Podcast
Questions and Answers
What must be signed by the Engineering and Electrical departments for cable route planning?
What must be signed by the Engineering and Electrical departments for cable route planning?
The cable route plan.
What types of areas should be avoided when planning cable routes?
What types of areas should be avoided when planning cable routes?
Low lying areas, rocky terrains, and proximity to Electrical Sub Stations.
Why is it important to incorporate cable duct provisions in tunnel design?
Why is it important to incorporate cable duct provisions in tunnel design?
To ensure proper routing and protection of cables within the tunnel.
How should cable drums be stored to ensure stability?
How should cable drums be stored to ensure stability?
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What direction should the cable drum be rotated while rolling for unloading?
What direction should the cable drum be rotated while rolling for unloading?
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What is essential to do with the ends of the cable during storage?
What is essential to do with the ends of the cable during storage?
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What should be used to avoid damage to cables while laying them in the trench?
What should be used to avoid damage to cables while laying them in the trench?
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What is the recommended storage location for cable drums?
What is the recommended storage location for cable drums?
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What should be checked before laying the cable in the trench?
What should be checked before laying the cable in the trench?
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How should the cable be laid if wheels are not available?
How should the cable be laid if wheels are not available?
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What should NOT be done when laying the cable?
What should NOT be done when laying the cable?
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Who should supervise the use of mechanized equipment for cable laying?
Who should supervise the use of mechanized equipment for cable laying?
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How should the cable be paid out from a damaged drum?
How should the cable be paid out from a damaged drum?
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What is the minimum width that cable trenches should have?
What is the minimum width that cable trenches should have?
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What material should be used at the bottom of the trench in rocky ground?
What material should be used at the bottom of the trench in rocky ground?
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What is required to cover the cable after laying it in the trench?
What is required to cover the cable after laying it in the trench?
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What should be done with boulders having sharp edges in the trench?
What should be done with boulders having sharp edges in the trench?
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What technique should be used to pay out the cable?
What technique should be used to pay out the cable?
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What precautions should be taken before using insulation testers on cable conductors?
What precautions should be taken before using insulation testers on cable conductors?
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How frequently should insulation tests be performed on signalling cables in dry weather?
How frequently should insulation tests be performed on signalling cables in dry weather?
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What action should be taken if a sudden drop in insulation resistance is detected?
What action should be taken if a sudden drop in insulation resistance is detected?
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What additional testing may be performed aside from regular dry weather inspections?
What additional testing may be performed aside from regular dry weather inspections?
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What maintenance practices should be followed for cable termination devices and related components?
What maintenance practices should be followed for cable termination devices and related components?
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What method may be used for laying Quad and OFC cables across the track based on site conditions?
What method may be used for laying Quad and OFC cables across the track based on site conditions?
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What is required to mark the route of cables?
What is required to mark the route of cables?
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How should cables be secured when entering a Cable room?
How should cables be secured when entering a Cable room?
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What should be done when the required depth for cable laying cannot be achieved due to rocky soil?
What should be done when the required depth for cable laying cannot be achieved due to rocky soil?
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Why should sharp cable bends be avoided?
Why should sharp cable bends be avoided?
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At what depth should cables be laid normally parallel to the track?
At what depth should cables be laid normally parallel to the track?
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What additional precautions should be considered when laying cables in station yards?
What additional precautions should be considered when laying cables in station yards?
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At what angle should cables cross the track?
At what angle should cables cross the track?
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How deep should tail cables be buried?
How deep should tail cables be buried?
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What materials can be used for cables crossing the track?
What materials can be used for cables crossing the track?
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What type of duct should be used for protecting laid cables?
What type of duct should be used for protecting laid cables?
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What method is recommended for crossing small culverts?
What method is recommended for crossing small culverts?
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What precautions should be taken when cables cross a metallic bridge?
What precautions should be taken when cables cross a metallic bridge?
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What is the suggested depth for cable laying in theft-prone areas?
What is the suggested depth for cable laying in theft-prone areas?
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What should be avoided when laying cables in trenches?
What should be avoided when laying cables in trenches?
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What is preferred regarding trench excavation during cable laying?
What is preferred regarding trench excavation during cable laying?
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How can future digging activities affect laid cables, and what should be done?
How can future digging activities affect laid cables, and what should be done?
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Where should the soil from excavated trenches be placed?
