Indian Railways - AC Traction Manual Volume III PDF

CHAPTER VIII COMMISSIONING OF NEW ELECTRIC LOCOMOTIVES AND EMUs 30800 Sanction of CRS Sanction is required from the CRS in respect of - 1 Introduction of electric traction on any railway or section of a railway. 2. Bringing into use any new type of electric locomotive or EMU or to operate any i...

CHAPTER VIII COMMISSIONING OF NEW ELECTRIC LOCOMOTIVES AND EMUs 30800 Sanction of CRS Sanction is required from the CRS in respect of - 1 Introduction of electric traction on any railway or section of a railway. 2. Bringing into use any new type of electric locomotive or EMU or to operate any in service at speeds higher than those already sanctioned. The term "New Type" includes: a) any alteration made in the existing rolling stock which will have an effect on the riding characteristics of the rolling stock. Generally, the points to be considered are axle load, unsprung mass, primary and secondary suspension systems and load transfer arrangements between body and bogies and bogies and wheel sets. b) any alteration in the traction electrical system which is likely to interfere with signalling system. 30801 Commissioning of New type of Rolling Stock When any new prototype loco/EMU are received for the first time from a manufacturer, the following are required to be ensured for inducting the rolling stock into services safely:-. First Stage: One time movement of the Rolling Stock The new prototype needs to be certified fit for movement, based on an application made to the COM of the Railway over which the loco is to be moved. The application is supported by - a) Certificate from RDSO regarding its overall dimensions, axle loads, curve radius etc. for fitness to move on IR tracks. b) Certificate from manufacturer of the locomotive from site of unloading/ interface with the zonal railway that the vehicle is fit to be moved. c) A note on origin, destination, route and special conditions of speed, escort, etc. under which the loco is to be moved. The COM of the zonal railway issues a movement order authorizing the movement of the locomotive, based on the application, and any other conditions which he may find essential to stipulate. Second Stage: Provisional running a) RDSO at the first instance shall furnish Provisional Speed Certificate for the particular loco type. In this certificate RDSO will indicate the maximum provisional speed of the rolling stock permitted to run with a particular type of track, nature of curvature, type of bridges, axle load, length of the rolling stock, ODC dimensions if any and type of traction installations. RDSO will also furnish the infringements for which the loco is over dimensional and Board's condonation for the same is required to be obtained. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill b) On receipt of the Provisional Speed Certificate, an application is made by the Chief Engineer of the concerned Railway to the concerned CRS for obtaining sanction. This is accompanied by Safety Certificate issued by CEE, CE, CSTE and CME. This certificate details restriction imposed and precautions to be observed for the movement of the loco. CRS in turn will then forward the same to the Secretary (Works), Railway Board along with his recommendations. Engineering Directorate at the Railway Board will finally communicate the sanction based on the safety certificate issued by CEE, CE, CSTE, COPS and CME and comments of the concerned CRS for the provisional running of the rolling stock. Third Stage: Instrumented trials RDSO will furnish the details of test and trials to be carried out on the rolling stock, generally, consisting of the following.. a) Oscillation trials: The trials are carried out for assessing the speed potential, the riding quality and stability at different speeds on straight and curved tracks of concerned sections. The parameters which are generally measured on the oscillograph car are lateral forces, lateral and vertical accelerations. Dynamic augment, bogie rotation and other parameters are derived. These trials are repeated for leading and trailing bogies with new and worn out wheel diameters. b) Braking Distance Trials: RDSO will conduct the braking distance trials with the loco hauling prescribed loads at different speeds. c) Tests regarding Interference with Signalling Circuits: The tests also will include measurements to determine the interference to signal and telecommunication circuits.. d) Performance trials : RDSO will conduct the trials to assess the performance ratings of the locomotives as per the extant instructions laid down. Fourth Stage Based upon the results of trials RDSO will issue a Final Speed Certificate indicating the maximum speed for which the new stock is considered fit, mentioning therein special precautions to be observed, if any. Based upon this certificate, the user Railway will issue a speed certificate signed jointly by CE, CEE, CME and CSTE and send the same to concerned Commissioner of Railway Safety (CRS). Final Stage Sanction of the Railway Board for commercial exploitation of the rolling stock is accorded. 