CHAPTER 9 POWER SUPPLY FOR TRACTION para No PDF

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CHAPTERIPOWERSUPPLYFORTRACTIONParaNo
CHAPTERIX
PREPARATIONFORCOMMISSIONING
20900Introduction
PriortocommissioningnewRailwayElectrificationschemes,detailedpreparationworkisa
necessaryprerequisite.Whileinstructionsareissuedseparatelyintechnicalmanualsof
variousequipments,salientpointsinrespectofthefollowingmajorheadsareoutlinedin
thischapter.
ITractionsubstations
IITransmissionlinesand25kVfeeders
IIIProtectiveequipment
IVSwitchingStations
VRemoteControlequipment
VIOverheadequipment
VIIGeneral
Thischapterisdevotedtothetechnicalaspectsofworkwhichcallforattentionduring
inspections,testsandtrialsbeforeenergization.ChapterXdealswithproceduresin
connectionwithenergizationandcommissioningandputtingtheassetsintobeneficialuse.
20901ReferencetoRulesandStatutoryRules
Thesafetyoftravellingpublic,railwaystaffandpropertyshallbeensuredbystrict
compliancewiththeruleslaiddownin:
i)IndianElectricityAct1910(latestrevision),
ii)IndianElectricityRules(latestedition),
iii)IndianRailwayAct(asamendedfromtimetotime),
iv)GeneralRulesforIndianRailwaysandassociatedSubsidiaryRulesprescribedbyZonal
Railways,
v)IndianRailways'ScheduleofDimensions,
vi)TheRulesforOpeningofaRailwayorSectionofaRailwayforPublicCarriageof
Passengers,1935(asamendedfromtimetotime),
vii)BondingandEarthingCode,CodeforEarthingforTractionInstallationsandRegulations
forPowerLineCrossings,
viii)RelevantISorIRSspecificationsandcodeofpracticesforvariousequipment.
http://www.indianrailways.gov.in/railwayboard/uploads/codesmanual/ACTractionIIPI/ACTractionIIPartICh9_data.htm
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Duringthepreparationsforcommissioning,theprovisionsofalltheserulesshallbekeptin
view.
WhereverextractsandAppendixetc.,oftheruleshavebeenincludedfromtheserulesin
theACTM,thefiguresandcontentswouldautomaticallygetamendedwithdatesof
amendments.
Methods/proceduresindicatedinthemanualareonlyforguidanceandmaybemodifiedas
perlatestmethods/standardsprescribedbyRDSO/approvedbyCEE.
20902PreCommissioningInspections
1.Precommissioninginspectionsandtestscovertwodistinctparts,viz.:
a)DetailedinspectionattheleveloftheAEEandSeniorSubordinates,and
b)GeneralinspectionattheleveloftheDivisionalOfficers.
Thesetwoinspectionsareprimaryinspectionscoveringalltheinstallationsandare
independentofanyinspectionswhichmaybecarriedoutbyAdministrativeofficers.
2.Officersandstaffofvarioussections(Departments)intheDivisionshouldassociate
themselveswiththefieldworkduringconstruction,acquaintthemselveswiththe
installations,satisfythemselvesabouthighstandardsandquality,ofworkandgetthe
defectsnoticedrectifiedthenandthere,whileworkisinprogress.
3.Thedepartmentalagenciesexecutingtheworkintheconstructionorganizationshallalso
keepconstantliaisonwiththeircounterpartsontheopenline,whowillberesponsiblefor
themaintenanceofassetscreatedbytheconstructionunit.
20903DefectandDeficiencyLists
Whentheworkisdeclaredashavingbeencompletedandreadyforinspection,thefield
officersandSeniorsubordinatesoftheopenline,alongwiththeircounterpartsofthe
constructionunitandrepresentativeofcontractors,ifany,willcarryoutjointchecks.The
checksshouldbethoroughandcovereverypartoftheinstallation.Inmakingthesechecks
thelatestdrawingsshouldonlybeused(supersededversionscanbemisleadingandshould
bepositivelyavoided).
Alldefectsnoticedduringsuchjointchecksshouldberectifiedbeforethesectionsaretaken
overbytheopenlinemaintenanceorganization.Thedefectswillbecategorizedinthree
typesandjointlysignedlistsbeprepared,accordingly:
CategoryADefectsconcerningvitalsafetyitemsandseriousshortcomings,whichmust
berectifiedbefore
eventestcharge.
CategoryBDefects,notaffectingsafetythoughtheirrectificationbeforecommissioningis
essentialfortroublefreeworkingofelectrictrainservice.
CategoryCMinordefects,whichneednotholdupcommissioningandcanberectifiedafter
commissioninginareasonabletime.
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Duringthepreparatoryperiod,theselistsshouldbeconstantlyreviewedjointlyand
progressofrectificationtobedonebyconstructionorganizationbewatched.
I.TRACTIONSUBSTATIONS
20904PlanningofPowerSupply
1.Substationsplayavitalroleinelectrictractionand,therefore,theneedforconsiderable
careduringerectionandcommissioningcannotbeoveremphasized.Ahighstandardof
workmanshipisessentialandtheprecommissioningtestsshouldbesystematicallycarried
outbycompetentstaff,usingdependableandcalibratedinstruments.
2.Whenalongstretchofsectionoftherailwayissanctionedforelectrification,detailed
planningofsectionbysectionenergizingbeundertakenandcommissioningforcommercial
operationofelectrictractionoverappropriatesectionswithpartialchangeoftractionbe
decided.Keepinginviewthefactthat100%trafficcannotbeswitchedovertillaviable
sectionoftheRailwayiscompleted,theorderinwhichthesubstationsshouldbebrought
onlineshouldbedecidedbyCEEinconsultationwithREandoperatingbranch.Thisdecision
shouldtakeintoaccountthereliabilityofsupplyfortheenergizedsection,thetariff
structureandthecommitmentsinregardtocontractdemandandminimumguaranteeto
supplyauthorities.
3.Thesupplyauthoritiesmaythenbeadvisedthedatesbywhichpowersupplywillbe
neededatthevarioussubstations.Agreementsmaybeenteredintoatappropriatetimeto
makesurethatthesupplyauthoritiesdonotdelaytheworkontheirpartandhave
adequatetimetocompletetheconstructionoftheirworksforconnectingthesubstationto
thegrid.
4.Thephasingdiagram,decidingwhichphasesofSEB'stransmissionlineswillbe
connectedatdifferentsubstationsshouldbefinalizedinconsultationwithsupplyauthorities
fortheentiresectionoftheZonalRailwayplannedforelectrification,keepinginviewpower
supplyonadjacentrailwaysystems.Theconnectionofthesubstationstothetransmission
linesshouldbeincyclicordersothattheloadduetoelectrictractiononthegrid,systemis
wellbalancedandremainwithinthepermissiblelimitsofunbalance.
5.Thepowersupplytotractionsubstationisconnectedthroughtransmissionline,which
oftencrossthetrack.Theapplicationforthe'TrackCrossing'shouldthereforebeprocessed
wellinadvancethroughSr.DEE(G),toavoiddelaysinthesupplyconnection.
20905CommissioningofTractionTransformers
Duringthepreparationforcommissioningoftransformersattractionsubstationsin
additiontomanufacturer'sinstructions,thefollowingstepsshallbetaken:
i)Dryingoutoftransformershallbeundertakenaspertheprocedurelaiddown.(ReferPara
20208)
ii)Tapchangingmechanismshallbecheckedforbeinginperfectoperatingcondition,both
electricallyandmechanically.Ratiotestshouldalsobedoneinthisprocedure.(ReferPara
20206)
iii)Transformerbushingsshouldbepaidspecialattentiontoensurethatthemanufacturers
sealisintactandthebushingsareinexcellentcondition.TheInsulationResistanceofthe
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bushingshouldbearound10,000MegOhm.
iv)Allgasketsshouldbeproperlycompressedandtightfitted.Noleakageofoilshouldbe
visiblefromvalves,pipejoints,gaugeglass,radiatorsoranyotherpartsoftransformer.
Theweldedjointsshouldalsobecheckedforoilseepageifany.
v)Forasubstationwithmorethanonetransformer,theyshouldpreferablybeidentical.
Thepolarityonbothshouldbechecked.
vi)Theoilfilledintransformershouldbefullydeaeratedtoavoidfalseoperationof
Buchholzrelay.
vii)TheBuchholzrelayshouldbeerectedasperinstructionsofthemakersandtestedfor
correctoperation.
viii)Allaccessorieslikesilicagelbreather,ventpipe,explosionventdiaphragm,circulating
oilpumpandspecialcoolingequipment,ifany,shouldbechecked.
ix)InadditiontoBuchholzrelay,(RejerPara20214)otherprotectivedevicesprovidedfor
theprotectionoftransformer(ReferPara20212,20213)shouldbeexaminedandchecked
carefullyandtestedaftererectionatsite.
x)Earthingoftransformersanditsneutralterminalshallbedoneinaccordancewiththe
"CodeofPracticeforEarthingofPowerSupplyInstallations"(AppendixIII).
20906PrecautionsDuringCommissioningofTractionTransformer
Whileworkingontractiontransformers,thefollowingspecialprecautionsshouldbetakenby
allthestaff:
1.Itisveryimportantthatanyoneworkingonatransformerwithanyofitscoversopen
shouldremoveallloosearticlesfromhisclothingsuchaspens,pencils,watches,money,
smokingarticles,toolsparticularlyiftheyareoily,astheyareliabletoslipandfallintothe
transformerinthecourseofwork.Thenumberofmenworkingontopshouldberestricted
totheminimum.Iftoolshavetobeusedtheyshouldbefastenedbylengthsofstringsto
theworkers'wristsortothetankrim.
2.Moisturelowersthedielectricstrengthofoil,andhenceeverypossibleprecautionshould
betakentopreventitsentry.Sweatonhandsandfaceshouldbewipedofffrequentlybya
dryclothandtoolsshouldbekeptcleananddry,especiallywhencomingincontactwithoil.
Anothersourceofentryofmoistureintothetankisbycondensation.Ifatransformerisata
lowertemperaturethanitssurroundings,condensatewillformontheexposedsurfaces.
Transformershould,therefore,beatorabovetheambienttemperaturebeforebeing
openedforworkatanytime.
Ifanycleaningorwipingisnecessary,thisshouldbedonewithclean,dryoilusingsoft,
nonfluffycloth,andneverbyusingcottonwaste.
20907TestsonTransformerWindings
i)Insulationresistancereadingsshouldberecordedwitha2500Vor5000Vmegger.The
followingaretheminimumpermittedvaluesatanambienttemperatureof30C.
Temperaturehasamaterialinfluenceoninsulationresistance,andthereforethetests
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shouldnotbeconductedwhenoilishot.
2000MegOhmbetweenEHVwindingandearth.
400MegOhmbetween25kVwindingandearth..
2500MegOhmbetweenEHVand25kVwindings.
ii)Testoninsulation:Thetestconsistsofapplyingdchighvoltage(2500Vor5000V),with
thehelpofamegger,continuouslybetweenwindingandearth,andnotingtheinsulation
resistanceattheendof10sec,60secand600sec.Tomaintainconstantvoltage,amotor
drivenmeggerispreferable.ThepolarizationratiosR60/R10andR600/R60shouldnotbe
lessthan1.4and1.2respectively.(R10,R60,R600aretheInsulationResistancevalues
after10sec,60secand600secrespectively).
iii)PhasingoutTest.Thisiscomparativelyeasy,assinglephasetransformersaloneare
providedattractionsubstationsifboththetransformersinstalledatasubstationareof
identicalmanufacturetheterminalconnectionswillbeidentical.Nevertheless,the
correctnessofpolarityshouldbecheckedbyapplying400Vacrosstheprimariesinan
identicalmannerandmeasuringtherelativevoltagebetweenthetwosecondariesof
transformersafterconnectingoneterminalofonesecondarywiththecorresponding
terminaloftheother.
iv)Oiltest:ThetestsontransformeroilshouldbedoneinaccordancewithIS1866foroil
inuse(SeeAnnexure2.03ChapterII).
