Phase II - Module No.

STC-TrD-3
 In order to achieve high reliability and ZERO
DEFECT OHE, and to ensure effective checks on the
maintenance work a minimum schedule of
inspections to be carried out each month by the
officers and Senior Subordinate in charge of operation
and maintenance of OHE and associated system.
 Schedule Of Monthly Inspections
S.No Nature of Inspection SSE JE

1 Locomotive Cab 2 2

2 OHE Inspection Car 4 6

3 Push Trolley 4 4

4 OHE Depot 4 -

5 Station 4 4

6 Night Inspection 2 2

7 Office Inspection 1 -
 The schedule of inspections is the minimum quota for
each official and should be independent of other tasks.

 They will not be of routine nature but shall be carried

out in depth to identify.

i) Deficiencies and short comings.

ii) Lack of skill amongst staff.

iii) Inadequacies in maintenance facilities.

iv) Constraints experienced.

v) Conditions of environment leading to poor

quality of work.
 The inspecting officials should programme their
inspections in such a manner as to cover the widest
areas in their jurisdiction over the year and so stagger
the inspections as to avoid over inspections of the
same section repeatedly, in a very short time while
neglecting other areas.
 The OHE is subject to dynamic oscillations due to the
constant contact and movement of the fast moving
pantograph coupled with wind pressure. It is
necessary to maintain the OHE in perfect condition
through proper checks on its geometry and all
parameters adopted in the design.
 The following schedules of maintenance for the OHE are
required to be followed to ensure good current collection
as well as safety of installations and personnel –

i) Foot Patrolling

ii) Trolley inspection

iii) Current collection Tests

iv) Special checks

v) Annual Maintenance and OHE Inspection Car Checks.

vi) Periodical Overhaul

vii) Re-tensioning of Unregulated OHE.

 The importance of OHE arises from the fact that it is
extensive, with a very large number of insulators, fittings
and other parts; failure of any one of which may result in
dislocation of train services for appreciable periods until
the defect/breakdown is rectified.

 The adjustment work is particularly important at

crossovers and at overlaps spans since any departures
from the standards laid down could cause entanglement
of the pantograph with the OHE, with serious
repercussions.
 The need for a thorough detailed inspection of every
part of the installation, mast by mast need not
therefore be over-stressed.

 The periodicity of schedules laid down below apply to

the majority of installations. The periodicity may
however, be modified by CEE, where local condition
so warrants.
 As regards new equipments, if schedules, have not
been drawn up, tentative schedules may be evolved
based on the Original Equipment Manufacturer’s
guidelines and RDSO’s recommendations, keeping in
the view the local conditions also and followed with
the approval of CEE.
 The object of foot-patrolling is to make visual
inspection of every part of the OHE (Including feeder
line) so that any defects and abnormalities noticed are
recorded and reported to the maintenance gangs for
attention.

 JE/SSE should foot patrol the section once in six

months.
 An experienced OHE Linesman 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 sections once a week. If this patrolling
is done thoroughly, many of the defects will be
noticed at the incipient stage, before they develop
into major defects.

 The Linesman on foot-patrol should be equipped with

signal flags, an emergency telephone instrument and
essential tools required for attending to defects on the
spot.
The Linesman on patrol duty should particularly look
for the following :-

(a) Chipped or damaged insulators;

(b) Displaced fittings and droppers;

(c) Excessive sagging or hogging of contact wire;

(d) Whether equalizing plate is tilted;

(e) Free movement of auto-tensioning device and

position of counterweight with reference to upper
and lower limits of movement marked on the mast;

(f) Presence of protective screens, caution and warning

boards and anti climbing devices;
(g) Structural soundness of height gauges at level
crossings;

(h) Bird-nests and pieces of stray wire likely to cause

short circuits and branches of trees likely to infringe
the OHE;
Stray wires / Bird Nest on B-series Mast
(i) Defective bonds and earth connections;

j) Defects in return-conductor connecting booster

transformers and its connection to rails. oil leakage if
any from BT & AT;

(k) Any obstructions including tree branches in the way

of free movement of pantograph and trains;
(l) Signs of heavy sparking when trains pass;

(m) Isolators blades being fully in and for signs of

sparking or overheating of isolators as also
condition of locks;

(n) General condition of switching stations en-route;

(o) Tilting of masts especially on high banks and masts

with sand- core foundations;

(p) Number plates.

(q) Any other abnormal/unusual situation.

 Major defects noticed by the Linesman which
endanger safety shall be reported forthwith to TPC
through the nearest telephone. Full details should be
given to enable the TPC to decide on the course of
action to be taken and if required to regulate train
movements in the affected section.
DROPPER HANGING
 The defects noticed should be entered by him in a
Register maintained for the purpose in the
depot/sub-depot. The Linesman must report the
defects on telephone to the depot/ sub-depot
followed by a written report in the Register on the
next day. The supervisor in-charge of the depot/ sub-
depot will carefully scrutinize the Register and take
prompt action to rectify defects reported, making
suitable entries in the Register.
 During patrol duty, the Linesman will speak to TPC
from every emergency telephone socket in route.
Such calls from patrolling Linesmen should be
recorded in a Register by the TPC indicating the
date, time and serial number/location of the socket
tested. Defective sockets should be reported
promptly to the S&T Department for rectification.
 Inspection of OHE by push trolley is essential except
in sections where use of trolley is prohibited. The
object of such inspection is to enable supervisors and
officers in-charge of OHE maintenance to observe
closely the OHE under their charge and should be
carried out during day time. SSE/JE should inspect
his entire section once a month.
 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.
 It is necessary to carry out 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.
 The current collection tests should be carried out by
the depot-in-charge once in 3 months over his entire
section. The ADEE/TRD should accompany the
depot-in-charge during such tests alternately so as to
cover their sections once in 3/6 months respectively.
Sr.DEE/TRD should accompany the depot-in-charge
so as to cover his jurisdiction once a year.
 While the majority of items require attention only
during Annual Maintenance and Periodical Overhaul,
items listed below will require more frequent attention
as indicated against each –

 Insulators: Generally insulators need cleaning once a

year along with the annual maintenance schedule. At
present 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 may have to be
done more frequently. With the application of silicone
grease, the interval for cleaning at such location can
be extended significantly.
 Section Insulators:

Section insulators on the main lines such as at neutral

sections and passenger yards should be attended to as
under once in three months -

(a) Clean Insulators and replace badly chipped or

even slightly cracked insulators.

(b) Check runners for flash-marks.

(c) Check level of the assembly and adjust as

required.
(d) Check for excessive contact wire wear near anchor
clamps.

(e) Tighten properly the PG clamps of droppers and

stiffeners.

(f) Check that pantograph passes underneath the

section insulator smoothly
 Isolating switches at Yards/Loading sidings:
The continuity and soundness of earth connections should
be checked once a month.

 Bi-metallic clamps: These should be checked for

tightness and signs of overheating once in 3months

 Earth Connections: Apart from general inspection of

bond and earthing connections during foot patrolling, all
such connections should be specially checked for
continuity and soundness of connections once in six
months. Particulars of all earthing connections (other than
structure bonds) should be entered in a Register station-
wise for each section and the dates of six-monthly
inspection entered therein.
 Feeders: Foot-patrolling of 25 kV feeders should be
carried out every month. During this check, the
Linesman shall also check that safety guards provided
under the feeders properly earthed, if the clearances
are adequate and caution notice boards are in position.