Where should the soil from excavated trenches be placed?
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What is the importance of suitable instructions issued by Railways regarding machinery along the track?
What is the importance of suitable instructions issued by Railways regarding machinery along the track?
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What specific cable length should be available at the approaches of a bridge?
What specific cable length should be available at the approaches of a bridge?
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What are the implications of using trenching for cable laying near running trains?
What are the implications of using trenching for cable laying near running trains?
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What measures should be taken if the desired depth cannot be achieved due to obstructions?
What measures should be taken if the desired depth cannot be achieved due to obstructions?
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What depth should cables be buried when laid parallel to the track?
What depth should cables be buried when laid parallel to the track?
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What is the function of using Half Cut DWC-HDPE pipes or RCC ducts during cable laying?
What is the function of using Half Cut DWC-HDPE pipes or RCC ducts during cable laying?
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How can the risk of theft be mitigated when laying cables?
How can the risk of theft be mitigated when laying cables?
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What should be avoided when laying Signal & Telecommunication cables?
What should be avoided when laying Signal & Telecommunication cables?
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Why might cables need to be laid at a deeper depth in theft-prone areas?
Why might cables need to be laid at a deeper depth in theft-prone areas?
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What design features should ducts have to protect laid cables from future digging activities?
What design features should ducts have to protect laid cables from future digging activities?
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What precautions should be taken when laying cables in station yards?
What precautions should be taken when laying cables in station yards?
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What should be checked before laying the cables in trenching work?
What should be checked before laying the cables in trenching work?
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What should be avoided when choosing locations for cable routes?
What should be avoided when choosing locations for cable routes?
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How should cable drums be handled during storage for safety?
How should cable drums be handled during storage for safety?
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What method is recommended for ensuring no kinks occur while paying out cable?
What method is recommended for ensuring no kinks occur while paying out cable?
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Which components of tunnel design should consider cable management?
Which components of tunnel design should consider cable management?
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What precautions must be taken when unloading cable drums from transportation?
What precautions must be taken when unloading cable drums from transportation?
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During laying, how should the cable be managed to avoid dragging effects?
During laying, how should the cable be managed to avoid dragging effects?
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What should be done to the ends of cables during storage to prevent water entry?
What should be done to the ends of cables during storage to prevent water entry?
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Why should cables laid in trenches avoid certain sharp objects or edges?
Why should cables laid in trenches avoid certain sharp objects or edges?
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What precautions must be taken before excavating near underground signal cables?
What precautions must be taken before excavating near underground signal cables?
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How frequently should the main signaling cables' insulation resistance be tested?
How frequently should the main signaling cables' insulation resistance be tested?
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What is the purpose of the Earth Leakage Detector (ELD) in signaling installations?
What is the purpose of the Earth Leakage Detector (ELD) in signaling installations?
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What maintenance action should be prioritized after the monsoon for protective works provided for cables?
What maintenance action should be prioritized after the monsoon for protective works provided for cables?
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What should be done after laying a signaling cable and after the first monsoon?
What should be done after laying a signaling cable and after the first monsoon?
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What clamping arrangement is necessary for cables entering a Cable room?
What clamping arrangement is necessary for cables entering a Cable room?
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What is the minimum distance that must be maintained between signalling cables and HT power cables?
What is the minimum distance that must be maintained between signalling cables and HT power cables?
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What is the recommended orientation for a cable crossing a track?
What is the recommended orientation for a cable crossing a track?
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What should be done to protect cables crossing under roads or banks?
What should be done to protect cables crossing under roads or banks?
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In what order should different cable categories be laid in the same trench?
In what order should different cable categories be laid in the same trench?
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How should signalling cables be supported when laid above ground?
How should signalling cables be supported when laid above ground?
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How should cables be placed when crossing a metallic bridge?
How should cables be placed when crossing a metallic bridge?
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What is the recommended distance for laying cables outside the station section from the nearest track center?
What is the recommended distance for laying cables outside the station section from the nearest track center?
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What is crucial to avoid when laying cables in trenches?
What is crucial to avoid when laying cables in trenches?
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What method is preferred for drilling when cables cross small culverts?
What method is preferred for drilling when cables cross small culverts?
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What extra length of cable should be kept at each end of the main cable after laying?
What extra length of cable should be kept at each end of the main cable after laying?