20908CircuitBreakersandInterruptors
Theinstallationofcircuitbreakersandinterruptorsshouldbecarefullydoneasper
InstructionManualofmakers.Thefollowingspecialchecksmaybemade.
Check,firstofall,ifthecircuitbreakermountingisquiteverticalandthebasefirmly
secured.Examinetheoperatingmechanismintheweatherproofhousingforcleanliness,
freemovementofrollers,bearingsandslidingsurfaces,whichshouldbeverylightlyoiled.
Openandclosethebreakerseveraltimestocheckthateverythingisworkingsmoothly.
Makesurethatallpins,lockingplatesandsplitpinsareinplace.
Ontheelectricalside,examinetheconditionofthewiring,itsinsulationresistanceand
tightnessoftheterminalscrews.Checkiftheopeningandclosingsolenoidormotorwhen
electricallyoperateddoesoperatesatisfactorilywithbatteryvoltage20percentlessand10
percentmorethantheratedvoltage.Checkalsothemanualoperationandrecordthe
operatingtimeforclosingandopening.Examinewhethertheheaterintheequipment
cabinetisinworkingorder.Observeiftheauxiliarycontactsarecleanandgoodandthe
terminalblockwellsecured.
Selectafewcircuitbreakersatrandomtoinspecttheinteriorofthearcextinctionchamber
tomakesurethatthemaincircuitbreakercontactsareinexcellentconditionandtheir
alignmentgood,buttakingcarenottocontaminatetheparts.Thepartshandledshouldbe
washedthoroughlywellwithgoodtransformeroilandputbackandoillevelrestored.
Checkandrecordthedielectricstrengthofoilineverycircuitbreaker,takingouttheoil
throughthesamplingcock.Ifthebreakdownvoltage(BDV)islessthan40kV,oilwillhave
tobedriedout.Thisiseasilydonebyasmallportableoilpurifierhavingacapacityof200
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litresperhour.Afterdryingout,repeattheBDVtest,takingtheprecautionsdescribedin
ChapterII.
Examineparticularlyifthereisanystrainonthecircuitbreakerporcelainhousingbecause
ofmisalignmentorrigidityoftheconnectionfromitsterminalstothebusbars.Usuallythis
ismadethroughflexibleconnectorsnevertheless,itiswisetocheckthepositionofthe
connectingleadswhentheboltsareloosened.Makesurealsothatthemetaltometal
contactisperfectattheterminalconnections.Anyimperfectionherewillresultin
overheatingoftheterminalwhichmayevenleadtoeventualfractureofthehousingitself.
Itisbesttomeasurethecontactresistanceby"Ductor"orsimilarlowresistancereading
instrument.
Finally,checkthegeneralconditionoftheequipment,finishandweatherproofnessofthe
cabinetandwhetheritisinsectproof,whetherfusesareintact,andiftheoperation
counter,whereprovided,worksproperlyandifthemetalsupportsandframearewell
earthed.
20909Isolators
Examinetheinsulatorscarefullyforanysurfacecracks,andmakesureifthesurfaceis
clean.Checkoperationofisolatormanuallytoseeifthemovementisfreeandsmooth,and
iftheswitchbladesarefullyopenorfullyclosedwhenthehandleislockedatthetopor
bottomposition.Examinethecontactsandcheckifthespringpressureisadequateand
bladesmakefullcontact.Checkterminalconnections,preferablywitha"Ductor".Examine
whethertheinterlockingbetweenthecircuitbreakeranditsassociatedisolatorfunctions
properlyandtheisolatorframeissolidlyconnectedtoearthbytwoindependent
connections.ForinterlockingschemeforEHVand25kVCBs&isolators,referencemaybe
madetoRDSODrawing(ETI/PSI/5212).
20910CurrentandPotentialTransformers
Checkandrecordtheinsulationresistanceofprimaryandsecondarytoearthandbetween
primaryandsecondary.CheckoillevelinPTifitisnotofthesealedtypeasalsoits
dielectricstrength.Topuptheoildrawnfortest.Make
surethattheterminalconnectionsarewellmadepreferablyrecordingthecontactresistance
ofCTconnectionsbya"Ductor".TheframesofthePTandCTshouldbewellearthedbytwo
independentconnectionstoearth.
20911LightningArrestors
Makeathoroughvisualexaminationoftheouterporcelainhousingforhairlinecracksand
chippedsheds.Cleantheoutersurfaceofalldust.Theconnectingleadstothearrestor
shouldbesolidanddirect.Theearthterminalofthelightningarrestershouldbeconnected
tothegeneralearthingmainatthesubstation,tothetransformertankbodyandfinallyto
anindependentearthelectrodeprovidedveryclosetothearrestor.
20912ShieldingandEarthing
Checkwhetherthewholeofthesubstationareaiswellprotectedagainstatmospheric
surgesbyscreeningconductorsstrungbetweensubstationstructuresandsolidlyconnected
totheearthsysteminaccordancewiththeapproveddrawing.
Checkvisuallywhetherthemetalliccasingofeverysubstationequipmentandtheneutral
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terminalsofthepowertransformersaresolidlyconnectedtothesubstationearthinggrid,
andconfirmthatthe"CodeforEarthingPowerSupplyInstallations"AppendixIIIiscomplied
withinallrespects.
20913BusbarsandInsulators
Acarefulinspectionshouldbemadeofeveryinsulatorsupportingabusbartodetectany
minutecracksonthesurfacepaintmarksordustshouldberemovedandthesurfacegloss
restored.
Timespentincheckingthecurrentcarryingjointsonbusbarsandterminalconnectionswill
payampledividends.Thecontactsurfaceshouldbeclean,smoothandwithoutany
irregularitiesandburrs,sothatwhentheyaretightenedtheareaofcontactislarge.The
pressureshouldalsobeadequate.Particularcareshouldbetakenwhenjointsaremade
betweentwodissimilarmetalslikealuminiumandcopper.Specialbimetallicfittingsshould
beusedinsuchcasestopreventelectrolyticcorrosion.Connectionsshouldbesuchasto
producenostrainontheequipment.
20914Clearances
Theminimumclearancesinmminairforliveequipmentshallbeasunder:
1.Betweenphases25kV66kV100kV132kV220kV
2.Betweenonephaseand,earthforrigidconnection.63090013002400
3.Betweenanypointswheremanmayberequiredtostandtothenearest500630900
13002100
(a)unsecuredconductorinair(mm)30003500350040005000
(b)securedconditioninair(mm)2000
4.Min.heightofbusbar.38004600460046005500
20915AuxilaiaryPowerSupplyforTractionSubstations&ControlRoom
Wheneverpossible,a3phase,415/240V,50Hzsupplyupto100kVAisobtainedtomeet
thepowerdemandsforerectionandcommissioningofthesubstation.TheLTcontrolboard
shouldalsohavematchingcapacityAnauxiliarytransformerof100kVA,1phase25kV/
240Visprovidedtocatertothesubstationandcontrolload.Thestationtransformershould
alsobesubjectedtodetailedinspectionandcheckasforthemaintransformer.
Thecontrolroombuildingshallbeneat,wellventilatedandprovidedwithastrongdoor.
Thecontrolpanelshouldhavesufficientspaceallroundtoprovideworkingspacetocarry
outthenecessarytests.
20916Batteries&BatteryCharger
TheBatteryroomshouldbeparticularlywellventilated,protected,dustfreeanddry,The
batteryroomfloorandwallsuptoaheightof2mshouldbepaintedwithantisulphuricacid
paint.Thebatteriesthemselvesshouldbewellsupportedonteakwoodstands,paintedwith
antisulphuricacidpaintandrestingonporcelaininsulatorstopreventleakage.Examinethe
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logbookfortheperiodduringwhichthebatterywasgivenitsfirstchargeandmakesure
thatthemanufacturer'sinstructionshavebeenadheredtoasregardstherateofchargeand
thenumberofchargeanddischargecycles.Makesurethereisnopossibilityofthebattery
gasesreachingtheequipmentroom.Observetheconditionofthebatteryplates,take
specificgravityofallthecellsandvoltageacrosseachcellonload.Checkifalltheintercell
connectorsaretightandwellvaselined.Checkfinallyifthebatteryfusesareofthecorrect
capacityandthereisnopossibilityofbatterysupplyfailure.Makesurethatthealarmbell
goesoffifthesupplyisinterruptedforanyreasontothecontrolpanels.
Thebatterychargershouldbeinspectedtomakesurethatitscapacityfornormalandboost
chargeaswellastricklechargeissufficientandthatitcomplieswiththetechnical
specifications,thatthemetersprovidedareindicatingproperlyanditiscompletewith
necessaryfusesandindicatinglamps.Themetalcasingshouldhavetwoindependent
earths.
20917General
Inspectthesubstationareatomakesurethatithasgooddrainage,thatithasgoodall
weatherroadaswellasrailaccess,thatthewholeareaiswellfencedinwithlockablegates
wideenoughtopermitentryofamotortruck.Ensurethatbafflewallinbetweentraction
powertransformerandsuitableoildrainagearrangementwithanoilsoakpithasbeen
madeinaccordancewithIERule64(2).Thenumberingoftransformers,isolators,circuit
breakers,incomingtransmissionlinesandoutgoing25kVfeederlinesshouldbecheckedto
seeifithasbeencorrectlydone,anddoescorrespondwiththenumberingschemeonthe
controlpanelsatthesubstationcontrolroom,andalsoonthemimicdiagramboardatthe
RCC.Fireextinguishersandfirebucketsfilledwithsandshallbekeptreadyathand.Station
nameboard,DangerandCautionboards,ProtectedAreaboardetc.shallbewelldisplayed.
20918GeneralInspectionofSubstationsandCommissioning
Afterdefectsobservedduringdetailedinspectionhaveallbeenrectified,theSr.DEE(TrD)of
theopenlineandtheDy.CEE(PSI)ofREorganizationshallcarryoutageneralinspectionof
everypartofthesubstationalongwiththeContractors'representative.Consideringthat
thesearehighvoltageinstallations,theinspectionshouldbethorough.Asmanyspotchecks
aspossibleshouldbeconductedtoascertaintheconditionoftheequipmentandthecare
takenduringerection.Particularattentionshouldbepaidtothesafetyaspectslike
clearances,operationofprotectiverelaysandfunctioningofthetripcircuitsandearthing.
ThestatutoryregulationssuchastheIndianElectricityActandRulesshouldbestrictly
compliedwithandtheinspectingofficersshalleachpersonallysatisfyhimselfbytestsand
measurementsthattheinstallationsarefitineverywaytobeenergizedandthenissuea
jointcertificatetothateffect.
AnapplicationshouldthereafterbesubmittedtotheCEEandtheElectricalInspectortothe
Railwayseekinghispermissionforthecommissioningofthesubstation,providedpower
supplywillbemadeavailablebythesupplyauthorityandtestingofprotectiverelayshas
beencompleted.Afterhissanctionisreceivedandtheprecautionsandproceduresdetailed
inChapterXarecompliedwiththesubstationmaybecommissioned.
Forthefirstthreedaysaftercommissioning,thesubstationequipmentshallbekeptunder
carefulobservationbyaseniorandexperiencedsupervisoryofficial.Thereafterdaily
inspectionshouldbecontinuedforthefirstfortnight.
Immediatelyafterenergizationthecorrectoperationofeveryprotectiverelayshallbe
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checked.ThesubstationshouldbetakenoveronRC.