OHE supported on steel girder bridges should be

examined as frequently as possible depending upon
traffic conditions.

 Bird nests: Vigil should be exercised especially

during the nesting season and the nests removed as
soon as possible.
Pre-monsoon checks :
Some of the items to be attended are -

i. Checking condition of insulators specially that of section -

insulators at major yards having mixed type of traction;

ii. Over-line structures for any water leakage on the OHE and
PVC insulators at major yards having mixed type of
traction;

iii. Trimming of trees branches;

iv. Condition of embankments with respect to stability of

masts;

v. Rod gaps
 This schedule must be carried out by Inspection
Car. During the schedule, fittings are not
generally dismantled, but all fittings which are
found defective must be replaced. In addition
clearances, heights, staggers etc. should be
checked and corrected.
 The details of work to be carried out during
this schedule are as under:

(i) Check rail level and setting distance against

markings on the masts and entries in the Register.

Variation above 30mm in setting distance and

20mm in rail level should be notified to the SSE
(P-Way) for correction. Variations, even within the
above limits, should not be permitted if the
Schedule of Dimensions are infringed.
(ii) Check all steel parts and remove rust, if any, from
painted steel work. Rusted portions, after
cleaning, must be given two coats of zinc
chromate primer followed by aluminium paint.

(iii) Check all anchors for tightness of bolts, nuts and

check nuts and pins. Lubricate all turn-buckles/
adjusters and pulleys.

(iv) Examine the base of each structure to ensure that

muffs permit drainage of water, clean the muffs
removing any muck or dirt. Cracked or damaged
muffs must be recast.
(v) Check all bonds thoroughly. Defective bonds must
be rectified and missing bonds provided.

(vi) Check and tighten all G.I.bolts and nuts.

(vii) Check all galvanized pipes and fittings. Where

galvanization is found to be chipped off, the fitting
of pipe should be replaced. Minor chippings may
be repaired using 'cold galvanizing paint'.

(viii) Examine register arm and all hooks and fittings for
cracks. Check for cracks on steady arm tube also.
(ix) Clean all insulators and carefully check for
cracks and broken sheds. If more than 2 sheds
are broken or there is any crack on the core the
insulator should be replaced.

(x) Check and adjust heights and staggers on the

basis of setting distance and rail level marked.
Close co-ordination with Permanent Way
Inspectors is required for keeping the permanent
way at the correct location.
(xi) Check presence and condition of caution notice
boards, number plates, coasting boards, etc. Paint
the boards as required. Ensure that they are all
well secured.

(xii) Ensure that the drain holes in the tubes are free
and not clogged.
 Check carefully condition of contact and catenary
wires, particularly for kinks and twists in contact
wire and broken strands of catenary wire.

 Any stranded conductor (catenary wire etc.) should

be spliced if more than 20 per cent of the strands are
broken.

 Check condition of PG clamps and jumpers after

opening the clamps and tighten properly.
 Check droppers and tighten bolts wherever
required.

 Make droppers vertical.

 With OHE Inspection Car running on main line
check up if pantograph glides smoothly under the
loop line OHE.

 With OHE Inspection Car running on loop line

check up if pantograph glides smoothly under the
main line OHE.

 Check stagger of both the OHEs at turn cuts.

(It shall not normally exceed 300 mm).
 Check that the main line OHE of overlap type turn
out is about 50 mm below that of the turnout OHE.

 Check up cross contact bar, if any, for displacement

and distortion.

 Check up for hit marks ,if any.

 Check up rail level and setting of the obligatory

mast.

 Check up for hard spots near rigid droppers, if any.

 Clean insulators and replace chipped or cracked
insulators.

 Check runners for flash-marks, hit marks and proper

adjustment.

 Check for excessive contact wire wear near anchor

clamps.

 Check the level of the assembly and adjust if

necessary.

 Tighten PG clamps of droppers and stiffeners.

 Check number plates for cleanliness and security.

 Check correctness of operation, alignment of contacts

and arcing horns.

 Check earth continuity where applicable.

 Lubricate moving parts and locks.

 Check interlocks where provided

 Check that the distance between male and female

contacts in open position is 380mm to 500mm
depending upon the type of isolator.
 Check beads for any crack.

 Check coating for electrical erosion.

 Check cleanliness of insulators.

 Check burning of arcing horns and arc traps.

 Check pantograph hit marks on the under side of

compression ferrules and end sleeves of the contact
wire insulators to ascertain need for adjustment to be
runners.
 Check for free movement of telescopic anti torsion
droppers.

 Check Elastomeric bellows for cracks

 Check Insulation resistance.

● Check height and stagger of OHE in the overlap
section.

● Check whether the normal minimum clearance of

500mm is available between the two OHEs in an
insulated overlap and 200mm in an uninsulated
overlap.

● Check whether the lifting of out-of run OHE is

correct.

● Check that parallel running of contact wires in the

overlap for a minimum 2m in the panto sweep region.
 Carry out all checks as for an insulated overlap in
case of overlap type neutral sections and as for
section insulators in the case of section insulator
type neutral section.
 Check and record horizontal and vertical clearances
and adjust OHE as required.

 Check for any flash-marks on the under side of the

bridge structures.

 Check that the prescribed height of contact wire is

available,

 Check that the gradient of contact wire on either

side does not exceed 3mm/m.
 Check that smoke screens are properly secured and
have adequate clearance from OHE. If not, get
these attended to by Engineering Department.

 In tunnels get necessary repairs done by

Engineering Department.

 Check rail level mark on sides of tunnels.

 Check height and gradient of contact wire.

 Check condition of road surface and clearance of

height gauge (a black band may be marked on the
uprights at a distance of 4m from bottom face of the
boom to facilitate measurement of clearance.)
 Check 'X' and 'Y' dimensions in the case of pulley
block type equipment and 'Z' and 'Y' dimensions in
the case of winch type equipment against prescribed
values for the temperature at the time of checking,
and adjust as required.

 Check that the compensating plate is vertical. If not,

adjust as required.

 Lubricate pulleys and other moving parts.

 Check if 20mm wide bands in black colour are
painted on the mast to indicate upper and lower
limits of movement of counter weight.

 Check condition of stainless steel wire rope for any

signs of corrosion and breakage of strands.

 Check condition of grooves on the drum/pulley of

regulating equipment.
• Check all bonds and replace defective or missing
bonds. Paint all bonds.

• Inspect earths and record earth resistance. Earths

having resistance of over 10 ohm should be
attended to.
• Check verticality of all masts with plumb-bob and take
remedial action as required

• Such sites should be specially checked and attended to

 Check guard wires at road crossings, if any.

 Check earthing of towers.

 Measure and record earthing resistance of towers.

 Clean insulators and replace those which are

cracked or chipped.

 Check the jumper connections, strain clamps, PG

clamps and bi-metallic strip.
 Check and clean oxide from surface.

 Apply corrosion inhibiting compound.

 Tighten to the prescribed torque.

