Signalling Equipment Testing Procedures PDF

19.8.2 Test Procedure (a) Systematic methods such as marking on Control Tables/Locking/selection tables and suitably and clearly marking on the circuit diagrams while checking the circuits and equipment should be adopted to ensure that all circuits have b...

19.8.2 Test Procedure (a) Systematic methods such as marking on Control Tables/Locking/selection tables and suitably and clearly marking on the circuit diagrams while checking the circuits and equipment should be adopted to ensure that all circuits have been completely checked. (b) Suitable proforma should be devised for recording the tests of electrical equipment before testing of the installation is taken up to ensure availability of records of the tests and their analysis. 19.8.3 Testing Instruments Suitable instruments like Multi-meter, Volt meter, Ammeter, Ohmmeter, Frequency meter, Bell tester, Earth Tester, Earth leakage detector, Cable fault locator, Cable route tracer, Relay contact testing/cleaning kit, etc. should be used in the testing of electrical signalling circuits. Calibration of these instruments should be checked periodically. 19.8.4 Physical Inspection of the Installation It shall be checked that the work has been carried out in accordance with the approved plans and that equipment is of proper type and is in good condition. The following aspects shall also be checked during site inspections: (a) The signals, location boxes and other out-door equipment are as per approved plans and are in good condition. Arrangements for proper ventilation, where provided, are not choked. (b) Each location contains all the apparatus required as per approved plans, the apparatus is of approved type and that the power supply equipment, batteries, fuses, etc. are installed according to the approved plan and specification. (c) The location of insulation joint, jumper wiring, traction bonding in electrified areas, point machines, switch locks and other apparatus is as per approved plans and their condition is satisfactory. (d) The electrolyte, inter-connections between cells, cell voltage etc. are in required condition as per relevant specifications or instructions. (e) Each wire is tagged or marked where feasible so that it can be identified at each end and the nomenclature on the tag corresponds to that on the wiring diagram. The tags or other sleeves of identification shall be of insulating material. (f) The number of wires terminated on each terminal or relay terminal boards or other devices are counted and tallied with the number of wires shown in the wiring diagrams. (g) All connections on terminals and binding posts are properly secured. (h) The lightning arrestors are properly connected and earthed as per plan. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 398 of 530  (i) Detailed specifications & instructions for inspection and testing of different types of equipment as applicable to them should be available. (j) All other equipment such as lever frames, LC gates, cable sheaths, signal screens, location huts, etc. in AC. electrified areas shall also be properly earthed as stipulated in Chapter 22 of SEM. (k) No equipment is due for overhauling. 19.8.5 Checking of the Wiring: (a) Point to point testing: Wiring shall be checked to ensure that it has been carried out as per approved wiring diagram. Point to point testing shall be carried out before plugging in the relays. Wires shall be tested one by one for continuity and insulation. While doing continuity testing, wire count test shall also be done to verify the number of wires present on each contact. (b) Wire Count Test: Prior to conducting continuity and insulation test, contact occupancy test must be carried out for each relay as per the contact analysis made. The number of contacts allotted and wires at each contact must tally. Recommended practice: while dealing with wiring alterations, it is recommended to adopt a clear system for deletions, additions such as colour code. For example, Green colour for deletions and red colour for additions. Similarly a system of checking of such deletions/additions by a tick and second level checking by cross tick on drawing sheets/separate wiring sheets or any other suitable protocol may be adopted duly explaining to staff concerned, to give clarity and avoid rework. 19.8.6 Test of Individual Circuits (a) It shall be checked that each individual circuit is actually controlled by the proper contacts of the relays and other devices as per wiring diagram. (b) Where feed to a particular device is controlled through two or more paths in parallel, the check of each path must be carried out separately. (c) Cases of intermittent or continuous extraneous feed of even small magnitude or wrong operation of any relay observed shall be investigated thoroughly and remedial action taken to rectify the fault. (d) Once the indoor wiring works are completed before conducting the system Integrity testing, simulation test must be conducted by simulating field gears such as Track circuits, Signals & Points on a simulation panel. This will ensure the correctness of indoor wiring before connecting to outdoor gears. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 399 of 530 19.8.7 Installation, Testing of other equipments & Cables Installation & Testing shall be done in accordance with specification & instructions applicable to each individual equipment: (a) Train Detection: Track circuits, AFTC, Axle Counters as per Chapter 17 of SEM. (b) LC Gates as per Chapter 14 of SEM. (c) Cables: All signalling cables shall be laid, Tested as per Chapter 15 of SEM. Note: At least two cores of cable shall be provided between two ends of the yard to cater for telephone communication for maintenance purposes in non RE areas. Where the yard is extending over a large area, the location boxes may be grouped and one socket may be provided in one of the location boxes in the group so that telephone communication is conveniently available for co-ordination with the cabin during maintenance or rectification of failures of various ground equipments. Where such groups are situated in different directions from the cabin, a separate pair of conductors shall be used for each direction connected to the cabin. In RE area, provision shall be made for telephone communication through a telecommunication cable if already available or a separate telecom cable shall be laid for the purpose. (d) Power Supply Arrangements: Power supply systems for Signalling Installations shall be as per Chapter 16. 