II.EHVTRANSMISSIONLINESAND25kVFEEDERSLINES
20919DetailedInspectionofTransmissionLines
Assoonasasectionoftransmissionlinebetweentwosubstationsisdeclaredbythe
Contractorasreadyforinspection,detailedinspectionshallbecarriedoutbytheAEE(TrD)
andhisstafftogetherwiththeircounterpartsontheconstructionorganizationand
contractors'representativesandajointnotepreparedoftheobservationmadeandtests
conducted.Alldefects,whethermajororminor,shallbearrangedtoberectified
immediatelysothattheremaybenodelayinenergizingthetransmissionlines.
20920CompliancewithRulesandApprovedDrawings
TheworkshallstrictlycomplywithIndianElectricityActandIndianElectricityRules,the
ContractSpecificationsandapproveddrawingsincludingsagtensioncharts,particularlyin
respecttoclearancesbetweenground(andotherstructures)toliveconductors.
20921VisualInspection
Thiswillcovereverymastlocationandcrossingacrossrailwaytracks,roadsetc.,special
attentionbeingpaidtoworkmanship,completenessofinstallationsandcleanlinessof
insulators.Thetightnessofboltsandnutsinstructuralsteelworkandfittingsshallbe
checked.Ifgalvanizingofsteelworkhasbeendamagedanywhere,thepartaffectedshallbe
properlyprotectedbypaintingwithcoldgalvanizingpainttothesatisfactionoftherailway.
Muffingforeachofthetowerfootingsshouldbecheckedtomakesurethatitextendsfrom
wellbelowthegroundleveltoatleast380mmabovethegroundinirrigatedfields,230mm
abovegroundlevelindrylocationand150mmabovethemaximumwaterlevelinwater
loggedareas.
Jointsintransmissionlineconductorsshallbenotlessthan15mfromthetower.There
shallbenojointsintensionlengthsoflessthan3spans,noranyinspansoverrivers,
railwaytracksorroads.Afewjumperconnectionsbetweenlineconductorsshallbeopened
atrandomtocheckwhetherthecontactsurfacesaregoodandjointcompoundhasbeen
applied.Atthesametime,thetightnessofallPGclampsshouldbechecked.
20922ClearancesandSag
TheminimumclearancesshallbeinaccordancewithI.E.RulesandIndianStandards.In
caseof132kVlinesundermaximumtemperaturecondition,instillair,theminimum
clearancesareindicatedbelow:
1.Openroute6.1m
2.Atallroadsandaccessibleplaces6.1m
3.Betweennearestliveconductorandanypartofanyfences,wall,buildingorother
structureonwhichamanmaystand,oragainstwhichaladdermaybeplaced.4.6m
4.Betweenthenearestliveconductorandthe6.1mEarth.
5.Betweenthenearestliveconductorandanytreeorhedgeinthevicinity.4.6m
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6.Minimumspacingbetweenconductors
Vertical3.9m
Horizontal6.8m
Theminimumclearancebetweenlivepartsandearthedtowerorcrossarmmembersfor
132kVshallbe
1.SingleSuspensionstringsinstillairandwhendeflectedbywindby30degreefromthe
vertical.1370mm
2.SingleSuspensionstringsinstillairandwhendeflectedbywindby60degreefromthe
vertical.1070mm
3.Strainstringsatstraintowers1530mm
4.Jumperconnectionsatstraintowerswhendeflectedbywindupto10degreefromthe
vertical.1530mm
Theheightofthelowestpartofconductorshallbecheckedandrecorded
1.Atmidspansattypicallocationsontheopenroute.
2.Aboverailwaytracks,roads,buildingsandpublicplaces.
Minimumclearanceoflivepartsshallbecheckedforeachtypeoftowerattypicallocations
andrecorded.Sagoftheearthwiresandconductorsshallalsobecheckedatselectedspans
andrecorded.
20923Earthing
Everytowerisindividuallyearthedbyconnectingoneofitslegstooneormoreearth
electrodesnearby,throughagalvanizedsteelflat40mmx6mmsothattheearth
resistanceisnotmorethan10Ohmbeforetheoverheadearthconductorisbondedtothe
structure.Examinewhetherthesteelflatisproperlyboltedtothestubangleironandwell
protectedbelowthegrounduptotheearthelectrode.
20924.InsulatorsandInsulationResistance
Suspensionandstraininsulatorsshallbeinspectedascloselyaspossibleforanychippings
orcracks,forcleanliness,andpresenceofarcinghornsatthelineendofeachsuspension
stringabovetheconductor,atbothendsofeachtensionstring,andatbothendsofeach
insulatorstringuptoadistanceof1.6kmonthetwosidesofasubstation.
Thenumberof255mmdiaporcelaindiscsshallnormallybe9forsuspensionstringsand10
fortensionstringsfor132kVsupply.Toprovidegradedinsulation,thenumberofdiscswill
bereducedbyone,namely8forsuspensionstringand9fortensionstringsuptoadistance
of1.6kmfromthesubstation.
Duplicatesuspension/tensionstringsshallbeprovidedforallroadcrossings.Forrailway
crossings,anchortypetowersshallbeprovidedonthetwosideswithduplicatetension
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insulators,thewholecrossing,beinginconformitywiththe'RegulationsforPowerLine
CrossingsofRailwayTracks'(AppendixIV).
Insulationresistanceforeachpowerconductorshallbemeasuredandrecordedfrom
substationtosubstation,usinga2500Vor5000Vmegger.Itshallbenotlessthan100
MegOhm.
20925ContinuityTest
Continuityofeachconductorshallbemeasuredfromsubstationtosubstationusinga
meggercontinuitytesterandtheresultsrecorded.
20926Accessories
Duringdetailedinspection,itshouldbeverifiedwhethereverytowerisfittedwithananti
climbingdeviceandenamellednumberplates.Inadditioncircularenamelleddiscscoloured
red,yellowandbluearetobeprovidedonterminaltowerstoindicatethephases.Danger
boardsshouldalsoexistonthetransmissionlinetowerswheretheyarenearroadsorother
publicplaces.
20927GeneralInspectionandEnergization
Afterdefectsnoticedduringdetailedinspectionarerectified,Sr.DEE/DEE(TrD)oftheopen
linetogetherwithhiscounterpartontheconstructionorganizationandContractors'
representativeshallcarryoutgeneralinspectiontomakesurethattheinstallationisingood
order.Duringthisinspection,theinspectionpartywillcarryoutasmanyspotchecksas
possibletoconfirmthatthedetailedinspectionhasbeenproperlycarriedoutearlier.Onthe
basisoftheirpersonalobservations,ajointcertificatewillbeissuedbytheinspecting
officersandcontractors'representativeconfirmingthattheinstallationisfitineveryrespect
forenergization.
Widepublicityshouldbegiventowarnthepublicthatthelineswillbeenergizedandofthe
accompanyingdangertoanytrespassers.AftergettingsanctionoftheCEEandElectrical
InspectortotheRailway,andclearancecertificatefromallconcernedinamannersimilarto
theprocedureforenergizingOHEdescribedinChapterX,thetransmissionlinesmaybe
energizedprovidedthesubstationandtheconnectedprotectivegearhavealreadybeen
testedandcommissioned.
2092825kVFeeders
Detailedandgeneralinspectionof25kVfeederlinesshouldbecarriedoutonthesame
linesasdescribedforthetransmissionlinesandtheOHE.Heretoo,eachtoweris
individuallyearthedbyaseparateelectrode,inadditiontobeingconnectedtogether
throughtheoverheadearthingconductor.Theclearancestoroadandrailcrossingsshould
becheckedwithrespecttoapprovedplans,duplicateinsulatorsbeingprovidedineachcase.
Noearthedstructure,otherthantheearthedsupportingstructureofthe25kVfeederlines
shallbenearestthan2mfromtheliveOHE.
Towerfootingresistance,insulationresistancesofbothphaseandreturnconductorsand
throughcontinuityshouldallbecheckedandrecorded.Ifthesubstationisalready
energized,the25kVfeederlinescanalsobeenergizedonlinessimilartoprocedure
describedforthetransmissionlinesandtheOHEaftertakingallprecautionsforsafetyof
equipmentandstaffworkingoncontiguoussections.
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III.PROTECTIVEEQUIPMENT
20929TestingofProtectiveRelays
Beforeanytractioninstallationiscommissioned,theproperoperatingofeveryprotective
relayshouldbeensuredsothatitcanbefullydependentuponinallcircumstances.Thisis
doneinthreestages
Checkingtherelayinthelaboratorypriortoinstallation.
Checkingafterinstallationandbeforethesubstationiscommissioned.
Confirmatorytestafterenergizationandbeforeintroductionofcommercialservices.
Incarryingoutthetests,theManufacturers'instructionmanualsshouldbestudied.The
commissioningengineershouldbewellacquaintedwiththeprinciplesofoperation,
constructionalfeaturesandthetractionloadconditions,sothattherelaysmaybecorrectly
set.
20930InspectionofSettingofRelaysandCalibrationofMeters
Protectiverelaysareusuallyreceivedwellpackedinseparatecases.Afteropeningthecase,
therelayshouldbecarefullyremoved,examinedforanyexternaldamageandtakeninto
theRelayTestingLaboratory.Beforeremovingthecover,removealltracesofdustfromthe
caseandthecover.Checkthenameplateparticularstoseeiftheyarecorrect.Check
carefullythedelicaterelaymovementandmakesureifitisquitefreemechanically,andall
partsarecleanandconnectionstight,takingcarenottodisturbthesettings.Seewhether
theflagoperatingandresetmechanismisfunctioningwell.Examinethecleanlinessand
wipeofcontacts.
Theperformanceoftherelayfordifferentsettingsshouldthenbecheckedusingstandard
relaytestingequipment,makingsuchadjustmentsasmaybefoundnecessary.Adetailed
recordofthetestsetupandthecalibrationcurvesshouldbeenteredinaregisterasa
permanentrecord.Theplugsettingsarethencorrectlymadetocaterfortheexpectedload
conditions.
Whererelayshavebothcurrentandpotentialcoils,asindirectionalandMHOrelays
particularcheckshouldbemadetoseewhethertheinternalconnectionsofthetwosetsof
coilsarecorrect.Ifthepolarityofonewithrespecttotheotherisnotright,therelaywillfail
tooperateonafault,whichshould,ofcourse,neverbepermittedtooccur.
Ifeverythingisalright,therelaycovermaybeputback,aftercheckingtheinterioronce
againandwipingalldustonthecover.Itisrecommendedthatthedateofcalibration
shouldbepaintedonthecaseforreadyreference.,Atestcertificateshouldbeissuedtothe
fieldofficerforrecord.
Simultaneously,maximumdemandandenergymetersshouldalsobegotcalibratedand
sealedinconsultationwiththeSupplyAuthority.
20931ProtectiveDevicesatSubstations
Thefollowingprotectiveandindicatingdevicesareprovidedforeachtractiontransformer.
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1.Differentialprotection
2.RestrictedearthfaultprotectiononEHVand25kVsides.
3.Buchholzrelaywithalarmandtripcontacts.
4.Windingtemperatureprotectionwithalarmandtripcontacts.
5.Oiltemperatureprotectionwithalarmandtripcontacts.T.
6.Protectionagainstlowoillevel.
Inaddition,alowoillevelindicatorisprovidedontheconservatortank.Localindicatorsare
providedonthetransformertankforexcessiveoilandwindingtemperatures,whereasa
commonindicationonlyisprovidedonthecontrolpanelattheRCCforexcessivewinding
andoiltemperaturesaswellasBuchholzrelay.
Thefollowingfurtherprotectiverelaysareprovidedforeachfeedercircuitbreakers:
1.Overcurrentrelayforfaultsclosetothesubstation
2.MHOrelayfordistanceprotection.