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What should be considered regarding the timeline of trench excavation for cable laying?
What should be considered regarding the timeline of trench excavation for cable laying?
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What should follow the laying of cables in trenches to ensure stability?
What should follow the laying of cables in trenches to ensure stability?
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What is required for underground signalling cables in station yards?
What is required for underground signalling cables in station yards?
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What is recommended for cable provisions at diversion points?
What is recommended for cable provisions at diversion points?
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What is necessary for cables laid in concrete, GI, or HDPE pipes when crossing tracks?
What is necessary for cables laid in concrete, GI, or HDPE pipes when crossing tracks?
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What precautions should be taken if cables must be laid between the tracks?
What precautions should be taken if cables must be laid between the tracks?
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What should be the minimum available cable length at bridge approaches?
What should be the minimum available cable length at bridge approaches?
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What type of joints should be used for cables after laying?
What type of joints should be used for cables after laying?
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What spacing should be maintained for cable supports to avoid sag?
What spacing should be maintained for cable supports to avoid sag?
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What precautions are necessary before excavation near underground signal cables?
What precautions are necessary before excavation near underground signal cables?
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What is the periodicity for testing insulation resistance of main cables?
What is the periodicity for testing insulation resistance of main cables?
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How often should insulation resistance be tested for tail cables?
How often should insulation resistance be tested for tail cables?
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What must be done after laying signalling cables and before the first monsoon?
What must be done after laying signalling cables and before the first monsoon?
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What type of detector should be included in all signalling installations for monitoring?
What type of detector should be included in all signalling installations for monitoring?
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What is the minimum percentage of spare conductors required in a main cable laid to the farthest point zone?
What is the minimum percentage of spare conductors required in a main cable laid to the farthest point zone?
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Explain the significance of conducting a foot survey when planning cable routes.
Explain the significance of conducting a foot survey when planning cable routes.
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What should be done with existing routes of power cables when creating a cable route plan?
What should be done with existing routes of power cables when creating a cable route plan?
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What is the role of auxiliary signals in cable planning according to the guidelines?
What is the role of auxiliary signals in cable planning according to the guidelines?
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How should circuits be distributed when multiple cables are laid along a route?
How should circuits be distributed when multiple cables are laid along a route?
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Which approvals are required for a cable route plan aside from Engineering and Electrical departments?
Which approvals are required for a cable route plan aside from Engineering and Electrical departments?
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When is it acceptable to not include spare conductors in a cable installation?
When is it acceptable to not include spare conductors in a cable installation?
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What should be indicated on a cable route plan aside from the alignment of the track?
What should be indicated on a cable route plan aside from the alignment of the track?
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What is the minimum distance cables must be laid away from an independent Earth for an O.H.E structure?
What is the minimum distance cables must be laid away from an independent Earth for an O.H.E structure?
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What is the maximum permissible use of metallic pipes near a feeding post?
What is the maximum permissible use of metallic pipes near a feeding post?
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What insulation resistance value should not be less than for buried cables?
What insulation resistance value should not be less than for buried cables?
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What type of insulation tester is recommended for Quad cables?
What type of insulation tester is recommended for Quad cables?
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What immediate action should be taken if insulation resistance is found to be lower than the acceptable level?
What immediate action should be taken if insulation resistance is found to be lower than the acceptable level?
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In what condition should the insulation resistance tests be conducted on signalling cables?
In what condition should the insulation resistance tests be conducted on signalling cables?
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What is the requirement for disconnecting cables before performing insulation resistance tests?
What is the requirement for disconnecting cables before performing insulation resistance tests?
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How should the bonding of metallic sheaths or metal work be treated during insulation resistance testing?
How should the bonding of metallic sheaths or metal work be treated during insulation resistance testing?
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What distance should cable trenches be dug from the nearest rail track?
What distance should cable trenches be dug from the nearest rail track?
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What impact does the proximity of an O.H.E structure have on the placement of cable trenches?
What impact does the proximity of an O.H.E structure have on the placement of cable trenches?
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What is the purpose of testing all conductors in signalling cables for insulation before commissioning?
What is the purpose of testing all conductors in signalling cables for insulation before commissioning?
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How often should all conductors in signalling cables be tested in dry weather?
How often should all conductors in signalling cables be tested in dry weather?
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Why should cable conductors be shorted or earthed before connecting an insulation tester?
