mm 7 mm
6. Control & selector switch labels - 7 mm
7. Labels under fuses and links. 25mm x 25 mm 3 mm
8. Reference labels(Interior of panel) 25mm x 15 mm 5 mm
9. Terminal block pillar numbering labels 10mm x 15mm 5 mm
10.Terminal numbers on terminal blocks - 3 mm
11.Function inscriptions on terminal blocks - 3 mm
Note: - However, in case of space limitations, the manufacturer may adopt suitable label
dimensions without affecting the legibility and aesthetic appearance of the panel.
Any other label not covered above shall be of matching size.
6.0 SCHEME OF PROTECTION
The scheme of protection provided at each of the traction substations and SSP/SPs
shall comprise of the following systems:
a) Incoming 220 or 132 or 110 kV HV line protection shall be under the scope of
supply authority. However HV bus bar protection shall be covered under this
specification and shall be under scope of the tenderer. Refer clause no. 2.2 (i)
and 5.1.1.
b) Protection of the 220 or 132 or 110 /25 kV transformer installed at the traction
substation.
c) Protection of the 25 kV traction overhead equipment.
d) Protection of capacitor bank equipment (if asked for by the purchaser in the
tender).
The relays to be provided shall have the following functional requirements.
i) They shall be immune to distorted power frequency waveforms caused by the

harmonics, phase shifts and transient faults.
ii) The relays shall be insensitive to power swings, permissible overload and transient
condition including magnetizing inrush current of locomotive transformers and
shall be suitably designed to compensate the effect of fault are resistance.
iii) All the relays except reverse power flow relay shall be immune to reverse power
flow in case of regenerative current going back into the grid.
iv) They shall of standard design and be fail safe in design. Any failure of the relay
shall either cause taking over of the functions of the relay by another relay or cause
it to fail in a manner so that the safety of the 25 kV distribution is not affected.
v) The relays with communication features shall have necessary interface equipments
and follow the standard communication protocol of IEC 60870-5-103.
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vi) The relays shall be suitable for operation from the 220 or 132 or 110 and 25 kV
current transformer and potential transformer to the following particulars:
TABLE NUMBER -13 Ratings of CT and PT on 25 kV side

S.No Description CT PT
1. Rated system voltage 25 kV rising up to 30 kV
2. Rated transformation 3000-1500/5A 25000/110V
ratio
3. No. of cores Two Two winding
4. Core-1 Core-2
5. Rated burden - - 100 VA
6. Accuracy class PS PS 0.2 as per IS: 3156 (part II)
& 3P as per IS: 3156 (part
III)-1992
* Two cores on 25 kV CTs are provided considering one core for differential bus
bar protection and other core for balance protection relays viz. DP relay, OCR.
TABLE NUMBER -14 Ratings of PT on 220 or 132 or 110 kV side

S.No Description PT
1 Rated system voltage 220 132 110
2 Highest system voltage 245 145 123
3 Rated transformation 220kV/110V 132kV/110 V 110 kV/110V
ratio
4 No. of windings Winding 1 Winding 2
5 Rated burden 100 VA 200 VA
6 Accuracy class 0.2 3P
TABLE NUMBER -15 Ratings of CT on 220 or 132 or 110 kV side

S.No Description CT
1 Rated system voltage 220 132 110
2 Highest system voltage 245 145 -
3 Rated transformation 300-200-100/5 600-400-200/5 1200-800-400/5
ratio
No. of cores four cores
Core 3 Core 2 Core 1&4
Protection Metering Protection
4 Rated burden 40 VA 40 VA -
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5 Accuracy class 5P20 0.2 PS
vii) The relays shall conform to accuracy class 10 as per IS: 3231-1965. However
distance relays shall be of class 5.
viii) The relay relays shall be provided with dust tight covers
ix) The current coils shall be rated for a continuous current of 5 Amps for relays on
type-I, II, III & IV panels. The voltage coil shall be rated for 110V. The
contacts of the relays shall be silver plated. The current coils shall be capable of
withstanding 20% overload for 8 hours.
x) The relays shall be designed for continuous service voltage of 110V d.c. and
shall be capable of satisfactory operation up to at least +15 %, - 30% fluctuation
in voltage.
xi) The contact of the relay shall be of silver or gold plated. The rating of output
contacts of the protective relays shall be adequate to operate the associated
output relays.
xii) The relays shall have nameplates with rating data, serial no. and manufacturer’s
name marked on them. The metal case shall be provided with separate earthing
terminals.
For protection of incoming HV line, transformer, substation equipment’s, feeders and

capacitor bank, the following relays shall be provided on a miniaturized control panels
housed in the masonry cubicle at the traction substation, SSP or the SP.
6.1 HV protection
a) Incoming HV line protection ( to be provided by supply authority)
1. Fiber optic line differential protection

2. Directional over current relay
3. LBBU relay (LBB- breaker failure relay)
4. Under voltage relay with time relay.
5. Over voltage relay with time relay.
b) HV bus bar protection to be provided by tenderer

Differential biased bus bar protections relay
6.2 Transformer Protection
i) Numeric Percentage biased differential relay

ii) IDMT over-current relays for the primary as well as for the secondary (25 KV)
side. The IDMT relay on the HV side is provided with an instantaneous over-
current element also.
iii) Instantaneous earth leakage relays on the primary side as well as on the secondary
(25 KV) side.
iv) High speed inter-tripping relay.
v) Auxiliary relays for transformer faults i.e. Bucholz, excessive winding and oil
temperature trip and alarm and low oil level alarm.
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vi) Reverse power flow relay.
6.3 25 kV Bus and Over head equipment protection.
The relays mentioned below are the main relays only. Other minor relays and
auxiliary relays required for functioning of the completed protection scheme have
not been indicated.
6.3.1 25 kV Bus and Feeder Protection at TSS
a) High impedance type differential protection relay for bus bar
b) Feeder protection
The following protections shall be provided–
i) Directional numerical distance protection relay with 3 zones and polygonal

characteristics.
ii) wrong phase coupling
iii) Directional definite time over current relay with instantaneous over current
element.
iv) PT fuse failure
v) Intelligent logic based auto recloser.
vi) Vectorial Delta-I Relay for detecting high impedance faults.
vii) Pantoflashover prevention & signalling relay (optional)
6.3.2 For SSPs
The following protection shall be provided for each circuit breaker–

i) Directional Numerical distance protection relay with 3 zones and polygonal
characteristics.
ii) Directional definite time over current relay.
iii) High impedance type differential protection relay for bus bar
iv) Panto flashover prevention & signalling relay (optional).
v) Intelligent Logic based auto reclosures.
vi) PT fuse failure.
6.3.3 For SPs
The following protection shall be provided for each circuit breaker–
i) Directional Numerical distance protection relay with 3 zones and polygonal

characteristics.
ii) Directional definite time over current relay.
iii) High impedance type differential protection relay for bus bar
iv) Over current protection relay for bridging CB
v) Under voltage protection relay for bridging CB
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vi) Panto flashover prevention & signalling relay.
vii) Intelligent Logic based auto reclosures.
viii) PT fuse failure
6.3.4 Shunt Capacitor Bank Protection.
(Optional only if demanded specifically by the purchaser)

The protection system for capacitor bank shall be as per the relevant RDSO
specifications of capacitor bank viz. ETI/PSI/67 (11/96) with A&C slip no. 1 to 7-
for shunt capacitor bank or TI/SPC/PSI/THYCAP/0030- for thyristor switched
capacitor bank or any other latest RDSO specifications.
6.4 Synchrocheck relay
For the TSSs which shall be operated in parallel, synchrocheck relays shall be
provided on transformer LV side breakers at TSS and at bridging CBs at SP. The relay
contacts shall be provided in the closing circuit of these CBs to ensure proper
synchronization between two sources. The relay shall have separate adjustable settings for
voltage magnitude (having range of 0-10% in steps of 0.5%) and phase angle (having range
of 0-5° in steps of 0.5°).
DETAILS OF PROTECTION SCHEME FOR HV INCOMING LINES
7.1 Details of incoming HV line protection including following shall be provided by

supply authority.
1. Fiber optic line differential protection

2. Directional over current relay
3. LBBU relay (LBB- breaker failure relay)
4. Under voltage relay with time relay.
5. Over voltage relay with time relay.
7.2 Differential biased bus bar protections relay
7.2.1 Protection against bus faults shall be provided by means of a sensitive differential
low impedance type protection relay. The relay shall be of the high speed type and operates
in less than 40 milli-seconds for 2 times the rated current and in less than 15ms at currents
of 10 times the set value. The following features shall be incorporated in the relay.
7.2.2 The current setting of the relay shall be adjustable in appropriate steps. The % error
in operating current shall not exceed + 5 %.
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7.2.3 The relay shall have overload current handling capabilities up to 2 times the set
current permanently & 40 times the set current for one second.
7.2.4 The relay shall not operate for maximum through fault current.
7.2.5 Three number out put trip contacts shall be provided on the relay to trip the desired
CBs simultaneously.
8.0 DETAILS OF PROTECTION SCHEME FOR 220/25kV, 132/25 kV,

100/25kV, 22/25 kV TRANSFORMER
8.1 Differential Protection
8.1.1 Protection against internal faults shall be provided by means of a sensitive single-
pole numerical differential protection relay. The relay shall be of the high speed type and
operates in less than 40 milli-seconds for 2 times the rated differential setting current and in
less than 15ms at currents of 10 times the set value. The following features shall be
incorporated in the relay:
8.1.2 There shall be no necessity for changing the setting of the relay when the
transformer tap is changed. The traction power transformer is provided with taps from
+10% to –15% in steps of 1.67% each.
8.1.3 The relay shall not operate for maximum through fault current. Necessary harmonic
restraining features shall be incorporated to prevent operation due to in-rush of
magnetization current when the transformer is charged either from the primary or the
secondary side. The relay shall have second harmonic magnetic inrush restraint feature in
order to prevent unwanted tripping. The relay shall be insensitive to inrush currents up to 5
times the differential setting of the relay. Also the relay shall be blocked for operation in
case second harmonics exceed a predetermined set limit. The limit of blocking the relay
shall be decided between the purchaser & tenderer after carrying out measurements as in
13.1. To start with, the relay shall be blocked for operation in case 2nd harmonic current
exceeds 15 % of the fundamental current.
8.1.4 The current setting of the relay shall be adjustable, preferably between the range of
20-50% in suitable steps. Percentage error of operating current shall not exceed + 5 %.
8.1.5 Adjustable bias setting shall also be provided. The bias at minimum operating
current setting shall be 15% to 50% in 6 steps for this relay to suit the tapping range of the
traction transformer and other design considerations.
8.1.6 The relay shall be connected to bushing type current transformers provided in the
bushings of 220/25 kV, 132/25 kV, 110/25 kV, 22/25 kV transformers. However it may be
optional to connect the relay to the separate current transformers (PS class core) provided
on the HV & LV sides of transformers. This way bus bar, CB and other equipments shall
be covered under the differential protection. However, interposing current transformers of
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suitable ratio and rating with matching characteristics of knee point voltage, excitation
current etc. are provided with the differential relay in order to boost up the bushing CTs
secondary current, at full load, to a value equal to relay rated current. Magnetization and
ratio error curves for the current transformers shall be supplied by the purchaser to enable
the tenderer to match the characteristics of the relays and interposing CTs with those of the
current transformers. The interposing CT shall be within the scope of supply by the
tenderer. The tenderer can also supply a software based integral CT ration compensation
instead of the conventional interposing CT.
8.1.7 The relay shall have overload current handling capabilities up to 2 times the set
current permanently & 40 times the set current for one second.
8.2 Earth-Leakage protection.
Back-up protection for internal earth faults within the transformer shall be provided
by means of a sensitive, high speed, earth-leakage instantaneous relay of very low pick up
current. Such relays shall be provided separately on both the primary and secondary sides
of the transformer. Both on the primary and the secondary sides the relays shall be
connected to separately mounted current transformers. The current setting for the relay
shall be adjustable between 10% and 80% of 5 Amps in equal step at 5%. The relay shall
be of T 10 class with operating time not exceeding 20 ms for currents of 5 times the relay
settings. The relay may be operated on voltage principle with suitable voltage setting
based on fault current levels of transformers.
8.3 Over current protection
Protection against over-current in the transformer shall be provided by means of