 The annual maintenance schedules can best be
organized by adopting the system of Integrated
Blocks. In this. scheme, a 3 to 6 km block (Jumbo
Block) is taken by introducing single line working
in the off peak traffic hours between any two
stations. Simultaneous work is carried out by
permanent way, signal OHE/PSI staff during day
light hours.
 This saves considerable time for taking and
returning blocks, which forms a sizeable proportion
of a short duration block. Effective use of available
man-power can also be made by using extra gangs
depending upon the nature of work. Such work may
be organized for 2 or 3 days a week in selected
sections and instructions issued in advance by
appropriate planning.
 The re-tensioning of unregulated OHE in
accordance with the tension-temperature chart
should be done ordinarily at the end of 6 months
from the date of erection and again at the end of 12
months.
 Thereafter the tension should be checked up once in
2 years and retensioning done as required.
 The aim of POH is to recondition and restore the
installation in the condition it was when it was first
commissioned, whereas preventive maintenance has
for its objective to take care of the wear and tear
during normal service and forestalling possible
failures by regular inspection and prompt attention.
The POH should be thorough and cover every part of
the installation.
 The work involved during 4-year POH is somewhat
greater in scope than the pre-commissioning tests,
since after years of service many parts would have
suffered wear and tear, of which necessary
adjustments will have to be made or repairs done to
make good the wear, or the irreparable items
replaced.
 The POH of OHE should be planned on a
programmed basis so that every part of the
installation receives detailed attention, repair and
overhaul at an interval of 4 years. For programming
POH, the entire section in each Division should be
divided into smaller sections.

 All POH work should be done under the direct

supervision of SSE/JE.
 To summarize, the object of POH is to make a
thorough inspection of the OHE and to replace such
of the worn- out or damaged parts by those, which
have been reconditioned earlier in the maintenance
depots and kept ready. The parts removed are sent to
the maintenance depots for dismantling, thorough
examination, re-conditioning if possible and re-
assembly for use again as required.
 Maintenance charts, prepared in different colours may
be made indicating the type of schedule each section
has to undergo. The same chart can be used to
indicate the progress of work and special works to be
done to exercise check over the tasks and targets.
In addition to the items detailed under annual
maintenance, the following items should be
attended during POH:

(i) At least one complete cantilever assembly per 10

track-km (this may be modified by CEE if
considered necessary) should be removed and taken
to the workshop for dismantling and detailed
examination of various components after thorough
cleaning. This test check would reveal the extent to
which other cantilever assemblies have to be
examined.
(ii) All regulating equipment should be replaced by
previously overhauled ones and the removed
equipment should be sent to the workshop for
overhaul.

(iii) As the bracket is articulated, check the position with

reference to the axis of the mast. The position will
vary with temperature and distance from anti-creep.
The register arm and steady arm should as far as
possible be in the same plane as the bracket.

(iv) Check adjustments of cantilever assemblies, their

slope and displacements at every structure for
compliance with the 'as erected' SEDs.
 Dismantle all jumper connections, clean the
conductors, clips etc. If the pieces show signs of
overheating, this may be because either they are not
tightened properly or the clips are deformed and
contact surface is insufficient. In the latter case they
should be replaced. In case of the contact wire, it is
the groove that has to be cleaned with either a fine
metallic brush or emery paper. The use of scraper or
file is forbidden. Replace frayed or damaged
jumpers.

 Remove kinks if noticed.

 Check the position of contact wire with respect to
tracks to comply with SEDS.

 Ensure that insulators of anchoring wires are

crossing the plane of OHE in correct position as per
plan.
 Check the height and gradient of the contact
wire and tally the same with 'as erected' .
 Check the height and gradient of the contact wire
and adjust as per SED.

 100 per cent OHE fittings in tunnels should be

replaced with new or previously over-hauled fittings
and the removed fittings taken to the Workshop for
detailed examination.
 Check the position of the contact wires with
respect to the track for compliance with SED.
 Examine wires for frayed strands, overheating,
pinching or corrosion, especially at suspension
clamps and PG clamps. Tighten junction sleeves.

 While tightening PG clamps ensure that all joints

are properly coated with veseline.

 Check tension in wires and adjust if necessary.

 Other overhead wires such as bypass feeders and
earth-wires should be inspected. The insulator
attachments should be dismantled, overhauled and
put back in position. The insulators should be
cleaned at the same time.
 During POH, fittings, which do not provide
prescribed margin of adjustment and proper fitting
should be replaced.

 All fittings on masts should be checked against "as

erected" drawings and any variation should be
recorded. and reported to Sr. DEE for changing the
drawings.

 The position of splice should be recorded in the

relevant lay out plans.
 Aluminium bronze fittings, bolts and nuts should be
cleaned and carefully examined if necessary with a
magnifying glass. Particular care should be taken to
see that the threads are in good condition. Fittings
which have developed cracks should invariably
discarded.

 All G. I. fittings and pipes should be examined for

deterioration of galvanization. Minor chippings may
be repaired by using cold galvanizing paint. (Sand
or emery paper should never be used for cleaning).
 In case of a major OHE break down, it is advisable
to remove the bracket assemblies in about 8 to 10
spans on either side and examine them critically for
cracks, twists, bends or other defects which may
cause failures later on.

 The regulating equipment should be dismantled and

every part should be cleaned. Bearings should be
fitted back after lubricating. Rubber washers/rings
should be replaced where necessary.
 Any grazing or rubbing on pulleys should either
be repaired if possible or the damaged equipment
should be replaced. All lubricating holes should
be free for passage of grease. The stainless steel
rope should be closely examined for damage to
the strands. Particular attention should be given to
the end fittings on the stainless steel rope. Only
approved type of lubricant should be used for
regulating equipment components.
 Depending upon the condition of the fittings,
rehabilitation of the OHE may be undertaken after a
period of 20 year. CEE may decide the assemblies to
be replaced after a special drive for condition
monitoring.
Phase II - Module No. STC-TrD-3
Diesel Electric tower car
 HEAD LIGHT

FLASHER LIGHT
FRONT
SEARCH LIGHT
VIEW
MARKER LIGHT
FOG LIGHT
OF
DETC
TOWER
CAR
 OHE Inspection car has a key role in the maintenance
of OHE and for attending to break-downs.

 The satisfactory upkeep of the car is, therefore, of

utmost importance.

 SSE(OHE) should ensure that the car under his

control is maintained satisfactorily and is available at
all times for attending to OHE and for use in the
event of break-downs.
 Each car should carry necessary tools for maintenance
of OHE and attending to break-downs, such as tackles,
straining screws, clamps, ropes, a minimum of two
ladders as well as an adequate stock of insulators,
lengths, of contact and catenary wires and other OHE
fittings.

 An approved list of tools and equipment to be carried

in each car should be issued by Sr.DEE (TrD).
SSE(OHE) should ensure that tools and equipment as
per the approved list are always available in the car.
 A monthly mechanical inspection of the bogies and
running gear of each car shall be done by a nominated
SSE(C&W) of the Mechanical Department,
headquartered close to the OHE depot where the car is
normally stabled.

 For each car on a Zonal Railway, the SSE(C&W)

responsible for monthly mechanical inspection will be
nominated and a joint circular to this effect issued by
CME and CEE laying down his duties.
 The SSE(OHE) in charge of the car will advise the
SSE(C&W) concerned the date on which it is required
to be inspected and running repairs carried out. Such
advise shall be given at least 48 hrs. in advance.
SSE(OHE) should ensure that this monthly advise is
issued regularly and the car is offered for inspection
and attended to every month.
 The SSE(C&W) will arrange for examination of
bogies., running gear, under frame, under gear fittings
and axle boxes only, in accordance with IRCA rules,
Part-III. He will also arrange for stenciling the date of
monthly examination on the sole bar of the car.