Why should cable conductors be shorted or earthed before connecting an insulation tester?
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What should be done if a sudden fall in insulation resistance is observed during testing?
What should be done if a sudden fall in insulation resistance is observed during testing?
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What is the significance of comparing test results from successive insulation tests?
What is the significance of comparing test results from successive insulation tests?
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How frequently should tail cables be tested for insulation?
How frequently should tail cables be tested for insulation?
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What actions should be taken to maintain cable termination devices and related apparatus?
What actions should be taken to maintain cable termination devices and related apparatus?
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In addition to dry weather testing, what other testing may be necessary?
In addition to dry weather testing, what other testing may be necessary?
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What should be recorded after insulation resistance tests?
What should be recorded after insulation resistance tests?
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What immediate actions should be taken if moisture or water leaks are discovered at cable termination points?
What immediate actions should be taken if moisture or water leaks are discovered at cable termination points?
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What is the minimum distance that cables should be laid from the nearest edge of the mast when the cable depth does not exceed 0.5 meters?
What is the minimum distance that cables should be laid from the nearest edge of the mast when the cable depth does not exceed 0.5 meters?
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What additional requirement is mandated if the cable is to be laid at a depth greater than 0.5 meters?
What additional requirement is mandated if the cable is to be laid at a depth greater than 0.5 meters?
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How should cables be protected when laid in proximity to traction substations?
How should cables be protected when laid in proximity to traction substations?
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What must be done if maintaining the minimum distances from overhead structures is difficult during cable laying?
What must be done if maintaining the minimum distances from overhead structures is difficult during cable laying?
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When laying cables near switching stations, what is the minimum required distance from the station earthing?
When laying cables near switching stations, what is the minimum required distance from the station earthing?
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Who must supervise the cable laying operation on-site?
Who must supervise the cable laying operation on-site?
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What is the purpose of placing cables in DWC-HDPE pipes or concrete ducts?
What is the purpose of placing cables in DWC-HDPE pipes or concrete ducts?
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What precautions should be taken regarding the distance of cables from substation earthing?
What precautions should be taken regarding the distance of cables from substation earthing?
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What is the significance of timely supervision during trench refilling after cable laying?
What is the significance of timely supervision during trench refilling after cable laying?
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What is required when digging beyond 0.50 meters near cable laying zones?
What is required when digging beyond 0.50 meters near cable laying zones?
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Study Notes
Cable Route Planning
- Cable routes should be planned to avoid low-lying areas, platform copings, drainages, hutments, rocky terrains, points and crossings, and proximity to electrical substations/switching stations.
- Separate cables of suitable size should be laid for point operation.
- In tunnels, provision of cable ducts should be included in the tunnel design.
- Suitable ducts, pipes, or other arrangements should be integrated into bridge designs for cable laying.
Cable Storage and Transportation
- Cable drums should be stored upright and stabilized with suitable stoppers.
- Drums should be accessible for lifting and moving.
- When rolling cable drums, ensure they rotate in the direction of the arrow marked on the drum.
- Avoid rolling drums over objects that could damage the cable's protective battens.
- When unloading cable drums from vehicles, use a forklift or ramp to avoid dropping the drum directly on the ground.
- Cable ends should be effectively sealed to prevent water entry.
- Store cable drums in a covered shed to protect them from direct sunlight.
Paying Out and Testing Cable
- Use cable wheels to pay out cables, ensuring no kinks form.
- Position the wheel with the drum at one end of the trench, free the cable end, and lay the cable along the trench.
- A group of laborers should move along the trench carrying the cable at suitable intervals to prevent damage.
- Visually inspect the cable before laying it in the trench for any damage.
- Test the cable for insulation and conductor continuity before laying. Maintain records of insulation and loop resistance tests.
- If wheels are not available, mount the drum on an axle at one end of the trench and pay out the cable manually.
- Do not roll the drum off onto the road or drag the cable on the ground for laying.
- Ensure trained operators under the supervision of SSE/JE(Signal) work with mechanized equipment.
- If the cable drum is damaged, use a horizontal revolving platform to pay out the cable.
- Rotate the cable drum to pay out cable, avoid pulling with excessive force.
Trenching
- Trench width should be commensurate with the number of cables, with a minimum width of 0.3 meters.