single-pole, non-directional over-current relay with inverse definite minimum time lag
(IDMT) characteristics both on the primary and the secondary sides of the transformer.
Further, an additional instantaneous over-current relay shall be provided on the primary
side. On the primary side the over-current relay shall be connected to separately mounted
current transformers.
On the 25 kV side the over-current relay shall be provided only on the live
(unearthed) leg of the power transformer through a separately mounted current transformer.
The over-current relay on the secondary side shall serve as back-up protection against
faults in the 25 kV overhead equipment and also against bus faults etc. The over-current
relays on the primary side shall serve as back up to the over-current relay on the 25 kV side
as well as back-up to differential and earth leakage relays against heavy faults. Proper
discrimination shall be maintained in the operation of these two sets of over-current relays.
The tenderer shall develop relay setting guidelines with supporting calculations and submit
to RDSO for scrutiny and approval. The setting on these relays shall be adjustable as under:
TABLE NUMBER 16 Setting range of IDMT Relay
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Sl. Item Current Setting Time Multiplier
No. setting
IDMT over-current on primary 80% to 320% as per IDMT 0.1 to 1
side. curve 3-sec at 10 Ir
Instantaneous over current on 400% to 1600% of IDMT -
primary side setting
IDMT over current on 80% to 320% as per IDMT 0.1 to 1
secondary side. curve 3-sec at 10 Ir
The instantaneous relays shall be of T 10 class with operating time not exceeding 20
milli-seconds at the set.
8.4 Intertripping Relay
The differential relay and earth leakage relay both on the primary and 25 kV sides
as also the over-current relays on primary side shall cause inter-tripping of the 220 or 132
or 110 and the 25 kV circuit breakers associated with the transformer. The inter-tripping of
the associated transformer circuit breakers on Primary and 25 kV side shall also be effected
due to other faults in the transformer, namely Buchholz trip, excessive winding temperature
and excessive oil temperature trip.
The IDMT over-current relay on the secondary side shall, however, trip the
respective circuit breaker on 25 kV side only. The inter-tripping of associated transformer
circuit breakers envisaged above shall be effected through a high speed tripping relay with
manual reset contacts. Such inter-tripping relay shall lock out the closing of circuit breakers
from all modes of closing commands viz. Remote control, local control at the panel and
also at the circuit breaker mechanism, until the inter-trip relay or the lock out relay (if
provided separately), is reset manually
Operating time inter trip relay shall not exceed 20 ms.
8.5 Other Protective devices.
The transformers as supplied by the purchaser shall be fitted with the following
warning and protective devices:
i) Low oil level alarm.

ii) Buchholz relay with alarm and trip contacts.
iii) Oil temperature indicator with alarm and trip contacts.
iv) Winding temperature indicator with alarm and trip contacts.
v) Pressure relief device with alarm and trip contacts.
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These contacts shall be wired up to a weather-proof terminal box mounted on the
transformer by the transformer manufacturer. The connections shall be extended to the
alarm and trip circuits as well as to annunciation scheme provided on the control panel.
9.0 DETAILS OF SCHEME OF PROTECTION FOR 25 kV OVERHEAD

EQUIPMENT
a) The substation equipment as well as the overhead equipment is protected against

short circuits and over-loads by means of feeder circuit breakers. The detailed feeding
arrangement has been indicated in the annexure 6 and the protection schemes at TSS, SSP
and SP are indicated in annexure 7 (3 sheets).
b) The normal zone of feed of a substation to a neutral section varies from 6.5 to 25
Km., The spacing between the adjacent TSS, SP & SSP is of the order of around 1-5 km.
Under emergency feed conditions, the zone shall be extended up to the next substation by
closing the bridging CB at the neutral section and will be about double the zone of normal
feed. Over current or plain impedance relays which operate below a certain impedance
level and which function independently on the phase angle between voltage and current,
will be unable to discriminate such faults. Therefore, a relay working on the principle of
discrimination of the argument of the impedance is required. The protection shall also have
directional elements to distinguish the fault in a particular zone.
c) The OHE protection scheme shall fulfill the following functions-
i) To detect all short circuits over the affected zone of overhead equipment and to
open the circuit breakers of the affected zone only. The healthy section shall
remain unaffected.
ii) In case a sub-sector has been isolated due to a fault, then the balance healthy
section left shall continue to have the effective protection operational.
iii) To operate with minimum delay in opening the circuit breaker.
iv) To refrain from operation at the maximum working current, i.e. to discriminate
between the maximum load currents and short circuit currents even though the
magnitude of the former (maximum working current) is at times more than the
latter (short circuit current), especially when the faults are remote from the
substation.
v) To detect and isolate faults on the OHE caused by accidental coupling of two
different phases from adjacent substations.
vi) To prevent flash-over at the insulated overlaps in front of the TSS, SSP overlaps
in the event of one of the wires of the OHE is switched OFF on transient faults
and a locomotive / EMU pantograph bridges the live and the unearthed OHE.
Relay shall also be able to give a signalling command as per user’s requirement
605
in case a communication link between adjacent TSS/SSP is not provided by the
purchaser. The purchaser shall specify his detailed requirement to this extent
while tendering.
vii) To provide high speed auto-reclosing of the feeder circuit breaker after a preset
time interval and to lock out if the fault reappears within a predetermined time
period. The autorecloser shall have built in logic / intelligence as described in
the subsequent para.
viii) To provide a suitable protection device to detect and trip the feeder Circuit
Breaker in the event of High impedance Earth Faults.
ix) The protection shall be immune to variations in arc resistance of the faults and
the excitation current of the traction locomotive and power transformers. To
avoid transient tripping due to high starting currents of EMUs/Locos, the relay
operation shall be blocked in case 2nd Harmonics exceed 15 percent or a value
as mutually decided between the purchaser and tenderer.
x) To be immune to the regenerative currents. The protection should not act in case
the regenerative currents are fed back into the system.
xi) The main feeder protective relays like directional numerical distance protection
relay with 3 zones and polygonal characteristics, intelligent logic base auto
reclosure etc. shall have necessary interface equipments to ensure the working
of the relay over communication channel if the purchaser so decide at a later
date.
The details of protective system shall therefore be as follows: -
9.1 Directional Numerical distance protection relay with 3 zones and

polygonal characteristics
9.1.1 The requirements are –

a) Relays to be single phase version
b) Impedance characteristic shall cater for –
i) Load encroachment
ii) Sudden loads due to locomotives start up.
iii) Short line sections
iv) High resistance fault currents very close to load currents
9.1.2 The relay shall have the following essential features

a) Relay shall have polygonal characteristics, which includes parallelogram
characteristics.
b) The relay shall have 3 distance zones. Each zone can be set individually for its R
and X values. Each of the zones can be set in forward or reverse or non directional
zone. Setting of relays for each zone shall be done depending on the measurements
as per clause 13.1. The relay shall trip instantaneously in zone-I and with present
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delay in zone-II and III. It shall be possible to set the delay in the range from 50 to
2000 ms in steps of 10 ms.
c) Zone-I extension.
d) Zone 2 and 3 with train start-up detection –
In case of train start-up loads, zone II, III may pick up. The relay should detect and
avoid tripping.
e) Back up Over Current protection
f) A “Switch onto fault” feature (SOTF) shall be provided in the relay to provide high
speed tripping (of the order of one cycle) in case the breaker is closed onto an
existing fault on the line.
g) Over and under voltage protection with voltage supervision along with time delay
(optional).
h) Auto reclosing.
i) The errors in the relay shall not be more than + 5% for R, X, V, I and the measured
Z value
j) Since the OHE parameters R & X shall be varying through out the section and also
shall be changing during the various phases of the work execution, the relay shall
be capable of changing the R & X values to all possible combinations of the OHE.
The relay shall also be capable of changing the fault angle over a range of 50 to 85
degrees in steps of 5+1 degrees.
k) The accuracy of the relay shall be + 5 % including for voltage input to the relay
from 125 volts down to 0.5 Volts, the frequency variations of 47 to 52 Hz and the
ambient temperature variation over the range + 5 OC to + 50 OC.
l) The relat shall give a command to the auto reclosure to bypass it in the event of a
fault in the 2nd zone or beyond.
m) The relay shall have facility to record and store fault waveforms for all CB tripping
cases with date and time stamping. 10 such waveforms shall be store as brought out
in details in the para 5 .1.2 above.
n) The impedance reach of each zone of protection shall be manually adjustable over a
range of 0.04 ohm to 50 ohm. For time delayed zones, it shall be possible to
independently vary the zone time settings in a range of 50 ms to 2000 ms. The timer
accuracy shall be + 5 % of setting.
o) The relay shall also be capable of changing the fault angle over a range of 50 to 85
degrees in steps of 1 degree (with accuracy of +1 %)
p) The relay shall continuously monitor the status of the feeder CB at TSS. In case the
feeder CB is not tripped after a preset time interval after initiating the trip command
then another trip command shall be given to the transformer CB to trip. Suitable
alarm confirming the failure of the concerned CB shall be displayed.
q) The relay shall continuously monitor the status of the feeder CB at SSP/SP. In case the
feeder CB is not tripped after a preset time interval after initiating the trip command in
zone-I then trip command shall be given to all the CBs connected to the concerned bus
of SSP/SP to trip. Suitable alarm confirming the failure of the concerned CB shall be
displayed
r) The PT voltage is continuously monitored by the relay in case of blowing out of the PT
fuse (conditions when PT is low but the current is less than the set current) an alarm
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shall be given out after suitable settable time delay. In case the PT voltage is low and
the current is more than the set current the relay shall trip the feeder CB.
s) The relay shall have feature of fault locator with an accuracy of +2 %. Necessary
interface equipments are to be provided to send the fault location in km. from relay
location to remote control centre through SCADA.
t) The relay shall be blocked for operation in case second harmonics exceed a
predetermined set limit. The limit of blocking the relay shall be decided between the
purchaser & tenderer after carrying out measurements as in 13.1. To start with, the
relay shall be blocked for operation in case 2nd harmonic current exceeds 15% of the
fundamental current.
u) The relay shall discriminate correctly between faults in the forward and reverse
directions on the event of voltage input to the relay falling down to 0 V. To maintain a
correct polarizing (directional reference) signal for the distance element and to enable
fast operating time under conditions of close-up faults, the relay shall utilize memory
polarization. The polarizing signal shall be derived from sufficient samples of the pre-
fault voltage held in memory.
9.2 High impedance type differential protection relay for bus bar.
Protection against bus faults shall be provided by means of a sensitive high