30802 Trial Runs on Open Line Subject to the condition that the operation of the particular new type of locomotive has already received the sanction of the CRS, trial runs on the open line may be undertaken, taking all the usual precautions. The Driver should be a senior and experienced man who has acquired the "feel" of the type of locomotive in question, as he would be in a better position to give his reactions as to the performance of the locomotive. Initially the locomotive should be run for short lengths at low speeds and subject to various equipment continuing to operate satisfactorily, the length of run and the speed may be progressively raised over a period of, a few days. Test in particular how the brakes function under the normal and emergency conditions. At the conclusion of each trip a detailed examination should be made of the equipment, particular attention being paid to the temperature rise, lubrication, protective devices etc. Every new rolling stock after initial run for a period of 15 to 20 days will be called back to the home shed and will be given a thorough inspection of all under- gear equipment with special attention to loosening of bolts. These bolts will be re-tightened and secured before the rolling stock is put back into the system. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill 30803 Commissioning of New Electric Rolling Stock 1. Locomotives and EMUs do undergo, before dispatch, detailed tests and trials at manufacturing units which include tests prescribed by RDSO. Nevertheless, it is necessary for officers and staff of open line to check up the equipment thoroughly before they are put into commercial operation. Sr. DEE/ DEE(RS) and the staff should make a detailed inspection of all parts of the rolling stock, one equipment after another, keeping a full record of defects observed and action taken to rectify. The inspection shall be broadly based on IC schedules. In any case, a report should be forwarded for every loco or EMU tested, to manufacturers and to RDSO so that they may in turn improve the design, revise the testing procedure and tighten up for final inspection. Such checks should also be normally carried out before commissioning a loco / EMU after an IOH/ POH by the shed / workshops. 2. Test certificates bound in book form issued by the Manufacturers / Production Units should be available in duplicate. These should contain results of actual tests and measurements carried out on the different components, duly countersigned by the Inspecting Officers. One copy should be preserved for reference in the loco shed and one copy in CEE's office. 3. The manufacturer is also required to submit guarantee / warranty of the loco components / sub- assemblies wherever applicable. Whenever a new type of equipment / sub-assembly is inducted into the locomotive, operation and maintenance instructions shall be furnished by the manufacturer, in advance, before dispatch of the locomotive. 30804 Electric Multiple Units The contents of paras 30801 to 30803 apply equally to every electric multiple unit, except that, in addition to the electrical equipment of the driving unit, the interconnecting pneumatic pipe connections and the brake equipment in each coach should be subjected to detailed examination for detection of leakage and. proper operation. Similarly the control cable connections between coaches should be checked for proper sealing at the ends to make them weather-proof. The running gear and brake equipment in all motor and trailer coaches should also be tested. Insulation resistance of the through wiring in the coaches, and internal wiring for lights and fans within the coaches should also be checked and recorded. Verify that the. different circuits are provided with individual fuses and the fuses are of the correct rating. All tests and trials should be conducted with the EMU without any passengers, except for the officials in-charge for testing , loading of the train may be done by sand box, etc. 30805 Additional Precautions Before Commencement of Commercial Operation 1. During trial runs, very close watch should be kept of the performance of new loco or EMU put into normal service. For the first few runs , the Driving Inspector, together with. a few key personnel, should accompany the loco or EMU and examine the equipment at frequent intervals and arrange for rectification of any defects which may show up. A separate History Sheet should be maintained for every electric locomotive or EMU. 2. The "trouble-shooting directory" should be got ready well in advance of introduction of a new type of loco/ EMU and the running staff adequately trained in the trouble shooting methods and operation of the type of loco/ EMU. INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill