TECHNICAL CIRCULAR NO, 10/98 INSPECTION (Docket no..N/245/ 1/5 dated 27.2.98) ‘The following should be ensured whenever a H.0.D. comes for inspection on the division: 1, The records as under should be made available for perusal: * Interlocking Plan ‘ Locking Table/ Selection Table © Dog Chart # Wiring Diagram © Cable Plan «Cable Route Pian © Battery Cards + Bulb Register © Fuse Register © Track Circuit Card # Cable Testing Register « Record of Measurement of Earth Resistance « Records of Replacement of Insulated Joints ‘© Chart of inspection by SSE/SE/JE (sig) & Officers ‘© Maintainer's movement chart © Record of overhauling of Lever frame and block instruments «© Details of locking tests of lever frames and slide frames © Chart having the pole alignment details «Test results of overhead wires or the underground cable(as the case may be) «© Signal Failures-Analysis ofthe section © GSR, SEM, Compendium of circular. 2. The staffin charge of the maintenance of the station must be present. 3. Following tools & meters should be available in addition to the normal tools of MSM / ESM. © AVO Meters, © Train Shunt Meters © Torch with cells working properly : . Keys ofall apparatus cases Portable Control Phone © Walkie talkie sets 4, The points that are required for discussion, should be listed out neatly and given before ‘commencement of the inspection 5. The following topics will generally be discussed during the inspection: =~ ‘¢ Cornpliance of previous Inspection notes of Railway Board Members, GM, CSTE & CSE. ‘¢ Implementation of orders issued. Staff problem. System improvement measure adopted ‘Stores Matters. Progress of Works. ‘© Problem of co-ordination with other department if any. 6. Staff will be questioned to test their technical knowledge and the knowledge of rules with special ‘emphasis to safety rule. CSE ‘Compendium 7 CSTENFRAas ne 14, 15. 16. 17. 21 224 24, TECHNICAL CIRCULAR NO. 11/98 INSTRUCTION FOR INSULATION RESISTANCE TESTING OF SIGNALLING CABLES (Docket no. N/245/1/5 dated 15.1.98) General ‘These instructions apply only to cable used for Railway Signalling viz., Main and tail cables and 4o not cover line wires and internal wiring Insulation resistance tests should be conducted in such a manner that safe operation of trains is not affected. While making the tess it should be ensured that no unsafe conditions are set up by application of testing equipment: ‘All conductors in signalling cable must be tested for their insulation at the time of commissioning and thereafter in dry weather every year during October to March. ‘The insulation resistance tests should be made when conductors, cables and insulated parts are clean and dry. In addition to the regular testing of the cables in dry weather, that is during October to March, random tests to the extent of 10% of conductors should also be carried out in wet weather during July and August to localise sudden deteriorgtion in insulation of cables. In case, any deterioration is observed, complete insulation tests should be made. ‘The conductors of a cable possess appreciable electrostatic capacity and may accumulate electro static charge. The cable conductors should be shorted or earthed to completely discharge any cumulated charge (i) before connecting the insulation tester while commencing the test, and i) before the insulation tester is disconnected when the test is completed. This isin the interest of Safety of personnel and protection of the equipment ‘A 5OOV insulation tester should be used for insulation t sting, The fact that the cable has capacitance means thet it has to be charged before a measurement of the insulation resistance can be made. The insulation resistance should, therefore, be recorded after the test voltage has ‘been applied for 1 minute or 50 when the indicator of insulation tester shows a steady reading. ‘Any metallic sheath and the metal work of any rack or apparatus case should be bounded to cearth during the test. PROCEDURE: Disconnect all cores of a cable at both ends. The disconnection be made through links of ARA terminals, if provided. ‘Connect one terminal of the insulation tester to the conductor