- The bottom of the trench should be leveled and free of sharp materials.
- In soft ground, lay the cable at the bottom of the leveled trench.
- In rocky ground, lay the cable on a layer of sand or sifted earth (0.05 meters thick) deposited at the bottom of the trench.
- Cover the cable with a layer of sand or sifted earth (0.10 meters thick) and then with a protective cover of a trough, bricks, split DWC-HDPE pipe, or other approved means.
- Clear the trench bottom of boulders with sharp edges.
- In rocky soil, fill the trench bottom with river sand or soft material and lay the cable on a smooth surface.
- Horizontal directional drilling (HDD) can be used for laying Quad and OFC cables across tracks, ensuring sufficient depth to prevent damage from future work.
- Use protective measures as specified in Drg. No. 15-D2 when achieving required depth is not feasible due to rocky soil or obstructions.
- Utilize suitable machinery for trenching, ensuring safety of running trains and following railway rules.
- Refer to joint circulars for guidelines on machinery operation.
Laying of Cables
- Follow the general instructions provided in this chapter, but consider specific precautions for station yards with existing utilities (detailed in joint circulars by the Civil Engineering, Signalling and Electrical Departments).
- Cables can be laid underground in trenches, ducts, cement troughs, pipes or in other approved manners.
- Main cables laid parallel to the track should be buried at a depth of 1.0 meters from the top of the cable to ground level, including those laid across the track (1.0 meter below the rail flanges).
- Tail cables should be buried at a depth of at least 0.50 meters.
- In theft-prone areas, lay cables at a depth of 1.2 meters with anchoring every 10 meters.
- Use half-cut DWC-HDPE pipe/RCC or approved ducts/pipes to protect cables.
- Ensure ducts are designed and sized to minimize future damage from digging activities.
- Provide suitable covers to prevent water pooling in the ducts.
- Protect cables in rocky areas where 1.0-meter depth is not feasible as outlined in Drg. No: 15-D2.
- Do not lay cables from other departments in the same trench as Signal & Telecommunication cables.
- Install approved cable markers at suitable intervals and at diversion points to indicate the route.
- Secure cables entering cable rooms, relay rooms, or apparatus cases with clamping arrangements to prevent downward displacement.
- Provide ducts, ladder supports, cable guides, etc. within the Cable room/Relay room and avoid sharp cable bends.
Cable Crossing
- When a cable crosses the track, ensure:
- It crosses at right angles.
- It does not cross under points and crossings.
- It is laid in concrete, GI, DWC-HDPE pipes, suitable ducts, or other approved methods while crossing the track.
- Consider HDD wherever feasible.
- Take cables underground across drain beds at a suitable depth for crossing small culverts with low flood levels. Consider HDD where feasible.
- Use HDD when cables cross roads, high banks, etc.
- Place cables in a metallic trough/GI pipe when crossing metallic bridges, and fill the pipe with sealing compound or suitable means as an anti-theft measure.
- Support cables across bridges to minimize vibrations and facilitate maintenance.
- Provide adequate cable length (2-3 meters) at bridge approaches.
- Avoid excavating long stretches of trenches and leaving them uncovered for extended periods.
- Lay cables and refill trenches on the same day.
- During excavation, avoid throwing soil on the ballast and dispose of it away from the track.
Testing and Commissioning
- Conduct insulation tests on all conductors in signaling cables in dry weather every three years (unless monitored through ELD, then annually before monsoon). Record test readings according to the format in Annexure 15-MS1.
- Test tail cables for insulation once a year.
- Compare successive test results for cables under similar conditions to detect trends in insulation deterioration. Investigate and repair or replace cables if sudden insulation drops occur.
- Conduct random insulation tests in wet weather if necessary to identify any sudden insulation deterioration.
- Keep cable termination devices, pillar boxes, cable heads, and glands clean and dry. Inspect these parts regularly and promptly address any signs of moisture or water leaks.
Cable Maintenance
- Conduct insulation tests on all conductors in signaling cables in dry weather every three years. This should be done annually if the cables are monitored through ELD, preferably before the monsoon season.
- Record the test readings according to the format in Annexure 15-MS1.
- Tail cables should be tested for insulation at least once a year.
- Compare test results between successive tests conducted under similar conditions to track the deterioration of the insulating material over time.
- Investigate and address the issue immediately if a sudden drop in insulation is observed.