 The POH of the car shall be done at an interval of 3

years in an EMU shop/electric loco shed/Electric
workshop, as decided by CEE. (Ref. Board’s letter No.
84/Elec/140/4 Vol. I dt. 1.3.90)
 The day to day maintenance of the diesel engines and
driving gear of the car will be the responsibility of the
SSE(OHE) concerned.

 The OHE inspection car drivers should carry out the

daily maintenance.

 Specialist staff conversant with the maintenance and

overhaul of diesel engines and driving gear should be
available on each division for attending to monthly
and six monthly maintenance of the diesel engines and
driving gear.
 Taking into account the total number of OHE
inspection cars and the need for relief of such cars for
purpose of POH etc. in each Zonal Railway, one or
more spare OHE inspection cars may be provided as
necessary.
The salient features of the OHE inspection cars
presently in use of on Indian railways are as under –

Mark II 4 wheeler manufactured by Kachrapara

Workshop/ Eastern Railway
1 Diesel engine 83 HP (Simpson make)
2 Axle load 6.8 tonnes
3 Pay load 3 tonnes
4 Speed potential 40Km/h
5 Transmission Gear box system
6 Brake system Vacuum
 Mark III 4 wheeler manufactured by Jamalpur
Workshop/ Eastern Railway

1 Diesel Engine 185 HP

2 Axle load 16 tonnes

3 Speed potential 75 Km/h

4 Transmission Hydraulic/Hydro mechanical

5 Brake system Compressed Air Brakes.

 OHE Inspection Car – 8 Wheeler

1 Diesel engine Single 530 HP or twin 285 HP

2 Transmission Volt’s Hydraulic Transmission

3 Axle load 16 tonnes

4 Pay load 10 tonnes
110 Km/h on level tangent track
Speed 30-40 km/h on 1 in 60 t rising gradient
5
potential while hauling a loaded bogie flat
wagon of 60t
6 Brake system Compressed air brakes.
 OHE Inspection Car – 8 Wheeler
Paying out facility on one drum each of contact and
7
catenary wires.
8 Small workshop fitted with drilling machine etc.
9 Two staff cabins with toilet
A small kitchen ,storage space for tools, spares, and
10
traction mast etc.
11 Adjustable lifting and swivelling platform.
Observation dome To watch pantograph and contact
12
wire interaction during motion.
1. General

i. Authorization:

No OHE inspection car may be operated by any

person unless he is specifically authorized to do so
after he has been trained and examined for his
knowledge of the rules prescribed.
ii. Scope

The following rules shall govern the working of an OHE

inspection car fitted with a pantograph for the purpose of
inspection of OHE either during commissioning of
completed sections of OHE or during periodical inspections
carried out by the OHE inspection car maintenance staff. All
staff in charge of operation of OHE inspection are shall
make themselves fully conversant with and act according to
the special instructions given below:

iii. Movement
The movement of OHE Inspection Cars on tracks will be
governed by all the rules governing movement of trains.
2. Driving

 OHE Inspection Car shall be driven only by an

authorized person, and no person shall be so
authorized unless he has knowledge of the section
(Road and Signals) on which the car is to operate
and is conversant with the operation and
maintenance of car. He should also be in
possession of competency certificate for the
purpose.
 The OHE Inspection car shall be driven at a speed not
exceeding 10 km/h when checking contact wire level and
stagger. This shall be done by running on the first gear.
Riding on the clutch for this purpose is prohibited.

 If the OHE inspection Car is driven for other than recording

operations, the speed should not exceed the designed speed
subject to the speed restrictions imposed in the section.

 In every depot, at least two OHE staff shall be trained and

issued with competency certificate to drive an OHE
Inspection Car in the event of an emergency.
3. Panto graph Operation.

 The pantograph mounted on the roof of the OHE

Inspection Car is electrically bonded to the
underframe by means of a cable connection. This
cable connection should be checked before starting
any operation for checking and adjustment of OHE.

 The pantograph should normally be kept in the fully

lowered position and clamped securely by means of
the special clamp provided for the purpose. No
string, cord, etc. shall be used for the purpose.
 Before any person goes up to the roof of the OHE
Inspection Car for commencing inspection and
adjustment, the section of the OHE concerned shall be
made dead and earthed on either sides. Additional
earths shall be provided where necessary. After
earthing the OHE, an additional earth shall be
provided near the OHE Inspection Car on the OHE of
the track on which it is standing. An authorized person
not lower in rank than a linesman shall then go up on
the roof and remove the clamps to release the
pantograph.
 Under no circumstances should the OHE inspection
car be worked with the pantograph raised without an
earth on either side of it on the section of the OHE in
which it is to be worked.

 In order to ensure that the pantograph does not enter a

section where the OHE is live the OHE inspection car
shall be protected on both the sides with banner flags
and other signal flags.
 The Driver shall always stop the OHE Inspection Car
ahead of all turn outs, cross overs, insulated overlaps
and section insulators first and then proceed only
after ensuring that the section ahead is dead and
earthed.

 Banner flags shall then be removed for the purpose of

admitting the OHE inspection car into the section
ahead.
 At the end of the Inspection and checking, the
pantograph, shall be lowered and clamped by an
authorized person not lower in rank than a linesman
working on the roof after earthing the OHE of the
track on which the OHE inspection car operating.

 The earths on the OHE near the OHE Inspection Car

shall then be removed after all persons working on
the roof have come down.
4. Operation of Lifting and Swivelling Platform

 The lifting and swivelling platform shall

ordinarily lie in the fully lowered position along
the length of the OHE Inspection Car.

 The swivelling platform shall be raised or lowered

only when the OHE Inspection Car is stationary.

 The platform shall be moved out of the normal

position only when the OHE Inspection Car is
stationary.
CONTROL BOX FOR
PLATFORM OPERATION
LIFTING PLATFORM
 The OHE Inspection Car shall be moved only after
the platform has been put back in the normal
position.

 If the OHE Inspection Car is to be moved with the

platform raised, it may be done at a speed not
exceeding 5 km/h.
Daily Schedule Maintenance of 8 Wheeler Tower Wagon
(To be carried out by TW driver at Depot)
1. Under Frame Items

i. Check wheel conditions for flat tyre, sharp flange, crack etc.
ii. Check Helical springs for any crack.
iii. Check any missing split pin, lock nut, U-bolts etc.
iv. Check Earth connection between panto & under frame.
v. Check Fuel level in tank & secure fuel tank cap.
vi. Check Lub. Oil level in engine fuel injection pump, check oil level
in transmission gearbox and final Axle drive.
vii. Check water level in Radiator & top up if required.
viii. Check BP pipe/vacuum hose.
ix. Check cattle guard & rail guard.
x. Check Brake rigging J-Brackets/safety slings etc.
xi. Operate Air drain valve of water separator.
2. Cab Items
i. Check headlight, marker light, flasher light, cab light and wiring etc.
ii. Test Horns, Wipers & Speedometer for proper functioning.
iii. Check the water level in radiator (top up if required)
iv. Check smooth starting of T/W by self.
v. Check any abnormal sound from engine & gears.
vi. Check trouble free forward, reverse movement.
vii. Check brake cylinders pressure as indicated in the gauge.