under test and other terminal to all the other conductors being bunched together and connected to earth. Repeat the procedure in para 2.2 by disconnecting earth connection, Similar test for remaining conductors of the cable one by one as in 2.2 and 2.2.1 The insulation resistance so measured should not be les than 1.0 Meg. Ohms irrespective of the length of the cable. If the insulation resistance is found to be lower than 10 Meg. Ohms, the cause should be investigated and steps taken to repair or replace the cable to prevent any mal- functioning of the equipment and circuits. The results of insulation resistance shall be recorded in a register in the approved proforma, enclosed herewith as annexure. Record of insulation measurement shall be maintained at all stations & major cabins. A comparison of test results between successive tests carried out on a cable under similar conditions will give an indication of the trend towards deterioration of the Compendium 18 CSTENFR{insulation resistence of the cable, If a sudden fall in insulation resistance is. observed, the cause should be investigated and immediate steps taken to repair or replaces the cable. CSTE ‘Annexure N.E.RAILWAY. Station Location Cores Size Grade Length ‘Type Insulation Date of installation/ Commissioning- ‘Name of manufacturer Insulation resistance in M. Ohms. Date, Month & 1 , Year of _test Weather condition Designation, | Insulation | Insulation | Insulation | Insulation valve Bs value value value Remarks ‘Signature ‘Compendium 19 CSTE/NFR21 ‘TECHNICAL CIRCULAR NO. 12/98 PERIODICAL TEST NV} WIRES ‘Docket no, N/62/1/ 10/1 (TC). Dated 3.4.98) ‘Test on overhead alignment shall be done quarterly. The quarterly tests shall be done on end to end basis ie. the tests shall be conducted over the entire control section keeping the intermediate offices disconnected. For controls with branches, each branch shall be separately treated as an individual section and tests separately conducted for each branch line in addition to centire control performance. In case the results obtained differ from the calculated value ‘sccording to the standards indicated below, further tests shall be conducted sub-sectionwise and faulty sub-section isolated. ‘The above quarterly tests shall be carried out according to the following schedile: Tests. 2) Line Transmission loss test b) Conduction test ©) Insulation test @) Loss in way station control phone ©) Point to point test for (a) to (4) ) Internal wiring at way station #) Conduction and insulation test on BLOCK wires. (Note: SI /section tobe associated during test). ‘Note: (a) to (d) and shall invariably be done in the 4" quarter irrespective of the fact that any subsection has been tested in the previous quarterly test (due to test entire control section or branch showing poor result). J a ‘The standards to be adopted for the different test results shall be as follows :- Line transmission loss. The actual values of the line transmission loss shall be less than the following calculated —values:~ Calculated values of line Transmission loss :- ‘Type.and Size of conductor. i) 68.4 KG/KM copper Weld Wire ii) ACSR 6/I/1. 89mm, dia. of Conductor iii) ACSR 6/1/1.5 mm. dia. of Conductor” iv) 28.4 KG/KM Iron Wire Ceiapendium 20 CSTENFR22 24 25 26 27 2nd Competidium a CSTENER, ¥) 177.3 KG/KM Iron 0.22 vi) 85.25 KG/KM Iron wire 0.19875 Conduction test: ‘The actual values shall not differ from the calculnted values indicated below to the extent of 4+ .% to— 1 % for Copper and ACSR wires and + 10% to ~ 4 % for Iron wites. The resistance of the two limbs of a pair shall not differ by more than 2 Ohms. Calculated values of Conductance: ‘Type.and Size of Conductor i) 684 KG/KM Copper Weld Wire 10375 Ht) ACSR6/1/1,89 mm. dia, of Conductor 3.14 {il) ACSR 611/1.5 mm dia, of Conductor ‘ » 562 {v) 28.4 KG/KM Iron Wire 48.43 ¥) 77.3 KG/KM Iron wire 34 vi) 85.28 KG/KM Iron wire 22 Insulation Test ‘This test shall be taken before sunrise preferably between 04.00 hrs. anid 06,00 hrs. for all Control and Telegraph wires and a minimum insulation of 8 Megohms per km. In dry ‘weather and 1.8 Megohms per km. in wet weather must be