impediance differential protection relay. The relay shall be of the high speed type and
operation in less than 40 milli-seconds for 2 times the rated current and in less than 15
ms at current of 10 times the set value. The following features shall be incorporated in
the relay.
The setting of the relay shall be suitably adjustable in appropriate steps. The
relay shall have overload current handling capabilities upto 2 times the set current
permanently & 40 times the set current for one second. The relay shall not operate for
maximum through fault current. Suitable number of out put trip contacts shall be
provided on the relay to tripthe desired CBs simultaneously.
9.3 Definite Time over current relay
9.3.1 Directional definite time over current relay with instantaneous over current element at
TSS.
A definite time over current protection shall be used with an adjustable current setting
ranging from 0 to 50 Amp and time setting from 0 to 5000 ms, with an instantaneous
over current element, adjustable from 0 to 100 Amp, which clear faults at the sub
station. The instantaneous element shall be with operating time not exceeding 20+2 ms
for the set current. Below the set current there shall be no operation of the relay. The
error shall not exceed + 5 % the set currents.
9.3.2 Directional definite time over current relay at SSP/SP
A definite time over current protection shall be used with an adjustable current
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setting ranging from 0 to 50 Amp and time setting from 0 to 5000 ms.
9.4 Wrong Phase coupling prevention Relay
An impedance relay for protection against wrong phase coupling which shall
operate on the principle that the relay identifies a wrong phase coupling condition when
the impedance lies between 2 to 60 ohm with adjustable lower & higher impedance
range and its angle lies in the second quadrants between 110o to 150o in the R-X plane.
All parameters expressed are in secondary values. The relay shall be immune to the
regenerative currents.
Logic Based Intelligent Auto recloser
9.5.1 Whenever a feeder circuit breaker is tripped due to operation of the following
feeder protective relays, namely distance, wrong phase, high impedance earth fault
relay and instantaneous over-current relays, the concerned auto reclosing scheme shall
close the breaker after a pre-set dead time of 0.5 second (adjustable from 0.1to 1
seconds). If the breaker trips again due to persistence of fault during the reclaim time
30 seconds (settable 6 to 60 seconds) of the auto reclosing scheme, the scheme shall get
locked out.
9.5.2 It shall be possible to reset the locked out state either locally or through remote
control. Necessary contacts for telesignalling the locked-out state and for resetting the
same shall be provided for interfacing with the remote control equipment. Irrespective
of whether the auto reclosing scheme is in the normal condition or in the locked out
condition, it shall be possible to operate the circuit breaker locally as well as through
remote control.
9.5.3 A single shot high-speed auto-reclosing scheme shall work in conjunction with the
Master Trip relay to operate the feeder circuit breaker. The auto-reclosing scheme shall
be designed for a dead time adjustable between 0.1 and 1 second in steps of 0.1 second
(normally to be set at 0.5 second) and a reclaim time adjustable between 6 and 60
seconds (normally to be set at 30 seconds, the operating duty of feeder circuit breaker
being 0-0.3s –CO –30 s- CO).
9.5.4 Any section is fed from both sides by circuit breakers at adjacent switching
posts – one on the TSS side and next on the other side. A fault on the OHE is cleared from
both directions so as to isolate the minimum possible section. After tripping, auto-
reclosure operates, and closes CB on TSS side first. Other side CB shall close after
assurance that the fault of temporary nature has been cleared. This shall be ensured by the
auto-reclosure of other side CB, which shall continue to sense the PT supply remains for a
period as set in the reclaim time, the auto-reclosure shall close the other side CB.
9.5.5 The auto reclosure shall be blocked in the event of high current earth faults
above 2000 to 10000 in steps of 1000 Amps on the OHE. Suitable sensing circuits shall
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be available for the relay from the current transformer to activate the bypass. The tenderer
shall make relay settings accordingly. A manual over -ride of this blocking shall be
provided.
9.5.6 The auto reclosure shall have facility to repeat the reclosing on the fault again
for the second time after a time lag settable from 10 sec to 60 sec in steps of 1 sec during
the reclaim time. Such facility can be switched ON or OFF by the purchaser to his
requirements. Such reclosures however shall be automatically blocked in event of high
current earth fault for the set currents as explained in para 9.1.2(l) & 9.4.5 or a fault
detected by the distance relay in the 2nd zone or beyond.
9.6 High Impedance Earth Faults (back up)
9.6.1 Instances of low current faults not getting deleted by distance protection relays
have been reported. Such faults sometimes get cleared by the transformer OCR (IDMT)
relay after a considerable period which may be dangerous.
9.6.2 Protection against such high resistance earth faults shall be provided by a
vectorial delta I type of relay. The relay shall work on the principle of detecting Delta I
scalar as well as the vectorial components of the delta I current to decide the tripping of the
relay. Also the relay shall have blinders of range 0.5 to 30 Ohms (selectable in steps of 0.1
Ohms). A trip command shall be generated after evaluating both the Scalar and Vectorial
component of the delta I.
9.6.3 The relays sensitivity shall be restrained by 50 % if second harmonics are

more than 12% and/or third harmonics are more than 15%. The setting range of the relay
shall be from 1 amp to 6 Amps settable in the steps of 0.1 Amps. The accuracy of current
setting shall be + 7.5 %. The restraining features of the relay shall be reviewed along with
RDSO after the measurements at 13.1 have been completed.
9.6.4 The relay shall act as a back up to the main directional distance protection.
The relays operating time in no case shall be more than 70 ms Additional time delays of
500 ms settable in steps of 25ms shall be provided to the relay. The relay shall
continuously sense the status of feeder protection relay and the MTR and give trip
command to the breaker only when these relays have failed to clear the fault. Detailed
calculations for the setting of the relays shall be carried out by the tender and approved by
RDSO before actually putting in the field.
9.7 Reverse power flow prevention Relay
In case of double-ended feed, reverse flow of power back into the grid from the
energized TSS is required to be prevented beyond a set limit. A suitable reverse power
relay shall be provided, sensing power from the 25kV side to trip the primary CB in case
the reverse power flow beyond the set regenerative reverse power levels. The relay shall be
set based on amount of reverse power and operate on time delay. The reverse power
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(current) shall be settable from 0 to 5 A (in steps of 0.01 A) and time delay from 0 sec to 30
sec. (in steps of 0.5 sec).
9.8 Panto Flashover prevention/signalling relay
9.8.1 Provision of this relay and associated communication media and interface
equipments at TSS/SSP/SPs shall be optional and provided if demanded specifically by the
Purchaser. Purchaser shall clearly specify whether the concerned subsector is to be made
dead by panto flashover relay or flasher light indication is tobe given for warning
locomotive drivers as per clause No.9.8.6.
9.8.2 In the event of a tripping of circuit breaker(s) due to intermittent fault on one of
the sides of the FP /IOL and an electric train entering from a live to a dead section of the
IOL, a heavy flash - over may occur, when the pantograph negotiates the IOL, depending
on the intensity of current being drawn, with chances of consequential damage to OHE. In
case of transient faults, auto reclosure of CB would obviate this but in case of persisting
faults or it reclosure gets delayed, the possibility of flashover will exist.
9.8.3 Such needs be managed by ensuring that the live subsector is made dead by
tripping the concerned CBs simultaneously. A logic for various such conditions in which
tripping of both CB’s of the FP IOL required shall be generated by a microprocessor based
logic/suitable relay scheme and whenever such trippings are required the same shall be
identified and done by the relay. Further, the relay shall have give tripping command to the
concerned CB at adjoining TSS/SSP/SP to make the live subsector dead.
9.8.4 Detailed calculations of tripping time, train operation time, relay operating time
and the CB tripping time shall be done by the tenderer and approved by RDSO before
developing the relay. The relay shall be developed in lines with RDSO specification no.
TI/SPC/PSI/PROTCT/2982 or latest.
9.8.5 For making the live subsector dead, Pantoflashover relay to be provided at
TSS/SSP/SP shall have communication features and necessary interface. On its actuation
relay shall give trip command to the circuit breaker at the concerned post and through its
communication trip the circuit breaker at adjoining post (TSS/SSP/SP) so as to make the
concerned sub-sector dead. The details of communication media between different
switching control posts (TSS/SSP/SPs) shall be furnished along with cost as option. The
purchaser may get this communication media supplied / erected from the tenderer or can
separately procure / erect between the posts as per the technical requirements given by the
tenderer. Works related to interfacing the communication media and C&R panel shall be
done by the successful tenderer. The tenderer shall also provide a continuous monitoring
system for this communication link and in case the communication link become
ineffective/ disconnected/short circuited an alarm shall be sounded to the user.
9.8.6 The relay in addition will be capable of closing a contact for initializing a
flasher light for warning locomotive drivers. Suitable relays / contacts capable of handling
the flasher light current shall be provided by the tenderer. The flasher light shall be capable
611
of working independently whether the communication links between the adjacent SSP, TSS
exists or not. The provision of the contactors & flashers light for warning & power supply
for the flasher lights and outside the scope of work to this specification.
9.9 Master trip Relay
The relays as explained above in item 9.1, 9.2, 9.3 shall trip the corresponding
feeder circuit breaker in case of fault, through a high speed self-reset type tripping relay to
be designated as Master Trip relay. The relay shall have a operating time of not more than
12 ms and a resetting time of not more than 100 ms. The relay shall be capable of handling
the current of the CB trip coil.
10.0 DETAILS OF 25 kV CAPACITOR BANK PROTECTION

