Cousre Material For App Technicians OHE

Course Material for App.
Technicians (OHE)
INITIAL TRAINING COURSE FOR

APP. TECHNICIAN OHE
CONTENTS
SL.NO. CHAPTER PAGE NO
1. FOUNDATION, MEASURING / PORTABLE TOOLS, 2-17
SAFETY, FIRST AID, FIRE FIGHTING, MATERIAL
HANDLING AND STORAGE, PROPER UPKEEP OF
WORK AREA.
2. GENERAL ELECTRICAL TECHNOLOGY AND 18-21
DEFINITIONS OF ELECTRICAL TERMS
3. READING OF DRAWINGS AND CIRCUIT DIAGRAMS 22-25
4. BASIC PROPERTIES OF ELECTRICAL MATERIALS 26-27
5. NAMES, SIZES, LOCATION OF MAJOR OHE 28-40
EQUIPMENTS
6. MAINTENANCE SCHEDULES, CRITICAL POINTS, 41-55
SETTINGS AND TOLERANCES OF MAJOR OHE
EQUIPMENTS
7. TESTING, ERECTION AND COMMISSIONING OF MAJOR 56-60
OHE
8. NAMES, SIZES, LOCATION OF MAJOR PSI, SUB 61-81
STATION AND REMOTE CONTROL EQUIPMENTS
9. MAINTENANCE SCHEDULES, CRITICAL POINTS, 82-88
SETTINGS AND TOLERANCES OF MAJOR PSI,SUB
10. TESTING, ERECTION AND COMMISSIONING OF MAJOR 89-94
PSI EQUIPMENT
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Course Material for App. Technicians (OHE)
1. FOUNDATION, MEASURING / PORTABLE

TOOLS, SAFETY, FIRST AID, FIRE FIGHTING,
MATERIAL HANDLING AND STORAGE, PROPER
UPKEEP OF WORK AREA
FOUNDATION:
Definition of Railway: “Railway” means a railway, or any portion of a railway, for the
public carriage of passengers, animals or goods, and includes:
1. All land within the fences or other boundary marks indicating the limits of the land
appurtenant to a railway.
2. All lines of railway, siding of branches worked over for the purpose of, or in
connection with a railway.
3. All stations, offices, warehouses, wharves, workshops, manufacturers, fixed plant and
machinery and other works constructed for the purpose of or in connection with a
railway.
4. All ferries, ships, boats, and crafts which are used on inland water for the purpose of
the traffic of a railway and belong to or hired or worked authority administrative the
railway.
Railway Administration: President has framed rules for convenient transaction to the
business of the Government of India. The subjects allocated to the Ministry of Railway
(Railway Board), who is a Minister of Cabinet rank. He is associated in his work by one
or more Ministers who are of the status of Minister of state or Deputy Minister. These
Ministers perform such functions as may be assigned to them in relation to the business
allocated to the ministry.
The Railway Board is the chief administrative and executive body
assisting the Minister of Railways in the discharge of his functions. It was constituted by
resolution of Government of India dated 18th Feb, 1905. The Railway Board has at
present consists of
1. Chairman, Railway Board.

2. Financial Commissioner of Railways and
3. Five members each in charge of Traffic, Staff, Mechanical Engg, Civil Engg and
Electrical Engg.
The Chairman of railway board is Ex-officio principal secretary to the Government of

India in the Minister of Railways. He is solely responsible under the Minister of Railways
for arriving at decisions on technical questions and advising the Government of India on
the matter of railway policies. The chairman also functions as member in respect of one
or the other subjects as decided and is also responsible for co-ordination.
Various Departments in Railways:
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1. Operating ______ Chief Operating Manager

2. Engineering ______ Chief Engineer
3. Mechanical ______ Chief Mechanical Engineer
4. Electrical ______ Chief Electrical Engineer
5. Signal and Telecom _____ Chief Signal and Telecommunication Engineer
6. Accounts ______ Financial Advisor and Chief Accounts Officer
7. Commercial ______ Chief Commercial Manager
8. Personnel ______ Chief Personnel Officer
9. Stores ______ Controller of Stores
10. Medical ______ Chief Medical Director
11. Security _______ Chief Security Commissioner
The following are Production units, working directly under railway board;
1. Chittaranjan Locomotive Works at Chittaranjan for manufacturing of Electric
Locomotives.
2. Diesel Locomotive Works at Varanasi for manufacturing diesel locomotives.
3. Integral Coach Factory at Perambur near Chennai for manufacturing of
coaches, Electrical Multiple Units.
4. Wheel and Axle plant at Bangalore for manufacturing axles.
5. Diesel Component Works at Patiala for spares.
6. Rail Coach Factory at Kapurthala.
Railway Zones:
1. Southern Railway Chennai
2. Central Railway Mumbai
3. Western Railway Mumbai
4. Eastern Railway Kolkata
5. Northern Railway New Delhi
6. North Eastern Railway Gorakhpur
7. North East Frontier Railway Guwahati
8. South Eastern Railway Kolkata
9. South Central Railway Secunderabad
10. East Coast Railway Bhubaneswar
11. South Western Railway Hubli
12. North Central Railway Allahabad
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13. East Central Railway Hajipur
14. North Western Railway Jaipur
15. West Central Railway Jabalpur
16. South East Central Railway Bilaspur
Various divisions in South Central Railway:

1. Secunderabad division
2. Hyderabad division
3. Vijaywada division
4. Nanded division
5. Guntakal division
6. Guntur division
Various workshops available in South Central Railway:

• Carriage Repair work shop --------- Tirupati
• Rayanapadu wagon work shop --------- Rayanapadu
• Carriage workshop --------- Lallaguda
ELECTRICAL DEPARTMENT: There are four sub departments in electrical department.

Those are:
1. Traction Distribution Department(TrD)
2. Traction Rolling Stock Organization – Operations (TRSO-O)
3. Traction Rolling Stock (TRS)
4. General Services(GS)
Traction Distribution Department (TrD): This department is responsible for efficient

maintenance and operation of the Traction power supply installations, OHE (Over Head
Equipment), PSI (Power Supply Installations) and RC (Remote Control) equipment.
Traction Rolling Stock Organization – Operations (TRSO – O): This department is

responsible for maintenance of electric locomotives and electric multiple unit stock (EMU)
outside the electric loco shed. Planning the requirements of locos and EMUs to meet
traffic requirements and preparation of loco/EMU links to suit traffic requirements. Making
available locos and EMUs as well as running staff as required for traffic and keeping a
watch over train operations and making suggestions for better utilization of available
stock.
Traction Rolling Stock (TRS): This department is responsible for efficient maintenance
and repairs of the electric locos based in the shed.
General Services (GS): This department is responsible for electrical repairs and
maintenance of service buildings (offices, railway quarters and station buildings), train
lighting and air conditioning.
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STAFF WELFARE MEASURES:
Though Railway run on commercial basis but being government under taking, it has to
fulfill certain social obligations towards its employees in order to have better human
relations between employer and employee. These social obligations are collectively
known as ‘Staff Welfare’.
It is one of the functions of the Personnel Manager to be handled by the Chief
Personnel Officer at headquarters of zonal railways. Under him a Personnel Officer
(Labour and Welfare) is posted and assisted by good numbers of welfare inspectors,
personnel inspectors and cooperative inspectors to look after day to day work of this
organization. In divisions this function is managed under the control of Senior Personnel
Officer attached to the division. He is assisted by Assistant Personnel Officer (Labour and
Welfare) and a team of Welfare Inspectors and Personnel Inspectors. Similarly on
workshop side such activities managed by a Personnel Officer attached to workshops
assisted by Welfare Inspectors.
The activities dealt within this organization are:

1. Provision of Railway Institutes and Clubs.
2. Provision of schooling facilities.
3. Grant –in- Aid
4. Educational Assistance, Re-imbursement of Tuition Fee and Hostel Subsidy.
5. Provision of Holiday Homes/Convalescent Homes.
6. Scouts and Guides
7. Provision of Canteens
8. Handicraft Centers / Vocational Training Centers.
9. Provision of Co-operative Societies
10. Mobile Libraries
11. Medical facilities
12. Staff Benefit Fund
Railway Institutes and Clubs: The institutes may be provided /organized as senior and
junior institutes and should cover as wide range of staff as possible. The growth of sports,
recreation clubs and association should be encouraged, the aim being to induce greatest
numbers of railway servants to participate in health physical exercises.
Schooling facilities and educational assistance: Provisions of facilities in railway

colonies to the extent that the state governments or other educational organizations are
not willing to provide them. Elementary education and where no high schools available in
the neighbourhood education up to the high school should be deemed as an inescapable
responsibility in railway colonies, if the only alternative is to let the children of railway
workers are without educational facilities. Where the railway servants are posted in out of
way places, some provision should be made getting their children educated in high
schools and colleges.
Grants in Aid: Grants in aid to non railway schools may be sanctioned by the General
Manager in consultation with their Financial Advisor and Chief Accounts Officer.
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Educational Assistance, Reimbursement of tuition fees and Hostel subsidy: The

Railway servants with not less than 3yrs service shall be eligible for the assistance for the
education of their children in accordance with the “Railway service 1988”.
Provision of Holiday Homes: Holiday homes have been established by the railway as a
measure of amenity to the railway servant.
Scouts and Guides: The scouting organization on the railway is a separate state
association on each railway as a branch of Bharat Scouts and Guides on conditions
similar to those applicable to other state association directly under the Bharat Scouts and
Guides.
Provision of Canteens: For the Canteens a subsidy to the extent to 70% of the wages
including DA allowance relief of canteen employees may be given for each canteen. The
object of giving this subsidy is to enable the canteens to supply food at cheap rates and to
bear cost of establishment.
Handicraft centers- Vocational training centers: Handicraft centers should be set up

for the benefit of the families of the railway men for imparting training to women members
of railway men families in handicrafts such as weaving, knitting, spinning, tailoring of
garments during their spare time with object of helping them in learning some trade to
augment the family income.
Vocational training centers should be established at suitable places where classes
should be held in evening to impart the technical training to unskilled and semiskilled
workmen during their OFF duty hours for improving their future prospects, and vocational
training to the children of railway employees.
Co-Operative Societies: There are the following three types of Co-operative societies
functioning in the railways; (1) Consumer Co-operative society, (2) Co-operative credit
society and banks, (3) Co-operative Housing societies. Government policy is directed
towards encouraging Co-operative movement on Indian Railways.
Mobile Libraries: They are intended to supply reading material to staff posted at wayside
stations where they are having any amenities. Mobile libraries having adequate number of
books may be set up either attached to the existing institutes or independently.
Medical Facilities: Railways have provided railway hospitals , dispensaries , child

welfare centers , family planning centers for the benefit of railway servants , their family
members including dependents and the assistance of welfare inspector could be availed
in case of any difficulty or guidance required .
Staff Benefit Fund:

1. To give education aid to the staff and their children when no assistance is admissible
under the rules.
2. Recreation and amusement for the staff and their children.
3. Relief of distress amongst the members of the staff and their families.
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MEASURING/PORTABLE TOOLS:
S.N Tool Material Size Uses Precautions

O. Used
1. Screw Driver Steel 10,15, Used for loosening or Avoid greasy or oily
20,30cm tightening or to keep handle. Do not use
screws in position in place of firmer
Chisel. Use proper
size for particular
Screws.
2. Combination Steel 15,20, For holding, twisting or Do not cut steel
Pliers 25 cm cutting wires. wires. Do not hold
any hot substance,
Do not use in place
of hammer.
3. Round nose Steel 10cm For holding, twisting or Do not cut steel
pliers or flat joining the wires at narrow substance. Protect
nose pliers places. from rust.
4. Electrician Steel 10 cm It has two blades, one for Protect from rust,
Knife Blade removing insulation of do not use it for
pipes and other for cutting wires.
cleaning the wires.
5. Electric Copper 25w,40w To solder the joints of While using
Soldering iron bit 65w, wires and winding wires. insulate your set.
125w Do not put hot iron
on the wires.
6. Tenon or steel 30.5cm, Used for cutting wooden Protect from rust.
Hand saw 40.5cm boards, blocks, casings When not in use,
etc. apply grease.
7. Cold chisel Steel 10cm, Used for chipping, boring Should not be oily.
15 cm and channeling in walls. Avoid flat heat.
8. Try square Steel 15cm, To check the right angle of Do not use as
20 cm, corners. hammer.
30 cm Keep it safe, avoid
rust.
9. Firmer chisel Steel 1.25cm, Used for chipping, Always strike with
1.9cm, scalping and grooving in mallet.
2.54cm wood. Grind it on water
stone. Do not use
in place of
screwdriver.
10. Poker Steel 10cm, Used for making pilot Do not use it on the
15 cm holes for fixing wood metals.
screws.
11. Hand drill Steel, 3mm, Used for making holes in Should be kept
iron and 6mm, wooden blocks and clean and without
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wood 12mm boards greasy handle,

Should be used
straight.
12 Hack saw Carbon 16,20, Used for cutting conduit Keep straight while
Steel 25,30cm G.I.pipes or mild steel. cutting. Keep safe
blades from rust during
storing. Apply water
on blade while
cutting.
13 Files(flat, Steel 3”to14” To smooth the surface or Do not use without

round, half 8cm to corners of any iron Board handle
round) 35 cm etc. Do not use it as
hammer of
screwdriver or
poker.
14. Auger bit Steel 6mm to For making holes in doors, Should not be used
25mm windows to pass wires. on iron. Keep safe.
15. Pipe vice Steel 25mm Used for holding very Should not be
50mm small jobs like pins. tightened too much
100mm to break pipe.
150mm
16. Bench vice Steel 50mm Used for holding any Should not be used
75mm substance for cutting or as base for
100mm filing. hammering.
125mm
17. Pipe wrench Steel 15cm to Used for tightening or Should not be used
60 cm opening conduit pipe. as hammer. Avoid
greasy handle.
18. Mallet Wood --- Used as hammer for soft Do not use on hard
metals. metals, other than
tin or use it on
nails.
19. Blow lamp Various 0.5,1, Used to heat up the iron While burning put
1.5litre soldering irons. the mouth of
blowlamp toward
walls or put a brick
infront of blowlamp.
20. Spanner Steel ---- Spanners come in Do not use key as
sets(Double different sizes to suit hammer. Use
ended, ring different purpose. These proper key for
spanners, are used to tighten and proper nut.
slide loosen the bolts, nuts and
wrenches, screws etc.
box
spanners)
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21. Crimping Steel 1.5mm, As soldering of aluminium Do not use it on

Tool 2.5mm, conductors difficult, this thin steel made
6mm plier is used to crimp the sleeves or lugs.
joint or lugs.
22. Measuring Steel or 10,20m Used for measuring the Do not twist the
tape cotton dimensions of the wiring. open tape. Avoid
cloth from rust (steel
tape).
23. Neon Tester ---- 500 V It consists of glass bulb Do not drop it.
containing neon gas and Do not use as
two electrodes. A high screwdriver if not
value of resistance specified.
connected in series with
one of electrodes for
limiting current.
24 Plumb bob Iron or ---- For drawing vertical lines Should not be
Brass while wiring. dropped on ground.
25 Wire stripper Steel ----- These are used for Use proper cutter
and cutter removing insulation of or stripper for
P.V.C etc. wires. These particular wire.
are available with
adjustable 22SWG and
onwards. Gauge setter for
striping and cutting P.V.C
insulated wires, automatic
self-adjusting wire.
FIRST AID:
Importance of first aid: Sudden illness or injury can often be serious unless proper care
is administered properly. First aid is immediate attention to one suffering from illness or
injury.
First aid does not replace the physician, but assists the victim until proper
medical assistance can be obtained. One of the most important principles of first aid is to
obtain medical assistance in all cases of serious injury. Even seemingly, minor injuries
should be examined by a physician if there is any possibility of complication.
General procedures:
No two situations requiring first aid are the same; however, the following procedure
is generally applicable;
Take charge or follow instructions. If you are first at the scene, instruct someone to
obtain medical help and others to assist as directed. If you arrive after someone else has
taken charge, do as you are asked by the person in-charge.
Secure the scene. Ask someone to remove or mark any hazards.
If several people have been injured, decide upon priorities in-charge for each of the
victims.
Make a primary survey of the victim.
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Care for life-threatening conditions.

Make a secondary survey of victim.
Care for all injuries in order of need.
Keep the injured person or persons lying down.
Loosen restrictive clothing if necessary.
Cover victim to keep warm and dry.
Keep on lookers away from the victim.
When necessary, improvise first aid materials using whatever is available.
Cover all wounds completely.
Prevent air from reaching burned surfaces as quickly as possible by using a
suitable dressing.
Remove small, loose foreign objects from a wound by brushing away from the
wounds with piece of sterile gauze.
Do not try to remove embedded objects.
Place a bandage compress and a cover bandage over and open fracture without
undue pressure before applying splints.
Support and immobilize fractures and dislocations.
Except for lower jaw dislocations, leave the reduction of fracture or dislocations to
a doctor.
Unless absolutely necessary, never move a victim until fractures have been
immobilized
Test a stretcher before use, carefully place an injured person on the stretcher and
carry the victim without any unnecessary movements.
Controlling Bleeding: Bleeding is the escape of blood from artery, vein or capillary. Most
bleeding can be easily controlled. External bleeding can be usually suppressed by
applying direct pressure to the open wound. Direct pressure permits normal blood clotting
to occur.
In case of severe bleeding, the first aider may be upset by the appearance of the
wound and the emotional state of the victim. Remember that small amount of blood
emerging from a wound spreads and appears as a lot of blood. It is important for the first
aider to keep calm, keep the victim calm and do what is necessary to relieve the situation.
When it is necessary to control bleeding, use the following methods.
Direct pressure: The best all around method of controlling bleeding is to apply pressure
directly to the wound. This is best done by placing gauze or the cleanest material
available against the bleeding point and applying firm pressure with the hand until a cover
bandage can be applied.
In severe bleeding, if gauze or other suitable material is not available, the bare
hand should be used to apply direct pressure immediately. This will control most bleeding.
Elevation: Elevating the bleeding part of the body above the level of the heart will slow
the flow of blood and speed clotting. For example, bleeding from a cut on the hand or arm
will be slowed by raising the arm over the head.
Treating Wounds: A wound refers to any break in the skin. The skin affords protection
from most bacterial or germs; however, germs may enter through even a small break in
the skin, and an infection may develop.
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First aid for wounds: The chief duties of a first aider in caring for wounds are to stop
bleeding and to prevent germs from entering the wound. If germs do not enter, there will
be much less chance of infection and the wound will heal quickly.
Carefully cut or tear the clothing so that the injury may be seen.
If loose foreign particles are around the wound, wipe them away with clean
material. Always wipe away from the wound, not towards it.
Do not attempt to remove any object impaled in the wound. Serious bleeding and
other damage may occur if the object is removed. Stabilize the object with a bulky
dress.
Do not touch the wound with your hands, clothing or anything i.e. not cleaned, if
possible.
Place a sterile bandage compress or gauze, when available, over the wound and
tie in place.
Dressings should be wide enough to completely cover the wound and the area
around it.
Protect compresses or gauze dressing with a cover bandage made from a cravat
or triangular bandage. Place out of dressing on all wounds except for wounds of
the eye, nose, chin, finger and toe or compound fractures of the hand and foot
when splints are applied. Use either a cravat bandage or triangular bandage to
cover the entire dressing.
Unless otherwise specified, tie the knots of the bandage compress and outer
dressing over the wound on top of the compress pad to help in taking the bleeding.
However, when a fracture is involved, tie away from wound.
Keep victim quiet and lying still. Any movement will increase circulation which
could restart bleeding.
Reassure the victim to ease emotional reaction.
Dressing for wounds: The following dressing is recommended for covering wounds.
Scalp, Temple, Ear or Face
To dress a wound for the scalp, temple, ear or face, proceed as follows.
Apply the pad of a bandage compress over the wound.
Carry one end under the chin and the other over the top of the head.
Cross at the temple in front of the ear on the side opposite to the injury.
Bring one end around the front of the head and the other end low around the back
of the head.
Tie on or near the compress pad.
Cover the compress with a cravat bandage applied in the same manner.
Burns:
Classification of burns: These are classified according to extent and depth of damage
as follows:
First degree minor Burned area is painful. Outer skin is reddened.
Slight swelling is present.
Second degree moderate Burned area is painful. Under skin is affected.
Blisters may form. The area may have a wet, shiny
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appearance because of exposed tissue.