3.MHOrelayforwrongcouplingbetweentwosubstations.
Properfunctioningofeachoftheserelaysandthecontactmechanismofeachshouldbe
checkedindividually.Atthesametime,thecorrectoperationofthefollowingannunciations
andtheassociatedcancellingbuttonsandflagindicationsshouldalsobechecked:
1.EHVtransformercircuitbreakerautotrip.
2."Buchholzalarm
3.Buchholztrip
4.Windingtemperaturealarm
5.Windingtemperaturetrip
6.Oiltemperaturealarm
7.Oiltemperaturetrip
8.Lowoiltrip
9.25kVtransformercircuitbreakertrip
10.25kVfeedercircuitbreakertrip
11.Transformercircuitbreakerintertrip
12.230Vacfailure
13.110Vdclowvoltage
14.24VdcLowvoltage.
Checkshouldbemadeofallindicatinginstrumentsonthecontrolpaneltoseeifthe
movementsarefreeandthereadingsarecorrect.Testplugswhereprovidedforchecking
relayoperationshouldbeexaminediftheyfitinproperly.Indicatinglampsshouldbe
functioningproperly,butaswitchshouldbeprovidedtocutthemoutwhenthestationis
unattended.
CheckshouldalsobemadeforproperfunctioningofdeviceprovidedfortrippingCBsinthe
eventof110Vdcsupplyfailure.
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20932ControlCircuitsandWiring
Afterinstallationofallequipmentandcompletionofcontrolcableconnections,adetailed
checkofthewiringshouldbeconducted,verifyingthecolourcodeandidentificationtags
andmarkingsontheterminalstripsontheequipmentandthecontrolpanelswithrespectto
theapprovedwiringdiagram.Insulationandcontinuitytestsshouldalsobetakenand
valuesrecorded.
Awordofcautionisnecessaryhere.Thedetaileddiagramsofcontrolcircuitandwiringof
controlpanelsuppliedbytheManufacturersshouldnotmerelybetakenontrust,but
subjectedtocarefulscrutinyastotheircorrectness.Errorsdooccurindrawingsandifthey
arenotdetectedattheveryearlystageitself,theymaycauseagreatdealofconfusionand
troublelater.Thebestmethodofdetectingerrorsindetailedwiringdiagramistopreparea
simplifiedschematicorfunctionaldiagramsothatthecircuitarrangementsbecomesquite
clearandobvious.Itwillthenbeknownwhatexactlytodoforanytest,whatlinkstoclose
oropenandwhatconnectionstomakeorbreak.Torestoretheconnectionsbacktonormal
afterthetestshavebeensuccessfullycompleted,adetaileddiaryshouldbekeptofevery
changeoralterationmadeforpurposeoftest.Ifanymodificationsarerequiredtocorrect
theerrorsdiscovered,theManufacturershouldbeadvisedimmediatelyandhisconfirmation
obtained.Whentheworkiscompleted,overalloperationmaybecheckedbymanually
closingtherelaycontactsandfindingoutwhethertheappropriatedevicehasoperatedor
not.
20933Fuses
Controlcircuitfusesshallbeofcorrectrating.Ifthetripbatterycircuitfuseisunderrated,
itisliabletodeteriorateduetoexcessiveheatingandfailultimately,whichcouldindeedbe
dangerous.Toguardagainstthispossibility,alarmsaresometimesprovidedtodrawthe
attentionoftheoperatorintheeventoffusefailure.Inactraction,failureofbatteryfuseis
automaticallyrelayedtotheRCCbuttheTPCcannotreplacethefusebyRC,someonehas
togoandreplaceitwhichmaytakeconsiderabletime.Inviewofthis,fusesinthecontrol
circuitmayerrbybeingslightlyoversized,butshouldneverbeundersized.Forthesame
reasonallconnectionsinthetripcircuitshouldbewellmadeandthefixingscrewskept
tight,butnotovertightwhichmaycauseexcessivepinchingoftheconnectingleadand
mayeventuallycauseabreakage.
20934InsulationandLeadBurdenMeasurement
Insulationresistancetoearthshouldbemeasured.Anyconnectiontoearthandwiringmade
deliberatelysuchas.earthinglinksoncurrentandvoltagetransformersandonDCsupply
shouldberemovedbeforethetestcarebeing
takentoputthembackassoonasthetestisover.Measureandrecordtheinsulation
resistanceofthefollowingcircuits
1.Currenttransformersecondarycircuit
2.Potentialtransformersecondarycircuit
3.DCtripcircuitwiring.
Whenmeasuringtheinsulationresistancetoearthofanindividualcircuitallothercircuits
shouldbenormali.e.earthlinksclosedtoensurethattheinsulationissatisfactorybothto
earthandallcircuits.
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Leadburdenshouldalsobemeasuredbetweencurrenttransformerandtherelaystoensure
thattheburdenimposedontheCTiswithinitscapacity.Thistestwillrevealifthereisany
poorcontactinthesecondarycircuitoftheCTorifthedistancebetweenthetransformer
andthecontrolpanelistoolong.WithaCTratedat5A,leadresistanceisparticularly
important
20935CurrentTransformerRatioandPolarityTest
EveryCTshouldbeindividuallytestedtoverifywhetherthepolaritymarkingsonthe
primaryandsecondaryterminalsarecorrect,usingthesetupshowninFig.9.01.
'A'shouldbeamovingcoilcentrezerotypelowrangeammeter.A6Vstoragebatterymay
beusedtoenergizetheprimarywindingthroughasinglepolepushbuttonswitch.On
closingthepushbutton,thedcammetershouldshowapositiveflick,andonopeninga
negativeflick.
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20936PrimaryInjectionTest
Thischeckiscarriedoutwitha"primaryinjectionset",whichisusuallyarrangedfor
connectiontothe240Vsupplymainsandfurnishesheavycurrentatalowvoltage.
Provisionusuallyexiststoconnectthesecondarywindingsofthetestseteitherinseriesor
inparalleltogetthenecessaryoutput.A10kVAtestsetusuallypermitscurrentsupto1000
Atobeobtainedwithfoursecondarywindingsinparallelandupto250Aatahighervoltage
withthewindingsinseries.Whendealingwithverylargecurrents,itisessentialthatthe
connectingleadsandareaofcontactandcontactpressureshouldbeadequateenough
otherwise,highervaluesofcurrentwillnotflow.
Themeritofprimaryinjectiontestisthatitgivesanoverallcheckonthecorrectnessofthe
entirecircuitry.
20937VoltageTransformerRatioandPolarityCheck
Polarityofthepotentialtransformercouldalsobecheckedusingthesamemethod
describedforcurrenttransformertesting.Inthiscase,however,careshouldbetakento
connectthebatterysupplytotheprimarywindingwiththemovingcoilammeterconnected
tothesecondarywinding.
Theratiocheckcanbemadewhenthe25kVbusbarsarefirstmadealive.ThePTsecondary
voltageisthencomparedwiththatofanotherPTknowntohavethecorrectratio,after
connectingittotheprimarybars.
20938ElectricalOperationofIndicatorsandAssociatedDevices
Allshuntconnectedindicators,annunciations,internalauxiliaryelements,DCauxiliaryand
mastertriprelays,shouldbecheckedforoperationattheminimumvoltagestipulatedby
theManufacturer.Seriesoperatedindicatorsorauxiliaryrelaysshouldbecheckedattheir
pickupvalues.Confirmthatauxiliaryrelaysresetwhenvoltageandcurrentsupplyis
removedafteroperation.
20939SecondaryInjectionTest
Thesetestsaredonewithasecondaryinjectiontestset.Normally,operatingtimesand
minimumclosingvaluesarecheckedforinductionrelays.Forinstantaneousattracted
armaturetyperelays,theminimumclosingandresettingvaluesarechecked.Fordirectional
relays,directionalcharacteristicsarechecked.
20940AlarmandTripCheck
Ensurethatallfuses,links,triplatchesetc.areinnormalposition.Byoperatingeachrelay
manually,verifyiftheappropriatecircuitbreakertrips.Intertrippingofprimaryand
secondarycircuitbreakersshouldalsobechecked.Thereshouldbenomaloperationofany
othercircuit.Ineverycaseoftripping,theappropriateflagindicationshouldtakeplaceon
theannunciator,accompaniedbyoperationofthealarm.
20941LoadTest
Afterthesectioniscommissioned,afinalcheckshouldbemadeoftheproperoperationof
allvoltmeters,ammetersandrelayswhennormalloadcurrentsareflowingthroughthe
circuits.Fordifferentialcircuits,spillcurrentsshouldbemeasuredtoprovethatprotection
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willbestableunderexternalfaults,byshortingthesecondaryterminalononecurrent
transformeroperationunderaninternalfaultshouldalsobechecked.Thedirectional
featuresofdirectionalrelaysshouldalsobechecked.Thisensuresthattherelativepolarity
ofCTandPTiscorrect.
20942ConfirmatorytestofOHEProtectiveRelays
1.AshorttimeafterOHEhasbeensuccessfullychargedat25kV,itisdeenergizedto
conductfinalconfirmatorytestontheoperationofOHEprotectiverelays.Althoughrelays
wouldnecessarilyhavebeentestedonthetestbenchatthelaboratoryandsubsequentlyin
thefieldaftererection,afinalconfirmatoryfieldtestisessentialbeforedeclaringthesection
asfitforcommercialoperationtoensurethatintheeventofafaulttherelaysdotrip.
2.TheovercurrentandMHOrelaysshouldallbesetforinstantaneousoperationas
mentionedearlier.Inall,thefollowingthreetestsarenecessaryandineachcaseallthe
feedercircuitbreakersandtheirassociatedrelaysshouldbetestedoneafteranother:
a)Adirectfaultonthebusbarsofthefeedingposttotestoperationoftheovercurrent
relays.
b)Afaultatthefarthestendofasinglelinesectionunderemergencyfeedconditionsto
checktheoperationoftheMHOrelayandalsotheundervoltagerelayatthesectioning
post.
c)Closingthebridginginterrupteratsectioningposttochecktheoperationofwrongphase
couplingrelay.
3.Test(a)canbeconductedassoonasthesubstationandfeedingpostsarecommissioned,
withoutwaitingfortheenergizationoftheOHE.IncarryingoutTests(b)and(c)onemust
provideandbepreparedfortheveryremotecontingencyoftheMHOrelayfailingtotripthe
circuitbreakerwhenitisclosedonthefault,duetopolarityofthepotentialcoiloftheMHO
relaynotbeingcorrectinrelationtothatofthecurrentcoil.Beforestartingthetest,trip
circuitoperationshouldbecheckedbymanualclosingoftherelaycontacts.Aresponsible
officialshouldremovetheMHOrelaycoverandbereadytoclosetherelaycontacts
manuallyandtripthecircuitbreaker,shoulditfailtodosoautomaticallywhenthecircuit
breakerisclosedonthefault.Shouldthishappen,theconnectingleadseitherofthe
potentialcoilorthecurrentcoilontheMHOrelayshouldbereversedandthetestrepeated.
4.Forcarryingouttheshortcircuittests,careshouldbetakentoearththelinebyasolid
flexible,jumperconnection(105mm2)toanearthedstructure.Athinwiresuchas14SWG
shouldneverbeusedforconnectiontoearth,underthemistakenimpressionthatthefuse
wouldblowoutandnotjeopardizesystemstability,shouldthe25kVcircuitbreakerfailto
trip.Itshouldberememberedthatthecircuitbreakerisdesignedtoclearthefaultwhereas
theimprovisedfuseisnot.Whenitblowsonaccountofheavyshortcircuitcurrent,theflash
overcausedbyitcandamagethegalvanizingofthemastandperhapsshatteranyinsulator
nearby.