(applicable, if asked for by the purchaser)
The protection system for capacitor bank if asked for by the purchaser in the tender
shall be as per the relevant RDSO specifications of capacitor bank viz. ETI/PSI/67 (11/96)
with A&C slip no. 1 to 7- for shunt capacitor bank or TI/SPC/PSI/THYCAP/0030- for
thyristor switched capacitor bank or any other latest RDSO specifications.
11.0 OTHER RELAYS AND PROTECTION
11.1 Low Voltage Tripping at the SP
An instantaneous under voltage relay shall be provided by the tenderer to trip the
bridging interrupter or circuit breaker at the neutral section in case of under voltage during
emergency feed conditions. The relay shall be connected to one of the existing PT Type II
and shall have voltage settings of 19 kV, 17 kV and 15 kV below which if the voltage at
the SP drops the sectioning circuit breaker shall operate.
12.0 INSPECTION AND TESTING

12.1 General
The inspection of the control and relay panel shall be carried out by an authorized
representative of the purchaser. Prototype inspection shall be done by RDSO. After
successful completion of all the type and routine tests as per this specification, prototype
approval shall be issued by RDSO. After approval of prototype, inspection and routine tests
on the balance quantity shall be done by the authorized representative of the Indian
Railways as per purchase order.
12.1.1 Only after all the design and drawings have been approved and clearance given
by Research Design and Standards Organization (RDSO) to this effect, the manufacturer
may take up manufacture of the first prototype unit for RDSO inspection.
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12.1.2 Before giving the call to RDSO for inspection and testing of the prototype of the
equipment, the manufacturer shall submit a detailed test schedule consisting of schematic
circuit diagrams for each of the tests and nature of the test, venue of the test and the
duration of the test and the total number of the days required to complete the tests at one
stretch. He should have carried out the routine tests himself and ensured that the relay and
the C&R panel is as per SOGP and this specification. The inspection call shall be given 30
days in advance from the actual inspection date at the factory.
12.2 TESTS
The entire prototype test on all the relays and control and relay panel shall be
carried out by RDSO engineers at the manufacturers works before the dispatch of the first
set of relays. Tests conducted at a prior date shall not be acceptable if not conducted in
presence of RDSO. The cost of the testing shall be borne by the tenderer.
12.2.1 Type Tests

The relays shall be type tested as per IS:3231, IS:8686 & relevant IEC. All
instruments, interposing CTs and any other equipments as the purchaser may desire shall
be type tested as per the latest version of respective standard IS/IEC Specifications
applicable. The following type tests shall be carried out on the prototype relays.
i) Temperature rise of the coil of the relay shall not exceed the limits of 55 oC
and 80 oC for Class- A and Class-B insulation respectively.
ii) Mechanical endurance test for 10,000 operations.
iii) Operating time test.
iv) Quadrature test
v) Reset value test.
vi) Reset time test.
vii) Making and braking capacity of contacts
viii) Overload test
ix) Impulse voltage withstand tests applicable test voltage class-III.
x) High frequency disturbance test applicable to test voltage class-III.
xi) Vibration test on the complete panel at a frequency 16.7 Hz, maximum
amplitude 0.4mm, 10 minutes each for back and forth for right and left and
for up and down. After this test the operational characteristics of relays will
be confirmed.
xii) Verification of characteristics of relays
xiii) Environmental Tests :-

(1) Dry heat test as per IEC 60068-2-2 (1974)
(2) Damp heat test, steady state as per IEC 60068-2-3
(3) Damp heat test, cyclic as per IEC 60068-2-30 (1980)
xiv) EM Compatibility tests: -

(1) Interference suppression as per IEC 60255-92-1 - 1 MHz burst test, 2.5
kV common mode & 1.0 kV differential mode. Test duration - more
than 2 secs.
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(2) Immunity to Electrostatic discharge as per IEC 60255-22-1
(3) Immunity to Radiated EM energy as per EN 61000-4-3, 80 – 1000 MHz,
10 V / m, Antenna, greater than 1 m from all sides.
(4) Electrical Fast Transient or burst requirements as per IEC 60255-22-4
(5) Surge Immunity as per IEC 61000-4-5
(6) Immunity to conducted disturbances.
(7) Power Frequency Magnetic Field Immunity.
(8) A.C. ripple in D.C. auxiliary
xv) In addition to the above, all routine tests detailed in Clause 12.2.2 below
shall also be carried out on the first prototype.
Only after clear written approval of the results of the tests on the prototype is
communicated by RDSO/Purchaser to the manufacturer, he shall take up bulk manufacture
of the equipment – which shall be strictly with the same material and process as adopted
for the prototype. In no circumstances shall material other than those approved in the
design/drawings and/or the prototype be used for bulk manufacture on the plea that they
had been obtained prior to the approval of the prototype.
12.2.2 Routine tests
All relays, instruments, interposing CTs and other equipments shall be subjected to
routine tests at the manufacturer’s works as per the relevant standards. The following
checks and tests shall be carried out on the complete control and relay panel:
12.2.3 Visual Checks
General check of the control board in respect of construction, wiring, provision of

various equipments/relays etc.
12.2.4 Operation Tests
Operation tests on all equipments, switches and tests to prove correctness of wiring
of various circuits including indications, alarms, operation of relays and annunciation etc.
12.2.5 Power frequency high voltage withstand test

Voltage test on the panels with all equipments and wiring for a withstand voltage of
2 kV (rms) to earth for one minute.
12.2.6 Insulation Resistance test
Measurement of insulation resistance of the complete panel wiring, and circuit by

circuit, with all equipments mounted on the panel, by using 1000 V meggar.
12.2.7 Auxiliary Power Consumption test

Power consumed by the panel with and without protective relays at 110 v d.c.
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13.0 ERECTION, COMMISSIONING AND PROVING TESTS
13.1 The Tenderer shall carry out the following test along with purchaser for
ascertaining the different parameters / values to be used for relay setting and its normal
functioning.
i) Harmonic analysis of each TSS on Primary and secondary side for current and
voltage harmonics for a period of 7 days.
ii) Wave form recording and analysis of each an every fault occurring on the OHE
for a period of six months.
iii) Actual field measurements of R & X value of the OHE in each sub sector and
including the values of rail impedance, earth wire impedance and OHE
impedance.
iv) To develop fault current characteristics v/s fault clearing time characteristics
and evolve which relay shall clear the fault for various recommended range of
settings of the relay to evolve time coordination and setting of various relay
times for effective coordination of the relays.
v) To record actual transient voltages coming on the 25 kV side for a period of six
months.
vi) Magnetic inrush currents generated due to switching on the traction transformer
and locomotive/EMU transformers shall be measured at site and harmonic
contents of inrush current determined for magnetic inrush period.
vii) Power factor on the 25 kV side of the TSS recorded for one month in order to
determine the maximum, minimum and average power factor at the TSS.
viii) Regenerative braking current fed back into the grid recording for a period of
one month.
ix) Ferro-resonance studies shall be carried out for each TSS location to ascertain
the possibility of any sub-harmonic resonance effect on the system during the
initial switching ‘ON’ of the supply.
x) Testing of impedance bonds of S & T department for their satisfactory
behaviour on harmonic load current and fault current impact on impedance of
the bond.
13.2 The erection and commissioning of relay shall be done by the successful
tenderer who shall arrange all tools, plants, instruments and other material required for the
purpose at his own cost. Tests shall be carried out during erection/commissioning of the
relay at the site in accordance with the testing guidelines finalized with RDSO. Tests shall
be carried out on the relay in the presence of the purchaser’s representatives to check the
erection and commissioning of the relay.
13.3 Three sets of the test report shall be supplied by the manufacturer to the purchaser
for records and reference.
13.4 Proving tests of protection system shall be done by the tenderer by actual
simulation of the faults in the field. The location of fault simulation shall be furnished by
615
tenderer to RDSO for approval. The protection system will be considered acceptable if the
dependability index is nearly 100% during the proving tests.
13.5 Commissioning of the protection scheme shall be done instages from one end of the
section under conversion. Satisfactory performance of section with two TSSs including its
parallel operation shall be observed for a limited period of minimum two months. Any
changes / modification required in the relays and C&R panel during above period shall be
carried out and shall be implemented in the subsequent sections without any financial
implications.
14.0 TECHNICAL DATA AND DRAWINGS
particulars for the equipment offered in the Performa attached as Annexure-4.
clause of the technical specification. If the tenderer wishes to deviate from the provision of
any clause/sub –clause, he shall furnish the full details with justification for such deviation.
14.3 The tenderer shall furnish descriptive pamphlets and the recommended relay setting
and time coordination with supporting calculations for complete protection scheme. The
range of setting available, calibrated in terms of single track OHE, shall be clearly stated
and adjustments available for intermediate setting explained. The scheme shall include the
condition of failure of main protection and clearing of fault by backup protection at
identified locations.
14.4 Successful tenderer shall be required to submit the following detailed outline
dimensioned drawings (including reproducible copies as per the Railways standard sizes of
210 mm x 297 mm or multiple thereof for approval). Also the approved drawing shall be
submitted in AutoCAD-14 or latest on a CD ROM.
(i) Dimensioned drawings of the control & relay panel indicating front and rear
views with the layout of instruments, mimic diagram, control switches,
indication LED’s, push buttons, protection modules and other equipment’s
etc. clearly marked.
(ii) Exploded view of the rear and front of the system indicating the disposition
of various equipments inside the control, protection and metering system.
(iii) Schematic diagram of D.C. control circuits for transformer protection, OHE
protection, capacitor bank protection and control of circuit breakers,
interrupters and motor-operated isolators (if any).
(iv) Schematic diagram of alarm, indication circuits and event logging system.
(v) Schematic diagram of A.C. circuits showing connection of CTs and PTs and
associated protective relays.
(vi) Drawing showing the legend of various reference/codes adopted for
equipments, protection modules and all other accessories used in the control,
protection and metering system.
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(vii) Drawing for name plates/identification labels engraving details.
(viii) Any other drawings considered necessary.
15.0 OPERATION, MAINTENANCE INSTRUCTIONS & TRAINING
15.1 The Control and Relay panel shall be maintenance free generally not needing
any maintenance, however the tenderer shall mention a maintenance schedule which shall
be detailed enough to guarantee failure free service of the relay to the purchaser. The
supplier shall supply free of cost 5 copies to the consignee of the Instruction Manuals for
operation and maintenance of the equipment. The manuals shall contain full particulars of
various components, full dimensioned drawings and circuit diagrams. The manual shall be
approved by RDSO prior to the issue to the consignee.
15.2 The tenderer shall train free of cost 10 of the associated engineers/supervisors
for 7 days in the maintenance, operation, relay setting procedure, trouble shooting and
commissioning of the relay. This training shall be done at the installation site and shall be
given to the basic users. The purchaser shall ensure that he gives to the supplier technically
competent officials for the purpose of this training. Graduate engineers shall be preferred
for this training.
15.3 The tenderer shall quote separately for maintenance tool, kits and test
instruments required for satisfactory maintenance and operation of the relay. The test kit /
jig shall be complete in all respects to test the individual cards of the C&R panel and the
complete kit as a whole. The tenderer shall quote for spares require for the relay for 5
years of trouble free operation beyond the warranty period.
15.4 The successful tenderer shall develop & provide a maintenance schedule and a
trouble shooting chart for effective, reliable and trouble free relay operation. The basic
maintenance schedule along with the troubleshooting, diagnostic chart shall be submitted to
RDSO and approved by RDSO prior to commissioning of the relay for the first time at the
sight.
15.5 The successful tenderer shall submit two sets of guide lines for relays setting
along with time coordination and supporting calculations, for complete protection scheme
to RDSO for scrutiny and approval before commissioning of the panel. After successful
completion of commissioning and proving tests in field the tenderer shall submit final relay
setting guide line to RDSO for scrutiny and approval. Five copies of approved relays
setting guide line shall be supplied to purchaser and two copies to DG (TI) RDSO
Lucknow for record.
15.6 The successful tenderer shall develop erection and commissioning manuals,
operating manuals, trouble shooting guidelines and after its approval by RDSO shall supply
five copies of to the purchaser and two copies to DG (TI) RDSO Lucknow for record.
16.0 WARRANTY
617
16.1 The control and relay panel supplied against a purchase order/contract in which this
specification is quoted, irrespective of original individual equipment (imported
/indigenous) shall be guaranteed for trouble – free and satisfactory performance for a
period of 30 months from the date of supply or 24 months from the date of commissioning,
whichever period is earlier, details of warranty clause, the extent of responsibility and other
relevant aspects shall be included in the purchase order or the contract. The tenderer shall
furnish detailed terms and conditions in this regard in his offer.
16.2 The successful tenderer shall make necessary arrangement for closely monitoring
the performance of the relay through periodical (preferably continuously for the first year
and once a month during the second year of the warranty period) visits to the relay
installation TSS for on the spot detailed observations. Arrangements shall also be made for
spare parts modules and other items to be kept readily available with the manufacturer/
supplier / successful tenderer to meet exigencies warranting replacement so as to put back
the relay in service without unduly affecting the operations of the TSS.
17.0 SERVICE SUPPORT AFTER WARRANTY AND AMC
17.1 The tenderer shall confirm the maintenance support of the relays / C&R panel
supplied by him for a period of at least 10 years from the date of commissioning on the
panel. The tenderer shall quote for maintenance spare, which the purchaser should have for
maintaining of the relays, C&R panel for a period of 5 years. The tenderer shall also quote
in his offer the maintenance equipment, instruments and T & P, which the tenderer should
have in order to maintain the relays and the C&R panel effectively.
17.2 The tenderer shall also quote for an option of maintaining the entire C&R panel by
him for a period of 10 years after the date of warranty period. Such AMC shall include
supply of all the material required for maintenance, repairs of relays and testing of the
relays at periodic intervals. The tenderer shall take necessary measures to ensure that the
downtime of the equipment is the least.
Purchaser may incorporate clause in the tender documents for AMC such that
payments are based on the availability/ downtime of the equipment in slab rates. A fixed
period of time after communication of the failure, for which downtime shall be reckoned,
will be decided by the purchaser/ railway.
18.0 SPECIFICATION CONFIRMATION
18.1 The tenderer shall go through each and every clause, drawings, Annexure of this
specification and indicate compliance to the specification. If there are deviations, detailed
reasons for the deviations supported by calculations, drawings, international practices shall
be essentially required for evaluating the tender offer. Wherever such deviations have not
been furnished it shall be deemed to be understood that the tenderer has accepted all the
tender conditions as mentioned in the specification.
618
18.2 The tenderer shall also enclose the schedule of guaranteed particular of the relay/
C&R panel in the format as mentioned in the Annexure 4. Extra information to bring out
the schedule of guaranteed particulars more effectively may be included separately.
18.3 The tenderer is advised to refer the material schedule for the particular section as
enclosed by the tenderer in the proforma as in Annexure 5. Tenderer shall go through the
Annexure 5 material schedule in details and submit his offer accordingly. Any clarification,
understanding of the requirement shall be clarified from the purchaser by the tenderer
before submitting his offer. Any minor modification essentially required for successful
integration and working of the Scheme/System shall be considered to be well within the
scope of the tenderer.
19.0 TENDERER’S CREDENTIALS