3. Over Roof Items

i. Locking of panto in lower position.
ii. Ensure railings of tower wagon are locked in lowered position.

NOTE:- Tower wagon driver should keep all safety items such as signal
lamps, flags, emergency phone, G&SR book, detonator etc. as per extent
rules.
Monthly Schedule Maintenance of 8 Wheeler Tower Wagon

(To be carried out by T/W driver, SSE(C&W) & Motor mechanics

at Depot)

1. Wheel Profile:

Check the wheel condition & measure tyre profile (Root wear
flange thickness wheel flat etc.) with the help of profile defect
gauge. Indicate defects noticed during inspection.
(Tower wagon to be sent for wheel turning in case of any non-
conformity/defective profile).
2.Bogie suspension:

i) Check helical springs for any crack.

ii) Check bogie frame & Bolster for any crack.
iii) Check split pin, lock nut, U-bolts etc.
iv) Top up Lub. Oil in suspension bearing and
cardium compound in gear cases.
3. Electrical System:

3(a) Common Items to be checked for all T/Wagon.

i) Check working of Hyd. Lifting platform. Check oil level in

Hydraulic tank, top up if required by Hyd. Oil Servo-68/
Torque-10.
ii) Check Electrolyte level, Specific gravity & voltage of battery.
iii) Apply Vaseline/petroleum jelly at the battery terminals.
iv) Check operation of contactors & relays.
v) Clean all contractors & relays with compressed air/air blower.
vi) Remove Alternator’s covers & clean commutator with
compressed air/air blower, check for any flashing, grove
marks for any abnormalities.
3(b) Items to be checked for ICF T/Wagon.

i) Check working of Hyd. Lifting platform.

Check oil level in Hydraulic tank, top up if
required by Hyd. Oil Servo-68/Torque-10.
ii) Clean all contactors, relays and master
controller with compressed air/air blower.
iii) Remove traction motor & Alternator’s
covers & clean commutator with
compressed air/air blower, check for any
flashing, groove marks for any
abnormalities.
4. Engine:

4(a) Common Items to be checked for all T/Wagon:

i) Check smooth starting of T/W by self.

ii) Check Lub. Oil level in engine (Top up if necessary)
iii) Check Lub. Oil level in fuel injection pump (Top up if necessary)
iv) Check leakage from radiator & water circulating system.
v) Check working of hydraulic cooling fans.
vi) Check hydraulic oil level in tank. Top up if necessary by
Servo-68.
vii) Check for any abnormal sound from engine.
viii) Clean oil bath air filters & fills with 20W40 or equivalent.
ix) Lubricate with oil can control to fuel injection pump, ball joints
of engine etc.
x) Grease with propeller shaft cross-joint with grease gun.
xi) Check & clean air filters & pre cleaner dustpan.
4(b) Items to be checked for BEML T/Wagon:

i) Clean oil bath air filters & fill with 15W40 or equivalent.

5(a) Axle Drive Gear Box (BEML – DHTC):

i) Check Gear oil level & its condition (Top up if necessary)

ii) Check for any abnormal sound from gears.

5(b) Transmission Gear Box (SAN – DHTC):

i) Check working of transmission gearbox.

ii) Check all Hydraulic pipes for any leakage.
6. Brake Power:

i) Check brake blocks, replace worn out brake block.

ii) T/Wagon should not move on 1st notch after full application
of brake.

7. Pantograph:

i) Check Panto pan for grooves, fixing screw.

ii) Check, if the Panto pan is horizontal with sprit level, adjust
if necessary.
iii) Replace strip if depth of groove is more than 1mm.
iv) Check Mainspring for crack/breakages.
v) Check Bow plunger for free sliding.
vi) Contact pressure (with dead weight)
vii) Check and adjust marking on Panto for correctness of
measurement of height & stagger of contact wire.
8. Safety Items:

i) Check Cattle guard & rail guard.

ii) Check BP pipe/vacuum hose.
iii) Check Head light, flasher light, Taillight, Cab light &
wiring etc. for proper functioning.
iv) Check Horns & Wipers for proper functioning.
v) Check for Brake rigging J-brackets/safety slings etc. for
proper functioning.
Half Yearly Schedule Maintenance of 8 Wheeler Tower Wagon.

(To be carried out by T/W driver, SSE(C&W) & Motor mechanics

at Depot)

1. Wheel Profile:

i) Check the wheel condition & measures tyre profile (Root

wear, Flange wear, Flange thickness, wheel flat etc.) with
the help of wheel profile defect gauge.
ii) Indicate defects noticed during inspection
(Tower wagon to be sent for wheel turning in case of any
non-conformity/defective profile)
2. Bogie suspension:

i) Check helical springs for any crack.

ii) Check bogie frame & Bolster for any crack
iii) Check split pin, lock nut, U-bolts etc.
iv) Top up Lub. oil in suspension bearing and
cardium compound in gear cases.
3. Electrical System:

3(a) Common items to be checked for all T/Wagon:

i) Check Electrolyte level, Specific gravity & voltage of battery.

ii) Clean battery terminal & apply Vaseline/petroleum jelly at the
terminals.
iii) Check working Hyd. Lifting platform. Check oil level in
hydraulic tank top up if required by Servo-68/Torque-10.
iv) Check functioning of cutout & voltage regulators.
v) Check operation of contractors & relays.
vi) Clean all contractors, relays with compressed air/air blower.
Remove Alternator’s covers & clean commutator with
compressed air/air blower, check for any flashing, groove
marks for any abnormalities.
3(b) Items to be checked for ICF T/Wagon:

i) Check operation of master controller, dead man

valve, other contractors & relays.
ii) Clean all contractors, relays, master controller
with compressed air/air blower.
iii) Remove traction motor & Alternator’s covers &
clean commutator with compressed air/air
blower, check for any flashing, grove marks for any
abnormalities.
iv) Check the size of brushes of Traction Motor &
Alternator’s, if they are below condemned size
replace it.
4. Engine:
i) Check for smooth start by self, clean brush coils, commutator
of dynamo.
ii) Refill new lub. Oil 20W40(BEML) & 15W40(ICF) in engine &
fuel injection pump.
iii) Clean pre-filter to fuel lift pump.
iv) Replace lub oil filter filament/elements.
v) Check for leakage from radiator & water circulating system.
vi) Check working of hydraulic cooling fans.
vii) Check hydraulic oil level in hydraulic tank (Top up if required
by Servo-68)
viii) Check for any abnormal sound from the engine.
ix) Clean oil bath air filter & fill with 20W40 oil to correct level.
x) Lubricate control to fuel injection pump, ball joints of engine
etc. with oil can.
xi) Grease propeller shaft cross-joint with grease gun.
xii) Replace air filters & fuel filter elements.
5. Axle Drive Gear Box (BEML-DHTC):

i) Refill new gear oil HP-90 in Axle drive gear box

ii) Check for any abnormal sound from gears.