5.Apointtobeensuredinparticularisthatnoneoftherelaysatthegridsubstationtrips
duringanyoftheseshortcircuittests.Thiscanbeensuredearlierbypropercoordinationof
relaysettingsatthetractionsubstation.Normally,thetractioncircuitbreakertripsout
withinabout250millesecondsfromtheoccurrenceofshortcircuit.TheSupplyAuthorities
shouldberequestedtosettheirrelaysallowingatimelagof0.5secondstoensurethatthe
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substationcircuitbreakerdoesnottripforfaultsontherailwaytractionsystem.
6.Itisquitepossiblethatintheseshortcircuittests,morethanonerelayassociatedwith
thefeedercircuitbreakermayoperateforexample,theMHOrelayinadditiontotheover
currentrelay,evenforafaultclosetothesubstation.Thisisquiteinorder,sincethis
automaticallygivesbackupprotection.Anoteshouldbemadeastowhichflagindications
haveoperatedtoascertainwhichoftheprotectiverelayshaveoperatedduringeachtest.
7.Whentestingthewrongphasecouplingrelay,itmaysometimeshappenthattherelayat
onesubstationalonemayoperateandnotatbothends,asmaybeexpected.Thisis
possibleiftheoperatingtimesofthetworelaysdifferevenslightly.This,however,doesnot
matteratall.Neverthelessifitisrequiredtochecktheotherrelay,therelaywhichhas
operatedmaybeblockedandtheperformanceoftheotherrelaytestedbyasecondtest.
8.Theoperationoftheundervoltagerelayatthesectioningpostforafaultatthefarthest
endunderemergencyfeedconditionscanbecheckedbypostingsomeoneatthesectioning
post.Thetestcouldhoweverbepostponedbyafewdaysandconductedafterintroduction
ofcommercialservices.
9.Sincetheseconfirmatorytestsaretobeconductedaftersuccessfulenergizationofthe
OHEandbeforeintroductionofcommercialoperation,itisessentialtocompletethetestsin
theshortestpossibletime.However,beingthemostsevereteststheseshouldnotbe
repeatedtoooften.Thiscanbeensuredbyorganizingtheworkproperlybypostingtesting
partiesattherightplacesandcontrollingalloperationsthroughtheTPCandbyRC.
IV.SWITCHINGSTATIONSANDBOOSTERTRANSFORMERSTATIONS
20943PowerSupply
Powersupplyforallswitchingstationsisarrangedthroughthe10kVA,25kV/240V
auxiliarytransformersconnectedtoUp&Dnlineindoublelinesection.Ifanac240V
supplynearbyisavailablefromthesupplyauthority,aserviceconnectionshouldbetaken
fromthissourceaswell.
A24hourrecordofvoltageshouldbetakenandthetapswitchoftheauxiliarytransformers
correctlyset.
20944InstallationofEquipment
Theinstallationofeveryitemofequipmentlikeinterruptors,isolators,busbars,lightning
arrestorsandwiringfromequipmenttothecontrolpanelintheswitchingstationscubicle,
72/110Vand24Vbatteriesandbatterychargersetc.shouldbechecked,keepingthe
pointsreferredtoinparas20915to20918inmind,exceptforthefollowingminor
variations.
1.Interruptorsareinstalledforcontrollingsuppliestothesubsectors.Theremarksmade
underPara20908areequallyapplicable,exceptthatnorelaysareassociatedwiththem.
2.Potentialtransformersforcatenarysupplyindicationaremountedontheswitching
stationgantry.
3.25kVlightningarrestorsarealsoinstalledonthegantry.
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20945Clearances
Checkwhetherthefollowingminimumclearancesfor25kVdoexist:
1.Heightofanyliveconductorfromgroundlevel.3m
2.Distancebetweenanylivepart(25kV)and
earthedpartorpartlikelytobeearthed.500mm
(Inspecialcircumstancesandwiththeapprovalofthedesignofficethiscanbe450mm.)
3.Betweenanylivepart(3kV)andearthedpart150mmsuchasreturnconductoror
returnfeeder.
Nolivepartmayprojectbeyondthefencedenclosureexceptataheightof6.1mormore.
Thisshouldbeparticularlycheckedtoguardagainstthepossibilityofdangertoany
memberofthepublicwhomaywalkbythesideoftheswitchingstationwithanumbrellaor
alongpole.
Checkandensurethatthedistancefromthecentreofthenearesttracktothefaceofthe
switchingstationgantryisnotlessthan3.5m.
20946AuxiliaryTransformers&BoosterTransformers
Theseshouldbeinspectedandtestedinaccordancewiththeproceduresearlierstipulated
under"substations"PartIabove.
Themountingofthesetransformersshouldbecheckedtoensureproperfitmentand
conformitywithscheduleofdimensionsandelectricalclearances.
Theboosterinstallations,inparticularshouldbecheckedforcorrectjumperconnections.
20947General
Verifywhethertheerectionoffencingisneatandallpartsaregivenagoodfinishwith
paint,thegateisprovidedwithagoodlockandanticlimbingdevicesaresatisfactory.The
areainsidetheswitchingstationshouldbelevelledatleast10cmabovethesurrounding
area.Gooddrainagemustbeprovidedsothattheremaybenopossibilityofwaterlogging
atanytime.
TofacilitateunloadingandloadingofheavymaterialstransportedbytrolleyorOHE
inspectioncar,asuitableloadingplatformshouldbeprovidedfromwhichapathwayshould
beavailableuptothegate.Whereverpossibleajeepableroadapproachshouldalsobe
providedfromthenearestpublicroad.
Whentheswitchingstationisatthefootoforatthetopofasteepembankment,suitable
footstepsshouldbeprovidedleadinguptothegate.
20948Interlocking
Verifywhetherthedoublepoleisolatorassociatedwitheveryinterruptorisequippedwith
aninterlockanditisfunctioningproperly.Itshouldnotbepossibletoopenorclosethe
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isolatorunlesstheinterruptorislockedintheopenposition.Itshouldalsonotbepossible
tooperatetheinterruptoreithermanuallyorbyRC,unlesstheisolatorislockedintheopen
orclosedposition.Toensurethis,theinterlockingdeviceshouldconsistofalockcombined
withanelectricalcontactorontheoperatingmechanismoftheinterruptortomakeorbreak
theRCcircuitandalockfortheisolatoroperatingmechanism,withacommoncaptive
interlockkeyforthetwolocks.
20949FeedingPosts
Atlocationswherethetractionsubstationisclosetothetracks,thefeedingpostmaybea
partofthesubstationif,however,itisfaraway,thefeedingpostclosetothetrackswill
receive25kVsupplyfromthetractionsubstation,with25kVfeedercircuitbreakerslocated
atthesubstationend.
Ineithercase,theneutralconductor(alsocalledthenegativeorreturnconductor)ofthe
feederlineshouldbesolidlyconnectedtothetrackrails,inadditiontobeingearthedatthe
tractiontransformerend.Thisconnectiontotherailsisvitallyimportantfortheproperand
safeworkingofthetractionsystemanditshouldundernocircumstancesbebroken.To
ensurethis,theneutralconductorisconnectedtotherailsbyeightindependentgalvanized
steelstranded(7/16)cablesforadoubletracksectionwithtwoconductorsforeachrail.
Theendsofstrandedcablesarebrazedorweldedontosuitableshoeswhicharerivettedto
therailwebs.
Examinealltheconnectionsandmakesurethatthecablesarewellbondedtotherailswith
sufficientlengthleftfreeforflexibility.Thedownleadfromtheterminaltowershouldbe
wellprotectedmechanicallytopreventitsbeingcutandstolen.
20950NumberPlatesandBoards
Checkthenumberingoftheinterruptors,isolators,PTsandthenjumperconnectionstothe
OHEtoseeiftheydocorrespondtothenumberingschemeonthecontrolpanelinthe
switchingstationequipmentroom,themimicdiagramboardattheRCCandthesubsector
numbers.
Checkalsoifthefollowingboardsandfittingsareprovidedateachswitchingstation:
1.Switchingstationnameboard,
2."Dangerboards"tocautionpublic,
3."Protectedplace"boardprohibitingunauthorizedentry,
4.Firebucketsandfireextinguisherinsidetheequipmentroom.
5.Firstaidboxand"RulesforResuscitationfromElectricShock"boardinsidetheequipment
room.
Essentialcautionboardsandnumberplatesshouldbepaintedwithfluorescentpaintsoas
tobebrightlyvisibleinlightatnight.
20951EarthingandBonding
Thestructuralsteelworkaswellastheneutralconductorofauxiliarytransformer,andthe
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metalcasesofeveryelectricalequipmentshallbeconnectedbytwoindependent
connectionstoearthinaccordancewiththe"CodeforEarthingTractionPowerSupply
Installations"videAppendixIII.AccordingtothisCode,HTandLTearthsshouldbe
providedseparately,butinterconnectedtogetherbyalink.Itisequallyimportanttocheck
thatthestructuressupportingthebusbarsaresolidlyconnectedbytwoindependent
connectionstothenontrackcircuitedrailwithsinglerailtrackcircuitortothemidpointof
impedancebondswherebothrailsareusedfortrackcircuiting.
Duringdetailedinspection,theresistancetoearthofeachelectrodeshouldbemeasured
andrecordedbyameggerearthtestersothatthecombinedresistanceoftheHTearthing
systemis2Ohm,orlessandoftheLTearth10Ohmorless,whennotconnectedtothe
rails.
V.REMOTECONTROLEQUIPMENT
20952ImportanceofRemoteControl
RemoteControlCentreisthenervecentreofthetractionsystem,fromwherefullcontrol
overeveryswitchingoperationontheentireelectrifiedrouteisexercised,itsefficient
operationis,therefore,ofprimeimportanceforsuccessfulworkingofthesystem.Itis
desirabletocompletealltestsandtrialsontheRCequipmentattheRCCandatthe
switchingstationsandtomakethemfullyfunctionalbeforeenergizationofOHE.Toachieve
this,testsandtrialsshouldstartaboutamonthearlier,bywhichtimethefollowingitemsof
workshouldbeready.
1.Derivativecablesfromthemaintelecommunicationtrunkcableshouldbeledand
terminatedinsidetheequipmentroominRCC,Substationsandeachoftheswitching
stations.Careshouldbetakentoensurethatthemetalsheathingofthederivativecableis
terminatedshortofthecableterminatingboxandkeptinsulatedfromearthinsidethe
equipmentroomandsurgearrestorsareprovidedforeachterminal.
2.Repeaterstationsshouldbefullyfunctioning.
3.AllcontrolphonesintheRCCandTPCtelephonesinthesubstationsandswitching
stationsbeinstalledandcommissioned.
4.TheairconditioningoftheRCCshouldbecompletebeforetheerectionofRCequipment
starts.
5.RCequipmentshouldbereadyandwiredupatRCCcontrolledposts.
6.Batteriesandbatterychargeralongwiththepowersupplyandchargingarrangements
shouldbeready.
20953ManningofSubstationsandSwitchingPosts
WhenRCequipmentisfirstbroughtintooperation,itwilltakeaboutsixmonthsbefore
teethingtroublesareovercomeandequipmentstabilizesfortroublefreeservice.Duringthis
time,itisnecessarytomanthesubstationsandswitchingstationstooperatethe
interruptorsmanuallyandgivereportstoTPCwhenrequired.Thissituationalsoarisesfor
longerperiodiftheRCCisnotreadybeforetenderization.
Theswitchingstationattendantsshouldbegivenadequatetrainingintheirdutiesand
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shouldnormallybeavailablefromaboutamonthbeforethedateofcommissioning.Itis
usuallypossibletointroducecommercialserviceonlimitedscale,beforecommissioningof
RCequipment.