The tenderer shall be a RDSO approved supplier for protective relays on I.R. for
the past 5 years or shall be a firm of International repute supplying protective relays to
railways for at least 5 years. The tenderer shall enclose necessary documents in support at
the time of submitting his offer. The tenderer should have been involved in developmental
activity for developing the main feeder protection relays for Indian Railways or any other
Foreign Railways.
20.0 IMPORTED RELAYS

The tenderer shall clearly specify at the time of tendering whether any imported
relays are being provided. If so the technical details of the relays shall be indicated by the
tenderer. All such relays are required to be type tested at manufacturer works abroad by
RDSO representatives before dispatch of the relays to the purchaser.
619
LIST OF ABBREVIATIONS ANNEXURE 1
Abbreviation Full Form of the Abbreviation
A Amperes
AFTC Audio Frequency Track Circuit
AMC Annual Maintenance Contract
ASNS Automatic Switched Neutral Section
BT Booster Transformer
C&R Control and relay panel
CB Circuit Breaker
DCTC DC Track Circuit
DMT Definite Minimum Time lag
GPS Global Positioning System
GTO Gate Turn Off Thyristor
IDMT Inverse Definite Minimum Time lag
IED Intelligent Electronic devices
IOL Insulated Overlap
LCD Liquid crystal diode
LED Light emitting diode
MSG Maintenance Study Group.
MTBF Mean Time Between Failure
MTR Master trip Relay
NC Normally closed.
NO Normally open
OHE Over Head Equipment
PTFE Poly Tetra Flouro Ethylene
RC Return Conductors.
RTU Remote Terminal Unit
SOTF Switch On To Fault
SP Sectioning Post
SR Self Reset
SSP Sub Sectioning Post
THD Total Harmonic Distortion
TRD Traction Distribution
TRS Traction Rolling stock
TSS Traction Sub Stations
WPC Wrong Phase Coupling
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ANNEXURE 2
DEFINITIONS
Item Definition
Audio In AFTC type of track circuit, Audio Frequencies in the range of 1500 Hz
frequency to 10000 Hz are used. The traction return is connected through an
track circuit impedance bond capable of handling the traction return load and fault
(AFTC) currents. The center point of it is connected to the traction return from the
TSS while the remaining 2 terminals it shall be connected to the rails.
Basic time The shortest operating time of distance protection, for example, the time of
the first step or zone in a stepped curve distance-time protection.
Breaking The maximum current and volt– amperes that the contact is able to
capacity interrupt successfully under specified conditions without significant
damage to contact.
Contract Means the contract resulting from the acceptance by the purchaser of the
tender either in whole or part
DC track DCTC is the conventional track circuiting generally available in all

circuit conventional system where the traction transformer neutral point is
connected to one or both the traction rails near the TSS. The masts are
earthed by connecting them to the traction rail and on the track circuit
portion only one rail is available for traction returns and in the non-track
circuit regions both rails are available for the purpose of traction return
currents.
Dead time Dead time is the period taken by the auto reclose mechanism to close the
breaker after the same would have tripped on fault. In other words, the
time from the instant of fault detection up to the instant of closing of
breaker by auto-reclose system.
Differential A unit protective system in which an algebraic comparison is made of

protective primary current at two or more points in the power system.
system
Double ended The adjacent TSS are on same phase and are connected in parallel. There
feeding may or may not be a neutral section on SP for such feeding arrangement.
Equipment Means all or any equipment considered necessary by the purchaser

engineers for the satisfactory operation as a whole of the installation
including structure, foundations etc.
Making The maximum current and volt–amperes the contact is able to make
capacity successfully under specified conditions without significant damage to the
contact.
621
Normally A contact, which is closed when the relay is de-energised.
closed contact
(NC)
Normally A contact, which is open when the relay is de-energised.
open contact
(NO)
Operating The time, which elapses from the appearance of the abnormal conditions,
time which cause the operation of the protection until the protection initiates
tripping or alarm.
Primary The primary side of the transformer shall be defined as the side with
incoming voltage from the Supply authority on 220, 132, 110, 22 kV as the
case may be.
Protected The part of an installation guarded by a certain protection.
zone
Purchaser The person / agency who has floated the tender for execution of the work
on or behalf of the president of India.
Railway Means Railway(s) in whose territorial jurisdiction the work is to be carried
out and includes the Government of India, Ministry of Railways (Railway
Board), and /or general manager of the railways concerned
Reclaim Reclaim time is the duration for which the auto reclosing mechanism
time remains ineffective after first reclosure of circuit breaker by auto-reclose,
irrespective of re-occurrence persistence of fault. In other words, the
breaker will not be reclosed second time by the auto-reclose device had the
same tripped on fault again within the reclaim time after its first reclosure
on the auto-reclose system.
Relay back- An arrangement, which provides an additional, relay using the same or
up different principle of operation from that of the main relay.
Remote An arrangement at the next station in the direction towards the source
back-up which trips after a delayed time if the CB in the faulty section is not
tripped.
Secondary The secondary side of the transformer shall be defined as the side feeding
the OHE i.e.25 kV side.
Sector Distance between the TSS and the SP
Single ended The TSS is feeding up to SP which is a neutral section. The phases on
feeding either side of the SP are different.
622
Sub-sector Distance between the TSS and the adjacent SSP/ SP or the distance
between the SP and the adjacent SSP/SP.
Switch on to SOTF feature for protective system becomes active once a CB has tripped
fault (SOTF) on a fault. CB is in open condition and when it is closed on fault existing in
feature the system. The feature starts by detecting V0 and I0 in the circuit at the
time of closing of the CB as a starting point for the SOTF feature. This
feature remains active for a period of around 200 milli-seconds from the
time of breaker closing. This feature shall give instantaneous operation of
the relay.
Synchronise The relay shall operate for close up faults in the forward direction but it
polarization shall restrain for close faults in the reverse direction. To ensure such
OR memory operation memory polarisation feature shall be provided in the relay for
polarisation correct direction discrimination.
Tenderer The vendor, supplier who intends to quote for the tender floated by the
purchaser. The agency who shall quote for tender floated by the tenderer.
Time lag Intentionally introduced time interval between start and completed
operation of the protection.
Track circuit It is the circuit providing passage of traction current through arrangement
of track bonding.
Unit A protective system, which is designed to operate for abnormal, conditions

protection inside and remains stable for abnormal conditions outside a specified zone
of the protective system.
623
ANNEXURE 3
GOVERNING AND RELATED SPECIFICATIONS
The relays shall, unless otherwise specified shall conform too generally to the latest
edition of Specifications mentioned below:
IEC 60068-2 Environmental Tests