6. Brake Power:

i) Check brake blocks, replace worn out brake

blocks.
ii) T/wagon should not move on 1st gear after full
application of brake.
7. Pantograph:

i) Check Panto pan for grooves, fixing screw.

ii) Check, if the Panto pan is horizontal with sprit
level, adjust if necessary.
iii) Replace strip if depth of groove is more than 1mm
iv) Check Main spring for crack/breakage
v) Check Bow plunger for free sliding.
vi) Check contact pressure (with dead weight)
vii) Verify and adjust marking on Panto for
correctness of measurements of heights & stagger
of contact wire.
8. Safety Items:

i) Check Cattle guard & rail guard.

ii) Check BP pipe/vacuum hose.
iii) Check Head light, flasher light, Taillight, Cab light
& wiring etc. for proper functioning.
iv) Check Horns & Wipers for proper functioning.
v) Check for Brake rigging J-brackets/safety slings
etc. for proper functioning.
Yearly Schedule Maintenance of 8 Wheeler Tower Wagon

(To be carried out by T/W driver, SSE(C&W) & Motor

mechanics at Depot)

1. Wheel Profile: (To be got certified from SSE(C&W))

Check the wheel condition & measure tyre profile (Root

wear, flange wear, Flange thickness, wheel flat etc.) with the
help of wheel profile effect gauge indicate defects noticed
during inspection.
Carry out Ultrasonic testing of Axles
(Tower wagon to be sent for wheel turning in case of any
non-conformity/ defective profile)
2. Bogie suspension:
(To be got certified from SSE(C&W))

i) Helical springs for any crack.

ii) Bogie frame & Bolster for any crack.
iii) Split pin, lock nut, U-boils etc.
iv) Check metal content in suspension bearing
& in gear cases.
v) Replace Lub. Oil of suspension bearing &
cardium compound in gear cases.
3. Electrical System:

3(a) Common items to be checked for all T/Wagon:

i) Check Electrolyte level, Specific gravity & voltage of
battery
ii) Clean battery terminal & apply Vaseline/petroleum jelly at
the terminals.
iii) Check working of Hyd. Lifting platform. Check oil level in
hydraulic tank top up if required by Servo-68/Torque-10.
iv) Check functioning of cut out & voltage regulators.
v) Check operation of contactors & relays.
vi) Clean all contactors, relays with compressed air/air blower.
vii) Remove Alternator’s covers & clean commutator with
compressed air/air blower, check for any flashing, groove
marks for any abnormalities.
3(b) Items to be checked for ICF T/Wagon:

i) Check operation of master controller, dead man

valve, other contactors & relays.
ii) Clean all contractors, relays, master controller
with compressed air/air blower.
iii) Remove traction motor & Alternator’s covers &
clean commutator with compressed air/air
blower, check for any flashing, grove marks for
any abnormalities.
iv) Check the size of brushes of Traction Motor &
Alternator’s if they are below condemned size
replace it.
4. Engine:

i) Check for Smooth start by self, clean brush coils,

commutator of dynamo.
ii) Refill new Lub. Oil in engine & fuel injection pump.
iii) Clean crankshaft and check for its crack / breakage.
iv) Remove cylinder head cover examine valves and taper
the clearances.
v) Check oil flow to valve rocker shaft assembly.
vi) Renew final fuel filter element.
vii) Clean pre-filter to fuel lift pump.
viii) Replace Lub. oil filter filament/elements.
ix) Check for leakage from radiator & water circulating
system.
x) Check working of hydraulic cooling fans.
xi) Check hydraulic oil level in hydraulic tank (Top up if
required by Servo-68)
xii) Check for any abnormal sound from engine.
xiii Clean oil bath air filter & fill with 20W40 & 15W40 to
correct level.
xiv) Lubricate with oil can control to fuel injection pump,
ball joints of engine etc.
xv) Grease propeller shaft cross-joint with grease gun.
xvi) Replace air filters & fuel filter elements.
xvii) Clean the diesel oil tank.
5(a) Axle Drive Gear Box (BEML-DHTC):

i) Refill new gear oil HP-90 in Axle drive gear box.

ii) Check for any abnormal sound from gears.

5(b) Transmission Gear Box (SAN-DHTC):

i) Check working of transmission Gear Box.

ii) Check all Hydraulic pipes for leakages.

6 Brake Power:

i) Check brake blocks, replace worn out brake blocks.

ii) T/Wagon should not move on 1st gear after full application of
brake.
7. Pantograph:

i) Check Panto pan for grooves, fixing screw

ii) Check, if the Panto pan is horizontal with sprit
level, adjust if necessary.
iii) Replace strip if depth of groove is more than 1mm
iv) Check Mainspring for crack/breakage.
v) Check Bow plunger for free sliding.
vi) Contact pressure (with dead weight)
vii) Check and adjust marking on Panto for correctness
of measurement of height & stagger of contact
wire.
8. Safety Items:

i) Check Cattle guard & rail guard.

ii) Check BP pipe/vacuum hose.
iii) Check Head light, flasher light, Taillight, Cab light
& wiring etc. for proper functioning.
iv) Check Horns & Wipers for proper functioning.
v) Check for Brake rigging J-brackets/safety slings
etc. for proper functioning.
 ENGINE CHECKS
• A CHECK - DAILY
• B CHECK -After 300 hrs or 6 months
• C CHECK -After 1500 hrs or 12 months
• D CHECK -After 6000 hrs or 24 months
POH
• 4 wheeler mark-II 4 years
• 4 wheeler mark-III 6 years
• 8 wheeler 6 years
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

Staff should neither sit

nor stand under the ATD
Balance weight.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Ropes, Pulleys, Pull-Lifts, come along lamps ‘D’

shakels and tirfors etc. should be tested once in six
months and keep record

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

No fallen wires shall be

touched unless power is
switched off and the
wire suitably earthed

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Do not wear loose

cloths such as kurta
pazama, lungi, safi etc.
while working.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Do not stand on bracket

tube insulator, while
maintenance of OHE.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

The following rules are supplementary to the General

and Subsidiary Rules.

1. Printed boards containing instructions regarding

treatment of persons suffering from electric shock
should be exhibited in every OHE maintenance depot,
equipment room, switching station, cabin, OHE
Inspection Car shed, loco shed, OHE Inspection Car
and wiring train and also in offices of SM, ASM, CYM,
AYM and HTXR.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

3. First Aid Boxes should be kept at every switching

station, maintenance depot, in OHE Inspection
Car, breakdown vehicle and wiring train.

4. Ropes, come-along clamps, tirfor etc. should be

tested once in six months at least, in the presence
of an SSE, and record of such tests maintained in
each depot.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 The SSE/JE (OHE) or other official supervising OHE

work shall have with him a complete set of structure
erection drawings, lay out plans, sectioning diagram and
general supply diagram etc. pertaining to the overhead
equipment under his charge. He shall also have with him
Station Working Rules for the stations between which he
is working. He shall, in addition, keep with him all
useful information regarding the running of trains over
his section.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

 It shall be the responsibility of the SSE/JE(OHE)

or in his absence the senior-most official in-
charge of the work to ensure that all safety rules
prescribed are actually observed by the staff when
carrying out work on traction installations. It shall
be the duty of the supervisor to remind the staff
periodically of the various safety rules to be
observed at work site.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Before commencing work on any part of the dead

OHE or within 2m of live OHE, a permit-to-work
shall be obtained from TPC or other authorized
person

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 The supervisory official in-charge of work on OHE

shall observe relevant provisions of GR and SR for
protection of trains before work on OHE is commenced
and for the whole time the work is in progress.

 Measures shall be observed by all concerned to prevent

accidental energization of the section under power
block on account of electric train movements.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 All metallic parts within reach (either directly or

through tools etc.) shall be earthed, after they are
made dead.