20954LevelMeasurements
Signallevelsshouldbemeasuredandrecordedbothatthesendingandreceivingendsat
thecontrolcentreaswellasateverysubstationandswitchingstation.Thesemeasurements
areoftwokinds:
1.Individuallevelsofeveryfrequencyonthe'send'channel.Thesearemeasuredbya
vacuumtubevoltmeter(VTVM)/Transistorizedvoltmeter(TVM)withitsselectorswitchin
"high"impedancepositionattheoscillatoroutputterminals.Theseshouldbeabout16dB.
2.Onthereceiveside,thelevelsaretakenwithVTVMinthe"high"impedanceposition,at
thedetectorinputterminals:thisshouldbebetween17and25dBm.
3.Compositelevelstakenbetweentheterminalsofthetelecommandandtelesignalcable
pairswithaVTVMwithselectorswitchinthe"high"impedanceposition.Readingsmayalso
betakenattheinputandoutputterminalsoftherepeaterstationandplottedonagraph
sheet.
4.Measurementsshouldbetakenofthelevelsofeverychannelonsendandreceivepairs
atthecontrolcentreusingtheSelectiveLevelMeter.Thelevelsforthesendchannels
shouldnotbelowerthan22dBmandforthereceivechannels22to30dBm.
5.Afterfinaladjustmentofthelevels,anoteshouldbemadeofthevaluesofthe
attenuationpadsincludedinallthecircuitsandkeptasapermanentrecordforpurposesof
comparisonandreference.
Itmaybenotedthatthelineimpedanceofthesendandreceivecircuitsis1120Ohm
whereasthatoftheamplifieroutputonly150Ohm.Amatchingtransformeristherefore
providedbetweenthetwo.Whenmeasurementsaretaken,careisrequiredtokeepthe
selectorswitchoftheVTVMinthe"high"position,aslongasthecircuitsarethrough,butif
theoutputlevelistobemeasuredwiththelineorequipmentdisconnectedtheswitchshall
bekeptatthe150Ohmor1120Ohmpositionasnecessarytoachievematching.
Anotherpointtobekeptinmindisthatalthoughtheindividuallevelofasinglechannelis
say22dBm,thelevelindicatedonthelineismuchhigherifmeasuredwithVTVMbecause
ofthepresenceofalargenumberoffrequencieseachofwhichhasalevelof22dBm.
Thusthecorrectreadingof22dBmisindicatedwhenaSelectiveLevelMeterisusedwith
frequencyrangeswitchinthe"frequency"positionbutthesamemeterwouldindicate
perhaps+5dBmiftherearesay12channelsandthefrequencyrangeswitchiskeptinthe
"flat"position.Distinctionshouldthereforebemadebetweentheindividualchannellevels
andcompositelevel,whereallfrequenciesarepresent.
20955DetailedInspectionofRCEquipment
Detailedprogrammeoferectionofequipment,sequenceofpreliminaryteststobecarried
outattheRCCandcontrolledstations,shallbefurnishedbythecontractortoenablethe
Railwaystafftocarryoutstageinspectionsandtestingofindividualpanels,equipment
cabinetsandcontrolunitsatthemasterstationandRemoteTerminalunits.'
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Whencontractorreportscompletionoferection,commissioningandalladjustmentsand
testingworkandnotifiesthattheinstallationsareready,detailedinspectionshallbecarried
outbyAEE(TrD)andopenlinestaffalongwiththeircounterpartsonconstruction
organizationandrepresentativeofthecontractor.Thedefectsnoticedshallberectified
immediately.
ContractorshallalsofurnishadetailedtestprogrammeforthefinaltestingoftheRC
equipmentfortheapprovaloftheRailwayEngineers.Thesetestswillbedonejointlyby
openlineofficers,REofficersandthecontractors'representative.Thetestprogrammeshall
covertheprovingtestsforalltheparametersandfacilitiesprovidedfortheoperationofRC
equipmentinthespecification.Thetestsatsiteafterinstallationandcommissioningshall
constitutetheacceptancetests,whichwillbecarriedoutafterthedetailedinspectionand
rectificationofdefectsiscompleted.Thoroughcheckingofallswitchingoperations,correct
operationofallalarm,indicationsandannunciationfacilities,telesignallingandtele
meteringarrangements,mimicdiagramdisplays,VDUdisplays,datalogginganddata
storage,diagnosticfacilitiesetc.shallbedonefrombothcontrolstandsofthemaster
stationaswellasfromtheremoteterminalunits.Operatingtimeforvariousoperationshall
alsobecheckedandrecorded.
Allthesetestscarriedoutjointlyshallberecordedsoastoestablish,authenticinitialrecord
oftheperformanceoftheequipmenttoensurethattheRCequipmentiscompleteand
troublefree.
20956InterlockingoftheBridgingInterrupter
InterlocksintheRCequipmentforthebridginginterruptoratthesectioningpostprovidefor
thefollowing:
1.Whencatenarysupplyisavailableonbothsidesoftheinterruptor,theinterruptorshould
notclose.
2.Whensupplyisavailableonlyononeside,theinterruptorcanbeclosed.
3.Whensupplyisnotavailableonbothsidesoftheinterruptor,theinterruptorcanbe
closedbutshouldtripimmediately.
Thisisachievedbyutilizing100or110Vacsupplyfrompotentialtransformersprovidedfor
thispurposeatthesectioningpost.
Provisionisalsomadeforthebridginginterruptortotripifthecatenaryvoltagedropstoo
low.Thissettingisadjustablebetween15kVand19kVandshouldbesetat19kV.
TheaboveinterlocksshouldbethoroughlycheckedwhencommissioningRCequipmentat
sectioningposts.
20957GeneralInspectionbyDivisionalOfficers
Afterdefectsnoticedduringthedetailedinspectionasabovehavebeenrectified,the
Sr.DEE/DEE(TrD)oftheopenlinetogetherwiththecounterpartontheconstruction
organizationandContractor'srepresentativeshallcarryoutgeneralinspectionoftheentire
installationtomakesurethatitisingoodworkingcondition.Duringthisinspection,
verificationofasmanytelecommandandtelesignaloperationsaspossibleshallbecarried
outfromtheControlCentre.Inspectionoftheinstallationsateverysubstationandasmany
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postsaspossibleshallalsobecarriedout.Levelandfrequencymeasurementsshouldbe
takenatrandomatafewpointstocomparetheresultsobtainedwiththoserecordedduring
thedetailedinspection.
TheDivisionalOfficerswillissueajointcertificateiftheyarefullysatisfiedwiththeir
observationsandtests,thattheRCinstallationsarefullyfitforcommissioning.Thereafter,
theRCmaybeputintoregularserviceanditsoperationcloselywatchedbymanningthe
switchingstationsandsubstationsasmentionedearlier.Detailedrecordofeveryfailure
shallbemaintainedbyTPCandthemaintenanceofficials.Eachofthesefailuresshouldbe
goneintofullytoascertainthecauseoffailure,whichincidentallywouldgivethestaff
excellentopportunitytogetfamiliarwiththecircuitryandfaultfindingprocedures.
VI.OVERHEADEQUIPMENT
20958DetailedJointInspectionofOHE
TheimportanceofOHEarisesfromthefactthatitisextensive,withaverylargenumberof
insulators,fittingsandcomponentsparts,failureofanyoneofwhichmayresultin
dislocationoftractionservicesforappreciableperiodsuntilthedefectisrectified.The
adjustmentworkisparticularlyimportantatcrossoversandoverlapspanssinceanywide
departuresfromthestandardslaiddowncouldcauseentanglementofthepantographwith
theOHE,withseriousrepercussions.Theneedforaverythoroughdetailedinspectionof
everypartoftheinstallation,postbypost,cannot,therefore,beoverstressed.
WhentheOHEcontractorreportscompletionofalladjustmentwork,detailedinspectionwill
becarriedoutbytheAEE(TrD)andstaffoftheopenlinewiththeircounterpartsonthe
constructionorganizationandrepresentativesoftheContractor,usingonOHEinspection
car,flattoppedwagonofwiringtrain,orladdersasmaybeconvenient.
20959CompliancewithLatestDrawings
TheOHEshallbestrictlyincompliancewiththelatestapprovedGeneralSupplyDiagram,
SectioningDiagram,LayoutPlanandStructureErectionDrawings,particularlyinregardto
1.runofconductorsstaggerandheight
2.dispositionofbracketsandclearances
3.correctnessofjumperconnections,especiallyatswitchingandboostertransformer
stations
4.numberingofinterruptors,circuitbreakersandisolatorsinrelationtotheelementary
sections,subsectorsorsectorscontrolled.
20960Infringements
NoneofthewaysideoroverlinestructuresshallcauseinfringementoftheScheduleof
Dimensions.Everysuchinfringementshallbeindividuallyrecordedandactiontaken
immediatelyeithertohavethemremovedor,wherethisisnotpossible,toobtainsanction
fromtheCommissionerofRailwaySafety.
20961ImportantPointtobeChecked
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Thefollowingpointsshallbecheckedduringthedetailedinspection:
1.CantileverAssemblies:Everycantileverassemblyshallbeadjustedstrictlyinaccordance
withtheapprovedstructureerectiondrawings,especiallyinregardtothepositioningofstay
arm,brackettubeandregisterarm.Theprojectionofbrackettubeandregisterarmandthe
allowanceinthestayarmshallbesufficientforslewingoftracks.Normallythisallowanceis
15cmto20cmfromthecentrelineofcatenarysuspensionbrackettoendofbrackettube
and20cm(min.)forregisterarms.Allnutsshouldbetightenedandlockingplatesprovided
withsplitpinsorchecknuts.MakesurethatalltemporaryearthsprovidedbyContractor's
menduringconstructionworkhavebeenremoved.
2.AnchoringPoints:Themovementofcounterweightsshallbefreeandnotobstructedin
anyway.Flexiblesteelropesshallmovefreelyandcentrallywithrespecttothepulley
sheavesandnotrubagainstanymember.Thedistancebetweenthepulleycentresandthe
heightofcounterweightabovethemufflevel,shallheasperthechartinrelationtothe
prevailingambienttemperature.Anticreepsshallbeproperlytensionedandpositioned.
3.OverlapSpans:Adjustmentsatinsulatedanduninsulatedoverlapspans,turnouts,
crossoversandsectioninsulatorassemblyshallbecorrectnotonlyinrespectoftherunof
conductorsandjumperconnections,butalsotheheightofcontactwire.Theseparation
betweendifferentOHEanddisplacementofcantileversatinsulatedoverlapsshouldbe
adequate.
4.Insulators.Insulatorsshallbeperfectlyclean.Shouldthesurfacebepollutedbydust,it
shouldbecleanedandglossrestored.Allinsulatorsonoutofrunwiresshouldbesolocated
thattheydonotfoulbutarewellawayfromthezonesweptbythepantographs.The
runnersofsectioninsulatorsshouldbesolocatedastobebeyondthezoneofsweepof
pantographsrunningonadjacenttracks.Thereshouldbenounduesagduetothesection
insulators,therunnersshouldbelevelandnotbetiltedtoonesidesothatthepantograph
maypasssmoothly.
5.HeightofContactWire.Thisshallbecheckedateverystructureandatmidspanfor
regulatedOHE.Apredeterminedsaginthecontactwireof50mmor100mmatmidspan
ona72mspanfor50or100mmpresagcompensatedOHErespectivelyshouldexistonthe
openroutes.Heightofcontactwireatlevelcrossingsshallnotbelessthan5.50m.
6.Stagger.Staggerintangenttrackshallbetotheleftandtotherightofthetrack
alternatively,notexceeding200mmoneithersideofthecentrelineofthetrack,except
whereotherwisespecifiedinStructureErectionDrawings.StaggerforinrunningOHEshall
notbemorethan300mmatthemast/structureontheoutsideofcurvesexceptincaseof
overlapspansandalsoattheturnouts.Staggerofcontactwireatmidspanintransition
portionofthecurvesshallbewithin200mm.