IEC 60255 -3 Single input energising quantity measuring relays with
dependent or independent time.
IEC 255 -6 Measuring relays and protection equipment.
IS-2705 (Pt. IV) Protective current transformers
IS 3231 Electrical relays for power system protection
IS 8686 Static protective relays
IS-2705 (Part I to IV) Specification for Current Transformer
IS-3156 Specification for Potential Transformer
IS-4237 Switchgear general requirements
IS-5578 & 11353 Panel wiring
IS-8623 Factory built assemblies of switchgear and control gear
for voltages unto and including 1000V a.c. and 12V
d.c.
IS-8828 Miniature circuit breakers

IS-9224 HRC cartridge fuse
IS-6875 Control switches/push button
IS-1248 Indicating instruments
IS-2147 Degree of protection
IS-694 PVC insulated cables for working voltages up to and
including 1100 V
IS-10810 (part 53) Methods of test for cables: part 53-flammability test
The above specifications shall be applied in a manner altered, amended or

supplemented by this specification and the latest Indian Electricity Rules wherever
applicable. Any deviations from the specifications proposed by the tenderer at the
tender/prototype stage, to improve the performance, utility or efficiency of the
equipment shall be given due considered provided full details of the deviation are
furnished by the tenderer to the satisfaction of the purchaser. In such cases the tenderer
shall quote according to the specification as well as with the deviations from the
specifications.
624
Other related and linking specifications of the equipment to which the relays get linked
or derive signals are –
TI/SPC/PSI/PTs/0990 220/132//100/66/25 kV PTs

ETI/PSI/90(6/95) with A&C 25 kV current transformer
1&2
ETI/PSI/117(7/88) with A&C 1 220/132/100/66 kV current transformer
to 6
TI/SPC/PSI/CB/0000 For 25 kV single poles, double pole and primary side
22 kV, 66 kV, 100 kV, 110 kV, 132 kV and 220 kV
two pole/three pole vacuum and SF6 CBs for AC
traction substations.
ETI/PSI/167(9/97) 25 kV interrupter
ETI/PSI/163(4/97) with A&C 1 21.6 MVA, 100/27 kV,22/27 kV single phase ONAN
traction power transformer
ETI/PSI/120(2/91) Code of practice for earthing
TI/SPC/PSI/PROTCT/2983 Prototype specification of pinto flashover protection

relay for 25 kV system
ETI/PSI/65(1/97) with A&C 1 Specification for C&R panel with static relays
TI/SPC/PSI/PROTCT/1982 Prototype specification for delta I fault selective relay

for fault selective system.
TI/SPC/PSI/OFC/0050 Specification for 24 core armoured optic fibre cable for
use in Indian Railway Traction Installation System.
625
SCHEduled of guranteed particular for
SPECIFICATION NO. TI/SPC/PSI/PROTCT/4050
(TO BE SUBMITTED BY THE TENDERER AT THE TIME OF SUBMITTING HIS
TENDER OFFER)
The tenderer shall be required to submit the following detail to the purchaser at the time of
tender scrutiny in order to technical capability of the tenderer to carry out the work.
AMBIGUOUS or incomplete information like “_”Or “shall be given later” can lead to
technical rejection of the other. WHEREVER deviation is quoted they shall be supposed to
be supported with detailed technical benefits and/or financial benefits.
S.No. Description Manufacturer’s details

1.0 General
Name of the manufacturer
Governing specifications TI/SPC/PSI/PROTCT/40
50
Are you an RDSO approved firm?
1.4 Have you been a regular supplier to Indian Railways
for past 5 years
1.5 Have you gone through the specification in details?
Attach a point wise compliance for each item as an
Annexure whether you shall be able to do the specific
item of the specification or not. Indicate clearly the
clause number of the specification not acceptable to
you. And give details, elaborate reasoning for clauses
not acceptable to you.
1.6 Does your company have a formal setup for training?
Elaborate training facilities and your experience in
preparation of quality training materials.
2.0 System Particulars
2.1 Have you gone through the specification in details
and also visited site of work to understand the in
depth requirement of the tender.
2.2 Will you be able to provide the scheme with the
desired accuracies so that up to 90 % of the trippings
occur only in the zone in which the fault occurs?
2.3 Will you be able to provide the scheme in a manner
explained in the specification so that there is no
impact whether the bus coupler CB’s at SSPs & SPs
are open OR closed condition, provided or not
provided and adjacent TSSs are operated in parallel
or not.
2.4 Name the relays, which shall be required to be
developed by you as per this specification.
626
2.5 Whether any relay used is an imported relay. Confirm
that the relay shall be tested by RDSO at its works
abroad before dispatch of the relay for Indian
Railways.
3.0 Particulars of C & R Panel

Units Values/details
3.1 Rated control voltage with Volt DC 110VDC +15/-30%
variation
3.2 Rated VA burden on CTs & VA Less than rated VA burden of CTs
PTs and PTs
3.3 Power consumption Watts
3.4 Impulse and power kVp & Impulse withstand voltage of
frequency withstand voltage kVrms 5kVp wave of 1.2/50µs and power
values frequency withstand voltage of
2kVrms for 1 min.
3.5 Dimensions: Length mm 1100
Width mm 1900 duplex & values are
Breadth mm 2300 indicative and actual
Weight of the relay grams sizes shall be decided during
drawing approval
3.6 Rated Vibration withstand microns As per clause 12.2.1(xi)
3.7 Shall the test kit for relay
testing be supplied? If yes
enclose technical
particulars.
3.8 How shall the C&R panel
be interfaced with SCADA
Serial Port or Hard wiring
3.9 Are there any deviations to
the RDSO specifications? If
yes enclose clause wise
deviations and reasons of
deviations.
4.0 Particulars of HV bus bar differential protection