obtained. This applies to both the ‘earth insulation and cross insulation measured at a test voltage of not less than 100 voli. ‘Way Station control telephones: ‘The insertion loss of the telephone equipment when measured shall not eaceed the following values: + Insertion Loss valuest- 1) ‘NIL? with handset on tho Hook / Cradle switch, {t) 0.2 4B, with hand set off the Hook / Cradle switch. lil) 3.0 dB. with “Press to Speak” switch pressed Internal wiring at way stations: ‘The internal wiring in way stations shall be tested with a 100V Megger. The insulation of LI and L2 to earth shall be more than 20 Megohms and insulation of LI and L2 shell be more than 10 Megohs. : Corrosion of GI Wire in Block clreults. Due to corrosion, diameter ofthe “G.1" wire will get reduged. It will also reduc the mastunsivel strength end change the electrical characteristics, Reduction upto 10 % in diameter for GI wires of 773 Ke, per Km, may be allowed. When replacement due to corrosion willl become ‘necessary, the same shall be done on the affected portios! only, thus lengths of each sub-sectiva may be replaced in small patches. During check of the alignment by TCM/L or by TCI (section) the above defect on the Block ‘wires should be noted. The diameter of the wires has to be measured by a Screw- gauge only ‘and change the section after ascertaining that the reduced diameter is more than 10%. Results of such tests should be entered in a register maintained separately st each TCI"s Headquarters and in the office of Sr. DSTE. é 5 : ‘Any ‘defects noticed during such tests should be rectified on the spot preferably before proceeding with further tests,5, Proforma of Maintenance is given in Tables I & Il. ste Table-I ‘Transmi a y colin a & # )es]=s a eb 2 i iets al 3 | [del telgl_4 leanne g \2 2/22/55 i ale leila 22 [2 |e |ée|22|#ba sie Loam: hoger SL. ‘Name KM ‘Type Instrument's Loss in dB ‘Remarks No. | of Distance _ ‘Station Tel 1 eee ai =! B Theoreti (a) Nil (b) 0.2 dB with hand set off the hook (©) 3.0 dB with "Press to tlk or switch pressed Compendium : 2 CSTEINFRTECHNICAL CIRCULAR NO._13/98 INSTALLATION AND MAINTENANCEPRACTICES FOR RACK CIRCUIT (Docket no. N/245/ 1 / 5 dated 23.4.98) D.C. Track circuits are used for ensuring the safety of arrival and dispatch of trains. It has been noticed that the practices for installation and maintenance for D.C track circuits are differing from division to division, There appear to be confusion regarding the maximum permissible length of DC track circuits ‘on wooden and concrete sleepers for different types of track Relays. In order to stream line the types of track relays, their excitation and other related parameters, RDSO, vide their leter No. STS/E/DC track circuit dated 25.1.95,have issued detailed instructions consisting of type of relays to be used, its specification, list of materials used, installation, commission and maintenance procedure, maximum permissible length, number of cells required and maximum excitation permitted for long and short length of DC track circuits ‘The above instructions issued by RDSO are incorporated in Annexure -A to J for strict compliance. CSE ‘Annexure-A Installation & maintenance practices for D.C. Track Circuit Equipment required for D.C. Track Circuit. 1. Track battery charger as per specification no, IRS - S 88 / 93 having provision of charging upto 4cells. 2, Regulating resistance (DRG. No. SA-20161-66/M). 3. _D.C.Track relay self type or plug - in type. 4. Secondary cell 40AH capacity as per specification No. 1651 / 1979. ‘Annexure -B Types of in D.C.Track. ‘SL_|TYPE_OF RELAY | SPECIFICATION NO. CONTACT CONFIGARATION 1. | SELF TYPE BS : 1659 1 4F/4B 5 2,_2F.2F/2B 2, | PLUG-IN-TYPE | BRS939A @ APPENDIX. [ 1. 2F/1B ~ rz F2OF BRS : 956 2._2F/2B ‘NOTE :- In case of self type Relay, the resistance of track relay should be 9 ohm for the longth of track Circuits upto & less than 100 meters or when track is laid on concrete sleepers. Tho resistance of the track relay should be 2.25 ohms with a maximum contact configuration of 2F.2F/B for length of track circuits above 100M when the track circuit is laid on wooden sleepers. Compendium ae CSTENFRAnnexure-C ‘Details of materials used in D.C.Track Cireuits a i RDSO bi 9. STS /E / IRS IML ‘ST | Description of materials Drawing No. / Specification No. No. 1. _| Glued Joint RDSO/T- 1276 2. [insulated Rail Joint TRS : S-40784 3. | Location Box ‘SA 21181/M, 20325 1M 4.