Third degree critical Intensive due to the destruction of nerve endings.
Skin is destroyed. Muscle tissues and bone
underneath may be damaged. The area may be
charred, white or grayish in color.
First aid for burns: The first aid given to a burn victim largely depends on the cause of
the burn and the degree of severity. Emergency first aid for burns should primarily be
Exclusion of air from the burned area.
Relief of the pain that immediately follows burns.
Minimizing the on set of shock.
Prevention of infection.
Remove all clothing from the injured area, but cut around any clothing that adheres to the
skin and leave it in place. Keep the patient covered, except the injured part, since there is
a tendency to chill.
First aid dressing for burns should be free of grease or oil. The use of greases or
oils in the treatment of burns makes it necessary to cleanse the burned area with solvent
before medical treatment can begin. This delays the medical treatment and is very
painful.
Fractures: A fracture is a broken or cracked bone. For first aid purposes, fractures can
be divided into two classifications:
Open or compound fracture. The bone is broken and an open wound is present.
Often the end of the broken bone protrudes from the wound.
Closed or simple fracture. No open wound is present, but there is a broken or
cracked bone.
Be careful when examining injured persons, particularly those apparently suffering from
fractures. For all fractures, the first aider must remember to maintain an open airway,
control bleeding and treat for shock. Do not attempt to change the position of an injured
person until he or she has been examined and it has been determined that movement will
not complicate the injuries. If the victim is lying down, it is far better to attend to the
injuries with the victim in that position and with has little movement as possible. If
fractures are present, make any necessary movement in such a manner as to protect the
injured part against further injury.
Material handling and working of equipments:

Push trolley:
Four locking pins to be checked before using trolley.
Hand flags of green, red to be kept, and red flag to be tied to the trolley top.
Red banner flag to be kept.
Detonators to be kept.
Truck
Battery to be checked.
Brake and horn to be checked.
Water to be filled in radiator.
Diesel oil to be checked in tank as required.
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Importance of up keep of materials:

All the materials concerned to the depot should be kept at their respective places.
Frequent change of materials from one place to another place is avoided.
Flammable material should be kept away from fire, heat and electric mains.
Fire extinguishers, sand and water are placed near to flammable material.
Steps to keep environment clean:

Concerned to stores:
The waste material is to be thrown far away from the depot premises.
The waste is to be collected in trays to avoid spillage.
In case the ground is greasy or oily, it must be cleaned with sand.
The premises should be prohibited for trespassers.
Store should be kept clean and tidy.
Concerned to office premises:
Office should be kept clean.
Bushes near to the office premises should be removed.
Plantation should be done in the office premises.
Concerned to outer field:
Muffing should be cleaned whenever possible before or after power blocks.
Mast should be painted to avoid corrosion.
Tree trimming should be along the track.
FIRE FIGHTING AND ELECTRICAL SHOCK TREATMENT:

Fires are classified as class A, class B and class C:
1. Class A: Fires which acquire in common computable material such as wood, paper
etc., these fires can be readily extinguished by water or solution containing large quantity
of water.
2. Class B: Fires involving kerosene oil, diesel or lubricating oil. For extinguishing these
fires some blanketing agent is required such as foam which deprives the fire of its oxygen
requirements
3. Class C: Fires which acquire in electrical equipments. The use of water in foam type
extinguished is not permitted. The fires are extinguished by employing some insulating like
sand or CTC (carbon tetra chloride) or CO2 (carbon-di-oxide).
Type of Class A Class B Class C

Extinguisher
Water Suitable Unsuitable. Unsuitable.
Water will spread Water being
and incur fire. conductor should
not be used on
live electrical
equipment.
Foam type Suitable for both Suitable. Unsuitable.
smothering and Smothering Foam being a
wetting action blanket does not conductor should
dissipate floats on not be used on
top of liquid. live electrical
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equipment.
Dry chemical Suitable for small Suitable. Suitable.
powder surface fires only Chemical releases Chemical is non
smothering gas conductor fog of
and shields dry chemical
operated from powder shields
heat. operated from
heat.
Carbon dioxide Suitable Suitable. Suitable.
Does not leave Non conductor
any residue or and does not
effect their damage
equipment or food equipment.
stuff.
Caution to be taken against Class A fires:

Glowing cigarette butts and matches shall not be thrown into waste buckets oil rag bins or
other place of fire hazard. Smoking and use of open flames shall be prohibited in oil
storage rooms, battery rooms and places where combustible material is kept. Before
starting welding and cutting operations it shall be ensured that sparks arising there from
do not lodge in wood work or ignite other combustible material.
Class B fires:
1. Petroleum containers shall be labelled and kept securely.
2. Oil filled containers and equipments in sub stations, store rooms etc., shall be located
such that fire from oil is not likely to do any damage.
3. Cable trenches inside stations containing tables shall be filled with sand.
4. Empty oil drum, boxes or other combustible materials shall never be piled near storage
oil tanks.
Class C fires:
1. Battery rooms shall have no loose connections and there shall be no sparking devices.
2. Flammable gases or material shall not be stored near electrical equipment.
3. Insulation strength of the equipment and cable shall be checked periodically.
4. Leakage or over loading of electrical circuits resulting in heating up of wiring must be
avoided.
Fire Extinguishers:
There are different types of fire extinguishers for different types of fires. The
commonly used types are described below.
1. Soda Acid Extinguishers: This type of an extinguisher is cylindrical or conical in

shape. Inside it, above a solution of soda and water, is a small glass flask containing
sulphuric acid. When the extinguisher is inverted the acid mixes the solution and reacts
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with soda to generate carbon di oxide. Gas pressure then forces the solution out of the
hose. It can extinguish fire which is up to about 10metres away from the fire extinguisher.
It is suitable for fires of wood, cloth, paper etc., but unsuitable for petrol, oil, spirit and
electrical fires.
2. Carbon di oxide (CO2) Extinguishers: This type of extinguisher has a horn like
nozzle and is, there fore easily distinguished from other types. It contains liquid carbon di
oxide. When released, the carbon di oxide forms flakes that vaporize and blanket the fire.
It is used to extinguish electrical fires and fires involving liquids. It is effective against
small surface fires and not used in the open air.
3. Foam Extinguishers: Foam extinguishers are used against inflammable liquids and
small fires in solids. They cannot be used against electrical fires as both water and foam
conduct electricity. A foam extinguisher contains water, sodium bi carbonate, an agent for
strengthening the foam and a phial and containing aluminium sulphite powder. When
mixed there form a foam of CO2 bubbles.
4. Carbon Tetra Chloride Extinguisher: It comprises a cylindrical metal container

containing carbon tetra chloride liquid. When released, it turns into a vapour i.e. heavier
then air and thus settles over the fire. It is suitable for electrical fires but is should not be
used in enclosed places as the vapour is poisonous.
ELECTRICAL SHOCK TREATMENT:

If an electrician or any person is still in contact with the live wire or equipment, he or
she must be quickly released from the electrical contact by:
(a) Switching OFF, if it is not available
(b) Pulling out plug, etc., if not possible
(c) Insulate your self from the ground, by using a rubber mat, dry wood or clothing and
then free the victim. A wooden stick can be used to knock the victim free.
Extinguish any spark (if there is) in the clothes of the patient. Ascertain whether he is
breathing or not. Send for doctor. Till the doctor arrives, give first aid for resuscitation. There
are three methods:
Methods of Resuscitation
1. Prone resuscitation
2. Mouth-to-mouth resuscitation
3. Mouth-to-nose resuscitation
Prone Resuscitation (a) Back Pressure arm lifts method (Holger-Nielsen Method):
There are several methods of giving artificial respiration in the prone position,
among which the Holger-Nielsen Method is the most common.
Here, the victim is made of lie on his stomach with his elbows bent and his hands
under his head. The person administering artificial respiration kneels down with his left
knee opposite the victim’s head and his right foot on the ground, near the victim’s left
elbow. He then places his hands on the back of the victim, the thumbs just touching, and
gently rocks forward until his arms are almost vertical and he is exerting pressure on the
back. The entire moment takes the seconds. The moment causes air to be exhaled.
ETTC/BZA Page 15
After this, the reviver rocks back gently counting “three” for one second and
places his hands under the victim’s elbows
The reviver then slides his hands past the victim’s shoulders until his hands can
grip the victim’s upper arm near to the elbows. Then he rises and pulls the victim’s arms
until tension is felt. This action, which is completed in two seconds by counting “four, five”,
causes air to rush into the lungs of the victim.
Afterwards, by counting up to “six” for one second, the reviver lowers the victim’s arms to
the ground and brings back his hands to the original position. This completes a full cycle.
10 to 12 full cycles are applied in a minute.
Mouth-to-mouth resuscitation:
The mouth-to-mouth method assures positive moment of air into the lungs.
Therefore this method is preferred when the victim cannot be placed on his back or if he
is still on a pole or a tower after receiving shock. The procedure for mouth-to-mouth
resuscitation is as follows:
1. Remove any obstruction from the victim’s mouth.
2. Place the victim on his back with his head tilted backwards and his chin pointing
upwards.
3. Open our mouth wide and take a deep breath. Place your mouth tightly over the
victim’s mouth and keep his nostrils tightly shut.
4. Blow gently into the lungs of the victim until the victim’s lungs get filled with air.
5. Remove your mouth and watch from the return rush of air from the victim’s lungs.
6. When the expiration is complete. Repeat the procedure until the victim resumes
natural breathing.
Mouth to nose Method:

1. Place him on back.
2. Clear his mouth and throat. Turn his head to side and remove any foreign bodies with
fingers.
3. Tilt his head back by holding lower jaw – open this air passage and keep tongue out of
throat.
4. You take deep breath of fresh air.
5. Place mouth over his nose. Hold mouth closed.
6. Blow into nose. Adults blow fully, children puff gently, watch chest rise.
7. Remove mouth let chest fall.
MATERIAL HANDLING AND PROPER UPKEEP OF WORK AREA :

Push trolley:
Four locking pins to be checked before using trolley.
Hand flags of green and red to be kept and red flag to be tied to the trolley top.
Red banner flag to be kept.
Detonators to be kept.
Road Vehicles / Tower Car:

Battery to be checked.
ETTC/BZA Page 16
Brake and horn to be checked.

Water to be filled in radiator.
Diesel oil to be checked in tank as required.
IMPORTANCE OF UPKEEP OF MATERIALS

Steps to be taken for proper up keep of environment clean:
All the materials concerned to the depot should be kept at their respective places.
Frequent change of materials from one place to another place is avoided.
Inflammable material should be kept away from fire, heat and electric mains.
Fire extinguishers, sand and water are to be kept at prominent places.
High standard of cleanliness shall be maintained. Waste material, oily waste or
rags etc. shall be removed from the premises daily and suitable disposed of.
Trees and rank vegetation shall not be permitted to grow in the neighbourhood of
substations, switching stations or other buildings. Roofs of buildings and the whole
area of the sub stations and offices shall be kept clear of dry leaves, packing cases
or other dry combustible material.
Before starting welding and cutting operations, it shall be ensured that sparks
arising there from do not lodge in wood work or ignite other combustible material in
the area.
While installing heating devices, hot water pipes, etc. suitable clearances from the
combustible material shall be maintained.
The vicinity of cables should be kept clear of oily dirt or other combustible material
Concerned to stores:
The released / unserviceable items are to be disposed off.
The waste is to be collected in trays to avoid spillage.
In case the ground is greasy or oily, it must be cleaned with sand.
The premises should be prohibited for trespassers.
Store should be kept clean and tidy.
Concerned to office premises:

Office should be kept clean.
Bushes near to the office premises should be removed.
Plantation should be done in the office premises.
Concerned to outer field:

Muffings of structures should be cleaned.
Mast should be painted to avoid corrosion.
Tree trimming should be along the track.
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2. GENERAL ELECTRICAL TECHNOLOGY AND

DEFINITIONS OF ELEICTRICAL TERMS
Electric circuit: It consists of battery or generator as source of supply, resistances and
switch or switches and the connecting wires. It is of three types.
1. Open circuit
2. Closed circuit
3. Short circuit
Open circuit: In this circuit, the switch is open, so current does not pass through this
circuit.
Closed circuit:In this circuit, the switch is in ‘ON’ position, so the current passes through it.
Short circuit: In this circuit, the resistance does not come into the circuit and the current
takes the short way. Such circuit takes more current than the normal current.
Current: Flow of Electrons in any conductor is called Current. It is represented by ’ I’.

The unit of current is Ampere.
Voltage (or) Potential Difference: The potential difference (V) between two points in a
circuit or electromotive force required to drive the current between them.
The unit of potential difference is same as of Electromotive force, which is volt.
Resistance: Resistance may be defined as that property of a substance, which opposes

the flow of electricity through it.
It is represented by ‘R’.
Power: It is the product of voltage and current. It is represented by P. The unit of power
is Watt. Power P=V x I.
Ohm’s Law: Ohm’s law states that in any closed circuit the current is directly proportional
to the voltage applied and inversely proportional to the resistance of the circuit , keeping the
physical conditions same.( Ex: temperature).
V=IR, where V = voltage applied to the circuit,

I= current flowing in the circuit,
R= resistance of the circuit.
Voltage Current Resistance Watts

V=IR I I=V/R R=V/I W=VI
V=W/I I I=W/V R=V2/W W=I2R
V=√(W*R) I=√(W/R) R=W/I2 W=V2/R
Work: It is said to be done by force F when the point of its application moves through a
distance S. The unit of work is Newton- metre or joule. Mathematically
Work= Force x distance. (W=F x S)
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Horse Power: It is the unit of mechanical power and it is defined as the work done per
minute or per sec by the machine. Electrically it is equal to 746 watts.
1 Horse Power=746 watts
Magnet: It is the substance having the properties of attracting iron and its alloys.
Properties:
1. The magnet always attracts iron and its alloys.
2. The magnet has two poles and when it is freely suspended, it comes to rest pointing
north and south directions.
3. Like poles repel and unlike poles attract each other.
4. If a magnet is broken into pieces, each piece becomes an independent magnet.
5. A magnet loses properties when it is heated, hammered and dropped from height.
6. A magnet can impart its properties to any magnetic material.
Electromagnet: The magnet, which loses its properties as soon as the magnetizing
force is removed, is generally known as electromagnet.
Magneto motive force (M.M.F): It is the difference of magnetic potential, which maintains
a magnetic flux in a magnetic circuit. It is just like E.M.F.
Generator: It is a machine, which converts mechanical power into electrical power.

It works on the principle of Faraday’s law of Electromagnetic Induction.
Motor: That machine converts electrical energy into mechanical energy. It works on the
principle that whenever a current carrying conductor is placed in a magnetic field, conductor
tends to move.
Cell: It is an electro chemical system that converts chemical energy into electrical energy.
Ex: dry cell, lithium cell.
Cells are divided into two types:

1. Primary cell
2. Secondary cell
Primary cell: When the chemical reaction is irreversible it is called a Primary cell.
Secondary cell: When the chemical reaction is reversible, it is called Secondary cell.
Battery: A number of cells connected together are called as ‘Battery’.

Alkaline Cell: These are of two types:
1. Nickel iron type known as Edison Cell.
2. Nickel cadmium known as junger cell
Edison Cell (Nickel iron type):

The Materials used in the cell are:
(a) Nickel oxide on the positive plate.
ETTC/BZA Page 19
(b) Iron oxide on the negative plate

(c) The electrode is 20% solution of caustic potash (KOH) along with some quantity (1%) of
lithium hydroxide (LiOH) whose effect is to increase the capacity of the cell.
Characteristics of Nickel Iron Cell:

1. Fully charged cell has emf of 1.4V. It decreases rapidly to 1.3V and then very slowly to
1.1V on discharge.
2. It has good mechanical strength due to steel plates.
3. The cell can withstand heavy charge and discharge current.
4. There is no harm to leave it in discharge condition for a long period.
5. Internal resistance is large and so efficiency is lower than the lead acid cell.
6. With increase in temperature, emf decreases slightly but the capacity increases
appreciably.
7. It is superior to lead acid cells in mechanical strength, durability and robustness.
Nickel Cadmium Cell: The positive cell is build up from a no. of steel tubes made of
perforated steel and the same electrolyte. However, the negative plate is of cadmium unlike
the Edison cell. The use of cadmium reduces the internal resistance of the cell.
Electromotive Force or Potential difference: The potential difference between the +Ve
and – Ve plates of a cell on open circuit is called the e.m.f of a cell and is represented by E.
Terminal Voltage or Potential Difference: The potential difference between the plates of
the cell when delivering the current to the external circuits is called the terminal voltage or
potential difference of a cell.
Internal resistance of a cell: The opposition offered to the flow of current in a cell is called
the internal resistance of a cell and is represented by ‘r’. The internal resistance of a cell
due to the resistance of (a) electrodes (b) terminals of the cell and (c) electrolyte. It
depends upon the size and spacing of plates and is independent of the current delivered by
the cell.
Grouping of Cells:
1. Cells in series
When cells are connected in series, total e.m.f. (E is given by the sum of their
individual e.m.f)
E=E1+E2+E3+……….. and similarly the combined internal resistance is given by
the sum of their individual resistances.
Combined internal resistance r=r1+r2+r3+………
If ‘n’ similar cells each of e.m.f. ‘E’ and resistance r, are connected in series, then
the total emf =n*E and total internal resistance =nr
If cells are connected to external resistance R, the current (I) through the circuit is
given by I=total e.m.f / total resistance=n*E / (nr+R).
For maximum current total resistance should be small as compared to the external
resistance.
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Cells in Parallel: When’m’ similar cells are connected in parallel, then the total e.m.f (E) =
the potential difference between A and B.
i.e., equal to the e.m.f of one cell (E).
So total emf = E.
The combined internal resistance of the circuit=r/m
If r is the external resistance in the circuit then the current (I) through the circuit is given by
I=E/(r/m+R) =mE/(r+mR)
For maximum current, external resistance should be small as compared to the total
resistance.
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3. READING OF DRAWINGS
Drawing instruments are used to prepare drawings easily and accurately. The following
are the drawings instruments, which are generally used:
1. Drawing Board
2. T-square
3. Set – squares 45º and 30 º - 60 º
4. Compass
5. Divider
6. Drawing Pencil
7. Scale
8. Protractor
9. Rubber Eraser
10. Drawing Pins
11. Drawing Paper
12. Mini Drafter (or) Drafting Machine
Drawing Board: It is placed on the table in front of the student with its working edge on
his left side. It is more convenient if the table top is sloping downwards towards the
student if such a table is not available the necessary slope can be obtained by placing a
suitable block under the distance longer edge of the board.
T- Square: It is used as the working edge and hence, it should be perfectly straight. The
T-square is used for drawing horizontal lines as well as vertical lines.
Set- Squares: They are triangular in shape with one corner in each a right angle. The 30
º - 60 º set square of 25 cm length and 45 º set square of 20 cm length are convenient
sizes.
Set squares are used for drawing all straight lines except the horizontal lines which
are usually drawn with T- square. Vertical lines can be drawn with the T- square and Set
square.
Compass: It is used for drawing circle and arcs of circles. It consists of two legs hinged
together at its upper end. A pointed needle is fitted at the lower end of the one leg, while
pencil needle is inserted at the end of the other leg.
Divider: It has two legs hinged at the upper end and are provided with steel points at both
the lower ends, but it does not have knee joints. These are used (1) to divide curved or
straight lines into desired number of equal parts (2) to transfer dimension from one part of
the drawing to another part and (3) to set off given distances from the scale to the
drawing.
Protractor: It is used to draw or measure such angles as they cannot be drawn with the
set square. A circle can be divided into any number of equal parts by means of the
protractor.
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Drawing Pins: These are used to fix the drawing paper on the drawing board. Clips or
adhesive tapes are also often used instead of the pins.
Mini Drafter: The uses and advantages of the T-square, set square, scales and
protractor are combined in the mini drafter. Its one end is clamped by means of a screw to
the distance longer edge of the drawing board. At its other end, an adjustable head
having protractor markings is fitted. It is used to drawing drawn horizontal, vertical and
inclined parallel lines of desired lengths can be drawn any where on the sheet with
considerable ease and saving of time.
Scales:
Drawings of small objects can be prepared of the same size of the objects they represent.
A 15 cm long pencil may be shown by a drawing of 15cm length. Drawings drawn of the
same size as the objects are called full size drawings. The ordinary full sizes scales are
used for such drawings.
Reducing and Enlarging Scales: It may not be always possible to prepare full size
drawings. They are, therefore, drawing proportionately smaller or larger. When drawings
are drawn smaller than the actual size of the objects (as incase of buildings, bridges,
large machines etc.) the scale used is said to be a reducing scale. Drawing of small
machine parts, mathematical instruments, watches etc. are made larger than their real
sizes. These are said to be drawn on an enlarging scale.
Representative Fraction: The ratio of the length of the drawing to the actual length of
the object represented is called the Representative Fraction (R.F). When a 1cm long line
in a drawing represents 1metre length of the object, the R.F is equal to 1cm/1m= 1/100
and the scale of the drawing will be 1:100 or 1/100 full size. The R.F of a drawing is
greater than unity when it is drawn on an enlarging scale. For example, when a 2mm long
edge of an object is shown in a drawing by a line 1cm long, the R.F is 1cm/2mm=5. Such
a drawing is said to be drawn on scale 5:1 or five times full size.
Types of scales: The scales generally used for general engineering drawings are 1:1,
1:2, 1:2.5, 1:5, 1:10, 1:20, 1:50,1:100, 1:200, 10:1, 5:1, 2:1. Scales used by civil
engineers and architects are 1:1, 1:2, 1:5, 1:10, 1:20, 1:50,1:100, 1:200,1:1000,1:2000
etc. All these scales are usually 30cm long and sub divided throughout their lengths.
The scale of a drawing is indicated on the drawing sheet at a suitable place near
the title thus, Scale 1:2 or Scale half full size.
Scales on drawings: When an unusual scale is used. It is constructed on the drawing

sheet. To construct a scale the following information is essential:
(i) The R.F (Representative Fraction) of the scale.
(II) The units which it must represent, for example, millimeters and centimeters, or feet
and inches etc.
(iii) The maximum length which it must show.
The length of the scale is determined by the formula:

Length of the scale = R.F x maximum length required to be measured.
ETTC/BZA Page 23
Various Types of Lines:
Outlines: Lines drawn to represent visible edges and surface boundaries of objects are
called outlines or principal lines. They are continuous thick lines (A).
Dashed lines: Interior or hidden edges and surfaces are shown by dashed lines. They
are also called dotted lines.
lines. They are of medium thickness (B) and made up of short
dashes of approximately equal lengths of about 2mm spaced at equal distances of about
1mm.
Centre lines: Centre lines are drawn to indicate the axes of cylindrical, conical or
spherical objects or details and also to show the centre of circles and arcs. They are thin
and long chain lines (C) composed of alternatively long and short dashes spaced
approximately 1mm apart.
Dimension lines: These lines are continuous thin lines (D). They are terminated at the
outer ends by ends by pointed arrow heads touching the outlines, extension lines or
centre lines.
Extension lines: These lines also are continuous thin lines (D). They extend by about
3mm beyond the dimension lines.
Cutting Plane lines: This line shows the location of a cutting plane. It is a thin and long
chain line, thick at the ends only (E).
Long Break lines: These lines are thin ruled lines with short zigzags within term (G).
They are drawn to show ling break.
Lettering: Writing of titles, dimensions,

dimensions, notes and other important particulars on a
drawing is called lettering. It is an important part of a drawing. It should be in plain and
simple style so that it could be done freehand and speedily.
ETTC/BZA Page 24
Single stroke letters: These are the simplest form of letters and are usually employed in
most of the engineering drawings. The word single stroke should not be taken to mean
that the letter should be made in one stroke without lifting the pencil. It actually means
that the thickness of the line of the letter should be such as is obtained in one stroke of
the pencil. The horizontal lines of letters should be drawn from left to right and vertical or
inclined lines, from top to bottom.
Single stroke letters are of two types: (I) vertical and (ii) inclined. Inclined letters
lean to the right, the slope being 671/2º to 75 º with the horizontal. The size of a letter is
described by its height. The ratio of height to width varies but in case of most of the letters
it is 6:5.
Lettering is generally done in capital letters. Different sizes of letters are used for
different purposes. The main titles are generally written in 10mm to 12mm size, sub titles
in 3mm to 6mm size while notes dimension figures etc. in 3mm size to 4mm size.
Gothic letters: Stems of single stroke letters, if given more thickness, form that are
known as gothic letters. These are mostly used for main titles of ink drawings. The
outlines of the letters first drawn with the aid of instruments and then filled with ink. The
thickness of the stem may vary form 1/5 to 1/10 of the height of the letters.
ETTC/BZA Page 25
4. BASIC PROPERTIES OF ELECTRICAL MATERIALS