- The cause should be investigated and immediate steps taken to repair or replace the cable.
- Random tests in wet weather are important to localize any sudden deterioration in cable insulation.
- Ensure all cable termination devices, pillar boxes, cable heads, and glands are kept clean and dry. These components should be inspected frequently.
- Any tendency for moisture or water leaks should be addressed immediately.
Construction Works Cable Route Planning
- Cable route plans must be approved by the Engineering and Electrical departments of executing agencies.
- Avoid laying cables in low-lying areas, platform copings, drainages, hutments, rocky terrains, points and crossings.
- Minimize proximity to Electrical Sub Stations/Switching Stations.
- Use separate cables for point operation.
- In tunnels, include cable duct provisions in the design.
- Incorporate suitable ducts/pipes/arrangements in bridge designs for cable laying.
Cable Storage and Transportation
- Never stack cable drums on their flat side.
- Use stoppers for stability when stacking drums.
- Ensure access for lifting and moving cable drums.
- Always rotate drums in the direction of the arrow marked on the drum when rolling.
- Avoid rolling drums over objects that could damage the cable's protective battens.
- Use forklifts or ramps for unloading to prevent damage from impact.
- Seal cable ends with end caps or approved methods to prevent water ingress.
- Store cable drums in covered sheds to protect them from sunlight.
Paying Out and Testing of Cable
- Mount cable drums on cable wheels for paying out.
- Prevent kinking during paying out.
- Place the drum at one end of the trench, free the cable end, and lay it along the trench.
- Use laborers to carry the cable at suitable intervals to prevent damage from dragging or bending.
- Use horizontal directional drilling for laying Quad and OFC cables across the track at sufficient depth to avoid damage from future work.
- Implement protective measures (refer to Drg. No. 15-D2) where required depth cannot be achieved due to rocky soil or obstructions.
- Employ suitable machinery for trenching, prioritizing safety during operation and adhering to railway rules governing machinery work.
Laying of Cables
- Lay cables according to the instructions in this chapter.
- Special considerations for station yards may be detailed in a joint circular by Civil Engineering, Signalling, and Electrical departments.
- Cables can be laid underground: in trenches, ducts, cement troughs, pipes, or other approved methods.
- Main cables laid parallel to the track should be buried 1.0 meter below ground level, including those crossing the track (1.0 meter below rail flanges).
- Tail cables should be buried at least 0.50 meters deep.
- Increase burial depth to 1.2 meters and anchor every 10 meters in theft-prone areas.
- Use Half Cut DWC-HDPE pipe/RCC or approved ducts/pipes for cable protection.
- Ensure ducts are designed and sized to prevent damage from future digging activities and have suitable covers to avoid water accumulation.
- Provide protection as illustrated in Drg. No: 15-D2 when laying cables in rocky areas where 1.0 meter depth isn't feasible.
- Avoid laying cables of other departments in the same trench as Signalling & Telecommunication cables:
- Maintain a 10 cm distance between cables of other departments and signalling cables.
- Separate signalling cables from LT power cables with bricks or approved methods.
- Maintain a minimum 3-meter separation from HT power cables.
- When laying multiple cables of different types in the same trench, prioritize placement starting from the track side:
- Telecommunication cable
- Signalling cable
- Power cable
- Outdoor signalling cables should generally be laid underground.
- In exceptional cases where above-ground laying is unavoidable:
- Suspend cables with wooden cleats, cable hangers, or approved methods to prevent mechanical damage.
- Space cable supports adequately to prevent sag.
- Lay cables in ducts with proper protection in station yards.
- Lay indoor signalling cables on ladders, channels, or approved methods.
- Refer to Section 3 for laying cables in RE areas.
- For cables crossing tracks:
- Ensure cables cross at right angles.
- Avoid crossing tracks under points and crossings.
- Lay cables in concrete/GI/DWC-HDPE pipes, ducts, or other approved methods while crossing the track.
- Consider horizontal directional drilling where feasible.
- When crossing drain beds, take cables underground at suitable depth or use horizontal directional drilling for smaller culverts with low flood levels.
- Employ horizontal directional drilling to cross roads, high banks, etc., where applicable.
- Lay cables in metal troughs/GI pipes filled with sealing compound (as an anti-theft measure) when crossing metallic bridges.