__| Track Lead Junetion Box SA 201017 3.__| Fuse Block DRG. NO. SA23748 6. ARA Terminal TRS : 'S75/91 or IRS:S 79/92 7.__| Cartridge Fuse IRS :S 78/92 8.__| 2 Core 2.5 Sq. mm Cable 9.__| Indoor Cable 7/0.37 Sq. mm. 10.__| Channel Bond Pin 1. [G1 Wire 8SWG. Annesure-E TION DURE While installing track circuit, the following preeautions are to be taken: ‘© Track feed equipment and secondary cells shall be installed in separate location box and as near as possible to the track. If maintenance free battery is used, this restriction shall not apply. Separate track feed shall be used for each circui For adjacent track circuit, the polarity on the rail shall be opposite as far es possible. ‘The No. of secondary cells required for track feed shall be selected as per sheet ‘The track feed charger cell selector knob shall be kept in a position of No. of cells selected. ‘The rating of the fuse at feed end shall be decided depending upon No of cells selected. ‘The track feed equipment wiring shall be done with 2.5 sq. copper cable. ‘The lead wires used for connecting the fecd'to TLIB shall be of 2 core, 2.50 sq. mm underground copper cable. . ‘©The connection between TLIB and rail shall be done with 2 core, 2.5sq. mm underground copper cable. The cable shall be clamped to PRC sleepers as per CSTE’s Office Drg. No.SK / 98 / OL (Annexure - J). ‘The track relay shall be located at the entry end of track circuit wherever possible. ‘Al the spare contacts of track relay shall be connected in parallel. Hn ion, installation & adiust SL Selftype Track | OT hype Track Relay Not Relay 1. | Maximum lengih of DC track Cireuit for [670M 610M double rail non-traction area on concrete sleeper. ‘Compendium 4 CSTE/NFRSL Description Selfippe Track | OT npe Track Relay No Relay 2. | Maximum excitation penned for maximum | 250% 250% 3 150% 150% Jength (up to_S0M )of track Circuit. | No. of secondary cells required for maximum | 172 2 SECONDARY length of track circuit. SECONDRY CELLS CELLS ‘No. of secondary cells required for short | 1 SECONDRY | 2 SECONDARY Jength of track circuit, CELL CELLS | Minimum regulating resistance required for _| 8 OHMS 3 OHMS ‘maxirmum length of track Cireuit. 7. | Minimum regulating resistance required for_| 15 OHMS 5 OHMS short length of track Circuit. Note:= 1) Regulating Resistance is 25 ohms adjustable, however figures given as 6&7 are Tor guidance. 2) With wooden sleepers, maximum length of track circuit must not exceed 1300 meters. Annexure--G Adjustment of D.C:Track Circuit using Self Type Relay ‘SL_| lem ‘Descriptions NO. 1. | Operating | RELAY RESISTANCE === F ohms 72.25 ohms parameters | PICK UP VOLTAGE —— 0368. /0.184 V relay DROP AWAY VOLTAGE —— 025V / 0.125 250% OF PICK UP VOLTAGE -——- 0.92 V / 0.46 V 150% OF PICK UP VOLTAGE = -——~ 0.552 V/ 027 V 125% OF PICK UP VOLTAGE ——- 046V/ 0.23 V 85% OF DROP AWAY VOLTAGE -—- 0.21 V/ 0.106 2 | Installation | (@) Measure length of track circuit and monitor ballast resistance. ‘funder rainy condition, it is less than 2 obms/km, reduce length of track circuit accordingly (b) After deciding the length of track circuit, follow sheet 'F to decide the no, of cell required and maximum excitation permitted. (©) Install the track cireuit as per sheet No.C. 3, | Adjustment | a) Adjust regulating resistance as per sheet 1 1b) Measure voltage across relay , it should be more than 125% of P.U voltage. ©) The voltage across relay should not be more than 250% of P.U voltage for max. length and 150% for short length of T.C. Ifit is, more, increase Regulating Resistante, 4) Apply a shunt of 0.5 ohms across track at relay end or feed end. Measure voltage across relay. It should be less than 85% of D.A value. If it is more, increase Regulating Resistance. Compendiuin 25 CSTENFRyags 60M OSNOUN2E? «=x HOLL.Y3OT ae t anion ,g3075 LNior daiinesmt SILIVed NOUV TFIVISNI CSTEINFR Compendium