Conductors: These are substances which offer such a small resistance that they rapidly
allow electricity to flow through them. Such as copper, aluminium, iron etc.
Insulators: These are substances which offer such an enormous resistance that they
allow practically no electricity to flow through them; such as rubber, asbestos, bakelite,
mica, ebonite.
Uses of Conductors and Insulators:

CONDUCTORS INSULATORS
Sl.No: Conductors Uses in Electrical Sl.No. Insulators Uses in
Field Electrical Field
1. Silver Special meters, 1. Mica In elements or
Contact points. winding
2. Copper Wires and 2. Rubber Insulation in wires
Accessories
3. Brass Switches(Terminals) 3. Dry Cotton Winding
4. Aluminium Wires(Conductors) 4. Varnish Winding
5. Iron Wires(Telephone) 5. Asbestos In the bottom of
Irons and Kettles
etc.
6. Carbon Generator and Motors 6. Porcelain Overhead line
insulators
7. All glasses Lamps 7. Glass Overhead line
insulator
8. Water Battery or 8. Ebonite Bobbin of
load(Electrolyte) transformer
9. Dilute acid Batteries(Electrolyte) 9. Fiber Bobbin making
and winding
insulation
10. Lead Joints and wire 10. Empire Cloth Winding insulation
covering
11. Mercury Special switches and 11. P.V.C Wire insulation
meters switch etc. Making
for insulation
12. Bakelite --do--
13. Slate Making panel
boards
14. Paraffin wax sealing
15. Plastic Wires insulation
or Switches Body
Dielectric Strength: The insulating material, which can withstand without break down
voltage, is called its dielectric strength. In other words, it is the maximum kilovolts per
millimetre or volt per millimetre, which a medium can withstand without breakdown.
ETTC/BZA Page 26
Dielectric Strength of various insulating materials:

Sl.no: Dielectric Material Dielectric Strength
o
kV/mm at 20 C
1. Mica 20-60
2. Asbestos 42
3. Rubber vulcanized 30-50
4. Micanite 20-40
5. Ebonite 30-40
6. Varnish oil 30-40
7. Varnished Paper 16-40
8. Bakelite 17-21
9. Insulating oil 10-16
10. Glass 8-12
11. Porcelain 8-12
12. Paraffin wax 12
13 Resin 12
14. Wood-impregnated 2-6
15. Ordinary paper 2-6
Thermal Classification of Insulating Materials:
Class Limiting Materials

Temperature(◦C)
Y 90oC Cotton, silk, paper of similar organic materials
neither impregnated nor immersed in any oil,
rubber, polyvinyl chloride.
A 105 oC Impregnated paper, silk, cotton (fibrous
materials), polymide resins.
E 120 oC Enameled wire insulations on basis of Polyvinyl
formed poly-urethane and epoxy resins, moulding
powder plastic etc.
B 130 oC Inorganic materials (mica, fiber, and glass,
asbestos) impregnated with varnishes or other
compounds.
F 155 oC Polyester epoxide varnishes and other varnishes
with a high resistance.
H 180 oC Composite materials on mica, fiberglass and
asbestos bases impregnated with silicones
rubber.
C 225 o C Mica, ceramics, glass, teflon
ETTC/BZA Page 27
5. NAMES, SIZES, LOCATION OF MAJOR OHE

EQUIPMENTS
MASTS:
Masts: Mast is a structure used for supporting the OHE. Electrical and mechanical
clearances are achieved by these structures. The structures are classified as:
1. BFB mast (Broad Flanged Beam)
2. RSJ mast (Rolled Steel Joist)
3. Fabricated mast
4. Temporary mast
5. TTC mast (Two / Three Track Cantilever)
6. Portals
1. BFB mast (Broad Flanged Beam): These masts are having flange width and web or
depth is same, and varies from 6”X6” to 16”X16” depending upon the load, for which the
masts are required to carry. These masts are suitable for single cantilever assembly on
tangent track and for umbrella masts. 8”X8” BFB masts are suitable for anchor masts.
There masts are good enough in bending moment but weak in resisting the twisting
moment.
2. RSJ mast (Rolled Steel Joist): These are available in different sizes but only 8”X6”
RSJ masts (200mmX150mm) are used for supporting the OHE. These masts are suitable
for resisting both bending and twisting moment in normal locations. They are also suitable
for anchor, anti creep centre and for double cantilever locations. Approximate weight of
mast is 53.3 kgs/mtr.
3. Fabricated mast: Normally two types of fabricated masts are used for 25KV A.C
traction .Those are K and B series. K and B series are used in traction and finally only B
series are being adopted in present electrification. Fabricated masts are light in weight
and able to withstand for different types of loading in 25 KV OHE. They are good enough
to resist bending, twisting and deflecting movements. Saving of steel is achieved but its
fabricated cost is more.
(a) K series: Cross section of this series is expressed in metric system. Depth
(fabricated side, across the track dimension) is constant and equal to 300mm and width of
the channel flange is variable and mast is designated as per the width of flange as Ex: K-
100, K-125, K-150, K-175, K-200, K-225 and K-250. One of the disadvantages of this type
of mast is due to larger depth of cross section i.e. 300mm and is not suitable for locations
where TCs (distance between two track centres) are inadequate.
(b) B series: This is the latest traction mast of 9.5mts long. This mast is similar to K
series in design, the two channels of same size are welded together with the help of
batten plates. It is designated as B-100, B-125 up to B-250.
ETTC/BZA Page 28
4. Temporary mast: These masts are used in accident relief and break down works for
giving the OHE fit within short time and with restricted speed. These are fabricated with
BFB, RSJ sections and fitted with special base.
5. TTC mast: Where adequate clearance is not available to erect independent masts, this
type of mast is used, which holds cantilevers of two or three tracks with one mast only,
where usage of portal is not possible. The length of mast is 12.21m and length of booms
is 5.50 &8.00 m.
6. Portal structures: The best design of an OHE layout plan is one, which makes the
maximum use of independent structures. But in big station yards, it is always not possible
to locate independent OHE structures in between two tracks. In such cases, portal
structures covering 2 to 8 tracks are used.
In general, portal is not used for holding OHEs of two tracks, but in special cases, it
is necessary to erect portals on platforms to provide adequate clearance for movement of
public. Mechanical independence of each track of OHE cannot be achieved in this type of
structure. Portals can be used for both regulated and un-regulated OHE.
Classification of portals:
1. N type: It is made up of four angles of 65X65X6mm kept at a distance of 450X450mm

welded together by means of lace rods of 16mm dia. The overall height of upright is
10.51mtr and maximum clear span is 20mtr. It can cover up to four tracks.
2. O type: This is made up of four angles of 75X75X8mm kept at a distance of
550X550mm welded together by means of lace rods of 20mm dia. The overall height of
upright is 10.61mtr and clear span is 30mtr. It can cover up to six tracks.
3. R type: This type of portal is made up of 4 angles of sizes 80X80X8mm and kept at a
distance of 600X600mm welded together by means of lacing rod of 20mm. It can cover
eight tracks. The overall height of upright is 10.66 m.
4. G type: It is made up of two channels of size, 400X100mm. Overall section of
400X250mm is used in place where adequate clearance is not available to erect ‘O’ type
fabricated upright.
DESCRIPTION N TYPE O TYPE R TYPE
CROSS SECTION 450X450 MM 550X550 MM 600X600 MM
LENGTH OF NU – 10.51 M OU – 10.61M RU – 10.66 M

UPRIGHT
END PIECE NE1 – 5.38 M OE1 –10.55 M RE1 – 11.55 M

NE2 – 5.88 M OE2 –11.05 M RE2 – 12.05 M
NB --- 1.5 M , 3.0 M , OB --1.5 M , 3.0 M RB – 7.5 M, 9.00 M,

CENTRE PIECE 4.5 M, 6.0 M, 7.5 M, , 4.5 M, 6.0 M, 7.5 10.5 M, 12M,13 M
ETTC/BZA Page 29
9.0 M M, 9.0 M
ROD LACING 65X65X6 MM 75X75X8 MM 80X80X8 MM
CLEAR SPAN 10 – 20 M 20 –30 M 30 – 36 M
NO. OF TRACK 4 NO. 6 NO. 8 NO.

(MAX)
DROP ARMS: These are suspended from the booms. Cantilevers are fixed on the drop
arms. The length of drop arm is 3mts. There are 3 types of drop arms: A, B and C.
A-TYPE DROP ARM: This is made up of 4 angles of size 35x35x6mm and kept at a
spacing of 300x200mm welded by means of 12mm diameter lace rod. This can carry only
one cantilever and fixed on 20mm side of drop arm.
B-TYPE DROP ARM: This is made up of 4 angles of 35x35x6mm and kept at a spacing
of 300x300mm welded together by means of 12mm diameter lace rod. This can carry two
cantilevers on one side or one cantilever on either side (back to back).
C-TYPE DROP ARM: This is made up of 6’’x6’’ BFB section. This can carry one
cantilever on one side and two cantilevers on either side (back to back).
CANTILEVER ASSEMBLY:
It is an insulated swivelling type structural member comprising of different sizes of

G.I tubes. OHE is supported with mast by means of cantilever assembly. The tubes are
designed to take the weight of conductors and radial tension acting on it. Insulation from
the mast is arranged through special solid core insulators called stay insulator and
bracket insulator. The cantilever assembly is so designed to keep the OHE system in
position to facilitate current collection by means of pantograph at all speeds without
infringement. The arrangement of cantilever depends upon height of contact wire,
encumbrance, setting distance, stagger and super elevations. A cantilever assembly
consists of the following.
Stay arm: It consists of 28.4/33.7mm size G.I tube and an adjuster at the end to keep
the bracket tube in position. It is insulated from the mast by stay insulator. The selection
of size of stay tube at the location shall be such that the adjuster is free for adjustment
upto 30mm in either direction.
ETTC/BZA Page 30
Register arm tube: It comprises of 28.4/33.7mm size G.I tube to register the contact wire
in the desired position with the help of steady arm.
Bracket tube: It comprises of 30/38mm (standard) or 40/49mm (large) G.I tube insulated
through bracket insulator. Catenary is supported from this member through catenary
suspension bracket and catenary suspension clamp. The size of the bracket tube shall be
decided at the time of selection of bracket assembly depending on the suspension
distance. The free length of bracket tube beyond the catenary suspension bracket fitting
is at least 200mm to facilitate future adjustment.
Steady arm: It is BFB section made up of 32/31mm aluminium alloy to hold the contact
wire to the required stagger and to take the pushup of the contact wire.
The arrangement of cantilever assembly depends upon the height and stagger
of the contact wire, encumbrance, super elevation and implantation. More than one
cantilever assembly is provided on the mast for over laps, turnouts/cross overs and
diamond crossings.
Cantilever assembly of special design may be adopted on bridges and tunnels
after making clearance steady. Cantilever assembly can be designed upto 3.50m
suspension distance only. If the suspension distance is more, bracket chair shall be used.
In polluted areas (near to seacoast/ saline prone areas) etc., long creepage insulators
shall be used on cantilever assembly.
AUTO TENSIONING DEVICES:
ATD means a device to give automatic tension during elongation or contraction of OHE
due to variation in temperature. There are three types of ATDs
1. Winch type
2. Pulley block type
3. Three pulley type
With all types of regulating equipments, the main purpose of maintenance is to ensure
that the counter weight is free to move up and down through the guide tube without any
obstructions.
Winch type ATD: This consists of two pulleys, the bigger pulley is fixed with mast
anchoring attachment is known as drum and is kept vertical, the smaller pulley is movable
and is kept horizontal and is known as auxiliary(small) pulley. The OHE is anchored with
the movable pulley through a 9-ton insulator, compensating plate, 9-ton adjusters for
contact and catenary with double strap and ending clamps. The length of steel rope is
10.50mts and overall diameter, 8.50mm.The mechanical advantage of this type ATD is
five.
Counter weight for conventional OHE winch type ATD=2000/5=400kg
Counter weight for tramway type OHE = 1250/5=250kg
Three-pulley type ATD: The equipment consists of three pulleys, wire rope, counter
weight and other fittings. The equipment is so designed that the three pulleys remain in
the same vertical plane, the block of two pulleys are fixed to the mast through pulley arm
and associate fittings. The third pulley which is connected to OHE through pulley arms
and associate fitting is movable with variation in the temperature. The stainless steel wire
ETTC/BZA Page 31
rope is same as used with winch type ATD, the one end of the rope is attached with the
pulley arms of the movable pulley fittings. The other end of the rope is passed round on
each of the pullies and attached to counter weights, through which the counter weight is
permitted to move freely on the guide tube. The mechanical advantage of this type ATD is
three.
Counter weight for conventional OHE to be 2000/3= 667kg
Counter weight for tram way type OHE =1250/3=415kg
DROPPERS:
The satisfactory performance of the OHE depends on the good profile of the contact wire.
Droppers transfer the load of the contact wire to centenary wire and maintain a correct
required profile of the contact wire. The following types of droppers are used in 25kV
OHE.
In span dropper
Register arm dropper
Adjustable dropper
Rigid dropper
Special dropper
Sl.no Type of dropper Location Size
1. In-span dropper In between Catenary and contact 5mm dia
wire
2. Register arm dropper Bracket tube and register arm tube 7mm dia
3. Adjustable dropper Section insulator 5mm dia
4. Rigid dropper Turnouts 107mm dia
5. Special dropper In between Catenary and contact 3mm thickness and
wire for special encumbrances 25mm width.
JUMPERS:
Jumper connection plays a vital role in maintaining the continuity of supply

of 25kV AC supply in OHE. When a pantograph passes, the strands of flexible jumpers
are liable to break down to some extent. To avoid this special attention should be given to
jumpers. The following should be ensured for jumpers.
1. Sufficient length and suitable looping should be provided for proper flexibility.
2. Suitable cross section is to be maintained to carry normal rated current.
3. Proper flexibility and tightness of PG clamp connections.
Types of jumpers:
1. In-span jumper (or) “C” jumper
2. Continuity jumper (or) “G” jumper
3. Potential equalizer jumper (or) “F” jumper
4. Cross feeder jumper
5. Isolator jumper
6. Anti theft jumper
7. Booster Jumpers
ETTC/BZA Page 32
S.No Type of jumper Location Size Length

1. ‘C’ jumper (or) Between Catenary and 50sq.mm 1.6m
in-span jumper contact for every 350m
2. ‘G’ jumper or Un-insulated Overlaps 105sq.mm 3.6m

continuity and turnouts to
jumper 4.2m
3. ‘F’ jumper or Insulated Overlap and 50sq.mm 1.6m

Potential Overlap at Neutral
equalizing Section
jumper
4. Cross feeder FP, SP and SSP 150sq. mm Variable length

Jumper
5. Isolator jumper At Isolators 105sq. mm Variable length

6. Anti-theft jumper At anchoring points 50sq. mm Variable length
7. BT Jumpers At Booster Transformers 105sq. mm Variable length
TURNOUTS:
Turnout is the arrangement of points and crossing with lead rails by means of which
rolling stock is diverted from one track to another. Wiring of turnouts is of three types
1. Cross type
2. Overlap type
3. Knuckle type
Cross type turnout: In this type of equipment, the contact wire of turnout crosses the
contact wire of main line at its contact height itself. It is placed just above the contact wire
of main line and in order to ensure least movement between contact wires, a contact bar
is used. This bar (contact wire consists of short length) of contact wire fixed on the top of
the contact wire for mainline by means of two PG clamps. Crossings of contact wire
should preferable lines towards, the where separation between centre line of main line
and that of turnout is 450mm. at crossings of wire staggered for main contact wire will be
+/- 150mm and stagger of turnout , contact wire is +/-300mm with cross type equipment.
Overlap type Turnout: Speed restriction on mainline undesirable therefore cross type
OHE is not preferable on mainline track, overlap or knuckle type of OHE is preferred. In
this the contact wire for the main and turnout run along each other for same distance the
contact wire of the turnout is lifted for anchoring the two contact wires never crosses each
other during their in running condition, the conductor of turnout is lifted in one span and
anchored in next span. On the double bracket, structure (obligatory mast) at the turnout
ETTC/BZA Page 33
the contact wire of turnout is kept 50mm above that of the main track. Since there is no
contact wires in midspan, it is obligatory to locate an obligatory mast in a certain length of
the track separation to ensure proper contact for locomotive negotiating turnout, provided
all other points are satisfied, the obligatory structure should be located between a point
where track separation is between 150mm and 700mm.
Knuckle type Turnout: In this type of turnouts, there is no speed restriction. This
arrangement is similar to overlap type turnout. The equipment joining the mainline i.e. the
turnout OHE is kept 50mm higher than mainline OHE. At the other end is provided with
one set of knuckle assembly.
OVERLAPS:
For the entire section of electrification, a continuous runoff cannot be provided

because of difficulty to string at a time for handling of contact wire and catenary wire
drum. However, the size and weight of each drum coil be such that it would be difficult to
transport to the site. For longer length during accident whole of the length will be affected
and whole section will be under breakdown.
There are two types of overlaps:

1. Uninsulated overlap(UIOL)
2. Insulated overlap(IOL)
Uninsulated overlap: In this type of overlap, electrical continuity is maintained even

though there is mechanical separation. In an uninsulated overlap, the OHE run parallel
under kept at a distance of 200mm. They are permanently connected together electrical
by continuity jumper called “G” jumper.
1. Three span UIOL
2. Four span UIOL
Insulated overlap: These are insulated mainly to provide insulating facility required for
the operation and maintenance of OHE. If two lengths of OHE belong to two adjacent
elementary sections, there will be insulated overlaps span. Insulated overlaps are
provided at feeding post (FP), sub-sectioning paralleling post (SSP). Insulated overlaps
are similar to uninsulated overlaps but the gap b/w two contact wires is increased to
500mm to provided insulation between them and also to prevent accidental contact
between them.
Electrical continuity between the section is maintained though jumper connections
is series with Isolator or BM interrupter with this arrangement a section can be made dead
end work can be done on the other equipment away from overlap.
1. Three span IOL

2. Four span IOL
ETTC/BZA Page 34
Sl.no Insulated overlap Uninsulated overlap

1. The distance between two OHE The distance between two OHE wires is
wires is 500mm 200mm
2. It has two ‘F’ jumpers It has one ‘G’ jumper
3. It has isolator It has no isolator
4. It is used at SSPs It is used at every tension length.
NEUTRAL SECTION:
As the supply of 25kV, 1-Φ, 50Hz traction load causes unbalance on the 3-Φ loads and
distribution of the grid authority adjacent substations are connected in cyclic order of two
different phases to minimize unbalancing. To prevent bridging of two different phases by
passing panto it is necessary to provide electrical discontinuity, for mechanical continuity
neutral section is provided midway between two substations, which is electrically isolated
from any of the section. Neutral section permits smooth passage of the pantograph from
one section to other. The function of neutral section is to avoid short-circuiting between
different phases.
Location of Neutral Section:

1. The neutral section should not be located on up gradients.
2. There should be no curvature.
3. There should not be anything near the neutral section, which may cause the
restriction to the speed of loco.
4. It should not be located in station limit area but preferably in midsection
between two stations.
5. It should be located away from the stop signals and level crossings.
Types of Neutral Sections:

1. Overlap type Neutral Section
2. Section insulator type Neutral Section (45m)
3. PTFE type Neutral Section
Sl.no. Type of Neutral section Length of Neutral section