 Each working party shall be protected by at least

two independent earths, one on each side of a
working party.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 If the distance between the working parties exceeds

1000m intermediate earths shall be provided in
such a manner as to ensure that the distance
between earths does not exceed 1000m.

 Even when earthing is provided by isolator

switches with earthing heels, additional temporary
earths as above shall also be provided.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

The following sequence of operations shall be

carried out while providing temporary earths on
OHE.

1. Men shall be posted on both sides of the site of work to

warn the working party of any approaching train on the
same track and adjacent track(s).

2. The permit-to-work shall be obtained prior to

commencing work to make sure that power supply has
been switched off.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

First fix earthing clamp of

discharge rod to rail/ mast

Hook top clamp

on contact wire

Test top clamp on RT/ BT

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

3. For providing temporary earth on the OHE or

other equipment after it has been made dead, only
discharge/ earthing pole assembly specially
designed for this purpose alone should be used.
The cable shall be flexible and should have
adequate cross-section (40 sq.mm) to be able to
withstand short circuit currents.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

4. Fix the earthing-clamp securely to a mast at least

one span away on one side of the work site after
making sure that the mast-to-earth rail bond of this
mast is intact. Alternatively, the clamp may be
fixed to the bottom flange of one of the traction
rails, taking the cable under the rails.

• In single-rail track-circuited sections, the

earthing clamp should be fixed to the traction
rail i.e. non-track-circuit rail; on double-rail
track-circuited sections the earthing clamp
should be fixed to the mast.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

• The mast-end or rail-end clamp of the discharge

/earthing pole assembly should be checked for
tightness just before connecting the top clamp on
to the OHE as the earthing clamp fixed to the rail
or mast in advance could have worked loose.

5. Hook securely with a snap action the top clamp of

discharge/ earthing pole assembly to the OHE
conductor close to the mast/structure and tie the
earthing pole to the mast/structure. Never hook on
the top hook of the earthing cable to the OHE, till
the other end has been first connected to earth.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

6. The earthing clamps should always be fixed to the

traction rail or mast / structure first and then the top
clamp should be hooked to the OHE to be earthed.

7. Repeat operations 4 and 5 for the second temporary

earth on the other side of the working party.

8. After temporary earths have been fixed on the OHE

on both sides of the work site, staff may proceed
with the maintenance work.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

9. After work is completed and men, materials and

tools have been removed and the OHE is clear, the
above earthing rods may be removed in the reverse
order i.e., first remove the hook on the OHE and
then the clamp fixed to the rail or mast/ structure.
After warning all staff that supply will be restored
and that they should keep away from live
equipment, the permit-to-work may be returned
and supply restored.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 The continuity of the cable connection between the

top clamp and the earthing clamp should be
checked once a fortnight.

• Cable should be renewed if more than 20%

strands are broken. During use, cable should be
continually examined for fraying and breakage
of strands.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

• Discharge/Earthing pole assembly should be

inspected by SSE/JE once a month.

 During accidents when slewing the OHE and in

similar circumstances, the discharge/ earthing pole
assembly should be provided at a location where it
is not likely to be interfered with during crane
working or due to work on the permanent way.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

When work is to be carried out on OHE or conductors,

which are not electrically bonded, following additional
precautions are required.

 The two sections of conductors or ends of conductor

which may have snapped may be at different
potentials. Each end should, therefore, be separately
earthed at two points after switching off supply to
both parts of the OHE or conductor.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

 This precaution should also be observed when

working on or in the vicinity of a sectioning point and
cut-in insulators.

 Neutral Sections should be treated as live equipment

and earthed separately at two points on either side of
the work party before commencing work.

 When work is to be carried out on an isolator, both

sides of the isolator should be earthed at two points or
more conveniently, isolator jumpered temporarily.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Even when earthing is

provided by isolator
switches with earthing
heels, additional temporary
earths shall also be
provided on both side of the
isolator.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 At the work-site, staff are advised to wear

helmets to protect their heads against any tools or
equipment which may drop down accidentally, as
well as to minimize head injury in case of
accidental fall from a height.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Always use safety

belt and helmet.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Staff working on structures or a ladder are

advised to protect themselves against an
inadvertent fall by wearing a safety belt for
supporting themselves by a rope sling.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 It shall be the responsibility of the supervisor to

ensure that ladders are stored in a protected
enclosure, properly maintained and reconditioned
as often as required.

 A ladder should never be in such a position so as

to likely to fall on a live part.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Ladder should be held

by one person on the
ground, while the top
end should be tied
with the supporting
structure/ rope.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Ropes used with ladders should be of cotton or jute.

Use of metallic ropes is prohibited. A ladder should
be held by one person on the ground to prevent
slipping, while the top end should be tied to the
supporting structure or conductor to keep it in
position and prevent it sliding away.

 Ladders should never be allowed to fall on or rest

against the contact wire.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Always provide
20/16 dia G.I. bolt
in step of ladder
which is used for
pull lift and
extension step.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 If the nature of the work involves risk of the

conductor breaking into two parts (due to opening
out of sleeves or splices) the ladder shall not be
rested against the conductor. Trolley ladders shall
be used in such cases.

 More than one person shall not normally be allowed

on a ladder as far as possible.

 Climbing on a ladder with wet or slippery foot-wear

is forbidden.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

More than one person should not

allowed on ladder
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

 Ladders should not be used for transporting

materials.

 A rope should be used to pass tools or any

equipment to the men working on a ladder.

 No one should stand directly below a work spot

under a ladder.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 The useful cross section of a conductor shall not

he reduced while making joints.

 Any contact with conductors, which are not

specifically earthed, is forbidden.

 The strength of the anchoring rope should be not

less than that of the cable to be anchored.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Temporary anchoring of conductors should only

be done by using stranded flexible steel cable at
least of the same tensile strength as the cable to
be anchored.

 Use of two cables of different strengths joined

together is prohibited. Use of cotton, jute or other
non-metallic ropes for anchoring is forbidden.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Structure bonds and cable connections of the

structure to earth shall be maintained in proper
condition. No heavy materials should be stacked
on the rail bonds; transverse bonds between two
rails of the same track as well as rails of different
tracks shall also be maintained in proper
condition.

 Where rails to which structures are connected are

replaced, the structure shall be connected to the
new rail immediately after it has been laid.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

 Power supply to auxiliary transformers is effected

through fuse-switches on the 25 kV side and the
LT Side is controlled through fuses or double-
pole iron-clad switch-fuses. Isolating fuse
switches should be opened out and fuses removed
both on the HT and LT sides and the transformer
earthed before starting work.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

No work on any span of any overhead line (LT power line

or other line) running parallel to an electrified track
where the minimum distance between the nearest
conductor of the overhead line and the centre-line of the
nearest electrified track is less than 8m, should be done
without switching off power from the 25 kV traction line.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

(In addition to making dead and earthing the overhead

line on which work is to be carried out in the normal
manner).

Except for the following specific items for work :

1 . Replacement of lamps, if below line.

2. Painting of structures / poles upto a distance

of 2m from the live wires of the power line.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

3. Reinforcement of foundations where such

reinforcement does not involve any prior
weakening of the foundation at any time during
the work.