Units Values/details
4.1 Manufacturer
4.2 Relay Identification number
4.3 Range of relay setting provided for the % 20 to 50% in steps
relay
4.4 Error in operating current for a set value % +/- 5%
of current.
4.5 Error in operating time for a set value of % +/- 10%
current.
627
4.6 Resetting time of the relay milli sec < 50ms
4.7 VA burden of the relay VA <0.2VA
4.8 DC power consumption of the relay Watt <5 watt
4.9 Short time current withstand capacity of Amps 40 times the set current for
the relay for 1 sec 1 sec.
4.10 Rated making & breaking capacity of Amps 30A for 3 sec
contacts
4.11 Rated D.C. voltage variation range for Volts 77V –126.5VDC
which relay operation is guaranteed
4.12 Rated relay voltage for the D.C. circuit Volts 110VDC
4.13 Rated relay current for the D.C. circuit Amps <0.2/110A
5.0 Particulars of Instantaneous Over Current Relay
Units Primary Side of
transformer
5.1 Manufacturer
5.3 Setting range of the relay % of 5 A 400-600% of 5A
5.4 Operating time at set current, 2 times set milli-sec <20ms
current, 3 times set current & 4 times the
set current.
5.5 Operating time at 5 times the set current milli -sec <20ms
5.6 Accuracy of operating time/Class +/- milli - +/-10% i.e. +/- 2 ms
sec
5.7 Resetting time of the relay milli -sec <50ms
5.8 VA burden of the relay VA 0.2VA
5.9 DC power consumption of the relay Watts <5watt
5.10 Short time current carrying capacity of the Amps 40 times the set current
relay for 1 sec
5.11 Current carrying capacity of the contacts Amps 5A
(normal)
(short duration 1 sec)
5.13 Rated making & breaking capacity of the Amps 30A for 3 sec
contacts.
5.14 Rated D.C. voltage variation range for Volts 77-126.5VDC
which relay operation is guaranteed.
6.0 Transformer OCR IDMT
Units Primary Side 25 KV
side
6.1 Manufacturer
628
6.3 Characteristics of the relay 3 sec curve at 3 sec
10Ir curve at
10Ir
6.4 Current setting range % of 5 A 80-320% of 5A 80-320%
of 5A
6.5 Time multiplier setting range 0.1 to 1 0.1 to 1
6.6 Error in operating current for a set value % +/-10% +/-10%
of current.
6.7 Error in operating time for a set value of % +/-10% +/-10%
current.
6.8 Resetting time of the relay milli sec <50ms <50ms
6.9 VA burden of the relay VA 0.2 0.2
6.10 DC power consumption of the relay Watts <5 watt <5 watt
6.11 Short time current carrying capacity of the Amps 100A 100A
relay for 1 sec
6.12 Rated making & breaking capacity of the Amps 30A for 3 sec 30A for
contacts. 3 sec
6.13 Rated D.C. voltage variation range for Volts 77-126.5VDC 77-
which relay operation is guaranteed. 126.5V
DC
6.14 Rated relay voltage for the d.c. circuit Volts 110VDC 110VDC
6.15 Rated relay current for the d.c. circuit Amps <0.2/110 A <0.2/110
A
7.0 Earth Leakage Protection Relay
Units Primary Side 25 kV
Side
7.1 Manufacturer
7.2 Relay identification number
7.3 Setting range of the relay 10 to 80 % in 10 to 80
steps of 5 % % in
steps of
5%
7.4 Operating time at 2, 3 & 4 times the set milli sec. 20+/- 2 ms 20+/- 2
current ms
7.5 Operating time at 5 times the set current milli sec. <20ms <20ms
7.6 Resetting time of the relay milli sec. <50ms <50ms
7.7 VA burden of the relay VA 0.2 0.2
7.8 DC power consumption of the relay Watts <5 watt <5 watt
7.9 Short time current carrying capacity of the Amps 100A 100A
relay for one second
7.10 Current carrying capacity of the contacts Amps 5A 5A
(normal)
7.11 Current carrying capacity of the contacts Amps 30A for 3 sec 30A
(short duration 1-second) for 3 sec
629
7.12 Rated making & breaking capacity of the Amps 30A(AC)(M) 30A(AC)
contacts. and 5 A & (M) and
0.5A 5A&
0.5A
7.13 Rated D.C. voltage variation range for Volts 250VAC. Cosφ 250VAC
which relay operation is guaranteed. = 0.4 . Cosφ =
220VDC, 0.4
L/R=45ms 220VDC
,
L/R=45
ms
7.14 Rated relay voltage for the D.C. circuit Volts 110VDC 110VDC
7.15 Rated relay current for the D.C. circuit Amps <0.2/110A <0.2/110
A
8.0 Transformer Differential Relay
Units
8.1 Manufacturer
8.3 Range of relay setting provided for the % Current setting: 15 to 80 %
relay in 8 steps.
8.4 Current limit for which the relay shall not Times of 5 times
operate for inrush currents set current
8.5 Error in operating current for a set value % +/-5%
of current.
8.6 Error in operating time for a set value of % +/-10%
current.
8.7 Resetting time of the relay milli sec <50ms
8.8 VA burden of the relay VA <0.2VA
8.9 DC power consumption of the relay Watt <5W
8.10 Short time current withstand capacity of Amps 40 times the set current
the relay for 1 sec
8.11 Range of bias setting % Bias setting: 15 to 50% in
min. 3 steps and max. 6
steps.
8.12 Whether the relay shall be effective for Yes
changes in the taps of the transformer
from –15 to +15%?
8.13 Whether relay should be insensitive to Yes
through fault up to 5 times the set
8.14 Whether the relay shall lock out in case Yes
2nd harmonic are more than 15%
8.15 Whether suitable interposing C.T. shall be
supplied
630
8.16 Rated making & breaking capacity of Amps 30A(AC)(M) and 5 A,
contacts 250VAC, Cosφ = 0.4 &
0.5A
8.17 Rated D.C. voltage variation range for Volts 77V-126.5VDC
9.0 Inter trip Relay
Units
9.1 Manufacturer
9.3 Operating time <12ms
9.4 Accuracy of operating time +/-10%
9.5 Resetting time of the relay <50ms
9.6 DC power consumption of the relay <5watt
9.7 Rated making & breaking capacity of Amps Making: 30A, 250VAC,
contacts 50Hz for 3 sec.
Breaking: 5A at 250VAC,
50Hz, Cosφ = 0.4
220VDC,L/R=45ms
10.0 Reverse power relay
Units
10.1 Manufacturer
10.3 Setting range of the relay 0 to 5A in steps of 0.01A
10.4 Operating time at set value milli sec <12ms
10.5 Accuracy of operating time/Class +/- milli
sec
10.7 VA burden of the relay VA 0.2
CT
PT
10.8 DC power consumption of the relay Watts <5 watt
10.9 Short time current carrying capacity of the Amps 100A
relay for 1 sec
(normal)
10.11 Current carrying capacity of the contacts Amps 30A for 3 sec
(short duration 1 sec)
10.12 Rated making & breaking capacity of the Amps 30A(AC)(M), 5A &0.5A
contacts.
631
10.16 Error in operating value +/-5%
10.17 Error in operating time +/-10%
11.0 Differential protection relay for 25 kV bus at TSS, SSP & SP
Units
11.1 Manufacturer
11.3 Range of relay setting provided for the % 20-50%
relay
11.4 Error in operating current for a set value % +/-5%
of current.
11.5 Error in operating time for a set value of % +/-10%
current.
11.8 DC power consumption of the relay Watt <5watt
11.9 Short time current withstand capacity of Amps 30A for 3 sec
the relay for 1 sec
11.10 Rated making & breaking capacity of Amps 30A(AC)(M), 5A &0.5A
contacts
12.0 Directional Numerical distance protection relay with 3 zone and
polygonal characteristics
Units
12.1 Manufacturer
12.3 Setting available in relays As per clause 9.1.2
12.4 Range in forward & reverse directions. Ohms/Nu R&X=0.04 to 50 ohms
(Indicate number of zones in forward & mber/mill Zone II operating time
reverse directions with operating time i sec 50ms for fault with in Zone
I and for the fault beyond
the Zone I
To= (Xm/Rxm)Tr+Tb
12.5 Range and steps of each settable parameter As per clause 9.1.2
as available on the relay
12.6 Operating time of each element.
12.7 Error in operating value and operating time +/-5%
of each element.
12.8 Resetting time of the relay of each element milli sec <50ms
632
12.10 DC power consumption of the relay Watts <5 watt
12.11 Short time current carrying capacity of the Amps 100A
relay for 1 sec
12.12 Operating time for I, II, III zone etc. range milli sec Operating time: 50 m – sec
of setting of additional time delay for zone for fault within zone 1 and
II & III for fault beyond the zone 1
to = (Xm/Rsm) Tr and Tb
= 50 to 150 m Ohm in
steps of 10 ms.
12.13 Whether the relay shall act for WPC type Yes Yes
of faults
12.14 Whether regeneration immunity shall be Yes
provided for the relay
12.15 Thermal withstand capability Amps 20 time of rated current for
1 sec.
12.16 Particulars of output relay
Make Amps
(b) Rating Amps
(c) NO, NC Contact details Number
12.17 Rated making & breaking capacity of Amps 30 A(AC) (M), 5A & 0.5 A
contacts
12.18 Rated D.C. voltage variation range for Volts 77 V- 126.5 VDC
12.19 Rated relay voltage for the D.C. circuit Volts 110 VDC
12.20 Rated relay current for the D.C. circuit Amps < 0.2/110 A
12.21 Whether 2nd harmonic restraint features as Yes
per clause 9.1.2(t) provided?
12.23 Whether switch on to fault (SOTF) feature
is provided?
12.24 Whether synchronous polarization feature
is provided?
13.0 Definite minimum time over current relay with instantaneous element for
feeder protection at TSS and DTOC relay at SSP/SPs
Units
13.1 Manufacturer
13.3 Current setting range Amp 50 A
a) Time delay element 5000 ms
b) Instantaneous element 0- 100 A
13.4 Time setting range Definite 0-5000, Ins 20
+/72
13.5 Error in operating current for a set value of % +/_ 5%
current.
633
13.6 Error in operating time for a set value of % +/- 10%
current.
13.7 Resetting time of the relay milli sec <50 ms
13.9 DC power consumption of the relay Watts <5 watts
13.10 Short time current carrying capacity of the Amps 30A for 3 sec.
relay for 1 sec
13.11 Rated making & breaking capacity of the Amps 30 A(AC) (M), 5 A & 0.5
contacts. A
13.12 Rated D.C. voltage variation range for Volts 77 V – 126.5 VDC
13.13 Rated relay voltage for the d.c. circuit Volts 110 VDC
14.0 Vectorial Delta I Relay
Units
14.1 Manufacturer
14.2 Rated current Amps 5A
14.3 Setting range & steps Amps 1 to 6 A
14.4 Error in operating current +/- 7.5%
14.5 Error in operating time +/-10%
14.6 setting range of ‘X’ blinder and steps of 0.5 to 30 Ohms ( in steps
its setting of 0.10 Ohms)
14.7 error in operating ‘X’ value +/- 10%
14.8 Rated short time current for 1 sec. Amps 100 A
14.9 Rated dynamic current Amps 250 A
14.10 Operating time (a) Normal milli-sec >70 ms
(b) With timer
14.11 Rated VA burden VA 0.2
14.12 Power consumption of control circuit Watts <5 watt
14.13 Maximum arc resistance that the relay can Ohm _
identify
14.14 Resetting time milli-sec <50 ms
14.15 Rated current carrying capacity of Amps 5A
contacts
14.16 Rated breaking capacity of contact Amps 5A & 0.5 A
14.17 Rated making capacity of contact Amps 30 A
14.18 Number of spare NO and NC contacts Number
14.19 Is the relay draw out type?

14.20 Are test terminals/test switches provided?
14.21 Have specimen calculations for the
recommended relay setting been enclosed
with the offer?
14.22 Rated D.C. voltage variation range for Volts 77 V- 126.5 VDC
634
14.23 Rated relay voltage for the D.C. circuit Volts 110 V DC
14.24 Rated relay current for the D.C. circuit Amps 0.2/110 A
15.0 Panto-Flashover Protection Relay
Units
15.1 Manufacturer
15.2 Operating time milli sec 40 ms +/- 5ms
15.3 Resetting time milli sec 1 sec.
15.4 Rated current carrying capacity of Amps 5 A continuous at 110
contacts VDC
15.5 Rated breaking capacity of contact Amps 5A & 0.5 A
15.6 Rated making capacity of contact Amps 30 A
15.7 Number of spare
(a) NO contacts Number
(b) NC contacts Number
15.8 Is the relay draw out type or card mounted Yes/No
type
15.9 Whether relay can identify extended feed Yes/No
condition?
15.10 Rated making & breaking capacity of Amps As above
contacts
15.11 Rated D.C. voltage variation range for Volts 77 V DC – 126.5 VDC
15.12 Rated relay voltage for the D.C. circuit Volts 110 V DC
15.13 Rated relay current for the D.C. circuit Amps < 10/110 A
15.14 Whether the relay shall be able to operate
the flasher/warn lights as also the panto
flashover prevention scheme.
16.0 Logic Based Intelligent Auto recloser
Units
16.1 Manufacturer
16.3 Range of dead time provided for the relay milli sec 0.1 to 1 sec.
16.4 Range of reclaim time provided for the Sec 6 to 60 sec.
relay
16.5 Whether the second reclose facility is Yes
available and can be switched OFF/ ON as
per the user’s requirement
16.6 For high fault level whether the auto Yes/No Yes settable 2000 to 5000
reclosure shall be bypassed. If yes what Amps A on OHE
shall be this current range Yes
16.7 Whether only one auto recloser shall close Yes/No 10-60 sec. In steps of 1 sec
when a tripping on fault occurs. during reclaim period
16.8 The time after which the 2nd auto recloser Sec 0.2
shall act for such a case as above.
16.9 VA burden of the relay VA
635
16.10 DC power consumption of the relay Watts < 5 watt
16.11 Rated making & breaking capacity of Amps 30 A(AC)(M),5A&0.5A
contacts
16.12 Rated D.C. voltage variation range for Volts 77VDC-126.5VDC
16.15 Rated voltage Volts 110VDC
17.0 Master Trip Relay
Units
17.1 Manufacturer
17.3 Operating time milli sec <12ms
17.4 Accuracy of operating time % +/-10%
17.6 DC power consumption of the relay Watts <10watts
17.7 Rated voltage Volts 110 V DC
17.8 Rated making & breaking capacity of Amps 30 A(AC)(M), 5A & 0.5A
contacts
17.9 Rated D.C. voltage variation range for Volts 77 V DC-126.5 V DC
17.11 Rated relay current for the D.C. circuit Amps <10/110A
18.0 Blower fan
Units
18.1 Manufacturer’s Name
18.2 Operating Voltage Volts 240VAC
18.3 Power Consumption at rated voltage Watts
18.4 Whether continuously rated?
19.0 Space Heater
Units
19.1 Manufacturer’s Name
19.2 Operating Voltage Volts 240VAC
19.3 Power Consumption at rated voltage Watts
19.4 Whether continuously rated?
636
ANNEXURE 5
MATERIAL SCHEDULE
(To be submitted by the purchaser for tendering)
MATERIAL SCHEDULE FOR THE SECTION ____________________________
S.No Item to be provided Quantity required at