1. Overlap type NS 41m
2. Section insulator type NS 45m
3. PTFE type NS 2.968 m
EARTHING AND BONDING:

The earth is taken as zero potential for the entire practical purposes any appliance
or parts of machine, when connected to earth attains zero potential it is said to be
earthed, the voltage of earthed body will be zero.
Purpose of Earthing
To save human life from danger of shock or death in case any frame or body of
equipment becomes charged due to fault or leakage current.
To protect all machines fed from OHE and due to lightning.
To serve the purpose of return path for traction rails.
ETTC/BZA Page 35
Types of Earthing:
1. System earthing
2. Equipment earthing
System Earthing: Earthing associated with current carrying conductor is normally

essential to the security of the system. At the traction substation one leg of 25kV side of
traction transformer has been solidly by connecting it to earth ring. One terminal of
secondary of PT, CT and AT has been connected to earth ring.
Equipment Earthing: Earthing of non current conductor and metal structure to safe
guard of human life, animals and property.
Earth Resistance: At each power supply installation, an earth ring comprising required
number of earth electrodes which are interconnected by means of M.S flat is provided.
The combined resistance shall not be more than the following values.
1. Traction Substation: 0.5ohms
2. Switching stations : 2 ohms
3. C.T and A.T : 10 ohms
BONDING:
Bond: It means an electrical connection between two rails or any structure to rail. The
resistance for a kilometre length of continuous track rail is 0.05 ohms. But the resistance
of fish plate joint is more than that or rail , hence in order to reduce the resistance of the
track as a whole, the joints are supplemented with a good conductor i.e., called bond.
Bonding of rails facilitates passage of return current from rail to earth and earth to
rail. It is therefore necessary to provide bonding in the vicinity of feeding stations where
return current has to back from earth to rail and back to the earthed leg of traction
transformer.
Type of Bonds:
1. Structure Bond
2. Rail Bond (or) Longitudinal Bond
3. Cross Bond
4. Impedance Bond (or) ‘Z’ Bond
Structure Bond: Bond connecting traction mast or structure to rail by M.S flat of size
40/6mm or stranded wire of 240 sq.mm. cross sectional area is called structure bond.
Rail Bond (or) Longitudinal Bond: It means an electrical connection across a rail joint
between two consecutive lengths of rails by means of M.S flat 40/6mm.
Cross Bond: It means a bond between two rails of same track or rails (IR or IT) of
adjacent track by means of M.S. flat size 40/6mm. The cross bonds are provided at FP,
LC gates, station yards and at a distance 350mtrs in open route.
ETTC/BZA Page 36
Impedance Bond (or) ‘Z’ Bond: These are provided in track-circuited areas. A special
rail bond provide, to bridge the traction rails at an insulated rail joint in A.C track circuited
sections is called ‘Z’ bond o f M.S.flat of size 40/6mm is used for ‘Z’ bond.
Difference from D.C system: In this case of D.C traction system the whole of the
traction return current particularly follows through the rails. Therefore bonding of rails is
necessary to permit passage of return current from electrical loco to the traction
substation.
On the contrary in case of 25kV A.C traction most of the return current flows
through the earth except in a zone over a few 100m on both sides of electrical loco or in
the vicinity of feeding station. Therefore bonding is more essential in D.C traction.
Span: Span is defined as the distance between two consecutive OHE structures and is
measured in metres.
Span lengths are chosen in multiples of 4.5m. The shortest span adopted is 22.5m
and the longest depending on the particular specification of the wind speed zone and the
type of equipment, being maximum of 72m. The difference between two consecutive
spans should not exceed 18m to ensure compatible flexibility over the adjacent spans.
Non-standard span lengths are permitted, only when special conditions do not permit
choice of standard span sizes, such as, while locating structures on bridge piers or if
structures are required to be located at a given location on bridge structure. The
maximum span length as permitted by the location should be aimed at. On tangent track,
this is the maximum permissible depending upon the particular specification of the
section. On curves, turnouts and crossovers, the span lengths are lower, being governed
by the maximum permissible stagger of the contact wire at the structure and in the middle
of the span; this limitation being guided by the design consideration of pantograph contact
surface, its sway and blow off of OHE conductors in wind. As a general rule, the
maximum stagger at a structure should not exceed 300 mm on curves and 200 mm on
tangent track. Mid span staggers should also not exceed the prescribed figures.
In case of regulated OHE, the maximum span used is of 72m, while this value is
67.5 m incase of unregulated OHE.
Stagger: In order to avoid damage to the pantograph and the OHE, it is of paramount
importance that there should be good current collection at all permissible speeds under all
weather and track conditions. It, therefore, becomes necessary that the contact wire
should always be within permissible limits of current collecting zone of pantograph.
If the contact wire is placed at the centre of the track throughout, the pantograph
will be touching the contact wire only at middle. This will result in formation of groove at
the middle of pantograph, which is not desirable. To avoid this, the contact wire is
staggered.
Stagger of contact wire: Contact stagger is the displacement of contact wire with
respect to pantograph axis.
On tangent track, the contact wire is normally given a stagger of 200mm at each
support alternatively on either side of the centre line of track.
Stagger of catenary wire: Stagger of catenary wire is the displacement of catenary wire
from the centre of the track.
On tangent track, the catenary stagger is zero for mast supporting single
equipment.
ETTC/BZA Page 37
Staggers on curved track: On curves, the stagger of the contact wire at supports
should not exceed 300mm. The stagger of the catenary has standard values of 0, +200,
-200.
Staggers at turnouts and crossovers: The stagger of the contact wire of the branching
line shall not exceed 300mm at any point in the span. This is achieved by selecting a
suitable location for the mast near the centre of turn-out incase of overlap type of
equipment and suitably adjusting the point of crossings of two contact wires in case of
crossed type equipment.
Implantation (Setting Distance): It is the distance between the centre line of track and
the nearest face of the mast.
The implantation has been standardized for certain values given below to facilitate
cutting of cantilever assembly tubes to standard sizes.
1. On tangent tracks and for locations on out side of a curve the implantation kept is
normally 2.5 m.
2. For locations, which are on inside of a curve the implantation kept, is 2.75m for open
route section.
3. For structures on platforms, the minimum implantation kept is 4.75m.
For portal upright or a mast carrying more than one OHE the setting distance adopted
should not be less than 3.0m
Encumbrance: It is the axial distance on vertical plane between catenary and
contact wire at the OHE support. The encumbrance shall normally be 1400mm at single
cantilever structure.
Sl.No. locations Encumbrance

1. Mainline 1400mm
2. Overlaps 400mm,750mm and 900mm
3. Over line structures 600mm,500mm,400mm and 300mm
TYPES OF OHE:
Over Head Equipment (OHE) means the conductors over the tracks together with
their associated fittings, insulators and other attachments by means of which they are
suspended and registered in position.
1) Regulated OHE
2) Unregulated OHE
3) Semi-regulated OHE
Regulated OHE: On the mainline OHEs compensated little variation in temperature. The
tension on the catenary and contact wire is maintained constant at all temperatures with
an equipment which is called regulated OHE. In this type of OHE, tension remains
constant at 2000kg, 1000kg for catenary wire and 1000 kg for contact wire irrespective of
temperature variations. All the variations are in temperature compensated by auto-tension
device provided on both ends of OHE. The tension of 2000kg is maintained by a balance
weight of 400kg made of cast iron counter weights. Mechanical advantage or weight
ETTC/BZA Page 38
transfer ratio of ‘5’ achieved with the help of ATD. This type of OHE helps for high speed
traffic hence used mainline.
Un-regulated OHE: It means, the OHE which is not regulated or which is not provided
with the regulating equipment at the ends. In this type of OHE both ends are directly
terminated on masts. The mid span height of the contact wire changes according to
temperature variation and hence the height of the contact wire is not constant. This type
of OHE is not suitable for current collection at high speed. In the interest of economy
where the speed is less, this type of OHE is provided. The tension length is 2000m and
the tension on is 3000kg. The height of contact wire is 5.75m at the support.
Semi-regulated OHE: It means, the OHE, which is regulated by means of regulating

equipment at one end and the other end being fixed. This type of OHE is used where the
length the OHE is less than 800m.
Difference between Regulated and Un-Regulated OHE:
Regulated Un-Regulated
1. Used for high-speed track on main line. 1. Used for unimportant lines where speed
is restricted.
2.Tension in conductors is 2000kg 2. Tension in conductors is 3000kg. 1700kg

for contact and 1300kg for catenary.
3. Height of contact wire is 5.55/5.6m at 3. Height of contact wire 5.75m at support.
support.
4. OHE anchored with ATD. 4. OHE anchored with fixed termination.
5. Anticreep wire at middle of tension length 5. Anticreep is not provided.
is provided.
6. Maximum tension length is 1600metres. 6.Maximum tension length 2000m.
7. Maximum span length is 72m. 7. Maximum span length 67.5m.
8.Normal maintenance is required 8. Normal and seasonal maintenance
required.
Over Dimensional Consignments (ODC):

ODC: When a consignment having with length, breadth such that one (more) of these
infringe the standard moving directions at any point during the run from start to
destination, then the consignment is called ODC. It is also known as out of gauge load. If
any package before loading exceed the following dimension. It is to be treated as ODC.
Length 13716 mm
Width 2997 mm
Top width 610 mm
Centre height 2734 mm
Corner height 2143 mm
Classification of ODC:
1. A class ODC
ETTC/BZA Page 39
2. B class ODC
3. C class ODC
1.A class ODC: A class load which have gross clearance that is clearance measured
center under stationary condition of 9 inches or above(2286mm) from the fixed structure
all around. These are committed to run in day and night with a speed restriction of
40kmph.
2. B class ODC: B class loads which have gross clearance of (152) 6 inches or above
but less than 9 inches. These will run during day light only with speed restriction 30kmph,
which must be further, reduced to 15kmph while passing station yards, curves and
tunnels. These loads are moved under special supervision of TXR. One brake van is
attached next to engine just after the load where the TXR will travel.
3. C class ODC: ODC, which have gross clearance, which have less than ‘6’ inches, but
more than 3 inches (76.2mm), is named on ‘C’ class ODC. It has speed restriction of
25kmph. It must be further reduced to 8kmph, while passing tunnels, crossings and
station yards etc. It can pass only at day light with dead slow speed while passing fixed
structure such as water column, signal supervision of TXR, PWI and T.I.
Moment of ODC in Electrified Section:

1. An ODC can be moved in the electrified section at unrestricted speed with power on
condition when the clearance is 390 mm from the contact wire.
2. An ODC having 390 mm to 340mm can be moved at Speed Restriction of 15kmph
with power ON condition.
3. An ODC having physical clearances between 340 mm to 100 mm can be moved
under power OFF condition with 15 Kmph.
4. No ODC with clearance less then 100 mm will be permitted in 25 kV electrified
section.
5. No person should climb on the roof of carriage or wagons when these are located
under the OHE except when the OHE is made dead and earthed.
6. A representative of TRD should accompany all ODC loads to supervise the safe
movement of ODC at locations where clearances of contact wire are critical.
7. A representative of TRD should accompany ODC loads having width more than
1981 mm for Broad Gauge.
8. Section Controller & TPC must co-ordinate while an ODC moves in electrified section
to ensure that masts are not damaged at location where the clearances is critical.
ODC Movement in Power OFF Condition:
When an ODC is permitted to move in an electrified section with the Power OFF, it would
be the responsibility of the Section Controller to arrange the Power block in concerned
with TPC. The power to be cut OFF before admitting the ODC in to the section. An
authorized representative of TRD branch will obtain confirmation from the TPC by
message confirmation from TPC by message supported by private number that the power
is switched OFF over the specified section only. On receipt of such MEMO the train,
carrying the ODC may be allowed to enter in to the section. Since such MEMO is not a
Permit To Work (PTW) earthing of OHE is necessary.
ETTC/BZA Page 40
6.MAINTENANCE SCHEDULES, CRITICAL

POINTS, SETTINGS AND TOLERANCES OF
MAJOR OHE EQUIPMENTS
MAINTENANCE SCHEDULES OF OHE
The following schedules of maintenance for the OHE or required to be followed. To

ensure efficient current collection as well as safety of installations and personnel.
1. Foot patrolling
2. Trolley inspection
3. Current collection test
4. Special checks
5. AOH (Annual over hauling) and tower wagon check
6. POH ( Periodical over hauling)
7. Retensioning of unregulated OHE
Foot Patrolling: The object of foot patrolling is to make visual inspection of every part of
the OHE so that any defects or abnormalities noticed are recorded and reported to the
maintenance gangs for attention. An experienced OHE lineman( accompanied by a
khalasi if deemed necessary by local conditions) should be deputed to patrol the section
on foot by day, so as to cover every part of the section including yards once a fortnight
and suburban section once in a week. If this patrolling done thoroughly, many of the
defects will be noticed at the incipient stage, before they develop into major defects. The
lineman on foot- patrol should be equipped with signal flags, an emergency telephone
instrument and essential tools required for attending to defects on the spot e.g., spanners
for tightening bond connections. The lineman on patrol duty should particularly look for
the following:
1. Chipped or damaged insulators
2. Displaced/damaged fittings, droppers and jumpers.
3. Excessive sagging or hogging of contact wire.
Trolley Inspection: Inspection of OHE by push trolley is essential except in sections

where use of trolley is prohibited. The object of trolley inspection of OHE is to enable
supervisor and officers in charge of OHE maintenance to observe closely the OHE under
their charge, and should be carried out during daytime. The depot in charge should
inspect his entire section by push trolley once in a month. SSE/AEE should inspect their
respective sections once in 3/6 months respectively by push trolley or motor trolley as
convenient. Sr.DEE/DEE(TrD) also should cover his section also should cover his entire
section at least once a year by push trolley or motor trolley.
Apart from trolley inspection as above, officers and senior subordinates shall travel
by the cabs of locomotives and EMU trains as often as possible but at least once a month
to observe the general condition of OHE and to get a first hand knowledge of operating
conditions.
ETTC/BZA Page 41
Current Collection Test: It is necessary to carry out the periodic tests to detect points at
which contact between the contact wire and pantograph is unsatisfactory resulting in
sparking. Such current collection tests are performed at night.
A mirror can be fixed in the front of the look out glass of the rear cab of a
locomotive and adjusted so as to get a reflection of the rear pantograph, which is normally
in service. A person travelling in the cab can then observe the mirror any sparking which
may takes place. The location where the sparking is observed and the severity of the
sparking should be immediately noted down and the OHE at the location got checked up
as soon as possible to find out and eliminate the cause of sparking.
The current collection tests as above should be carried out by the depot in-charge once in
3 months.
Special Checks:
While the majority of the items require attention only during annual maintenance
and POH, some items require more frequent attention. They are
1. Cleaning of insulators: Generally, insulators need cleaning once a year along with
the Annual maintenance schedule. At locations subject to smoke pollution on
account of steam locos or pollution due to industrial dust, the frequency of cleaning
will have to be fixed based on the extent of such pollution. Where pollution is heavy,
cleaning has to be done more frequently. With the application of silicon grease, the
interval for cleaning at such locations can be extended significantly.
2. Section Insulator checks: Section insulators on the main lines such as at neutral
sections and passenger yards should be attended to as under once in three months.
Check the pantograph passes underneath the S.I. smoothly
Clean insulators and replace badly chipped or even slightly cracked
insulator.
Tighten properly the PG clamps of droppers and stiffeners.
At yards, load sidings etc. the continuity and soundness of earth connection
should be checked once in a month
Bi-metallic clamps
Earth connections
Feeders
OHE supported on steel girder bridges.
Bird nests
3. Pre monsoon checks:

Check the condition of insulators.
Overline structure for any water leakage.
Trimming of tree branches.
Condition of embankment with respect to stability of mast.
Rod gaps for electrical clearances.
Annual over Hauling (AOH): This schedule must be carried out once in a year during
the schedule, fittings are not generally dismantled, but all fittings, which are found
defective, must be replaced.
ETTC/BZA Page 42
Masts, Portals and Cantilever supports:

1. Check rail level and setting distance against marking on the mast variation
about 30mm in the setting distance and the 20mm rail level should be
notified to PWI for correction.
2. Check all anchors for tightness of bolts and provision of check nut and pin.
3. Examine each structure to ensure that muffing permits drainage of water
outwards, clean the muffing.
4. Check all bonds thoroughly and replaced missing bonds.
5. Examine study and register arm hooks for possible cracks.
6. Clean all insulators and replace the cracked insulators.
7. Check and adjusted height and stagger of OHE.
8. Record A, B and C values, Encumbrance, steady clearance and adjust if
required.
9. Replace rested bolts and nuts.
10. Check the pressure of caution bolts and no. of plates.
Contact and Catenary wires: Thoroughly examine the condition of contact and catenary
wires particularly for kinks and twists in contact wires and broken strands of catenary
wire. Catenary wire should be spliced if more than 20% of strands are found broken.
Check the tightness of PG clamps and jumpers.
Droppers: Check droppers and tighten bolts wherever required.
Turnouts:
With tower car running on loop line check up the panto passes smoothly under the
mainline OHE.
With tower car running on mainline check up the panto passes smoothly under the
loop line OHE.
Check stagger of both the OHEs at turnouts. (It shall not normally exceed 300mm).
Check up mainline OHE of overlap type turnouts is at least 50mm below that of the
turnout OHE.
Check cross contact bar for any displacement.
Check up rail level and setting distance of obligatory mast.
Check up any hit marks on the obligatory mast.
Check up for hot spot near rigid dropper.
Section Insulator:
1. Clean the insulators and replace badly chipped or slightly cracked insulators.
2. Check up runners for flash marks.
3. Observe hit marks on runners.
4. Check for excessive contact wire wear near anchor clamps.
5. Tighten PG clamps of adjustable droppers for stiffness.
6. Check the stagger of S.I is between 0-100mm
Regulating Equipment:
1. Check Z&Y values in case of winch type equipment and X&Y values in case of
3-pulley type equipment. These values should be as per prescribed values for the
ETTC/BZA Page 43
temperature at the time of checking. If necessary adjusts Z value making use of 9-

ton adjuster.
2. Check the compensating plate is vertical. If not, adjust it.
3. Lubricate all moving parts.
4. Check 20mm wide bands in black colour are painted on the mast to indicate upper
and lower limits of movements of counter weight.
Isolators:
1. Check number plate of isolator.
2. Check corrections of operation and alignment of contacts and arcing horns.
3. Check earth continuity where applicable.
4. Lubricate moving parts.
5. Check the interlocks.
6. Check that the distance between male and female contacts in open condition
380mm to 500mm depending on type of isolator.
Overlaps:
1. Check height and stagger of OHE in overlap section.
2. Check whether normal minimum clearance of 500mm is available between two
OHEs in an insulated overlap and 200mm incase of uninsulated overlap.
3. Check whether the lifting of out of run OHE is correct.
4. Check for parallel running of contact wires in the overlaps and check for the panto-
sweeping zone, which should be above 4mts.
5. Check for the correct position of droppers and see that all droppers take load.
6. Check the condition of jumpers and replace if necessary.
Contact wire thickness: Measure and record the contact wire thickness at all vulnerable
locations.
Over line Structures:

1. Check and record horizontal and vertical clearances and adjust the OHE if required.
2. Check for any flash marks underneath the bridge structure
3. Check that the gradient of contact wire an either side does not exceed 3mm/m
Level Crossings:
1. Check the height of the contact wire.
2. Check and adjust height and slope of contact wire
3. Record height with height gauge.
Periodical Over Hauling (POH): The aim of POH is to recondition and restore the
installation to the original condition when it was first commissioned. POH should be
thoroughly complete and cover every part of the installation. POH is carried out once in
4years (now once in 54 months) to every IOH will be a POH (Every IOH will be within a
span of 18months). The work involved in POH is somewhat greater than the pre-
commissioning test, since after years of service the parts would have somewhat wear and
tear.
Necessary adjustments will have to be made or repairs done to make good to the
wear or if it is not possible the materials, irreparable items should replaced. The POH of
OHE should be planned on a programme basis so that every part of the installation
receivers detailed attention.
ETTC/BZA Page 44
To summarize the object of POH is to make through inspection of OHE and to

replace such of the worn out or the damaged parts by new parts. The parts replaced are
taken back to the depot for dismantle, through examination, specify and re-assemble for
use again as required.
The following items should be attended during POH:

1. Cantilevers all the items detailed under POH should be followed. At least one
cantilever assembly for 10kms should be removed and taken to the work shop
For dismantling and detailed examination. After through cleaning this would review the
extent to which the other C.L. assemblies have to be examine.
2. All regulating equipments should be replaced by previously over hauled equipment.
The removed equipment should be brought to the workshop for complete overhaul.
3. Check the position of bracket tube w.r.t. the axis of the mast, register arm steady
arm should be in the same place as the bracket tube.
4. Check and adjust cantilever for the slope and displacement at every structure as per
the approved structure erection drawing (SED).
5. Dismantle all jumper connections; clean the conductors if the places show signs of
overheating. This may be because either they are not tight and proper or the clamps are
deformed. The deformed clamps should be replaced.
6. The contact wire dia at all vulnerable locations should be recorded. Check the
condition of splices, remove kinks.
Overlaps: check and adjust if necessary the position of contact wire with respective
tracks to comply with SED. Ensure that insulators or anchoring wires are crossing the
OHE are in correct position.
Check the height of contact wire above the track and gradient of contact wire near
over line structures check clearance between bottom most part of over line structure
and catenary and adjust if required
Turnouts: Carefully check and adjust the position of contact wire with respective
tracks as per SED.
Re-Tensioning Of Un-Regulated OHE: Re-tensioning of un regulated OHE should be

done normally at the end of 6 months from the date of erection and again at the end of
12months, thereafter the tension should be checked once in 2years and if required
retensioning is to be done.
MAINTENANCE RECORDS AND THEIR IMPORTANCE:

OHE:
Records to be maintained: Particulars of other essential records to be maintained about
OHE maintenance are given below:
1. Daily Report of OHE Maintenance to be submitted by the supervisor in charge of
fieldwork to SE.
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2. Register for Foot patrol Reports: The reports regarding foot patrolling should be
entered by the linesman in a Register to be maintained for the purpose by each Section
Supervisor.
3. Cantilever assembly maintenance Register: This should be maintained by each
depot/sub-depot.
4. Register of contact wire diameter measurement.
5. Register of clearances under over line structures.