7.GradientofContractWire:Onbothsideofoverlinestructures,tunnelsandlevel
crossings,thegradientofcontactwireshallbeinaccordancewiththeapprovedprofile.
8.Clearances.Thelivemetalliccapsofinsulatorsonoutofrunwiresshallbeatleast2m
awayfromadjacentearthedmast/structure(otherthantheOHEstructure).Thedistanceof
theseinsulatorsshallbe3mfromthebracketsupportingtheOHEincaseofinsulated
overlaps.Clearanceof2mshallnormallyexistfromnearestpointoftwoadjacent
elementarysectionsexceptatthesectioninsulators.Whereclearanceof2misnot
available,itshallbenotlessthantheminimumlongdurationelectricclearanceof320mm.
WhenevertheOHEsoftwoelementarysectionscrossoneanother,necessarycutin
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insulatorsshallbeprovided.
9.Bonding.Everymast/structuresupportingOHEaswellasplatformstructures,footover
bridgesetc.shallbeproperlybondedtotherailsandearthedinaccordancewiththe
BondingandEarthingcode.(AppendixII)
10.ReturnConductorsofBoosterTransformerInstallations:Thereturnconductor
connectionbothattheOHEandtherailshouldbecheckedfromthepointofviewofgood
electricalcontactandsecurityfrommechanicaldamage.
11.TelephoneorPowerCrossings:Keepaclosewatchforanyoverheadtelephone
crossingsovertheOHE,whichmaynothavebeenremovedbyoversight.Immediatesteps
shouldbetakentohavetheseremoved.Highvoltagetransmissionlinecrossingsacrossthe
tracksshallbecheckedagainsttheapprovedplanauthorizingthecrossing,particularlythe
clearancebetweentheOHEandtheguardwires,dulyrecordingtheresultsindividually.If
thecrossingisnotinaccordancewiththeapprovedplan,theSupplyAuthorityshouldbe
contactedimmediatelyandtheinfringementsshouldeitherberemovedornecessary
relaxationbeobtainedfromCEEandElectricalInspectortotheRailway.
20962NoticestobeDisplayedCautionBoardsandNumberPlates
Duringthedetailedinspection,specialattentionshallbepaidtoverifywhetherthefollowing
noticeshaveactuallybeendisplayedatthevariouslocationsindicatedbelow:
1."Treatmentforelectricshock"boards,givinginstructionsfortreatmentofelectricshock
inEnglishandtheregionallanguage,atallrailwaystations(ASM'sorSM'sOffices)
signallingcabins,PWI's,SubPWI'sandIOW'sOfficesanddepots,SignalInspectors'Officers
anddepots,OHEMaintenancedepots,OHEinspectioncarsheds,substations,switching
stationcubicles,locoshedsetc.
Itshouldbenotedthatstandardprintedchartsfor'Treatmentforelectricshock'aremeant
forvoltagesupto1100volts.Apersonincontactwithhighervoltagesshouldbeisolated
onlyafter'switchingoffpower.
2.General'CautionNotices'regardingdangerofhighvoltagetractionwiresforpublicat
variousentrancestorailwaystationandforstaffatprominentplacesateachstation,
particularlyonstanchionsorpillarssupportingplatformroof.
3."25kVCautionsBoards"shallbeaffixedontothescreenserectedonfootoverandroad
overbridges.
4."Danger"boardsonlevelcrossingheightgauges.
5."EngineStop"boards,atterminationofOHEinthesectionstobeenergized.
6."CautionUnwiredTurnout"boardsaheadofallunwiredturnoutsorcrossoverstaking
offfromwiredtracks.
7."Warning"boardsforneutralsections.
8.Boardsfor"Switchingon"and"Switchingoff"ofpoweratneutralsections.Fourboards
arerequiredforeachtrackasdetailedinChapterII,Vol.I.
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9."Danger"boardstobeinstalledonOHEnearwateringstations,ifany.
10."25kVCaution"boardsatsubstationsandswitchingstations.
11."Caution"noticesonalldiesel,electricandsteamlocoswhichworkontheenergized
section,includingthoseownedbyprivateparties.
12."Caution"boardsatsuchsignalpostswhereprotectivescreeningcannotbeprovidedfor
signalandtelecommunicationstaff.
20963RecordingofDefectsandRectifications
Duringthedetailedinspection,defectsanddeficiencylistsasindicatedinPara20903shall
bejointlyprepared.
Assoonasthedefectsarerectified,theopenlineofficersshouldbeadvisedandsuitable
remarksmadeagainsteachitemofthelist.Theopenlineofficerandhisstaff,ifdeemed
necessary,rechecktheinstallation,toensurerectificationofdefects.
20964GeneralInspectionoftheOHEbyDivisionalOfficers
Afterallmajordefectsobservedduringdetailedinspectionhavebeenrectified,Sr.DEE/DEE
(TrD)oftheopenlineandDy.CEE(OHE)oftheconstructionorganizationshallcarryouta
"GeneralInspection"oftheentiresectionproposedforenergization,alongwiththe
Contractor'srepresentative.Forthispurpose,anOHEinspectioncarfittedwithpantograph
shallbeusedandrunataspeednotexceeding8km/hobservingallsafetyprecautionslaid
down,suchasearthingtheOHE.Thepantographmaybeusedtomeasureheightand
staggerofcontactwire,whichshouldbetestcheckedatleastattwolocationspertrackkm.
Theobjectofthis"GeneralInspection"istomakesurethattheOHEandconnected
installationsareingoodorderandarefitfortenderization.Duringthisinspection,thewhole
installationshallbeinspectedvisuallyobserving,inparticular,thefollowingdetailsand
lookingforanythingunusualorabnormalintheinstallation:
1.Cantileverassemblies,positioningoffittings,staggerofcontactwire,liftofthesteady
armincurveswheretheradialpullofcontactwiretendstomovethesteadyarmupwards,
kinksortwistsincontactwire,infringementofsectioninsulatorsandconductorsinoverlap
spansoranydeformitysufferedanywhere.Anyloosewireshanginganywhereorother
obstructionsshallbeobserved,andanyabnormalityremovedorrectifiedimmediately.
2.Clearancestolivemetalpartsofinsulatorsonoutofrunwiresshouldbeatleast2m
fromtheadjacentstructures(otherthanOHE).
Duringthisinspection,spotchecksshallbeconductedatasmanyplacesaspossibleto
verifywhetherthedetailedinspectionbytheseniorsubordinateshasbeenthorough,to
confirmthatthedefectsnoticedearlierhavebeenrectifiedandtomakesurethatthe
installationsareinexcellentorderandsuitableforenergizationsubjecttofinalpre
commissioningtests.
20965LappingandPolishingofOHE
AftertheOHEisreadyinallrespect,lappingandpolishingofcontactwirebeundertakento
removealldirtcollected
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onthecontactfacewiththepantograph.Forthispurposeanelectriclocowithpantograph
raisedandhauledbyadiesellocomaybeusedataspeedof15to20km/hduringthefirst
runandnotmorethan40km/hinsubsequentruns.Alternatively,anOHEinspectioncar
maybeused.Itisanadvantageifbeforelappingbypantograph,theundersideofthe
contactwireismanuallycleanedbyrubbingandwipingwithawetclothanddetergentand
finallywipedwithcleancloth.Normally3to4runsforlappingandpolishingmaybedone.
Whenlappingandpolishingisinprogresssuitablesafetyprecautionstoblockthesection
andearthingofthelineasperrules,shouldbetakenandworkissupervisedatalevelnot
lessthanCTFO.
20966ProcedureforFinalTestsofOHE
AftertheOHEisdeclaredasfitforenergizationandallconstructionstaffhavebeen
withdrawnfromthefield,insulationandcontinuitytestsshallbeconductedjointlyby
officersoftheconstructionorganizationandtheopenlinewithassistanceofsenior
subordinates.Thisshouldbedoneatleastadayinadvanceofenergization.Thesetests
shouldbeconductedforeveryelementarysection.Thefollowingpreliminaryactionshallbe
takentopreparethecircuitsforthetest.
Tocarryoutthetestsinasystematicmanner,adetailedprogrammeofworkshouldbe
prepared.Asenior,experiencedofficialshouldbenominatedforcontrollingthemovements
ofallworkingpartieseachofwhomwillbegivenacopyoftheprogrammewithspecific
instructionastothesequenceofswitchingoperationstobecarriedout.Thispreliminary
actionshouldbetakenatleastaweekinadvanceofthedatefixedforthetest.
Onthedayoftest,interruptorsandcircuitbreakersatallswitchingstationsshallbetaken
on'local'controlandRCputoutofoperation.Allinterruptorsanddoublepoleswitchesare
thencpenedandlockedintheopenposition.'DangerMenWorking'boardsshouldbe
attachedtotheoperatinghandleofeach25kVisolatoratfeedingposts.Allpotentialand
auxiliarytransformeratswitchingstationsshouldbetemporarilydisconnectedfromthe
busbars.Allotherisolatingswitchesinthevariousyardsandotherlocationsprovidedfor
isolationofelementarysectionsshallalsobeplacedinthe"off"position.Whenallthese
operationsarecompleted,aconfirmatorymessageshallbesenttotheTPC.
ThetestshallbecontrolledbyoneseniorofficialwhoshallcontinuouslyremainattheRCC
anddirectalloperationsasrequired.Basically,thesetestscomprise
1.Measurementofinsulationresistanceofeveryelementarysectionwithrespecttoearth.
2.Checkingelectricalindependenceandinsulationresistancebetweenadjacentelementary
sectionsandalsoadjacentsubsectors.
3.Checkingelectricalcontinuityofeverysubsector.
Thetestshallbecarriedoutbyonecontrolpartywiththeassistanceoftwoormorefield
partiesasrequired.Thecontrolpartyalonewillcarrywithitalltestinstrumentsandtake
measurements.Thefieldpartieswillmerelycarryoutinstructionsgiven.Theyshouldhave
withthemnecessaryjumperconnectionsandearthingpolesforearthingtheequipment
whendirectedtodoso.Thefieldpartiesareforbiddentocarryoutanyoperationsontheir
own.Asthedifferentworkingpartieswillbeworkingatdifferentlocations,independent
fromoneanother,theyshouldcarrywiththemportabletelephonesthroughwhichtheywill
remainincontinuouscontactwithTPCthroughemergencytelephonecircuit.Incasethe
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emergencytelephonecircuitisnotavailable,alternativearrangementsshallbemadebythe
S&TDepartmentfortelephonecommunication.
Alongwiththecontrolpartycarryingoutthetests,theContractorshallattachaworkparty
whowillaccompanythecontrolpartyfromlocationtolocationandrectifyanydefectswhich
maycometolightduringthetests.
20967InsulationTests
Startingfromthefeedingpost,thecontrolpartywillmeasureandrecordtheinsulation
resistanceofeveryelementarysectiontoearthbya2500Vmegger,afterarrangingwith
theoutfieldpartiesto(i)isolatetheelementarysectionconcernedand(ii)earthadjacent
elementarysections.Thistestwillshow
1.theinsulationlevelofeveryelementarysectionand
2.theelectricalindependenceoftheelementarysection,fromadjacentelementary
sections.
Ifthetestsforallelementarysectionsatthatlocationaresatisfactory,thecontrolparty
mayproceedtothenextelementarysectionandcarryoutsimilartests,whenall
elementarysectionsataparticularstationhavebeentested,thecontrolpartywillmoveto
thenextstation,directingthefieldpartiestodolikewiseandcarryoutthetestsoneach
elementarysectionatthatstationasbeforeuntileveryelementarysectioninthesectorhas
beentested.