TSS SSP SP
EQUIPMENT ON THE FRONT OF THE PANEL
1.0 Set of push button switches for control of -
1.1 HV Incoming line breaker and bus coupler
breaker
1.2 Transformer breaker primary side
1.3 Transformer breaker 25 kV side
1.4 25 kV breakers & bus coupler
2.0 Switches for local/remote change over -
breaker
2.2 Transformer breaker on HV side
2.3 Transformer breaker on 25 kV side
3.0 Automatic semaphore indicators for -
breaker
4.0 Manually operated semaphore for -
4.1 220 or 132 or 110 or 22 kV isolators
4.2 Isolators on 25 kV side
5.0 Set of Red & Green indication LEDs
for close and open positions of -
breaker
5.3 Breakers for transmission line
sectioning arrangement.
6.0 Set of push button and annunciation
LEDs for -
6.1 Trip circuit of CB fail (Yellow LED)
6.1.1 HV Incoming line breaker
6.1.2 Transformer breaker on primary side
6.1.3 Transformer breaker on 25 kV side
6.1.4 25 kV feeder breakers
637
S.No Item to be provided Quantity required at
TSS SSP SP
6.2 D.C. supply fail for control/alarm and
annunciation circuit (yellow LED)
6.3 OHE supply/PT fuse fail (Red LED)
7.0 No. of blue indication LEDs for the blower
fans of each transformer -
8.0 A.C. Ammeters on 25 kV side, Scale 0-
600/1200 Amps with associated range selector
switch
9.0 A.C. Voltmeter on 25 kV side, Scale 0-30 kV
10.0 A.C. Ammeters Scale 0-200/400 Amps for
220/132/100 kV system.
11.0 A.C. Voltmeter for 220 kV or 132 kV or 100
kV system, Scale 0-260 kV or 0-160 kV or 0-
150 kV
12.0 Annunciation system comprising –
12.1 No. of LEDs for annunciation

12.2 No. of columns of LEDs
12.3 No. of rows of LEDs
12.4 Annunciation alarm accept push button
12.5 Annunciation alarm re-set push button
12.6 Annunciation testing push button
12.7 D.C. bell operated off 110 V
(to be mounted inside)
13.0 110 V D.C. supply supervision and
annunciation scheme thereof -
13.1 Push button for DC fail alarm test
13.2 Push button for DC fail alarm accept
13.3 Indication LEDs (yellow) for DC fail
indication (240 V a.c)
13.4 A.C (240V) hooter for DC supply fail alarm
14.0 Cut off switches for disconnection of
14.1 110V DC supply to alarm and indication
circuits
14.2 240V AC supply to AC hooter and DC fail
indication lamps
15.0 Test switches & test terminal block for use

with external meters
16.0 Any other item(s) considered necessary by the
purchaser or recommended by the tenderer for
meeting the requirement of scheme
638
EQUIPMENT INSIDE THE CONTROL PANEL
1.0 Space heaters with switches (240 V A.C)
2.0 Blower fan with switches (240 V A.C)
3.0 240 V, 5 A, 3-pin socket & switch
4.0 Cubicle illumination incandescent lamp with
two door switches
5.0 Corridor illumination incandescent lamp with
two door switches
6.0 Terminal blocks
7.0 HRC or rewirable fuses and links
8.0 Earth links
9.0 Any other items considered necessary
EQUIPMENT ON THE REAR OF THE PANEL (RELAY PANEL)
1.0 For the protection of transformer
1.1 Differential relay
1.2 IDMT over current relay on the primary side
1.3 Instantaneous over current relay on the
primary side
1.4 Instantaneous earth fault relay on the primary
side
1.5 IDMT over current relay on the 25kV side
1.6 High speed inter tripping relay (hand reset
contacts)
1.7 Lockout relay (if provided) separately
1.8 Aux.Relays for transformer fault i.e. Buchholz,
excessive winding and oil temperature tripping
1.9 Aux. Relays for transformer alarm i.e.
Buchholz, excessive winding, oil temperature
and low oil level alarm.
1.10 Interposing CTs for provision in differential
protection circuit (to be mounted inside).
2.0 For the protection of OHE -
2.1 Polygonal characteristics 3 zone time graded
distance protection with wrong phase coupling.
2.2 Definite time OCR with instantaneous element
2.3 Directional definite time OCR at SSP/SP
2.4 High speed tripping relays (master trip relay)
2.5 Panto flash over protection relay at
TSS/SSP/SP* as per clause
(a) 9.8.5
(b) 9.8.6
2.6 Delta-I type fault selective relay
2.7 Logic based intelligent auto-recloser
3.0 Details for protection of capacitor bank
equipment (optional) –
639
* Note: Detailed requirement for its provision, communication media etc. shall be given
in the tender as optional.
4.0 Relays for annunciation and D.C. supervision

scheme
4.1 A set of aux. Relay necessary for annunciation
(such as annunciation relay, flasher and bell
relay etc.)
4.2 Aux. relay for d.c. supply supervision
4.3 Aux. Relay for d.c. fail alarm cancellation
4.4 Any other item(s) considered necessary by the

purchaser or recommended by the tenderer for
meeting the requirements of the scheme.
5.0 Test blocks with test plugs for testing the
relays covered above against 1.0, 2.0, 3.0, 4.0,
5.0 & 6.0.
6.0 Notebook laptop Computer (Intel M 750
Centrino based 512 MB DDR, 80GB,
CD/DVD/RW 14.1” TFT or latest) with
required latest version of softwares/ waveform
analyzing software with safe carrying cases.
7.0 HP DeskJet portable printer for printing the

waveform data
8.0 Provision of fault locator in the relay.
9.0 Differential biased bus bar protections relay

on HV side
10.0 High impedance type differential protection

relay for bus bar on 25 kV side
11.0 Reverse power relay
640
641
Annexure7(1of3)
642
Annexure-
(Sheet2of3)
643
Annexure-7(Sheet 3 of 3)
644
ANNEXURE-8
Addendum to RDSO Specification no. TI/SPC/PSI/PROTCT/4050 for Control

& Relay Panel only for the purchase of MRVC work of Design, Supply , Erection, Testing
and Commissioning of 110 kV / 25 kV Traction Substation at Jogeshwari & 9 switching
station in Mumbai Division of Western Railway at Mumbai (India)
Sr Reference Page
No. Clause
1. 12.1 610 Wherever “RDSO” is appearing in the clause to be replaced
with “MRVC/RDSO”
“Inspection &
Testing”
2. 12.2 611 Wherever “RDSO” is appearing in the clause to be replaced
with “MRVC/RDSO”
“Tests”
3. 15.0 615 (i) Wherever “RDSO” is appearing in the clause to be
replaced with “MRVC/RDSO”
“Operation (ii) Wherever “DG”(TI) RDSO” is appearing in the clause to
Maintenance be replaced with “MRVC”
Instruction &
Training”
645

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RESEARCH DESIGNS AND

HOT DIP ZINC GALVANISATION OF STEEL MAST,

(ROLLED & FABRICATED)

TUBES AND FITTINGS USED ON 25KV AC OHE

No. ETI / OHE / 13 (4 / 84)

HOT DIP ZINC GALVANIZATION OF STEEL

MAST, (ROLLED & FABRICATED)TUBES

AND FITTINGS USED ON 25 KV AC OHE

Printed November, 1984.

TRACTION INSTALLATION DIRECTORATE

S.No. Title of Specification Specification No. Page No.

1. Hot dip zinc galvanization of Steel ETI/OHE/13(4/84) with A & 4 - 18

2. Solid Core Cylinderical Post ETI/OHE/64 (10/88) with 19 - 30

3. 25 kV AC single pole & Double ETI/OHE/16(1/94) with A & 31 – 64

6. 220 kV or 132 KV or 66 kV or 25 TI/SPC/PSI/PTs/0990 with 156 - 190

8. 25 kV / 240 V, 5 KVA, 10 KVA & ETI/PSI/15(08/2003) or 205 - 238

14. Earthing of power supply ETI/PSI/120(2/91) 447- 461

15. Low Maintenance Lead Acid 40 RDSO/PE/SPEC/TL/0040- 462 – 485

17. Outdoor Circuit Breaker for TI/SPC/PSI/CB/0000 with 504- 569

18. Control and Relay Panel for TI/SPC/PSI/PROTCT/4050 570 - 645

In preparation of this specification, assistance of the following Indian Standard and

(i) IS : 4759-1979 : Specification for Hot Dip Zinc Coatings on

(ii) IS : 209-1979 : Specification for zinc.

(iii) IS : 2629-1966 : Recommended Practice for Hot Dip

(iv) IS : 6158-1971 : Recommended Practice for Safe-guarding

(v) IS : 2633-1972 : Method of Testing Uniformity of Coating on

(vi) IS : 6745-1972 : Method for Determination of weight of Zinc

(vii) ASTM A-123 : Spec. for Zinc (Hot Galvanized) Coatings on

3.1 QUALITY OF ZINC : Zinc conforming to at least grade Zn 99.95 specified in IS :

Class of Material Environment where Minimum average weight

Rolled steel masts, angles, Suburban and lightly 610

-do- Marine and chemically 1,000

Malleable iron castings. Suburban and lightly 610

-do- Marine and chemically 1,000

Structural tubes all 610

5.1 TYPE TESTS

(a) Visual Inspection (Clause 7.1)

Each test shall be conducted on three samples.

5.2 ACCEPTANCE TESTS

(a) Visual Inspection (Clause 7.1)

5.3 ROUTINE TESTS

(a) Visual Inspection (Clause 7.1)

6. SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY.

6.2 SCALE OF SAMPLING : Samples in accordance with TABLE 1 shall be taken, at

7.2 ADHESION OF GALVANISED COATING :

7.3 UNIFORMITY OF GALVANISED COATING :

7.4 MASS OF GALVANISED COATING :

7.4.3 Stripping method : In case of materials galvanized without purchasers’ inspection,

7.4.4 Magnetic thickness gauge method :

APPENDIX “A” (Cl. 4.2)

DEFECTS, THEIR CAUSES AND REMEDIAL MEASURES

Defects Causes Recommended actions Ground for rejection

Bare spots Scale or rust residues Check pickling practices

Withdrawal speed too high Remove work slowly

Stale flux burnt on during Refresh or renew flux

Expansion of entrapped Check steel quality

Effect sometimes observed Use shot blast instead of Yes, if blistering is

(Extracted from IS : 6745-1972)

Dissolve 20 g of antimony trioxide (Sb2O3) or 32 g of antimony trichloride (Sb Cl3) in 1000

M = mass of zinc coating, in g/m2, of surface.

1. Clause 6.1 shall be revised as under :

2. Table 1 under clause 6.2 shall be revised as under :

101 and above. 13 1