6. Register of Earth resistance measurements.
7. Register of current collection tests.
8. Register of Regulating Equipment: It shall be maintained by each depot/sub-depot

for its jurisdiction. This register should have a page allotted for each regulating
equipment. Particulars of adjustments carried out, amount of catenary and contact wire
cut etc., shall be recorded in this register, indicating the dates on which these items of
work have been done.
9. A register for isolator switches: It shall be maintained by each depot/sub depot

indicating dates on which the isolators have been inspected and the details of carried out.
10. A register for turnouts and cross overs: It shall be maintained by each depot/sub
depot. This should indicate the date on which each turn out/cross over has been checked
for adjustment and particulars of work done.
11. Register of Vulnerable Foundations: This should contain details of checks carried
out of foundations at vulnerable locations, such as on over bridges, embankments
susceptible to erosion etc.
12. Register for feeder lines: It shall be maintained by concerned depots/sub depots to
indicate particulars of patrolling of 25kV feeder lines and maintenance carried out on such
feeder lines.
13. Register of critical implantations: The annual check of implantation at critical

locations shall be recorded in this register.
14. Register of level crossings: This should contain dates on which height of contact
wire at level crossings as well as the height gauges of level crossings have been
checked.
15. Register of splices.
16. Register of OHE breakdowns: Each depot/sub depot should maintain particulars of
OHE breakdowns occurring in its jurisdiction. For each Breakdown, a page should be
allotted. Reference to detailed reports submitted should also give to facilitate
investigations subsequently.
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The registers should be of A4 size. Registers required for permanent record and
should be cloth bound (khaki color). The nomenclature of the register should be shown on
the cover in 6mm black letters.
The supervisor of the depot/sub depot will be held personally responsible for
ensuring that these registers are maintained up to date. Officers and senior supervisors
during their inspections should scrutinize these registers and initial a few important
entries.
PSI:
1. Sub-station Equipment Register.
2. Switching Station Equipment Register.
3. Capacitance Value Register.
4. Earth Resistance Value Register.
5. Equipment Failure Register.
6. Equipment History Register.
7. Transformer History Register.
8. Battery Maintenance Register.
9. AT Maintenance Register.
10. AT History Register.
11. Register for C.B Tripping.
12. H.T Meter Reading Register.
entries.
OHE BREAKDOWNS:
Types of Breakdowns: These are four categories of breakdowns pertaining to electric
traction
1. OHE and feeder lines
2. Switching stations
ETTC/BZA Page 47
3. Remote control equipment

4. Rolling stock
OHE and feeder line breakdowns: Every breakdown of OHE whether major or minor
should attend immediately as it given generally interferes with traffic. There are different
types of OHE Break downs.
Uprooting off or damage to OHE mast because of cyclones, derailments.
Entanglement of pantograph with OHE.
Snapping of OHE conductor.
Flash over or other damage to insulator.
Faults on account of stay wire.
Cutting of SS ropes of ATD.
Theft of OHE.
Component failure.
Hitting of mast due to open door of wagons.
All breakdowns or effects in OHE which affect the train service shall be
reported to TPC. The person reporting regarding breakdown to TPC should give detail
information as possible about the nature of breakdown, its location if mast has been up
routed both lines in double track section have been affected etc.
Action for safety of moving trains: After getting the information the TPC should
isolate the faulty section of OHE, the TPC shall inform the section controller about the
isolated faulty section to enable him to check the movement of trains or adjacent tracks.
The section controller shall immediately inform the SM to stop the first train entering on
the other line and issue a caution order to the driver to observe a SR of 20kmph in
daytime and 10kmph in nighttime. The driver has to look out for any defects or obstruction
on the line /lines. The driver should stop at the start of obstruction or at the next station
and report the condition of the track and OHE or any other infringement to the section
controller or TPC. The section controller on receipt of this information from the TPC to
take suitable action to continue or switch off power in the effected section.
Breakdown staff: On receipt of the first report about the breakdown, TPC shall
direct nearest OHE maintenance, staff to proceed to site immediately by available
Breakdown vehicle. A quick assessment should be made based on information available
and where necessary more gangs on both sides of the site may be asked to proceed to
the spot. If the accident spot cannot be reached by tower car vehicle equipped with
emergency stores, and staff may be directed to site.
If the tower car or wiring train is required to attend the breakdown,
the section controller on request from TPC shall arrange for quick passage of tower car or
wiring train to the accident spot. Restoration work may commence only after on
emergency power block has been obtained from TPC. All other precautions necessary for
protection to the staff should be taken.
Work must proceed simultaneously at any point. The wiring train
generally consist of stores/tool van, a work shop van, the staff and kitchen van, a reel van
loaded with one drum of catenary and one drum of contact wire, a BFR loaded with masts
with a suitable crane for erection of masts, a power car with two generator sets and
adequate quantity of OHE materials, the van should have platform to facilitate working on
the roof.
ETTC/BZA Page 48
Procedure:
1. Information to TPC regarding the nature of breakdown.
2. TPC to isolate if necessary inform to section controller.
3. Issue caution order to driver.
4. TPC shall inform to nearest OHE depot.
5. The staff should reach the spot with the material as early as possible.
6. The staff should proceed to breakdown spot by the B/D vehicle.
7. After arriving to BD spot, contact TPC and take PTW.
8. Provide discharge rod on both side duly taking necessary safety precautions.
9. Assess the work involved and inform TPC for getting more staff and material.
10. Before starting work all safety precautions both OHE staff and staff of other
department, if any should be taken.
11. Keep one person in emergency circuit to contact TPC.
Site Management:
1. To communicate with (TPC) controlling centre, patrolling of site, information to
the control centre/details of damage, necessary help, expected time to be taken
clear the breakdown, section in which power and traffic block is required.
2. To place the gang in different places where they are required, to make sure the
availability of spare parts and tools on the site.
3. To arrange earthing locate the place where discharge rod is to be installed to
take power block from controller and power block section should be earthed.
Gang - I:
1. To lift the counter weight from the tirfor above the ‘Y’ sign according to temperature
2. To restore the counter weight to its original position, when the catenary has been
restored or when splicing has been completed.
Gang - II:
To loose the anti creep centre.
To plumb the cantilever of the anti creep centre.
To tighten the anti creep centre then the load on catenary has been restored or when
it has been specified.
Gang – III:
To takeover, the catenary load through tirfor by providing come along clamp.
To make loose the two catenary suspension clamps of both sides from the catenary
breaking point (it makes the movement of catenary and plumbing of cantilever to
easy)
Splicing of catenary wire.
While taking and giving load, first ensure that the counter weight has been lifted and
anti creep centre has been loosened.
To make contact between control and site gang frequently.
Gang – IV
To lift the counter weight from ‘Y’ location according to temperature.
ETTC/BZA Page 49
To arrange the counter weight when gang-III has taken the load.
To remove the discharged rod and to inform the controller to give supply to OHE as
usual
Precautions:
1. When gang in going by means of road transport, the site supervisors should be
fully aware about the conditions of road. Jurisdiction road map should be exhibited
in the depot for the guidance of staff.
2. To confirm the power block sections after seeing the section layout and to take all
precautionary measures while taking power block.
3. Every gang should work under the protection of discharge rod. To ensure that
discharge rods are placed at right places and to count the discharge rods.
4. To make contact between supervisor and gang through walkie-talkie or with hand
flag. To make continuous contact with the controller through emergency telephone.
5. To make clear the instructions given by the supervisor.
6. If the catenary breakdown takes place near turnout and crossovers then the
tension length should be checked by tower wagon pantograph.
Special Tools:
Gang – I: Tirfor, sling, D-shackle, rope etc.
Gang – II: ordinary tools.
Gang – III: Tirfor sling for catenary cum along clamp, D-shackle, Hacksaw blade.
Gang – IV: Tirfor, sling, D-shackle.
Panto Entanglement:
When any point of pantograph comes in between OHE wire or vice versa, panto
entanglement takes place. Panto entanglement causes damage to panto or OHE or
both resulting in inconvenient to electric traction traffic at this location.
Reasons for panto entanglement:
1. OHE defects
2. Panto defects
3. External defects.
OHE Defects:
1. Damaged OHE equipment such as insulator, Cantilever tubes, Jumpers, droppers
etc., may fall with the movement of pantograph and resulting in entanglement. To
avoid this check periodically insulators and other components for any cracks.
2. In Overlaps, if overlap adjustment is wrong panto oscillations to OHE. This static
force is normally kept at 7kg. If this force is, less large oscillation will cause the
pantograph to leave its contact with OHE resulting in sparking and local heating
which may damage the contact wire.
3. Missing pins and fasteners: Provision of split pin must be ensured during every
inspection and when ever the pan is changed. This split pin at critical location of
articulation arrangement and full complement of proper shunt helps in reducing
panto defects.
ETTC/BZA Page 50
4. Cracks is mechanical parts: The effect of broken components of P.G such as

cracks in plunger, balancing rod and articulation rod lead to damage of panto pan,
ultimately resulting in panto entanglement during run.
Checks after Panto Entanglement: After panto entanglement, it is necessary to check

quickly the following items pertaining to OHE and pantograph. This should be done
without causing any delay in the restoration hour.
1. Measurements: Measurements of height and stagger of contact wire of main line and
turnout/cross over and vertical height of steady arm clamp from the register arm, the
measurements so recorded totally with the measurement in SED.
2. Location of hit marks: Search for hit marks in steady arm and register arm tubes, PG
clamp, dropper, dropper clip, contact wire, splice and jumpers. Any hit marks observed in
these locations should be noted.
3. Condition of cracks on the fittings: The condition of cracked OHE fittings such as
clamps, suspension bracket and clips should be checked to record whether the cracks
are fresh or old.
4. Check the free vertical movement of steady arm: This observation will be made on
every mast with at least 500mm in the rare of the location entanglement.
Pantograph side:
1. Check that the pantograph-wearing strip is properly fixed with panto pan and check for
bent strip or deep groove on the strip. Check that the grease plate should be properly
fixed or not.
2. Check that the plunger box for free siding and check that the split pins are intact.
3. Check the horizontal and vertical free movement of panto pan.
4. Check the availability of split pin at all location of the pantograph.
5. Check the broken parts of pantograph should be inspected to check whether cracks
are fresh or old.
6. Take the measurement of panto pan.
PRACTICAL STUDY AND SAFETY PRECAUTIONS:
1. Working /using of Aluminium ladders:

(a) One person only should work on the ladder.
(b) Slippery chappals should not be worn while climbing the ladder.
(c) One person should exclusively hold the ladder straight b pulling with the help of
rope and another person should hold the bottom portion of the ladder firmly to
avoid slipping.
(d) The ladder should be dealt gently while placing on OHE; sliding on OHE and while
removing from OHE.
2. Power block working:

(a) An authorized person should place requisition with TPC to avail power block.
(b) Other gangs working in the same section should take sub-permit to work by
exchanging private number.
ETTC/BZA Page 51
(c) Every gang should arrange protection by putting two discharge rods for their safe
working.
(d) If the distance between two gangs exceeds 1000 meters additional discharge rods
should be arranged covering the entire place of their working.
3. Difference between Elementary section/sub-sector/sector:

(a) Elementary section: the smallest section of OHE which can be made dead
manually by opening the isolators only.
(b) Sub-sector: The section of OHE that can be made dead remotely by opening
the interrupters on either side switching stations.
(c) Sector: The section of OHE that can be made dead by opening the interrupter
at feeding post along with paralleling interrupter at SP.
4. Significance of SSP and SPs:

SSP: Sub-sectioning and paralleling post:
It is a supply control post where sectioning and paralleling interrupters are

provided. In SSPs total 3no’s interrupters are provided 2 no’s sectioning
interrupters, 1noparalleling interrupter.
SP: Sectioning and paralleling post:
It is a supply control post situated midway between two feeding points at the
neutral section and provided with 2 no’s bridging and 2 no’s paralleling
interrupters.
5. Ladder Trolley as its protection while working in traffic block.

In traffic block working no traffic will be allowed and it is quite safe to wok with
ladder trolley on the track.
6. Maintenance and testing of tool (with regard safety).

The OHE tools like fifers, come along clamps, pull lifts, etc… should be load tested
once in 3 months and record to be maintained. Discharge rods, aluminum ladders,
manila ropes etc should be maintained in good conditions. Steel slings having
broken strands should not be used. Procedure for testing and overhauling of T&P
items shall be learnt at school.
7. Testing Jig for insulators testing.
Load testing of stay, bracket and 9 ton. Cut in insulator should be learnt at the
OHE depots.
8. Preparation of various types of bonds.
Manufacturing of (a) structure bonds, (b) Cross bonds, (c) Rail bonds, (d) inter
track bonds should be learnt practically.
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9. Practical training:
Can be learnt at the OHE depots.
10. S.I. Erection: Can be learnt with the OHE maintenance gangs.
11. PTFE erection: As per manufactures guidelines(ARTHUR FLURY)
12. ATD adjustments: X-Y value adjustment as per TL and temperatures.
13. Technique of using the T&P without causing break-down.

Tirfor: Load should be taken up to the permissible limit. Beyond the friction point
tirfor should not be over loaded to avoid failure of tirfor.
Pull lift: Load should be taken up to the permissible limit only to avoid failure of
pull lift.
Come along clamps: Suitable come along clamps should be used for the
particular wire for which they are meant to avoid slipping.
Discharge rods: Care should be taken for the cable and its connection at the top
hook and also at the bottom clamp cable should be wound around the wooden
rods to avoid breakage while applying the discharge rod.
Slings: Slings with broken strands should not be used. They should be carried for
working and should not be thrown from the top of mast/ladder to the ground.
Aluminum ladder: Should be carried carefully by two people. Should be applied
gently on OHE and slided carefully, at the work spot. One person only should work
on the ladder. Ladder should not be allowed to slip or slide while staffs are
working.
14. How to deal minor/major breakdown:
Minor B.D: The B.D which can be restored with in less period is minor
Break down. Asses the damage done to OHE, and get prepared with required men
and material to restore the OHE within less period.
Major B.D: The B.D is said to be major when major derailments caused and
up and down tracks damaged. i.e., for the restoration of track and OHE much time
will be taken. Depute the appropriate staff for the specific restoration works of
OHE. When once track is restored, the OHE can be finally checked with Tower car
including the adjustments, if any. Before the track is given fit, the OHE restoration
works should be completed with temporary restoration i.e., by erecting temporary
masts, cantilever assembly erection, splicing of snapped OHE conductors, etc.
15. Observation of safety while working on bridges:

(a) Choose the staff to work on bridge more carefully.
(b) The tools used should be taken proper care so that they will not slip and fell
down in the river.
ETTC/BZA Page 53
(c) Tower car should be braked firmly and then staffs attend OHE after discharging
it. After completion of work and men got secured on the Tower car, then only it
should move to the next location.
(d) After cleaning the insulators and applying the silicon grease, care should be
taken so that that staff should not fell down with greasy/slippery hands.
16. Safety precautions in the maintenance work of isolator and knowledge to
take PB for the maintenance:
(a) Power block should be taken on two elementary sections on either side of the
isolator.
(b) Before opening the male contacting operating rods, it should be discharged
from potential buy means of a jumper wire/G.I.wire.
17. Knowledge to manufacture cantilever assembly of various implantations.
Depending upon implantation of the OHE mast, the measurements of stay,
bracket, register arm tubes and steady arm will vary.
The cantilever assembling should be practically learnt in the OHE work
shop.
18. Practical knowledge to adjust height and stagger of contact wire:
When tower car is available, the adjustment of height and stagger is much
easier.
Due to track alterations, the variation of height and stagger of contact wire
will occur.
On should know to adjust the height and stagger of contact wore by working
with the ladder and pull-lift.
19. Knowledge to provide rail jumpers when track renewals works are in
progress:
When ever the track rails are changed, the rail jumpers should be invariably
used to facilitate the return current path. This practice should be done being the
safety measure.
20. Safety observations while working with ladders:
Adequate protection by putting flags men, banner flag at 800 meters should
be employed.
The approaching train movements should be informed to the working gangs
by working the hand signal flags to clear the ladders/ladder trolleys away from the
track.
21. Types of protection and their observations.

(a) Longitudinal protection: Trains should not enter the power block zone in the
same direction of traffic and their protection is called ‘longitudinal protection’.
(b) Transverse protection: Trans should not enter the power block zone from the
turnout/cross over movements and this protection is called transverse
protection.
22. Knowledge to attend & remove the bending/twist of OHE masts:
ETTC/BZA Page 54
By using the 3/5 ton Tirfors and Rail clamps(from engg Dept) the bending/twist of OHE
masts can be attended and removed
COMPETENCY CERTIFICATES:
Each authorized person will be given a competency certificate defining the
works, which is certified as competent to carry out after he has been trained, examined
and found fit.
Authorized Person:
Authorized person is one who is duly authorized to perform specific duties
pertaining to his employment. The authorization being made by the competent authority
empowered for the purpose by the railway administration.
Designation Competency Certificate Issued authority

No:
KHALASI/OHE TR01 SE/SSE After oral test
LINES MEN/OHE TR02 ADEE/TRD After oral test
SUPERVISORS/OHE TR03 DEE/TRD After written and

oral
OHE INSPECTION CAR TR04 DEE/TRD After written and

DRIVER oral test.
KHALASI/PSI TR01 SE/SSE After oral test

ARTISAN/PSI TR05 AEE/TRD After oral test
SUPERVISOR/PSI TR06 DEE/TRD After written and
oral test
ARTISAN/SUPERVISOR OF TR07 AEE/TRD After written and
SAFETY RELAYS oral test
ARTISAN/RC TR08 AEE/TRD After oral test
SUPERVISOR/RC TR09 DEE/TRD After written and
oral
ETTC/BZA Page 55
7.TESTING, ERECTION AND COMMISSIONING

OF OHE EQUIPMENT
ERECTION OF VARIOUS OHE ASSEMBLIES CRITICAL ITEMS TO BE
CHECKED:
1. Cantilever Assemblies: Every cantilever assembly shall be adjusted strictly in
accordance with the approved structure erection drawings, especially about the
positioning of stay arm, bracket tube and register arm. The projection of bracket tube and
register arm and the allowance in the stay arm shall be sufficient for slewing of tracks.
Normally this allowance is 15cm to 20cm from the centre line of catenary suspension
bracket to end of bracket tube and 20cm (min) for register arms. All nuts should be
tightened and locking plates provided with split pins or check nuts. Make sure that all
temporary earths provided by contractor’s men during construction work have been
removed.
2. Anchoring Points: The movement of counter weights shall be free and not obstructed
in any way. Flexible steel ropes shall move freely and centrally with respect to the pulley
sleeves and not rub against any member. The distance between the pulley centres and
the height of counter weight above the muff level, shall be as per the chart in relation to
the prevailing ambient temperature. Anti creeps shall be properly tensioned and
positioned.
3. Overlap spans: Adjustments at insulated and un insulated overlap spans, turn outs,
cross overs and section insulator assembly shall be correct not only in respect of the run
of conductors and jumper connections, but also the height of contact wire. The separation
between different OHE and displacement of cantilevers at insulated overlaps should be
adequate.
4. Insulators: Insulators shall be perfectly clean. Should the surface be polluted by dust,
it should be cleaned and glass restored. All insulators on out of run wires should be so
located that they do not foul but are well away from the zone swept by the pantographs.
The runners of section insulators should be so located as to be beyond the zone of sweep
of pantographs running on adjacent tracks. There should be no undue sag due to the
section insulators, the runners should be level and not be tilted to one side so that the
pantograph may pass smoothly.
5. Height of contact wire: This shall be checked at every structure and at mid span for
regulated OHE. A predetermined sag in the contact wire of 50mm or 100mm at mid span
on a 72m span for 50 or 100mm presage compensated OHE respectively should exist on
the open routes. Height of contact wire at level crossings shall not be less than 5.50m.
6. Stagger: Stagger in tangent track shall be to the left and to the right of the track
alternatively, not exceeding 200mm on either side of the centre line of the track, except
where otherwise specified in structure erection drawings. Stagger for in run OHE shall not
be more that 300mm at the mast/structure on the outside of curves except in case of
ETTC/BZA Page 56
overlap spans and at the turnouts. Stagger of contact wire at mid span in transition
portion of the curves shall be within 200mm.
7. Gradient of contact wire: On both side of overline structures, tunnels and level
crossings, the gradient of contact wire shall be in accordance with the approved
profile.
8. Clearances: The live metallic caps of insulators on out of run wires shall be at least 2m
away from adjacent earthed mast/structure (other than the OHE structure). The
distance of these insulators shall be 3m from the bracket supporting the OHE in case
of insulated overlaps. Clearance of 2m shall normally exist from nearest point of two
adjacent elementary sections except at the section insulators. Where clearance of 2m
is not available. It shall not be less than the minimum long duration electric clearance
of 320mm. whenever the OHEs of two elementary sections cross one another,
necessary cut in insulators shall be provided.
9. Bonding: Every mast/ structure supporting OHE as well as platform structures, foot
over bridges etc., shall be properly bonded to the rails and earthed in accordance with
the bonding and earthing code.
10. Return conductors of Booster Transformer Installations: The return conductor

connection both at the OHE and the rail should be checked from the point of view of
good electrical contact and security from mechanical damage.
11. Telephone or Power Crossings: Keep a close watch for any overhead telephone
crossings over the OHE, which may not have been removed by oversight. Immediate
steps should be taken to have these removed. High voltage transmission line
crossings across the tracks shall be checked against the approved plan authorizing
the crossing, particularly the clearance between the OHE and the guard wires, duly
recording the results individually. If the crossing is not in accordance with the
approved plan, the supply authority should be contacted immediately and the
infringements should either be removed or necessary relaxation be obtained from
CEE and Electrical Inspector to the Railway.
PROCEDURE FOR FINAL TESTS OF OHE:
After the OHE is declared as fit for energisation and all construction staff have
been withdrawn from the field insulation and continuity test shall be conducted jointly by
officers of the construction organization and the open line with assistance of senior
subordinates. This should be done at least a day in advance of energisation. These tests
should be conducted for every elementary section. The following preliminary action shall
be taken to prepare the circuits for the test.
The test shall be controlled by one senior official who shall continuously remain at the
RCC and direct all operations as required. These tests comprise:
1. Measurement of insulation resistance of every elementary section with respect to earth.
ETTC/BZA Page 57
2. Checking electrical independence and insulation resistance between adjacent

elementary sections and also adjacent sub-sectors.
3. Checking electrical continuity of every sub sector.
Insulation Tests: Starting from the feeding post, the control party will measure and
record the insulation resistance of every elementary section to earth by 2500 megger,
after arranging with the outfield parties to (i) isolate the elementary section concerned and
(ii) earth adjacent elementary sections. This test will show
1. The insulation level of every elementary section and
2. The electrical independence of the elementary section, from adjacent elementary
sections.
If the tests for all elementary sections at that location are satisfactory, the control party
may proceed to the next elementary section and carry out similar tests. When all
elementary sections at a particular section have been tested, the control party will move
to the next station, directing the field parties to do likewise and carry out the tests on each
elementary section at that station as before until every elementary section in the sector
has been tested.
Continuity Tests: When insulation tests are completed for all the elementary sections,
the control party may proceed in the reverse direction towards the feeding posts carrying
out continuity tests as described below:
In this test, the various control switches which might have been opened out earlier
should be put back to their final positions as indicated in the station working rules, as in
normal operation. Any temporary earths provided for earthing adjacent sections shall be
removed. When this is done, the various elementary sections are automatically joined up
electrically and each sub sector is made through. The continuity test is then conducted by
a low reading ohmmeter by measuring the resistance of each sub sector from the feeding
post and with each sub sector earthed at the farthest point towards the neutral section.
The through continuity of every sub sector shall be checked individually. It is important to
note that a megger insulation tester is unsuitable for measuring continuity as it may read
zero even when the resistance is as high as 1000 ohms.
Certificate to be obtained just prior to energisation of OHE:

The following certificates should be obtained just prior to energisation of the OHE:
1. Joint certificate by DEE (OHE) of the construction organization and DEE (TRD) of the
open line to the effect that:-
All electrical installations have been inspected and found to comply with approved
drawings and specifications and prescribed notices and boards have been displayed.
The requirements of the Bonding and Earthing code, schedule of moving dimensions etc.
are fully complied with and clearances to live equipment are adequate and in conformal
with the standards.
The installations at sub-stations, switching stations and booster transformer installations
as well as the OHE are fully fit for energisation.
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2. Certificate by DSTEs of construction organization and open line to the effect that the
S&T installations have been modified to suit AC traction, that necessary rule books have
been distributed to all the staff concerned, that all communication circuits have been
provided including emergency telephones.
3. Certificate by DOS of open line and construction organization to the effect that
supplementary station working rules have been issued to all concerned and that a
detailed each station, showing various elementary sections in different colours.
4. Certificate by open line officers, countersigned by DS, conforming that staff of all
departments have been issued with General and Subsidiary Rules, special working rules
for 25kV traction, Instructions for safe working etc. and that assurances have been
obtained from station, running and maintenance staff that they are fully conversant with all
the instructions.
5. Certificate from DEE (TRS) that electric rolling stock has undergone necessary tests,
trials and is ready for working on 25kV.
6. Certificate of clearance from P&T for energisation of the OHE.
Commissioning certificates:
Public notification regarding energisation
Public notification regarding level crossings
Joint certificate by DEE (TRD) and DEE (OHE construction)
Certificate regarding bonding and earthing
Joint certificate by Divisional officers regarding safety instructions
Certificate by DS regarding safety measures
Sanction of CEE and electrical inspector for energisation
Certificate by S&T department
Clearance certificate by P&T department
Clearance certificate for 25kV feeder lines
Clearance certificate for OHE
Clearance certificate for switching stations
Clearance certificate for booster transformer stations
Clearance certificate for P&T and S&T works
Clearance certificate by OHE contractor
EIG (ELECTRICAL INSPECTOR TO THE GOVERNMENT) SANCTION:
1. Application shall be submitted at least a fortnight before energisation to CEE and

Electrical Inspector to the Railway for the following:
(a) Formal approval, if not ready received to the design and layout of all high voltage
equipment including traction substations, transmission lines, 25kV feeders, switching
stations, booster stations etc.
(b) Approval for energisation of HT installations mentioned above including OHE.
ETTC/BZA Page 59
2. The following documents shall accompany the application for EI’s sanction.
(a) Copies for press cutting of public notification as mentioned in para21008.