Duringthecourseofconstructionwork,erectionstaffusuallyprovidetemporaryearths,
usingashortpieceofbindingwireontheOHEatcertainlocationstosafeguardthemselves,
butaftertheworkiscompletedthesetemporaryearthsmaynothavebeenremovedby
oversight.SuchtemporaryearthsontheOHEwillgivemisleadingreadingsduringthefinal
insulationtestandcauseannoyance.Topreventthis,Contractorsshouldbeparticularly
instructedearliertoremoveallsuchtemporaryearths.
GuideLinesforMinimumPermissibleInsualtionResistance
Itisverydifficulttolaydownanyspecificrulesinregardtotheminimumpermissible
values,astheydependuponanumberoffactors,whichshouldbetakenintoaccountwhen
fixingthevalueinanygivencase.Someofthesefactorsarementionedbelow:
1.Voltageratinghasanimportantbearingontheminimumvaluenecessary,before
switchingonsupply.Obviously,thehigherthevoltagerating,thegreatershouldbethe
insulationresistance.
2.ConditionofEquipment:Theinsulationresistancefornewequipmentshouldnecessarily
bemuchmorethanforthesameequipmentafterafewyearsofservice.Similarly,the
valuerequired(afteranequipmenthasbeenoverhauled,cleaned,driedout)beforebeing
turnedoutoftherepairshopshouldbeappropriatelyhigherthanwhenthesameequipment
wasinservicebeforebeingbroughtintotheshops.Aunitwhichislyingidleforsometime
mayshowacomparativelylowmeggerreadingmerelybecauseofabsorptionofmoisture
andyetitsinsulationmaybegoodanditwouldworksatisfactorilywhenputintoservice
theabsorbedmoisturewouldsoonbedrivenoutwhenitisloadedupandtheinsulation
resistancewouldautomaticallyimprove.
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3.Typeofequipment:Itisafundamentalfactthatthelargerthenumberofleakagepaths,
thelowerwouldtheinsulationvaluetendtobe.Assumingthatthevoltageratingandthe
typeofinsulationprovidedfortwoarmaturesareidenticalitisobviousthattheonewitha
commutatorwillhavealowervalueofinsualtionresistance,thanonewithmeresliprings.
Forthesamereason,theinsulationresistanceof25kVOHEtendstobequitelow,
Assumingthateachsupportinsulatorhasavalueof500megohm,anelementarysection
mayhave50oftheminparallel,bringingdowntheoverallvalueto10megohoms.Smoke
pollutionwillgreatlydiminishthistoo.Asinglebadlypollutedsectioninsulatormayeasily
bringdownthevaluetohalfamegohmorless.Whileonewouldnotdreamofswitchingon
supplytoa3.3kVtransformershowingsolowareading25kVsupplyiscommonly
switchedontotheOHEeveninsuchcasessincetheaccumulateddustandsmokeparticles,
whichareresponsibleforthelowvalueofresistance,soongetburntout,andtheinsulation
resistanceusuallyimprovesgreatlyafterenergization.
4.Sizeofplant:Someoftheformulaecommonlyusedare
V
LargeACmotors___________________at75C
1000+(kW/100)
V
LargeDCmotors:___________________at75C
1000+kW
Havingreferredtothevariousfactorswhichshouldbetakenintoaccountinfixingthe
minimumvalueofinsulationresistance,afewthumbrulesaregivenbelowforguidance:
Insulationresistanceinmegohomstoearthatroomtemperature(40C)
1.Internalwiring50/numberofoutlets.
2.Powerequipmentingeneral2Meg/kVdesirable1Meg/kVminimum
3.Transformerwindings400V2Meg.,11kV50Meg25kV200
Meg.,132kV2000Meg.
4.CircuitBreakersdodo
5.OHEElementarySectionNewinstallation25Meg.desirable
Onsectionshavingsteamtractionandseveralsection
insulators.1Meg.
(These,however,wouldneedtobecleanedto
improveIR)
6.TractionMotors1Megformotorsupto750Vand3Megformotors
ofhighervoltage(at75C).
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20968ContinuityTests
Wheninsulationtestsarecompletedforalltheelementarysections,thecontrolpartymay
proceedinthereversedirectiontowardsthefeedingpostscarryingoutcontinuitytestsas
describedbelow
Inthistest,thevariouscontrolswitcheswhichmighthavebeenopenedoutearliershould
beputbacktotheirfinalpositionsasindicatedintheStationWorkingRules,asinnormal
operation'.Anytemporaryearthsprovidedforearthingadjacentsectionsshallberemoved.
Whenthisisdone,thevariouselementarysectionsareautomaticallyjoinedupelectrically
andeachsubsectorismadethrough.Thecontinuitytestisthenconductedbyalow
readingohmmeterbymeasuringtheresistanceofeachsubsectorfromthefeedingpost
andwitheachsubsectorearthedatthefarthestpointtowardstheneutralsection.The
throughcontinuityofeverysubsectorshallbecheckedindividually.Itisimportanttonote
thatameggerinsulationtesterisunsuitableformeasuringcontinuityasitmayreadzero
evenwhentheresistanceisashighas1000ohms.
Ifthetestsshowupanydefectsontheline,theyshouldberectifiedatonce.Sometimes,it
maybefoundthatalthoughtheinsulationresistanceisallright,thereisnothrough
continuityonsomesubsectors.Themostprobablecauseforthisisadisconnectedjumper
connectionatanoverlapspan.Thisshouldalsobeimmediatelytracedandrectified.
20969DivisionalOfficers'JointCertificate
ThetestresultsshallberecordedandsignedbySr.DEEOpenlineandConstructionand
forwardedtoCEE,alongwithotherpapersforsanctioningenergizationinhiscapacityas
ElectricalInspector.
VII.GENERALARRANGEMENTS
20970PreparationforOperatingElectrifiedServices
Whiletheengineersarebusycarryingouttestsandtrialsofelectricequipmenttoget
everythingreadybythetargetdatefixedforcommissioning,severalstepshavetobetaken
bytheOperatingDepartmenttobereadytooperatetheelectrifiedserviceswhenthe
sectioniscommissioned.TheDOMoftheopenlineandtheDOMoftheconstruction
organizationshallbothbejointlyresponsibleforthefollowing:
1.TheRulesandRegulationsconcerningoperation,namelyGeneralandSubsidiaryRules,
RevisedStationWorkingRulestocomeintooperationafterintroductionofelectrictraction,
relevantChaptersofthisManualshallbehandedovertoeveryStationMasteronthe
sectiontobeelectrified.Inadditionitisessentialthattheimplicationsoftheserulesand
proceduresshouldnotonlybeexplainedtotheconcernedstaff,buttheyshouldbe
examinedverballytomakesurethattheydounderstandthemandfurther,theirassurance
inwritingtothateffectshouldbeobtained.
ThetrainingofStationMasters,SectionControllers,Cabinstaffandothercategoriesinthe
specialrulesandproceduresapplicableto25kVtractionisbestarrangedatashort
orientationcourseforthepurposeintheZonalTrainingSchool.
2.(a)Ateverystationontheelectrifiedsection,alargescaleSectioningDiagram,shouldbe
exhibited,
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withthedifferentelementarysectionspaintedindistinguishingcolourstohelpbetter
understanding,alsoshowinglocationofisolatingswitches,wiredandunwiredlinesetc.The
meaningoftheseshouldbeexplainedtotheconcernedstaff.
(b)AcompletesectioningdiagramoftheOHEfortherelevantsectionshouldalsobe
exhibitedintheofficeoftheSectionControllerinasimilarmanner.Thesediagramshallbe
keptupdatedbyOHEsupervisors,markingthechangesmadefromtimetotime.
3.Sufficientnumberof'YellowWarningCollars'shouldbesuppliedtoeachofthesignal
cabinsthecabinstaffshouldbeinstructedregardingtheirpurpose.Theyshouldalsobe
toldthatnoelectrictrainorEMUshouldeverbepermittedtoenteranunwiredlineora
sectionforwhichpowerblockhasbeentaken.Thattheyunderstandthenewprocedures
shouldbeconfirmedbytheminwriting.
4.StationMastersandSectionControllersshouldalsobefullyconversantwiththesystem
ofpowerblocksandtheneedforlongitudinalandcrossprotectiononelectrifiedlines,and
theprecautionstobetakenbytheminregardtotrainmovementsespeciallyoversize
consignments.
5.StationMasters/Assistantstationmastershouldbeissuedwithcompetencycertificates,
aftergivingpracticaltraining,toenablethemtooperatespecificisolatorsunderinstructions
ofTPC.
6.FirstAidboxesandchartsshowingresuscitationofpersonswhohavesufferedelectric
shockshouldbekeptateverystation.Asmanypersonsaspossibleshouldbetrainedinthe
correctmethodofrenderingartificialrespiration,preferablybyadoctor.
7.TheextremedangerofanyonecomingnearlineOHEshouldbefullyexplainedand
widelypublicizedamongstallstaffandmembersofthepublic.Nooneshouldbepermitted
torideonroofsofcoachesandlocomotives.
8.TherulesforwateringofcarriagesshouldbedistributedtoallTXRandstationstaff
concernedandtheprocedurefullyexplainedandassuranceobtainedfromtheminwriting.
9.Onallsteamanddieselengineswhichmayentertheelectrifiedsection,'Caution'legends
shallbepaintedonthesidepanels.SteamengineDriversandtheFiremenshouldbe
particularlywarnedthattheyshouldundernocircumstancesclimbupthecoalstackonthe
tenderorwieldthelongsteelrakesoastocomeanywhereneartheOHEandneverdirect
jetsofwateronthecoalinthetendersortowardsthetractionwires.Experiencehasshown
thatinspiteofsuchwarnings,manyanunfortunatelocoDriverorFiremanhavesuffered
electrocution:byforceofhabittheyclimbupthecoalheapforlocoforsomework,
forgettingthepresenceofOHEinanewlyelectrifiedsection.DriversandFiremenshouldbe
repeatedlywarnedofthedangerofdeathduetosuchcarelessness.
10.Trafficstaffshouldbeadvisedoftheprovisionofemergencytelephonesocketsandtheir
locations,andinstructedinthecorrectwayofplugginginthesetelephonesintothesockets.
AfterthetwoDOMshavetouredtheareaandassuredthemselvesthatalltheabove
preparatorystepshavebeenimplemented,theyshallrenderacertificatetotheeffectthat
thesectioncanbeopenedforpubliccarriageofpassengersunderelectrictractionwithout
endangeringthesafetyofthetravellingpublicoroftheemployeesoftherailway.
20971PreparationbytheEngineeringDepartment
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TheDivisionalEngineeroftheopenlineandhiscounterpartontheconstruction
organizationshallalsowarnengineeringstaffinregardtotheprecautionstobetakenby
themwhileworkingonelectrifiedsections.ThePWIsandthemaintenancegangsshouldbe
particularlyadvisedthatthealignmentofthetrackwithrespecttotheOHEstructures
shouldbestrictlypreservedandmaintained.Theirattentionshouldbedrawntothe
instructionscontainedinChapterIIPart'J'ofIRPermanentWayManualfortakingthe
necessarystepstoeducatethePermanentWaystaffandtoequipthemwiththe
accessories.
20972PreparationbytheS&TDepartment
Introductionofac25kVtractioninvolvesaconsiderableamountofworktobedonebythe
S&TDepartment,tomodifytheexistingcircuits,shiftingofsignals,introductionofcolour
lightsignalsandlayingofappreciablelengthsofsignalcablesapartfromproviding
telecommunicationfacilitiesrequiredforelectrictraction.Theprecautionstobetakenin
testingandcommissioningtheS&Tequipment,whichshouldprecedeelectrification,arethe
responsibilityoftheS&TDepartmentandis,therefore,notdealtwithhere.
33/33

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