4. Replacement of aerial fuses.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

To isolate a booster transformer for maintenance or

other work, the following sequence of operations
should be carried out

1. Where no isolator is provided a permit-to-work

should be obtained for both the elementary
sections, the BT should be disconnected from the
OHE and the OHE made through by jumpering.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

2. When an isolator is provided to disconnect the BT

primary winding from 25 kV lines, power must be
switched off from both the elementary sections to
which the BT is connected after which the isolator
should be opened to disconnect the BT from the
OHE and to make the OHE through.

3. The secondary winding of the BT should be

disconnected from the return conductor and the
return conductor made through by jumpering.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

4. The return conductor should be earthed at the

location where the BT has been disconnected; and
the midpoint rail links on both sides of the BT
should be opened so that booster cells on either
side will extend over a longer section temporarily.

5. With the OHE and return conductors made

through, 25 kV power supply may be restored

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

• It should be noted that during the period when a

BT has been disconnected from service, the
interference on adjacent communication circuits
will be enhanced. In view of this the defective
BT should be replaced with a good BT with the
least possible delay.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

 Isolating Switches on the 25 kV system shall not

be opened or closed when current is passing
through them. Normally, isolators should only be
opened or closed, after power supply to the section
has been switched off by opening the appropriate
interruptor

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

The following arrangements/precautions

would be necessary:

Arrangements

i) An equipotential link between the petroleum sidings

installation earth and the track via a switch

ii) Setting up of neutral zones (insulating joints) in the

track to avoid any risk of propagating stray current.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

iii) Setting up of neutral zones/sections in the contact wire

similar to loco inspection pits.

iv) The tracks must be provided with longitudinal bonds

on both the rails as well as transverse bond (30 m
intervals). All masts and metallic structures in the
vicinity of the track/ sidings should be provided with
structure bonds. Copper rivets should be used for
bonding.

v) 10 ohm earths must be connected to the petroleum

siding on each side at the insulated joint.
Phase II - Module No. STC-TrD-3
CAMTECH, Gwalior

i) No oil tanker is. permitted to stable under live

OHE for inspection purpose.

ii) Fuelling to be done by side filling arrangement

only.

iii) Pipe lines in the vicinity of the track should be

properly earthed.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

iv) Minimum 2 m electrical clearance from live OHE

of the adjacent track or only other structure
nearby must be maintained.

v) During filling/loading and unloading of

petroleum products the isolators at the neutral
section of OHE should be kept open to ensure
that the OHE is dead and earthed.

Phase II - Module No. STC-TrD-3

CAMTECH, Gwalior

Phase II - Module No. STC-TrD-3

Phase II - Module No. STC-TrD-3
 The periodic current collection tests would reveal
points where sparking takes place. Apart from'
Investigating and rectifying the cause of such
sparking, it is also important that the roughened
surface of the contact wire be attended to, failing
which, there will be further rapid deterioration,
with successive passage of pantographs resulting
In reduced life of contact wire.

Phase II - Module No. STC-TrD-3

 Sparking occurs when there is loss of contact (or
improper contact) between the pantograph and
the contact wire.

 The common causes attributable to the OHE

are:

1. Incorrect tension in regulated OHE due to

maladjustment or sluggish operation of
regulating equipment;

2. Inadequate tension of contact wire in the

case of unregulated OHE; Phase II - Module No. STC-TrD-3
 3. Deposit of soot on contact wire due to
steam and diesel traction and the
resulting roughness of contact face
during current collection;

4. Kinks in contact wire.

 If OHE on the main line is unregulated, the

tension in the contact wire should be checked
and adjusted if need be once in 2 years.

 The speed being low in yards and sidings, the

adverse effect of incorrect tensioning will be less
pronounced and re-tensioning at longer intervals
of 3-4 years will be adequate. Phase II - Module No. STC-TrD-3
 Deposits of soot on account of steam and diesel
traction may cause trouble due to sparking at
points where steam engines halt for long
periods. Particular note should be made of such
locations and cleaning done at shorter intervals.

 Kinks detected during patrolling and inspection

should be straightened or/removed without
delay. After re-tensioning it is particularly
necessary to inspect the section for kinks.

Phase II - Module No. STC-TrD-3

Conventional method for current collection
test is by fixing mirror in rear-cab of
locomotive.
Image of pantograph of Electric Locomotive is
seen in this mirror.
Whenever spark is observed location is being
asked by technician in rear cab from the
technician in front cab who is continuously
viewing OHE mast number.
This information is conveyed either through
Walkie -Talkie or by audio signal.
Locations are noted down manually.
Phase II - Module No. STC-TrD-3
This test is conducted in night as such many
times locations are missed out.
In-spite of utilising the best manpower, the
results recorded are not very accurate.
Therefore, field staff have to waste time in
locating actual location.
Thus, it not only reduces the efficiency of
maintenance men but also require Power Block
of longer duration.
More men in operating cabs of locomotive
disturb attention of locomotive crew.

Phase II - Module No. STC-TrD-3

• The OLIVIR-G Plus is developed to assist Over
Head Equipment (OHE) spark detection using a
video camera. The hardware units consist of a
GPS receiver which track the current position of
the locomotive in which the ‘OLIVIR-G plus’ is
mounted.

Phase II - Module No. STC-TrD-3

This is a far superior system than the existing one.
It enables to pin point the locations with accuracy
of 3-4 meter at 130 Kmph train speed without any
need to look out side.
Only one Traction Supervisor is required in
locomotive operating cab to operate the system
without verbal instructions.
Therefore, No disturbance to Loco crew.

Phase II - Module No. STC-TrD-3

FROM
LOCO
STEP UP
TRANSFORMER
110V

Phase II - Module No. STC-TrD-3

Phase II - Module No. STC-TrD-3
FIXING OF OLIVER-G CAMERA

Phase II - Module No. STC-TrD-3

CONNECTING CAMERA, GPS ANTEENA AND POWER SUPPLY WITH LAPTOP

Phase II - Module No. STC-TrD-3

Camera and Light

Phase II - Module No. STC-TrD-3

GPS Anteena

Phase II - Module No. STC-TrD-3

Processing & Login Unit

Phase II - Module No. STC-TrD-3

GPS Unit

Phase II - Module No. STC-TrD-3

 The OLIVIR mate RT software supplied
with the unit identities sparks in real time
and save them as images with locations, at
the same time continuous video film is also
recorded in hard drive. These images can
be analyzed to recognize the type of spark
(mega pixel) with their locations.

Phase II - Module No. STC-TrD-3

 The OLIVIR-G Plus is developed to
observe OHE (Contact wire) spark
detection using the video camera. The
hardware units consist of a GPS receiver
which track the current position of the
locomotive in which the OLIVIR is
mounted.

Phase II - Module No. STC-TrD-3

OLIVIR-G Plus generates two types of
reports:
i. Graphical Report

ii. Text Report

Phase II - Module No. STC-TrD-3

i. Focus light operated at 110V AC/DC supply.
ii. Camera and light
iii. GPS antenna
iv. Processing & login unit
v. GPS unit
vi. Serial cable
vii. Battery charger
viii. Track feature collection unit
Phase II - Module No. STC-TrD-3
 It can show total number of images recorded during
current collection test.

 The category of spark can be adjusted as per

customer requirement.

 It gives the correct position of spark with its

location.

 The size of spark value can be adjusted during

current collection.

 It automatically saves all recorded data in the laptop

datewise Phase II - Module No. STC-TrD-3
Phase II - Module No. STC-TrD-3