(b) Certificate regarding OHE (proforma 10-03)
(c) Certificate regarding bonding and earthing (proforma 10-04)
(d) Certificate regarding safety instructions and precautionary measures (proforma,
10-05).
(e) Certificate by DRM regarding safety precautions (proforma 10-06)
(f) Copies of insulation resistance test results of OHE
(g) Insulation test results values for auxiliary and booster transformers.
(h) Test results for equipment in switching stations and sub stations and their safety
certificates, if earlier sanction for the energizing this is not obtained separately.
(i) Clearance certificates from Deptt. of Telecommunication.
(j) Any other data, test results and certificates required by the Electrical Inspector.
The sanction of the Electrical Inspector may be issued in the proforma 10-07.
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8. NAMES, SIZES, LOCATION OF MAJOR PSI,

SUB STATION AND REMOTE CONTROL
EQUIPMENTS
The power is received from the supply authorities at individual traction substations
(132 or 220 or 110kV). It is step down to 25kV through single phase transformer, the
primary is connected to any two phases and the secondary side one terminal of the 25kV
is connected to OHE. The second terminal is being solidly earthed and connected to
running track rails.
Each transformer has its associated breakers on primary and secondary sides,
with a separate set of 25kV feeder breakers for feeding the OHE. Adjacent substations
are from different phases of the 3Φ system in rotation. Neutral sections are provided on
the 25kV OHE for segregating the phases.
In between two traction substations, switching station called S.P and S.S.P are
provided. The 25kV supply is switched ON and OFF through interrupters which do not
open on fault but, can be closed on fault. The fault is cleared by the feeder C.B’s.
The 25kV transformer breaker serves as a backup protection. Normally power
supply from a substation extends up to the neutral section on either side. Incase of
emergency power supply from adjacent substation on either side is extended by bridging
the neutral section through the interrupters.
The factors to be considered for location of traction substation are as follows:

1. Availability of adequate and reliable power supply
2. Traffic to be handed in the section
3. Gradients of the section
4. Anticipated traffic in feature
5. Characteristics of the locomotive and speed
6. Allowable voltage drop at the farthest end
7. Suitability of standard equipment
8. The load is within the standard ratings of the transformer and other equipments
under normal and extended feed conditions.
9. Location to be closed to main railway station.
10. It should be 3kms away from the airport station.
On an average the spacing between the substations has adopted in earlier
electrification were about 50 to 80kms. But with the increase in passenger and goods
traffic the spacing has been reduced to 40 to 60 KMS
TRANSFORMERS:
Transformer is a static device that transfers an alternating current / voltage from one
stage to another stage. The transformer basically works on mutual induction between the
two circuits linked by a common magnetic field. They are two types.
1. step up
2. step down
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Step up Transformer: The step up transformer transfers a low voltage level to high
voltage level with out change in frequency. The primary consists of a few number of turns
compared to secondary side.
Step Down Transformer: The step down transformer transfer’s high voltage to low
voltage with out change of frequency. The primary consists of large number of turns
compared to secondary side turns.
Main parts of Transformers:

1. Core
2. Winding
3. Tank
4. Bushings
5. Radiators
6. Conservators
7. Breather
Transformer mainly consists of

1. Magnetic circuit consisting of limbs, core and clamping structures for providing the
flux path
2. Electric circuit consisting of low voltage and high voltage windings
3. Di-electric circuit consisting of insulation in different places in the transformer.
4. Tank accessories etc.
Transformation Ratio:
Vs/Vp = Ns/Np
Is/Ip = Vp/Vs
Where Vp= Primary side voltage
Vs= Secondary side voltage
Ip= Primary side current
Is= Secondary side current
Np= No. of turns on primary
Ns= No. of turns on secondary
Transformer Regulation: It is defined as the charge of secondary terminal voltage
between no load and full load condition.
Secondary no load voltage – Secondary full load voltage

%Regulation = -------------------------------------------------------------------------------- x100
Secondary no load voltage
= (Es - Vs) x100/ Es
Efficiency of transformer: It is the ratio of out put to the input of the transformer.
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Out put
% Efficiency =
Input
% Impedance of the transformer = IsxZsx100/Vs
Is secondary current
Zs impedance on secondary side
Vs secondary side voltage
Principle of transformer: Transformer is a static device which transfers electric

power from one level to other level with out change in its frequency.
Ideal transformer: An ideal transformer is one which has no losses compared to

another transformer.
All day efficiency: it is the ratio of output in KWH to the input in KWH.
Output in KWH
All day efficiency =
Input in KWH
EQUIPMENTS:
Traction transformer: Transformer ratings are standardized on average spacing

between substations, loads to be hauled and gradients of the section. In the initial stage
7.5 MVA and 10 MVA transformers are used , but later on 13.5 MVA transformers were
used with introduction of heave hauled trains and increased dropping, transformers with
13.5/20 MVA dual rating, 20 MVA and 21.6 MVA ratings are being used.
The traction transformers are subjected to rapid load variation and frequent short
circuits. Therefore windings of these transformers are specially reinforced to with stand
the high stresses developed due to the following service conditions.
1. Repeated short circuits
2. Frequent load variation
3. Frequent variation in supply voltage
4. Magnetization rush of current due to repeated switching ON and OFF
5. Over loading the transformer as specified.
The traction transformer experiences frequent short circuit due to various
reasons.
1. Insulators failure
2. Switching surges
3. Accidents
4. Theft of wires
5. Faults in loco roof bar
6. Mechanical failure of the OHE fitting etc.,
To limit the magnitude of fault current the percentage impedance for traction
transformer has been specified as 12.5% for 13.5 MVA transformers.
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Fittings and Accessories of Traction Transformer:

1. Winding
2. Bushings
3. Conservator
4. Tap changer
5. Breather
6. Pressure reducing valve
7. Oil temperature indicator
8. Winding temperature indicator
9. Oil level indicator
10. Buchholz relay
11. Radiators
WINDING: In traction transformer the primary and secondary winding consists of

concentric disc coils wound with paper insulated continuous electric copper conductor
(Class A). A separate tapped winding is provided on the secondary side for connection of
OFF load tap changer, the tap ends of the 25KV LV winding is connected to the left hand
side terminal of the transformer when viewed from the LV side.
BUSHING: Bushings are used to bring out coils and connect with out touching the tank.
There will be two sets of bushings for the HV and LV side. Oil impregnated paper
condenser bushings are used for 132KV and synthetic resin bonded condenser bushings
are used for 25KV side. The bushing has non breathing oil expansion chamber.
Adjustable horns are provided with a gap setting of 500 to 900mm and 150 to 300mm for
HV and LV bushings respectively. The 132 and 25KV bushing are provided with station
type current transformer called current C.T which can with stand terminal and mechanical
stress resulting from frequent short circuits. These are used for differential protection.
CONSERVATOR: It is a small cylindrical tank on top of oil cooled transformer and

connected to the main tank by a small pipe. It performs the following three functions.
1. Provides space for expansion and contraction of oil.
2. Minimize oxidation of oil by limiting the surface of oil in contact with air.
3. Confines the oxidized oil to the conservator only.
An oil level indicator shows the oil level variation in the conservator.
TAP CHANGER: This is required to be provided to change the ratio of transformer to suit
the voltage variation. The tap changer used for traction transformer is OFF load tap
changer provided on L.V. side the tap changing process can be done from near the
transformer as well as from control panel. The tap changer can only be operated when
both 132KV and transformer LV CB is in open position.
BREATHER: It is a device through which all movements of air from and into the
transformer takes place. Air enters when oil cools, the breather is provided at one end of
conservator tank absorbs moisture from the air passing through it. So, only dry air can
enter the tank. Silica gel is blue in color when dry and turns pink when it absorbs
moisture. It can be
ETTC/BZA Page 64
reconditioned by heating and drying. The breather will have an oil cap at the bottom which
absorbs dust particles
RADIATORS: The radiators are provided for cooling of transformer oil; the oil is circulated
through radiator fins and cools according to atmospheric temperature.
W.T.I (Winding temperature indicator) and O.T.I (Oil temperature indicator) : WTI
indicates the temperature of winding and OTI indicates the temperature of oil. OTI
consists of capillary tube which is provided in pocket and kept on the top of the
transformer, oil will be filled in pocket and the temperature of the oil heats the capillary
tube which moves the disc of which the indicator is connected.
PRESSURE RELIEF DEVICE: This safe guard’s transformer in case of from pressure
developed in the transformer in case of any internal fault in the winding. This will have a
thin diaphragm with air tight cover. In case of high pressure, this diaphragm bursts and
releases the pressure to safe guard the tank.
CIRCUIT BREAKER:
It is a mechanical switching device designed to automatically open circuit under the
specified abnormal condition without damage to the equipment. Every electrical system is
susceptible to fault and damages or breakdowns, this may be caused due to short circuit
and due to falling on the wire, short circuits by birds etc causing reduction in insulation
and surges due to lightening, such abnormal condition resulting high short circuit current.
To clear these abnormalities the circuit breakers are installed in electrical system to
isolate the equipments to protect against over load, short circuit, earth leakage under
voltage etc. is provided by incorporating suitable relays.
ESSENTIAL QUALITIES OF CIRCUIT BREAKER:

1. Reliability: This is required to protect and improve reliability of the whole system,
as protective relays are sensitive and act within limits. They should be simply
robust and easy to maintain and inspect.
2. Discrimination: This is important as it is not advisable to cut out the healthy
section on account of faulty section i.e., it should not have any adverse effect on
the characteristics on the other devices protected in the healthy section.
3. Quick Operation: This is required to avoid damages done to the generators,
transformers and other equipments by short circuit currents.
Circuit Breaker Serves Two Functions:
1. Switching during normal operating condition for the purpose of operation and
maintenance.
2. Switching during abnormal operating condition such as short circuit and
interrupting the fault currents
MINIMUM OIL CIRCUIT BREAKER:

In MOCB the current interruption takes place in a closed time of insulated material
by porcelain. Hence the clearance between the live parts and the enclosure can be
reduced and lesser quantity of oil is required for internal insulation. In MOCB nearly 10%
oil of BOCB (Bulk Oil Circuit Breaker) is used for extinction of arc.
ETTC/BZA Page 65
In each pole there are two chambers separated from each other but both filled with
oil. The upper chamber is arc extinction chamber; the oil from this chamber does not mix
with that in the lower chamber, the lower chamber acts like dielectric support.
SULFHUR HEXA FLOURIDE GAS CIRCUIT BREAKER:

It is an inert gas, color less, odor less, non toxic, not harmful to healthy, non
inflammable, its density is 5 times that of air at 200 centigrade at atmospheric pressure,
the gas starts liquefying at 15Kg/cm2 and it is not suitable for above 15kg/cm2. During arc
extinction process SF6 is broken down to some extent in SF4 and SF2. The dielectric
strength of SF6 gas is more than that of dielectric oil. It permits smaller clearances and
small size of the equipment for the same rating of KV. In SF6 gas CBs the entire breaker
is filled with SF6 gas at a single pressure 5 kg/cm2 . The breaker is a sealed unit during
the opening stroke the buffer cylinder moves along with the contact against fixed position.
The gas compressed between buffer cylinder and piston releases through the nozzle of
insulating material, the compressed gas flows through the nozzle at a high velocity and
takes away the heat of arc. The arc quenched at current zero. The high dielectric strength
of the gas is useful in giving good withstand voltage. SF6 series are explosion free, can
quench capacitance, short current easily.
The maintenance and check execution standard depends upon the working
conditions of the CB. The checks to be carried out, their frequency and scope are broadly
as under:
Types of Frequency Scope
checks
Patrol Every week The patrol inspection is an external check of the circuit
inspection breaker in live condition for irregularities.
Ordinary After every The ordinary inspection is inspection performed by tuning
inspection 1000 OFF the circuit breaker for a relatively short time for simple
operations inspection and service with emphasis on functional checks
e.g. visual check of irregularities and cleaning of dust and
dirt.
Detailed After every The detailed inspection is an inspection performed by
inspection 3000 turning OFF the circuit breaker for a relatively long time, to
operations dismantle and inspect the mechanism for irregularities for
the purpose of continuously maintaining the performance
Incidental --------- The incidental inspection is performed when inspection
inspection and repair are necessary due to the detection of an
irregularity during patrol inspection or during operation.
VACUUM CIRCUIT BREAKER: It comprises one or more sealed vacuum interrupter unit
per pole. The moving contact in the interrupter is fixed to an insulating operating rod
linked with mechanism box. Contact travel in vacuum is of the order mm. The separation
current carrying contact causes the vapor release from the contact giving rise to plasma.
The vapor density depends upon the current in the circuit, the interruption of arc is
possible then vapor density varies in phase with the current and arc remains in defused
state. As the contact separation is high in vacuum (10-8 mm of Hg) the arc continues till
natural current zero of the wear, due to metal vapor vanishes at current zero.
ETTC/BZA Page 66
The maintenance and check execution standard depends upon the working
conditions of VCB, such as the environmental condition, current switching frequency and
others. The checks to be carried out, their frequency and cope are broadly as under:
Type of Frequency Scope

check
Patrol check Daily Check VCB under daily operating condition
Ordinary Once every 3 years or once Check VCB after disconnection main
check every 1000 switching times supply and local remote switch in LOCAL
position.
Detailed Every 6 years ,, ,,
check
Provisional When a trouble occurs ,, ,,
check
The earth is taken as zero potential for the entire practical purposes any appliance
or parts of machine. When connected to earth attains zero potential it is said to be
earthed, the voltage of earthed body will be zero.
Purpose of Earthing
To save human life from danger of shock or death in case any frame or body of
equipment becomes charged due to fault or leakage current.
To protect all machines fed from OHE and due to lighting.
To serve the purpose of return path for traction rails.
Types of Earthing
1. System earthing
2. Equipment Earthing
System Earthing: Earthing associated with current carrying conductor is normally

essential to the security of the system. At the traction substation one leg of 25KV side of
traction transformer has been solidly by connecting it to earth ring. One terminal of
secondary of PT, CT and AT has been connected to earth ring.
Equipment Earthing: Earthing of non current conductor and metal structure to safe
guard of human life, animals and property.
The metallic frame work of all outdoor equipment such as transformers, circuit
breakers, interrupters and isolators, as well as steel structure shall be connected to the
Earthing grid by means of GI flat of size as indicated below:
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S.No. Equipment (KV) System voltage and fault level Ground conductor
size
1. Equipment on the 66KV,upto 3000 MVA 50mm x 6mm
primary side of traction 110KV, upto 5000MVA
power transformer 132KV, upto 6000MVA
220KV, upto 10000MVA
66KV, above 3000 upto 6000MVA

110KV, above 5000 upto 10000 75mm x 8mm
MVA
132KV, above 6000 upto 12000
MVA
220KV, above 10000 upto
20000MVA
2. Equipment on the 50mm x 6mm

secondary side of
traction power
transformer
3. Fencing uprights / steel 50mm x 6mm
structures
4. Doors/fencing panels 6 SWG G I wire
Earth Resistance: At each power supply installation, an earth ring comprising required
number of earth electrodes which are interconnected by means of M.S flat is provided.
The combined resistance shall not be more than the following values.
1. Traction Substation: 0.5 ohms
2. Switching stations : 2 ohms
3. C.T and A.T : 10 ohms
Earthing Stations:
Each Earthing station shall consist of one galvanized pipe 40mm dia, at least 3mts
long provided with a spike at one end. A suitable leg is welded at the other end for
connecting M.S flat of required size. The pipe shall be embedded vertically into the
ground. When rock encounter at a depth of less than 3mtrs, electrode may be buried
inclined to the vertical. The inclination being limited to 300 from the vertical axis. Earth
electrode shall be embedded as far apart as possible from each other. Mutual separation
between them shall preferably be not less than 6mts.
If the required value of earth resistance cannot be achieved with a reasonable
number of electrodes connected in parallel, such as in rocky soil or soil high resitivity,
surrounding of each electrode shall be chemically treated. The earth electrode shall be
surrounded in earth pit by alternative layer of crushed coal or charcoal and salt at least
150mm all-round. Though substantial reduction in earth resistance can be achieved by
chemically treated electrodes, this method results in rapid, corrosion of electrode and also
steel plates to which it is bonded coke treatment shall be used where absolutely
necessary.
The size of earthing grid conductor shall be decided based on the incoming system
voltage and fault. The sizes shall be given below
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S.No System voltage Fault Level (MVA) Diameter of grid

(KV) conductor (GI rod) in mm
1. 66 Upto 4000 32
Above 4000 upto 5000 36
Above 5000 upto 6000 40
2. 110 Upto 6000 32
Above 6000 upto 8000 36
Above 8000 upto 10000 40
3. 132 Upto 7000 32
Above 7000 upto 10000 36
4. 220 Upto 12000 32
Above 12000 upto 16000 36
Above 16000 upto 20000 40
Clearances:
No live part may project beyond the fenced enclosure expect at a height of 6.1 m or
more. The distance from the centre of the nearest track to the face of the switching station
gantry is not less than 3.5 m.
S.No Distance
1. Height of any live conductor from ground level 3m
2. Distance between any live part (25KV) and earthed part or part likely to 500mm
be earthed
3. Between any live part (3KV) and earthed part 150mm
The minimum clearances in mm in air for live equipment shall be as under:
S.No 25KV 66KV 110KV 132KV 220KV

1. Between phases - 630 900 1300 2400
2. Between one phase and earth for
rigid connection 500 630 900 1300 2100
3. Between any points where man
may be required to stand to the
nearest
1. unsecured condition in air 3000 3500 3500 4000 5000
2. secured condition in air 2000 ------- ------- ------- -------
4. Minimum height of bus bar 3800 4600 4600 4600 5500
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BONDING:
Bond: It means an electrical connection between two rails or any structure to rail. The
resistance for a kilometer length of continuous track rail is 0.05 ohms. But the resistance
of fish plate joint is more than that or rail , hence in order to reduce the resistance of the
track as a whole, the joints are supplemented with a good conductor i.e., called bond.
Bonding of rails facilitates passage of return current from rail to earth and earth to
rail. It is therefore necessary to provide bonding in the vicinity of feeding stations where
return current has to back from earth to rail and back to the earthed leg of traction
transformer.
Types Bonds
1. Structure Bond
2. Rail Bond (or) Longitudinal Bond
3. Cross Bond
4. Impedance Bond (or) ‘Z’ Bond
Structure Bond: Bond connecting traction mast or structure to rail by M.S flat of size
40/6mm or stranded wire of 240 sq.mm. Cross sectional area is called structure bond.
Rail Bond (or) Longitudinal Bond: It means an electrical connection across a rail joint
between two consecutive lengths of rails by means of M.S flat 40/6mm.
Cross Bond: It means a bond between two rails of same track or rails (IR or IT) of
adjacent track by means of M.S flat size 40/6mm. The cross bonds are provided at FP,
LC gates, station yards and at a distance 350mtrs in open route.
Impendence Bond (or) ‘Z’ Bond: These are provided in track circuited areas. A special
rail bond provide to bridge the traction rails at an insulated rail joint in A.C track circuited
sections is called ‘Z’ bond o f M.S.flat of size 40/6mm is used for ‘Z’ bond.
Difference from D.C system: In this case of D.C traction steam the whole of the traction
return current particularly follows through the rails. Therefore bonding of rails is necessary
to permit passage of return current from electrical loco to the traction substation.
On the contrary in case of 25KV A.C traction most of the return current flows
through the earth except in a zone over a few 100m on both sides of electrical loco or in
the vicinity of feeding station. Therefore bonding is more essential in D.C
BATTERIES:
Cell: The cell is a device which converts chemical energy into electrical energy.
Battery: It is a combination of cells connected in series to get the required voltage.
Guidelines for Maintenance of Batteries:

As the entire system of protection at sub-station depends upon a sound battery it
should be always be in proper condition. It should under no circumstances be
ETTC/BZA Page 70
disconnected when the sub-station is in operation. The points to be observed during the
inspections are summarized below
1. General condition of the battery room and cells
2. specific gravity of electrolyte in the cells
3. charging current
4. Cell voltage
5. Condition of the plates and extent of deposits
6. inter cell connectors
1. General condition of the battery room and cells: Smoke or use of open flames on
tools which may generate sparks is strictly forbidden in the battery room. The battery
room should be well ventilated and dust free and should have acid proofing done on
the walls and flooring.
2. Specific gravity: The specific gravity of the electrolyte should be maintained et about
1.210 at 27°C and when it drops to 1.150 the cell may be considered discharged.
Temperature correction hydrometer of specific gravity shall be as follows:
for each 1°C above 27°C, add 0.0007 to the observed reading
for 1°C below 27°C deduct 0.0007 from the observed reading
3. Charging current: Lead acid batteries are very sensitive to overcharging as well as
over discharging. A long life for battery is achievable if the battery is kept floating on a
battery charger so that the terminal voltage of each cell is maintained close to 2.15V.
4. Cell voltage: The voltages of a cell at the end of a charge is not a fixed but vary
depending on the age of the battery, the temperature, specific gravity of the electrolyte
and charging rate. The voltage of new cells at the end of a full charge will be about 2.5
to 2.75V. No cell should ever be discharge below the point where the cell voltage
reaches 1.85 V as measured when the cell is discharging at the normal 10 hour rate.
5. Condition of the plates and deposits: The chief indication of weak cells are badly
colored plates, irregularity in gassing or entire to gas and a fall in voltage and specific
gravity below that of the other cells. By examining carefully the physical condition of
the plates such as cracks, distortions, accumulation of whitish deposits etc.,
6. Inter cell connectors: The inter cell connectors of the battery should be examined to
ensure that they are clean and tight, making perfect contact with lugs and that no
corrosion is taking place. Light Vaseline should be applied to prevent corrosion.
Batteries and Battery Chargers:
Take specific gravity and cell voltage of every individual cell and enter in the
register.
If the battery is not in a fully charged condition, boost charge should be given as
required and trickle charging rate increased to the extent required. This should only
be done by a supervisory official after investigating the causes for excessive
discharge.
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Make a general examination of battery charger. Check earth connection to the

body.
Auxiliary Transformers: Auxiliary transformer in electrified section is required for CLS

equipment for signal light, switching stations and traction substations. Auxiliary
transformer provides 240v supply for cabins, cable huts, SP’s, SSP’s, level crossings,
RRI’s etc.
The auxiliary transformer winding shall have the following insulation levels
Sl.No Primary Secondary