- Support cables across bridges to minimize vibrations and facilitate maintenance.
- Ensure adequate cable length (2-3 meters) at bridge approaches to allow for movement.
- Avoid long stretches of uncovered trenches and aim to complete laying and backfilling on the same day.
- During excavation, do not throw soil on the ballast. Discard soil away from the track.
- Do not excavate near underground signal cables without a representative of the Signalling & Telecommunications department present and adequate safety precautions.
- Regularly inspect protective works for cables at track crossings, culverts, bridges, etc., paying special attention after the monsoon.
Earth Leakage Detector (ELD)
- Equip all signalling installations with an Earth Leakage Detector (ELD).
- Interface ELDs with a datalogger (where feasible) for remote monitoring.
- Refer to Annexure: 15-MS2 for ELD maintenance schedules.
Periodical Testing of Signalling Cables
- Carry out the first insulation resistance measurement after laying the cable and again after the first monsoon for all conductors.
- Re-megger all cables after major yard work.
- Conduct periodic insulation resistance tests based on cable types:
- Main Cable: Every 2 years
- Tail Cables (Signal/Track/Points): Once a year
- Spare conductors: Once a year
Appendix Information
-
Appendix I:
- Annexure 15-MS1: Cable Maintenance Schedule, Cable Insulation Resistance Test Sheet, Instructions for Insulation Resistance Testing of Signalling Cable.
- Annexure 15-MS2: Maintenance Schedule of Earth Leakage Detector (ELD).
-
Appendix II:
- Drawing 15-D1: RCC Cable Marker Drawing
- Drawing 15-D2: Drawing for Cable Laying with Rock Facing (300 mm, 400 mm, 600 mm)
Cable Requirements for Signalling Circuits
- Railway signalling circuits should be routed through approved cables.
- Extant guidelines from Railway Board, RDSO, and PCSTE should be followed for cable laying.
Cable Planning
- When planning for cabling, the number of conductors required should be determined first, depending upon the circuits.
- Recommended core sizes as per specifications shall be used.
- Provide sufficient spare conductors (at least 20% of total conductors) in each main cable up to the farthest point zone, beyond this provide at least 10% spare conductors.
- Spare conductors are not required if a cable uses 3 or less conductors.
- Spare conductors should be placed on the outermost layer.
- Circuits should be distributed in a way that allows disconnecting cables for maintenance with minimal traffic disruption.
- Separate cables should be used for different lines, functions, and auxiliary signals.
- After deciding the size and number of conductors in the different types of cables, a foot survey should be carried out to determine the best route for the cable.
- The route should be clearly marked on a cable route plan showing the actual alignment of track, offsets from permanent way or permanent structures, road and track crossings, crossings with power cables, water and sewage mains, and other important points.
- It is preferable to chart the route on a plan that shows existing routes of power cables.
- Any changes should be incorporated in the chart/plan.
- The cable route plan should be approved by Engineering and Electrical departments.
- Approval from S&T open line is also required when prepared by other than open line.
- When laying cables within 1 meter from the sleeper end, digging beyond 0.50 meters should be done in the presence of an Engineering Department official.
- Laying of the cable and refilling of trench should be done with minimal delay.
Cable Laying in RE Area
- Only unscreened approved type underground cables should be used for signalling purposes.
- Cables should be laid at least 1 meter away from the nearest edge of masts supporting the catenary or any other live conductor, provided the depth of the cable does not exceed 0.5 meters.
- When the cable is laid at a depth greater than 0.5 meters, maintain a minimum distance of 3 meters between the cable and the nearest edge of the O.H.E structure.
- If maintaining these distances is difficult, the cable should be laid in DWC-HDPE/Concrete Ducts or other approved means for a distance of 3 meters on either side of the Mast.
- When laid in ducts, the distance between the cable and the mast may be reduced to 0.5 meters.
- These precautions are necessary to avoid damage to the cable in the event of an overhead insulator failure.
- In the vicinity of traction substations and feeding posts, the cable should be at least one meter away from any metallic part of the O.H.E and other equipment at the substation fixed on the ground, and at least one meter away from the substation earthing.
- Lay the cable on the side of the track opposite to the feeding post as much as possible.
- Lay the cable in concrete or DWC-HDPE pipes (approved type)/Split RCC pipes or other approved means for a length of 300 meters on either side of the feeding point.
- In the vicinity of switching stations, the cable should be laid at least one meter away from any metallic body of the station fixed in the ground, and at least 5 meters away from the station Earthing.
- The 5-meter distance may be reduced to one meter if cables are laid in concrete pipes/DWC-HDPE-pipes of approved type/ducts or other approved means.
- If an independent Earth is provided for an O.H.E structure, i.e. where the mast is connected to a separate Earth instead of being connected to the rail, the cables should be laid at least one meter away from the Earth.
- When laying cables along routes with O.H.E structures, the cable trenches should be dug, as far as possible, not less than 5.5 meters away from the centre of the nearest Track.
- Do not use G.I pipes or any form of metallic pipes within a distance of 300 meters from the feeding post.
- Similarly, galvanized iron metallic pipes are prohibited in close proximity to the switching station earth or traction mast (Para 20706 (vi) of ACTM).
Insulation Resistance Testing of Signal Cables
- These instructions apply only to cables used for Railway Signalling, not internal wiring.
- Insulation resistance tests should be carried out when conductors, cables and insulated parts are clean and dry.
- Use a 500 V insulation tester for signalling cables and a 100 V insulation tester for Quad cables.
- Any metallic sheath or metal work of any rack or apparatus case should be bonded to earth during the test.
- Disconnect all cores of a cable at both ends, through links of ARA/Modular terminals, if provided.
- Connect one terminal of the insulation tester to the conductor under test and the other terminal to all the other conductors bunched together and connected to earth.
- Test remaining conductors of the cable one by one as described above.
- The measured insulation resistance should not be less than 5 mega ohms per km at buried temperature.
- Investigate and address any insulation resistance lower than 5 mega ohms.
- Insulation Resistance tests should be conducted in a way that does not affect safe operation of trains or create unsafe conditions.
- All conductors in signalling cables must be tested for their insulation before commissioning.
- Conductors may accumulate electrostatic charge. Short or earth cable conductors to discharge any accumulated charge before and after insulation testing for safety.
- Record the results of the insulation resistance tests in approved proforma.
- Comparing test results between successive tests under similar conditions will show the trend towards cable deterioration.
Maintenance of Cables
- Test all conductors in signalling cables for insulation in dry weather every three years, provided cables are monitored through ELD, otherwise test annually, preferably before monsoon.
- Use the instructions specified in section 4 for testing and record readings as per the format in Annexure: 15-MS1.
- Test tail cables for insulation once a year.
- Comparing test results between successive tests under similar conditions will show the trend towards deterioration of insulating materials.
- Investigate and address any sudden fall in insulation.
- Conduct random tests in wet weather if needed to localize any sudden deterioration in cable insulation.
- Keep all cable termination devices, pillar boxes, cable heads, and glands clean and dry.
- Frequently inspect these parts and address any tendency for moisture or water leak.
- Do not excavate near underground signal cables without a representative of the signal & telecommunication department present and suitable precautions for the safety of existing cables.
- Regularly inspect protective works for cables at places like track crossings, culverts, bridges, etc.
- Focus on protective works soon after the monsoon.
- Provide Earth Leakage Detectors (ELD) in all signalling installations.
- Interface ELD with Datalogger (where ever feasible) for remote monitoring.
- Refer to Annexure: 15-MS2 for ELD Maintenance Schedules.
Periodical Testing of Signalling Cables
- Conduct the first measurement of insulation resistance after laying the cable and after first monsoon for all the conductors.
- After major work in a yard, megger all cables afresh.
- Periodically test insulation resistance as listed:
- Main Cable: every 2 years
- Tail Cables (Signal/Track/Points): once a year
- Spare conductors: once a year
Annexures
- Annexure 15-MS1: Maintenance Schedule of Cable, Cable Insulation Resistance Test Sheet, Instructions for Insulation Resistance Testing of Signalling Cable
- Annexure 15-MS2: Maintenance Schedule of Earth Leakage Detector (ELD)
Drawings
- Drawing 15-D1: RCC cable marker
- Drawing 15-D2: Cable laying when rock faced at 300 mm, 400 mm, and 600 mm.
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This quiz focuses on the essentials of planning cable routes and managing cable storage and transportation. It covers best practices for avoiding hazards, integrating cables into structures, and safely handling cable drums. Test your knowledge on these critical aspects of cable management.