1. Rated voltage between winding and earth 25KV 240KV
2. Rated short duration power frequency withstand 70KV (rms) 3KV (rms)
voltage
3. Rated lighting impulse withstand voltage 190KV --------
(peak)
4. Induced over voltage withstand 80KV (rms) --------
Current Transformer: It is basically a step up transformer. It is used in measuring high

value of current by reducing the secondary current to rated value. It is connected in series
with the circuit, whose current is to be sensed. Since the primary is connected in series
with the power circuit, the voltage drop across its terminals is very small and the primary
current is independent of the secondary current contrary to power transformer when the
primary current depends upon the secondary current.
If a current transformer has its secondary circuit opens when current is flowing in
its primary circuit a very high flux density is produced in the core owing to the absence of
ampere turns from the secondary winding. This high flux density results in a very high
induced voltage in the secondary winding which may result in damage of insulation and
danger to the personnel.
Potential Transformer: It is basically a step down transformer. It is used in measuring

high value of voltage by reducing the secondary voltage to rated value. It is connected
across the circuit. The potential transformer is similar in construction to the power
transformer. The main difference between the two is that whereas the secondary current
in the power transformer depends upon the loading conditions.
There are two types of potential transformers:
1. Instrument potential transformer
2. Capacitance potential transformer or potential divider.
(a) coupling capacitor potential device
(b) bushing potential device
Capacitance potential devices are used for protective relaying for operating voltages
exceeding 66KV when these are sufficiently less expensive as compared to the potential
transformers.
INSULATORS:
The insulators for overhead lines provide insulation to the power conductor from
the ground. These are mainly made of either glazed porcelain or toughened glass. The
materials used for porcelain are silica 20%, feldspar 30% and clay 50%. The dielectric
ETTC/BZA Page 72
strength of porcelain should be 15KV to 17KV for every one tenth inch thickness.
Porcelain is mechanically strong, less affected by temperature and has minimum leakage
problem.
There are three types of insulators used for overhead lines:
(a) pin type
(b) Suspension type
(c) Strain type
Pin type insulator: It consists of a single or multiple shell adopted to be mounted on a

spindle to be fixed to the cross arm of the supporting structure. The design of shell is such
that when the upper most shell is wet due to rain the lower shells are dry and provide
sufficient leakage resistance. The pin type insulators are normally used up to 33KV.
Suspension type insulator: These insulators consists of one or more insulator units
flexibly connected together and adopted to be hung for the cross arm of the supporting
structure and to carry a power conductor as its lowest extremity.
Suspension insulators being free to swing, the clearance required between the
power conductor and the supporting structure are more as compared to pin type
insulators.
The suspension insulators, in addition to being economical as compared to pin type for
voltages more than 33KV, have the following advantages:
1. Each insulator is designed for 11KV and hence for any operating voltage a string of
insulators can be used. For example, for 132KV transmission, the number of
insulators required is 12 (maximum).
2. In case of failure of one of the units in the string, only that particular units needs
replacement rather than the whole string.
3. Since the power conductor and string swing together in case of wind pressure, the
mechanical stresses at the point of attachment are reduced as compared with the
pin type of insulator where because of the rigid nature of the attachment fatigue
and ultimate brittleness of the wire result.
4. The operating voltage of the existing transmission can be increased by adding
suitable number of discs in the string instead of replacing all the insulators as is
necessary in case of pin type insulators.
Strain Insulator: The strain insulators are exactly identical in shape with the suspension
insulators. These strings are placed in the horizontal plane rather than the vertical plane
as is done in case of suspension insulators (discs are in vertical plane in case of string
insulators). These are used to take the tension of the conductors at line terminals, at
angle towers, at road crossings and at junction of overhead lines with cables. These
insulators are, therefore, known as tension or strain insulators.
LIGHTNING ARRESTORS:
Lightning arrestors are used to protect equipment from over voltage due to lighting
and switching.
Location of lightning arresters: The normal practice is to locate the lightning arrester as
close as possible to the equipment to be protected. The following are the reasons
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This reduces the chance of surges entering the circuit between the protective
equipment and the equipment to be protected.
If there is a distance between the two (equipment and lightning arrester), the
equipment may experience a surge twice as high as that of the lightning arrester.
There are three classes of lightning arresters:
Station type: The voltage ratings of such arresters vary from 3KV to 312KV and are
designed to discharge currents not less than 100000 amps. They are used for the
protection of substation and power transformers.
Line type: The voltage ratings vary from 20KV to 73KV and can discharge currents
between 65000amps and 100000amps. They are used for the protection of distribution
transformers, small power transformers and sometimes small substations.
Distribution type: The voltage ratings vary from 8KV to 15KV and can discharge
currents up to 65000amps. They are used mainly for pole mounted substation for the
protection of distribution transformers upto and including the 15KV classification.
There are different types of lightning arrestors. They are

1. Horn gap
2. Surge diverter
Rod gap
Expulsion type lightning arrestor
Valve type lighting arrestor
1. Horn gap Features
Longer time for operation
Even after voltage surge diverted. Arc continues to stay
Uses:
Used at AT’s and PT’s
low cost
It is used to protect low rating transformers.
2. Surge Diverters:
These will not pass any current at rated voltages
These will break down as soon as high frequency voltage arise
These will interrupt power frequency follow current after the surge is discharged
to ground
Valve type lightning arrestors uses non linear resistance blocks.
Uses:
It is used to protect higher rating equipment.
High cost
RELAYS:
The function of protective relay is to interrupt any element of power system when it
is subjected to a short circuit or when it starts to operate in any abnormal manner that
might cause or interrupt with effect operation of the rest of the system. The relay
equipment is aided to perform this task by its C.B.
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Functions and Characteristics of Relays:

1. Sensitivity: It will be able to detect abnormality what ever small it may be.
2. Selectivity: It will be able to differentiate the faulty current and the healthy current or
normal load current.
3. Speed: Relay should be speedy and fast acting expect when intentional relay is
incorporated.
4. Reliability: The protective relay should be very reliable. They are two types of relays.
Primary relay
Back up relay
Primary relays are quick in action and back up relays are slow in action.
Differential relay: this protection is against an internal fault of the transformer .this works
on the principle of unbalanced current between C.T's provided on 132KV and 25 KV
bushings of the transformer.
Normally the secondary current going through restraining coils is equal, in case
of an internal fault like short circuit between the terminals. The current in the C.T.
secondaries will not equal the difference current flows through the operating coil of the
relay and operates the relay and energizes the tripping circuits of the C.B’s to isolate the
transformer. To avoid UN wanted operations of the relay percentage by us differential
relays are used.
Difference of current
% bias= ------------------------------- x100
Total current
Instantaneous Earth Fault Relay:

It is provided as backup protection for the internal earth faults of the
transformer. It is a sensitive, high speed, earth leakage protection relay. Relays are
provided separately for both primary and secondary side of the transformer. The relays
are connected to separately mounted C.T’s; the current setting for the relays shall be
adjustable between 20% and 40% of 5Amps in equal steps at 5%.
Instantaneous Over Current Relay:

These are provided for instantaneous protection against OHE to earth fault which
are occurring close to the sub station. This relay has a special advantage of reducing the
time of operation to a minimum for a higher fault current. The instantaneous relay
effective, only when the impedance is small compared to the fault near ‘SP’. When the
fault is near sub station the fault current is more than the full load current, hence over
current relay are provided both on primary and secondary side. These are connected to
separately mounted transformer.
IDMTL Relay or O.C.R:

Inverse Definite minimum time lag relay works on single pole non directional
over current relay with inverse definite time lag characteristics. These relays are provided
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both on primary and secondary of the transformer. Setting of over current relays is on
primary side 400 to 600%.
IDMTL setting 80 to 320%.
MHO relay:
The MHO relay can sense fault if the difference in phase angle of load current
and short circuit current. The relay should able to discriminate between the load current
and fault current. It is having first zone of operation from 0.33ohms to 12ohms and an ex
tended zone of operation up to 600 ohms. The impedance setting is made by adjustment
of tapings of C.T indicated by K1 and K2 and potentiometer K3. The extended reach of a
relay when the feed is extended will be obtained by variable potentiometer K4 in series
with restraining coil.
Wrong phase relay (W.P.C)

This is installed for giving protection against wrong coupling of different phases. If
the twp phases are bridged at neutral section a circulating short circuit current is set up
between the two stations and the rated voltage may be higher or less than 25KV. If the
voltage is higher OCR will trip and in case the voltage is less the wrong phase coupling
will operate. This is similar in construction to MHO relay but maximum fault angle is set up
for 124° that is it gives protection for fault where phase angle from 75° to 125°.
Auto Reclosing of Feeder circuit breaker:

It is a simple shoot auto Reclosing relay for 25KV feeder circuit breaker for A.C
traction. Sub station has been adopted to facilitate Reclosing of 25KV feeder circuit
breaker automatically after a pre-set time delay on tripping of the circuit breaker on OHE
faults. This feature will help in quick restoration of traction power supply to OHE, if the
fault is transient in nature. It will also help in checking / restricting the continuous of arc in
the event of panto graph of a moving locomotive causing the over lap opposite feeding
post at some moments and thus protecting the OHE.
Inter tripping of feeder circuit breaker:

In the event of failure of traction sub station 25KV supply is extended from the
adjacent sub stations by closing the bridging interrupters at S.P’s under such emergency
feed conditions, wrong phase coupling may be caused at the over lap opposite the field
sub station by panto graph of a passing locomotive. Resulting in the tripping of 25KV
feeder breaker at any one of the two sub stations through wrong phase coupling relay.
This may result in the formation of an arc at the overlap due to which the OHE may be
damaged. The damage due to the arc can be minimized by tripping the feeder circuit
breaker at the at the other sub stations also. This is achieved by inter tripping
arrangement through the remote control equipment.
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S.No Description Type design Rating / Setting

1 Bias differential relay DDT-12 (87%) Current setting 40% to
100% of 5 amps.
20%,30% or 40% bias
setting
2 IDMTL over load relay CDG-26 80% to 320% of 5
(HVIDMTL) amps
3 Instantaneous over current CAG-30 400% to 600% of 5
relay (51HVOCR) amps
4 Restricted earth fault relay CAE-14 10% to 40% of 5
(64RHV) amps
5 IDMTL over load relay CDT-160 80% to 320% of 5
25KV side (LVIDMTL) amps
E.g: The phase angle of the current on fault is about 70° (dead short circuit near sub
station is about 89°) where as that for normal full load current. When the loco is closed to
sub station the phase angle is around 37° and it is 40° when it is 60KM from the feeding
post for a double track section. Taking in to consideration of the above as per MHO relay
has been used for feeder protection.
Protection of Overhead Equipment:

For feeder protection the following relays are provided.
1. over current relay
2. distance protection relay
3. wrong phase coupling relay
OHE Protection
S.No Description Type Designed Rating / Setting

1 MHO type Directional YCG-40 0.33 to 12 ohms
Distance Protection relay extended zone reach up
(DPR or MHO) to 60 ohms with MTA
75°
2 MHO relay for protection YCG-40 0.33 ohms to 12 ohms
against wrong phase zone reach up to 60
(coupling WPC) ohm with MTA 125°
3 Instantaneous high set over CAG-77 100% to 800% of 5
current relay on 25KV side (LVOCR) amps
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ISOLATORS:
Isolators operate under no-load or no-current condition. Isolators can be called as

disconnecting switches. Isolators are designed to open under no current conditions.
Isolators are not designed to make a circuit under load or short circuit conditions. Isolators
do not have rated making current or breaking current capacity. As the name implies
isolator isolates one portion of the circuit from another.
Types of isolators based on:

1. No. of poles: These may be of single pole, double pole or triple pole, but generally in
power systems three pole isolators are used. These isolators have three identical poles.
Each pole consists of two or three insulators posts mounted on a fabricated supports. The
conducting parts are supported on insulator posts. The conducting parts consists of
conducting copper ‘or’ aluminum rod, fixed and moving contacts.
2. Service indoor /outdoor: The isolators, which are not exposed to atmosphere
(arranged in a control room etc.), are called as indoor isolator. The isolators, which are
exposed to atmosphere (arranged in a substation etc.), are called as outdoor isolators.
3. Earthing Isolators: Earthing switch is connected between the line conductor and
earth. Normally it is open. When the line is disconnected, the earthing switch is closed so
as discharge the voltage trapped on the line. Though the line is disconnected, there is
some voltage on the line to which the capacitance between line and earth is charged.
This voltage significant in high voltage system. Before proceeding with the maintenance
work these voltages are discharged to earth, by closing the earthing switch.
4. Number of Breaks:
(i) single break (centre break) type isolator: These isolators are used for voltages of
the order of 11KV to 220KV. The triple pole isolator has three identical poles mounted on
the base frame or rolled steel sections. Each pole comprises two insulators stacks of post
type insulator. The insulator stack mounted on a bearing and the whole stack can be
rotated about its vertical axis though about 900, the arrangement is such that one stack
swings clockwise and at the same and the swings counter clockwise. The contact arms
swing in horizontal plane and the isolation takes at the centre.
(ii) Double break (Center rotating isolator): in this type construction, there are three
isolator stacks per pole. The two on sides are fixed one at the centre is rotating type. The
central insulator stacks can swing about its vertical axis though about 900. The fixed
contacts are provided on the top of each of the stacks on the side. The contact bar is
fixed horizontally on the central isolator stack. In closed position, the contact shaft
connects the two fixed contacts. While opening, the central stack rotates though 900, and
the contact shaft swings horizontally giving a double break.
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SCADA:
Over view of SCADA:
The SCADA system is designed to monitor the status and control of 25kV
electrified traction system. It is fully integrated hardware and software system, with a
central control monitor and controls the field devices located at remote sites. The SCADA
system can be classified into two categories:
1. Remote Control Center (RCC)
2. Remote Terminal Unit (RTU)
Remote Control Center (RCC):

It is designed for monitoring different types of data like catenary indication, device
status and telemetry from various control stations. It also controls field equipments like
CBs, BMs and Transformer tap position changing etc. RCC stores the data regarding
alarms, events and telemetry to help the user to analyze the status of the overhead
equipment and switching stations. This data can be used for maintenance purpose also.
For example RCC helps the user to easily identify the fault in OHE located in
various sections, for immediate rectifications
1. Main and stand by computers

2. Operator workstation computer
3. Communication processors with modems.
4. Printer and print share switch
5. Modem
6. UPS
7. Battery
The main and stand by computers are industrial grade PCAT486 with 14 inches
color monitor.
The main computer interacts between the communication processor and work
station computers. It collects the formatted RTU information from the communication
processor and sends the processed information to the operating workstation computers,
which enables the user to understand the field conditions.
The main computer also updates the available information with slave computer,
which should have the same information. Whenever the main computer fails, then the
slave will become main with updated information. The main computer is used to configure
the engineering details, which are essential for the process of RTU data into the CWS
computer or vice versa. The main and standby computer system software is developed
under the UNIX operating system with C language.
The workstation computers are industrial grade PCAT486 with 19 inches color
monitor.
RTU (Remote Terminal Unit):

It is designed to control and monitor field equipments. It accepts digital and analog
input signals from the remote field equipment. It receives the control command from the
RCC.
It can be divided into four parts:
1. Logic Chassis
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2. Interface unit
3. Transducer
4. Modem
RTU accepts digital and analog input signals from the remote locations
(TSS/SP/SSP) and receives the control command from the RCC to perform the following
tasks.
1. Status input monitoring and change of status
2. Control output operation
3. Analog input monitoring
4. Communication with RCC
The RTU provides the following basic data acquisition functions:
1. Data acquisition for status input and analog input
2. Control outputs
3. Analog output
4. RTU/Master station communication
RTU: It consists of the following parts

1. Power supply unit
2. Logic chassis
3. Interface unit
4. Modem
5. Terminal section
Logic Chassis: It is the main part of RTU, and is based on microprocessor. It is used to
control and process all field signals. Each logic chassis supports 96digital input / output
signals; 64 analog input/output signals and 4RS232 communication modules.
Interface Unit: It receives and controls the field signal devices. Transducer, which are
part of the interface unit used to convert the field analog signals like voltage and current.
Modem: It is used to convert the digital information to analog information suitable for 4
wire based communication cable and vice versa
The equipment is designed to work one VF loaded quad of the S&T cable. The
equipment designed to incorporate a number of safe guards to ensure reliable operation
under adverse field conditions. The input and output are sufficiently isolated from the
equipment by means of transformers or relays.
The modular construction makes the system expansion at any stage. The PC
modules to meet the additional capacity can be added to itself at any stage without
involving any wiring change.
For monitoring the critical points in the circuit for quick identification of faults LED's
indication are provided In each functional module. The faulty module can be replaced
readily by spare module. The fault modules components on individual cards can be
localized by a suitable test procedure at RCC.
Transmission Path:
Under ground telecommunication track cable is provided for transmitting the signals
from and to the RCC and that control remote terminal units. Three pairs of conductors
1. One pair for send
2. One pair for receive and third as spare available
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Remote Terminal Unit (RTU):

The RTU is a micro processor based and includes its associated digital
input/output modules, alarm input modules, all analog input modules, watchdog
transducers, memory modules, inter posing relays, summations CT’s power supply units,
surge arresters and other items necessary for its proper working.
Isolating Transformers:
To limit the buildup of longitudinal induced voltage eon account of induction
effects of 25kV traction. Isolating transformers are provided on the cable circuit at
intervals of 10 to 15 KM. the cable is tapped at the RCC and each control station and
three pairs of conductors are terminated on a terminal board. Isolating transformers of
impedance ratios 1120:1120 is provided at the tapping.
FMVFT Equipment: The control signals from the RCC as well as the indication signals
from the various controlled posts are transmitted on separate channels with in the voice
frequency range of 420 to 2460 C/S with a 120 C/S separation. This will make available
18 channels. Frequency modulation ensures reliabilities and prevents mal-operation,
taking care of level variations, cross-talk and other interferences met with on the line.
The second unit for each channel comprises of an oscillator modulator, an
amplifier and a send filter. The individual channels are grouped together at the output of
the send filters and passed onto a trans-amplifier and then to cable lines through a
150:1120 tapping transformer. The signals are sent over a two wire circuit in one direction
only.
On the receive side, the impulse train passes through an 1120:150 tapping
transformer to the receive amplifier. After amplification the signals are passed through the
filters and then to detector units. The output of the detector that is code pulse, actuate the
mechanism concerned to carry out the required operation. The selection of each
apparatus to be executed and the order to be executed are achieved by coding of the
impulses. Common to primary and secondary circuits in termed as auto transformer.
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9. MAINTENANCE SHCDULES, CRITICAL POINTS,

SETTINGS AND TOLERANCE OF PSI , SUB
No work of any kind shall be done in the vicinity of live equipment unless power
supply to the particular path has been switched OFF and all other safety measures
prescribed are taken.
Fortnightly maintenance:
General inspection by supervisor.
Remove any vegetation, cut any tree branches.
Examine all traction boards; inspect fire extinguishers, fire buckets and first aid box.
Inspect all indication lamps and control panel for correct working.
Battery:
Check all cells for cleanliness, level of electrolyte

Take specific gravity and cell voltage of pilot cells and record in a register.
Top up with distilled water to the correct level for every cell.
Check operation of battery chargers and note trickle charging rate in the register.
Monthly Maintenance:
I. Bonding and Earthing:
1. Bonding and earthing (40/6 old, 50/6 new, 75/8 earth mat)
2. Visually inspect all earth connections and see that they are in order and make sure
that every equipment has got duplicate earths.
3. Tighten the connections on bolts and nuts.
4. check the substation structures are properly bonded
II. Various oil levels:
1. Check oil levels in transformers, CB, CT, PT, AT and BM’s in site gauge glass.
2. Examine all joints, valves, plugs etc. for all leakage.
3. Rectify leaky parts if any and restore the oil level.
III. Insulators:
1. Clean insulators of transformers, CBs, BMs etc. with dry cloth and look for any
flash over marks, cracks, chippings etc.
2. Insulators which are badly chipped should be replaced. Minor chippings can be
rendered impervious to moisture by a light coating of araldite or similar epoxy
resigns.
IV. Traction Transformers:

1. Clean externally the tank, conservator, radiators, bushings, oil level indicators and
gauges etc. with dry cloth.
2. Check explosion diaphragm for any damage and presence of oil.
3. Note in the register, the maximum temperature reading of transformers i.e., oil and
winding temperature and reset the indicator.
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4. Check all split pins, lock nuts, check nuts for proper condition.
5. Check for correct alignment of arcing horns
6. Operate the isolator slowly, check for simultaneous operation of blades on the
poles and correct alignment of blade tips in the fixed contact jaw. Adjust if required
to ensure that the blades are fully resting between the contacts when the handle is
in closed position.
7. Check locking arrangements.
V. Control Panel:
1. Make a note of flag indications, if any, then reset.
2. Remove cob-webs and wipe of accumulated dust with dry cloth.
3. Check the tightness of all the connections.
4. Check the relays for manual operation put back over and make sure that they are
dust tight.
5. Check the settings are in order.
6. Examine fuses for signs of overheating or ageing.
Half Yearly Maintenance:

I. A.T, P.T and C.T: Check the fuse holders on the CT side to see if they are in order and
are making good contact and are in secured position.
II. Traction Transformer:

1. Test oil sample for breakdown voltage, if it drops below 45kV oil should be purified
2. Check whether the arcing horn gap setting on bushings on transformers are in
order as per makers drawing.
3. Measure and record insulation resistance values of winding with 2.5kV megger
Primary to earth is more than 5000M ohms
Primary to secondary is more than 5000 M ohms,
Secondary to Earth is more than 2000 M ohms.
4. Check all alarm trip devices for proper working
III. Isolators:
1. Observe for any signs of overheating, clean blade tips and fixed contact figures
and apply petroleum jelly to the contact making surfaces.
2. Clean all articulated joints, sliding and bearing surfaces with spirit.
3. Inspect bushing gaskets for links and tighten bolts
4. Move the tap setting switch up and down for few times so that good contact is
assured. Set the tap finally at the correct position. Make sure that tap corresponds
to position of main contacts.
Record IR values with 5KV megger and calculate, record the polarization
value between HV to LV, HV to Earth and LV to Earth.
IR 60 Seconds
Polarization Index = -----------------------------------------
IR 10 Seconds
Conduct ratio test at all taps and record.
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IV. Bus-Bar Connections:

1. Measure with low resistance measuring instrument, contact resistance of all
connections which are carrying heavy currents.
V. Batteries:
1. Make sure that all the cells are in good condition and fully charged, give an
equalizing charge and correct specific gravity when essential only when the cell
has spilled out. When essential by adding dilute sulphuric acid. This is to be done
only when the cell has been over watered and consequently the electrolyte has
spilled out and record cell voltage.
2. The battery is not very healthy condition of there is excessive accumulation of
sediments, the whole battery is taken out for shop attention replacing into another
good spare battery.
3. Open out the covers of batter charge and blow out all dust. Check tightness of all
connections bolts and nuts, measure and record the insulation resistance of the
transformer winding of the battery charger.
VI. Auxiliary Transformers:

1. Measure and record IR values, HV to LV, HV to earth with 2.5kV megger and LV to
earth with 500v megger.
2. Check that the 25kV drop out fuse holder drops out or drops down freely by raising
the spring latches.
3. Check the continuity of neutral conductor and also measure the earth resistance.
4. Test oil sample for breakdown voltage.
VII. Potential Transformers and Current Transformers:

1. Test oil sample.
2. Measure insulation Resistance.
3. Check condition of fuses of PT’s and terminal connections for CT’s.
IX. Maintenance Schedule for MOCB/Interrupters:

This schedule will apply to all circuit breakers and interrupters with the
following provision.
132kV Circuit Breakers: Every 12 months or after 6 Trippings on short circuit.
25kV circuit Breakers: 30 Trippings on short circuit.
25kV Interrupters: 250 openings on normal currents for minimum oil time.
The following points are to be checked:
1. Open the extinction chamber, examine the contact rod arcing tip upper and lower
contact fingers and fixed arcing contacts for burnings or pitting. Check contact
springs for loss of temper breaks or there deterioration, replace where necessary.
Remove any beads of fused material from arcing tips and clean pitted surfaces.
Change the contacts when the wear reaches the limits prescribed by the
manufacturer; tighten up all bolts and current carrying parts. Check contact rod for
correct alignment and setting.
2. Test oil sample for Breakdown voltage, if it falls below 40 kV for 132kV CB's and
30kV for 25kV CB’s and interrupters the oil should be purified or replaced.
ETTC/BZA Page 84
3. Clean the explosion chamber with dry and clean cloth, remove the carbon deposit
if any, wash out all traces of moisture a from all parts with fresh oil having high
dielectric strength and refill with good oil.
4. In addition the operating mechanism of CB’s and BM's should be attended to
annually as under.
Lubricating bearing surfaces of rollers, bearings and sliding surfaces with
good quality machine oil.
See that all links and levers move freely. Operate the mechanism slowly by
hand to see that all parts move freely.
Check all pins, latches etc. for binding and misalignment. Check latch
carefully to see that it is not getting warm so as to cause UN latching from
vibration or sticking and fails to trip.
Check the mechanism, operates with 80% of the normal operating voltage.
Check and record the insulation resistance.
Observe operation of trip coils during electrical tripping and the plunger for
fast action and free from any stickiness. The plunger should have sufficient
travel to ensure adequate impact that will positively release the breaker
latch, check insulation resistance of the coil.
Check if breaker mechanism operates smoothly and freely without binding.
Check that the contactor rod is not binding against its guide.
Wash out bearings, pivots etc. with CTC (carbon tetra chloride)
Examine the accelerating spring and see that adjusting nuts are locked
type.
Measure the length of the breaker stroke and check and adjust in
accordance with manufacturer instructions
Check opening and closing position of the auxiliary contacts with respect to
the main contacts adjust where necessary.
Check the condition of contact and refinish with finite file if burnt of
corroded. Ensure that good contact is made with out excessive friction.
Drain oil from correct level with fine grade oil. Measure the duration for
which the motor runs to charge the spring.
IX. Maintenance of Sulfur Hexa Fluoride Gas Circuit Breaker:
1. Patrol Inspection: Every week the patrol inspection is an external checking of the
circuit of the circuit breaker in live condition for any irregularity.
2. Ordinary Inspection: After every 1000 operations the ordinary inspection
performed by turning OFF the circuit breaker for a relatively short time for simple
inspection and serving with emphasis on functional checks and cleaning of dust
and dirt.
3. Detailed Inspection: After every 3000 operations the detailed inspection is an
inspection perform by turning OFF the CB for a relatively long time to dismantle
and inspect the mechanism for irregularities for the purpose of continuously
maintaining the performance.
4. Incidental Inspection: the incidental inspection is performed where inspectional
repairs are necessary due to the detection of an irregularity during patrol inspection
ETTC/BZA Page 85
or during the following points are to be paid attention during ordinary and detailed
inspection.
Switch OFF control compressor motor supply. Discharge all the air in the air
reservoir through the drain valve.
The circuit breaker is to be inspected in the open position on unless
otherwise specified at the open position of the breaker. The safety pins for
preventing closing and opening must be inserted. On completion of the
inspection the safety pins must be removed.
Good quality grease used adequately
Circlips and split pins which are removed must be replaced with ones.
Remove O rings and replace with new one. While handling and placing O rings
in the grooves care should be taken to avoid dust falling on them.
Yearly Maintenance:
1. Open all the trench covers and clean them completely.

2. Inspect the fencing all round the substation. Bonding between metal fencing panels
to earth is to be checked. Repaint any of the rusted structural parts.
I. Lightening Arrester:
1. Check earth terminal and earth strip for proper condition. Clean the insulator
thoroughly.
2. Record the insulation resistance values with 2.5KV/5KV megger. It should not be
less than 10000Mohms.
II. Bonding and Earthing:

1. Check physically the soundness of bonding and earthing connection to every
electrical equipment, steel structures, lightening arresters etc. and also control
panel earthing.
2. Record earth resistance to body of electrical equipment.
3. Check if the terminations of overloaded shield wire covering whole substation are
in good mechanical condition and are properly bonded electrically to the structures.
4. Check the record resistance of each earth pit of after disconnecting it common
earth system. Improve if necessary.
5. Record combine earth resistance of substation.
III. Traction Transformer:

1. Test oil sample for acidity.
2. Check oil level in bushings,
3. Check the explosion vent diaphragm for any damage or presence of oil.
4. Check silica gel breather, if it is pink in appearance replace with dry silica gel and
recondition with old silica gel. If the silica gel is too wet, check the dielectric
strength of transformer oil.
5. Check for any gas in Buchholz relay.
6. Check for any leakage of oil. If leaking, take corrective action by tightening the
bolts and replace gaskets if necessary.
7. Check the heater in the marshalling box (20 watts).
ETTC/BZA Page 86
IV. Circuit Breaker and Interrupter:

1. Open the cover of mechanism box and remove the accumulated dust, check
whether proof gaskets on good condition. If not replace them to make the
mechanism box, water type and rust proof.
2. Check all pins and check nuts are in place, check also tie rod nuts for tightening.
3. Operate the mechanism at least two times manually keeping the door open;
operate mechanism, from remote control centre.
Observe whether the mechanism functions smoothly without rubbing or obstruction.

Examine the commutator of the motor and clean with mull cloth. Examine the carbon
brushes and replace if necessary.
4. Check the heater from proper functioning

5. Check the interlocks of the device.
6. Check local position indicator and also semaphore indicator.
7. Observe for correct operation of counters.
After complete checking close the cover and test the breaker for operation from
RCC, from Control panel and local.
V. Isolators:
Manually operate the isolator several times and observe if it operates smoothly and
correctly. Check interlocks and lubricate moving parts and applying petroleum jelly for
both male and female contacts.
VI. Bus bar connections:

If any connection is too hot it indicate poor contact, open the connector and clean
the contact surface.
VII. Control and Relay Panel:

1. Clean the panel externally.
2. Check the indicating instrument for proper working.
3. Make a note of flag indication if any, all relays should be reset.
VIII. Battery and Battery Charger:
1. Take specific gravity and cell voltage of every individual cell and enter in the
register.
2. If the battery is not in a fully charged condition, boost charge should be given if
required. Boost charging rate should be only done by supervisory official after
investigating the cause for excessive discharge.
3. Make a general examination of the battery charger, check earth connection to the
body.
ETTC/BZA Page 87
MAINTENANCE RECORDS AND THEIR IMPORTANCE:
Records to be maintained: Particulars of other essential records to be maintained about

PSI maintenance are given below:
1. Sub-station Equipment Register.
2. Switching Station Equipment Register.
3. Capacitance Value Register.
4. Earth Resistance Value Register.
5. Equipment Failure Register.
6. Equipment History Register.
7. Transformer History Register.
8. Battery Maintenance Register.
9. AT Maintenance Register.
10. AT History Register.
11. Register for C.B Tripping.
12. H.T Meter Reading Register.
entries.
ETTC/BZA Page 88
10. TESTING, ERECTION AND COMMISSIONING

OF MAJOR PSI EQUIPMENT
TRACTION TRANSFORMER:
During the preparation for commissioning of transformers at traction sub stations in

addition to manufacturer’s instructions, the following steps shall be taken:
i) Drying out of transformer shall be undertaken as per the procedure laid down (refer
para20208)
ii) Tap changing mechanism shall be checked for being in perfect operating condition,
both electrically and mechanically. Ratio test should be done in this procedure (refer para
20206)
iii) Transformer bushings should be paid special attention to ensure that the
manufacturers seal is intact and the bushings are in excellent condition. The insulation
resistance of the bushing should be around 10,000 Mega Ohm.
iv) All gaskets should be properly compressed and tight fitted. No leakage of oil should
be visible from valves, pipe joint, gauge glass, radiators or any other parts of transformer.
The welded joints should also be checked for oil seepage if any.
v) For a sub station with more than one transformer, they should preferably be identical.
The polarity on both should be checked.
vi) The oil filled in transformer should be fully de aerated to avoid false operation of
Buchholz relay.
vii) The Buchholz relay should be erected as per instructions of the makers and tested for
correct operation.
viii) All accessories like silica gel breather, vent pipe, explosion vent diaphragm,
circulating oil pump and special cooling equipment. If any, should be checked.
ix) In addition to Buchholz relay, (refer para 20214) other protective devices provided for
the protection of transformer (refer para 20212, 20213) should be examined and checked
carefully and tested after erection at site.
x) Earthing of transformers and its neutral terminal shall be done in accordance with the “
code of practice for earthing of power supply installations”.
CIRCUIT BREAKERS AND INTERRUPTORS:
The installation of circuit breakers and interrupters shall be carefully done as per
instruction manual of makers.
ETTC/BZA Page 89
The following special checks may be made:

Check, first of all, if the circuit breaker mounting is quite vertical and the base firmly
secured. Examine the operating mechanism in the waterproof of housing for cleanliness,
free movement of rollers, bearings and sliding surfaces, which should be very lightly oiled.
Open and close the breaker several times to check that everything is working smoothly.
Make sure that all pins, locking plates and split pins are in place.
On the electrical side, examine the condition of the wiring, its insulation resistance
and tightness of the terminal screws. Check if the opening and closing solenoid or motor
when electrically operated does operate satisfactorily with battery voltage 20 percent less
and 10 percent more than the rated voltage.
Check and record the dielectric strength of oil in every circuit breaker, taking out
the oil through the sampling cock. If the break down voltage (BDV) is less than 40KV, oil
will have to be dried out. This is easily done by a small portable oil purifier having a
capacity of 200 litres per hour. After drying out, repeat the BDV test, taking necessary
precautions.
ISOLATOR:
Examine the insulators carefully for any surface cracks, and make sure if the
surface is clean. Check operation of isolator manually to see if the movement is free and
smooth, and if the switch blades are fully open or fully closed when the handle is locked
at the top or bottom position. Examine the contacts and check is the spring pressure is
adequate and blades make full contact. Check terminal connections, preferably with a
“Ductor”.
CURRENT AND POTENTIAL TRANSFORMERS:
Check and record the insulation resistance of primary and secondary to earth and
between primary and secondary. Check oil level in PT if it is not of the sealed type as also
its dielectric strength. Top up the oil drawn for test. Make sure that the terminal
connections are well made preferably recording the contact resistance of CT connections
by a “Ductor”. The frames of the PT and CT should be well earthed by two independent
connections to earth.
LIGHTNING ARRESTORS:
Make a thorough visual examination of the outer porcelain housing for hair-line
cracks and chipped sheds. Clean the outer surface of all dust. The connecting leads to
the arrestor should be solid and direct. The earth terminal of the lightning arrester should
be connected to the general earthing main at the substation, to the transformer tank body
and finally to an independent earth electrode provided very close to the arrestor.
SHIELDING AND EARTHING:
Check whether the whole of the substation area is well protected against
atmospheric surges by screening conductors strung between substation structures and
solidly connected to the earth system in accordance with the approved drawings.
ETTC/BZA Page 90
Check visually whether the metallic casing of every substation equipment and
neutral terminals of the power transformers are solidly connected to the sub station
earthing grid, and confirm that the “Code for Earthing Power Supply Installations” .
BUSBARS AND INSULATORS:
A careful inspection should be made of every insulator supporting a bus bar to

detect any minute cracks on the surface; paint marks or dust should be removed and the
surface gloss restored.
The contact surface should be clean, smooth and without any irregularities and
burrs, so that when they are tightened the area of contact is large. The pressure should
also be adequate. Particular care should be taken when joints are made between two
dissimilar metals like aluminum and copper. Special bi-metallic fittings should be used in
such cases to prevent electrolytic corrosion.
CLEARANCES:
The minimum clearances in mm in air for live equipment shall be as under:
SL.NO: 25kV 66kV 110kV 132kV 220kV

1. Between phases ------ 630 900 1300 2400
2. Between one phase and 500 630 900 1300 2100
earth for rigid connection
3. Between any points
where man may be
required to stand to the
nearest 3000 3500 3500 4000 5000
(a) unsecured conductor
in air (mm) 2000 ------- ------- ------- --------
(b) secured condition in
air (mm)
4. Min. height of Bus bar 3800 4600 4600 4600 5500
BATTERIES AND BATTERY CHARGER:
The battery room should be particularly well ventilated, protected, dust free and
dry. The battery room floor and walls upto a height of 2m should be painted with anti
sulphuric acid paint. The batteries themselves should be wall supported on teakwood
stands, painted with anti-sulphuric acid paint and resting on porcelain insulators to
prevent leakage. Examine
The log book for the period during which the battery was given its first charge and make
sure that the manufacturer’s instructions have been adhered to as regards the rate of
charge and the number of charge and discharge cycles. Check finally if the battery fuses
ETTC/BZA Page 91
are of the correct and there is no possibility of battery supply failure. Make sure that the
alarm bell goes OFF if the supply is interrupted for any reason to the control panels.
The battery charger should be inspected to make sure that its capacity for normal
and boost charge as well as trickle charge is sufficient and that it complies with the
technical specifications, that the meters provided are indicating properly and it is complete
with necessary fuses and indicating lamps. The metal casing should have two
independent earths.
PROTECTIVE RELAYS:
Before any traction installation is commissioned, the proper operating of every
protective relay should be ensured so that it can be fully dependent upon in all
circumstances. This is done in three stages:
• Checking the relay in laboratory prior to installation
• Checking after installation and before the substation is commissioned.
• Confirmatory test after energisation and before introduction of commercial
services.
The performance of the relay for different settings should then be checked using standard
relay testing equipment, making such adjustments as may be found necessary. A detailed
record of the test set up and the calibration curves should be entered in a register as a
permanent record. The plug settings are then correctly made to cater for the expected
load conditions.
CONTROL CIRCUITS AND WIRING:
After installation of all equipment and completion of control cable connections, a
detailed check of the wiring should be conducted. Verifying the colour code and
identification tags and markings on the terminal strips on the equipment and the control
panels with respect to the approved wiring diagram. Insulation and continuity tests should
also be taken and values recorded.
The detailed diagrams of control circuit and wiring of control panel supplied by the
manufacturers should not merely be taken on trust, but subjected to careful scrutiny as to
their correctness. Errors do occur in drawings and if they are not detected at the very
early stage itself, they may cause a great deal of confusion and trouble later. The best
method of detecting errors in detailed wiring diagram is to prepare a simplified schematic
or functional diagram so that the circuit arrangements become quite clear and obvious.
FUSES:
Control circuit fuses shall be of correct rating. If the trip battery circuit fuse is under-
rated, it is liable to deteriorate due to excessive heating and fail ultimately, which could
indeed be dangerous. To guard against this possibility, alarms are sometimes provided to
draw the attention of operator in the event of fuse failure. In ac traction, failure of battery
fuses
is automatically relayed to the RCC but the TPC cannot replace the fuse by RC, someone
has to go and replace it which may take considerable time.
ETTC/BZA Page 92
AUXILIARY TRANSFORMERS & BOOSTER TRANSFORMERS:
The mounting of these transformers should be checked to ensure proper fitment and
conformity with schedule of dimensions and electrical clearances.
The booster installations, in particular should be checked for correct jumper connections.

The structural steel work as well as the neutral connector of auxiliary transformer, and the
metal cases of every electrical equipment shall be connected by two independent
connections to earth in accordance with the “Code for Earthing Traction Power Supply
Installations”. According to this code, HT and LT earths should be provided separately,
but interconnected together by a link.
During detailed inspection, the resistance to earth of each electrode should be
measured and recorded by a megger earth tester so that the combined resistance of the
HT earthing system is 2 ohm or less and of the LT earth 10 ohm or less, when not
connected to the rails.
Commissioning certificates:
Public notification regarding energisation.

Public notification regarding level crossings
Joint certificate by DEE (TRD) and DEE (OHE construction)
Certificate regarding bonding and earthing.
Joint certificate by Divisional officers regarding safety instructions
Certificate by DS regarding safety measures
Sanction of CEE and electrical inspector for energisation.
Certificate by S&T department
Clearance certificate by P&T department
Clearance certificate for 25kv feeder lines
Clearance certificate for OHE
Clearance certificate for switching stations
Clearance certificate for booster transformer stations
Clearance certificate for P&T and S&T works
Clearance certificate by OHE contractor
EIG (ELECTRICAL INSPECTOR TO THE GOVERNMENT) SANCTION:
1. Application shall be submitted at least a fortnight before energisation to CEE and

Electrical Inspector to the Railway for the following:
(a) Formal approval, if not ready received to the design and layout of all high voltage
equipment including traction substations, transmission lines, 25KV feeders, switching
stations, booster stations etc.
(b) Approval for energisation of HT installations mentioned above including OHE.
2. The following documents shall accompany the application for EI’s sanction.
(a) Copies for press cutting of public notification as mentioned in para21008.

(b) Certificate regarding OHE (proforma 10-03)
ETTC/BZA Page 93
(c) Certificate regarding bonding and earthing (proforma 10-04)

(d) Certificate regarding safety instructions and precautionary measures (proforma, 10-
05).
(e) Certificate by DRM regarding safety precautions (proforma 10-06)
(f) Copies of insulation resistance test results of OHE
(g) Insulation test results values for auxiliary and booster transformers.
(h) Test results for equipment in switching stations and sub stations and their safety
certificates, if earlier sanction for the energizing this is not obtained separately.
(i) Clearance certificates from Dept. of Telecommunication.
(j) Any other data, test results and certificates required by the Electrical Inspector.
The sanction of the Electrical Inspector may be issued in the proforma 10-07.
*********xxxxxxx********
ETTC/BZA Page 94

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INITIAL TRAINING COURSE FOR

1. FOUNDATION, MEASURING / PORTABLE

1. Chairman, Railway Board.

The Chairman of railway board is Ex-officio principal secretary to the Government of

Various Departments in Railways:

1. Operating ______ Chief Operating Manager

1. Southern Railway Chennai

2. Central Railway Mumbai

3. Western Railway Mumbai

4. Eastern Railway Kolkata

5. Northern Railway New Delhi

6. North Eastern Railway Gorakhpur

7. North East Frontier Railway Guwahati

8. South Eastern Railway Kolkata

9. South Central Railway Secunderabad

10. East Coast Railway Bhubaneswar

11. South Western Railway Hubli

12. North Central Railway Allahabad

13. East Central Railway Hajipur

14. North Western Railway Jaipur

15. West Central Railway Jabalpur

16. South East Central Railway Bilaspur

Various divisions in South Central Railway:

Various workshops available in South Central Railway:

ELECTRICAL DEPARTMENT: There are four sub departments in electrical department.

Traction Distribution Department (TrD): This department is responsible for efficient

Traction Rolling Stock Organization – Operations (TRSO – O): This department is

STAFF WELFARE MEASURES:

The activities dealt within this organization are:

Schooling facilities and educational assistance: Provisions of facilities in railway

Educational Assistance, Reimbursement of tuition fees and Hostel subsidy: The

Handicraft centers- Vocational training centers: Handicraft centers should be set up

Medical Facilities: Railways have provided railway hospitals , dispensaries , child

Staff Benefit Fund:

S.N Tool Material Size Uses Precautions

wood 12mm boards greasy handle,

13 Files(flat, Steel 3”to14” To smooth the surface or Do not use without

21. Crimping Steel 1.5mm, As soldering of aluminium Do not use it on

Care for life-threatening conditions.

appearance because of exposed tissue.

Material handling and working of equipments:

Importance of up keep of materials:

Steps to keep environment clean:

FIRE FIGHTING AND ELECTRICAL SHOCK TREATMENT:

Type of Class A Class B Class C

Caution to be taken against Class A fires:

1. Soda Acid Extinguishers: This type of an extinguisher is cylindrical or conical in

4. Carbon Tetra Chloride Extinguisher: It comprises a cylindrical metal container

ELECTRICAL SHOCK TREATMENT:

Mouth to nose Method:

MATERIAL HANDLING AND PROPER UPKEEP OF WORK AREA :

Road Vehicles / Tower Car:

Brake and horn to be checked.

IMPORTANCE OF UPKEEP OF MATERIALS

Concerned to office premises:

Concerned to outer field:

2. GENERAL ELECTRICAL TECHNOLOGY AND

Current: Flow of Electrons in any conductor is called Current. It is represented by ’ I’.

Resistance: Resistance may be defined as that property of a substance, which opposes

V=IR, where V = voltage applied to the circuit,

Voltage Current Resistance Watts