19.8.8 System integrity Testing (SIT): This is a complete testing involving both Indoor & Outdoor signalling equipment for functional working & safety. To be done in a new installation, at every interlocking alteration or periodically once in five years. (a) After the individual tests mentioned in previous paras for outdoor equipments and Testing of Relay Interlocking/Electronic Interlocking as given in Chapter 21 of SEM have been carried out, the signalling installation as a whole must be tested with detailed operational, functional and safety tests as per approved Control Table/Route Chart and Signalling & Interlocking Plan. (b) These tests shall be planned carefully with men, material, Tools, public address system, Walkie-Talkie Sets, Transport vehicles & other logistics. In a working installation, Non-interlocking/Disconnection duration shall be reasonable and commensurate with yard complexity and to be decided in consultation with Operating department and planned much in advance. All required sanctions/approvals shall be ensured before hand. (c) Requisite number of staff considered essential for carrying out such tests shall be mobilized at site, briefed suitably as per planning made and working protocols explained and deputed to concerned locations with relevant wiring diagrams & Tools. They should be equipped with requisite tools, meters, portable telephones and/or walkie talkie sets, so that they are in contact with the official incharge of testing and other testing parties and take such action as directed. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 400 of 530  (d) Complete System Integrity testing shall be initiated only after all the field functions are connected to the Relay Interlocking/Electronic Interlocking (during Non-interlocking/Disconnection period in a working installation) and simulation testing is completed and all errors removed. (e) Complete tests shall be carried out against approved Selection Table/ Control Table/Route Control Chart. Checks against signalling plans for main signal routes and a few spot checks of the remaining routes shall also be carried out. (f) Field Correspondence Tests: Full correspondence of field gears such as aspects of Signals, Condition of Points, Status of Track circuits, LC gates etc. with that of Control Panel/Control Terminal/VDU with respective position of knobs, switches, and indications, must be verified and corrected to obtain 1:1 correspondence, before signing safety certificate (and ending Non- interlocking/disconnection in a working installation) and allowing any signalling installation being opened to Train traffic. 19.8.9 Following simple two line station example is given for an understanding on how to conduct system integrity tests: (a) Signal Control Circuits Each route shall be set individually by operating control lever or switch(es) and/or button (s) as the case may be. After checking that the signal for this particular route has been cleared, each track circuit controlling the signal shall be shunted individually to check that the signal goes back to danger. Similar tests shall again be made by de-energizing point detection relays and other relays controlling this route. Each such relay will be de-energized individually and it shall be checked, that the signal goes back to danger. (b) Approach Locking Each route shall be set up individually. After ensuring that the signal for this particular route has been cleared, each track circuit controlling the approach locking shall be de-energised in turn. The signal shall be put back to 'ON'. Efforts shall be made to alter the route under test and to set up conflicting route. It shall be checked that it is not possible to cancel the route set up and/or to set up a conflicting route and/or to individually operate any point in the route under test. This locking shall be effective till the set route is cancelled and the time release circuit has operated, provided the track beyond the signal is not occupied. (c) Dead Approach Locking Where dead approach locking is provided, the same test procedure as in para 19.8.9 (b) shall be adopted except that there is no controlling track circuit to be de-energised. After the signal has been taken 'OFF', the approach locking shall be effective till the signal is put back to 'ON' and time release circuit has operated. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 401 of 530 (d) Route Release (i) Tests shall be carried out to ensure that once a signal is cleared for a particular route, position of none of the points in the route can be changed when track circuit immediately in advance of the signal is de- energised. (ii) Where sectional route release is provided, it shall be ensured that a sub route does not release only by picking up of the concerned track relay (s) but the same should be released only after the next track circuit has also dropped and picked up except for the berthing portion of track circuits. (iii) Where sectional route release is not provided, tests shall be made to ensure that the entire route remains locked when any of the track circuits beyond the signal up to the track circuit controlling the last point is de-energised. (iv) In cases where the route is controlled by single track circuit, the route shall be released after prescribed time delay to be effective after the concerned track circuit has been occupied and cleared by the train. (e) Time Release Time release, where provided, shall be tested to ensure that it will be possible to alter the route or set up a conflicting route or change the position of the points in the route only after the signal is put back to 'ON' and the prescribed time interval has lapsed. Similar tests shall be carried out for overlap release, where time release is provided for releasing the overlap after clearance of last track circuit in rear of berthing track and occupation of the berthing track, if any. Also overlap shall get released only after concerned signal knob/button is normalized wherever required. (f) Signal Indication Circuits Indication of 'ON' position of all signals shall be checked for its correspondence with aspect displayed at site. Each signal shall then be cleared after setting its route and the indication of each aspect shall be checked for its correspondence with the aspect displayed at the site. This test shall be carried out for each signal as well as for direction type route indicator where provided. In the case of later, it shall also be ensured that the indication relay is not energised and the indication does not appear until the minimum number of lamps/LEDs as required are actually lit. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 402 of 530 (g) Point Controlling Circuits (i) Each point shall be set to reverse position by operating the controlling lever/switch/buttons. After the point has been fully reversed, each track circuit controlling the point shall be individually shunted in turn and operation of points to normal position shall be attempted. It shall not be possible to operate the point under these conditions. These tests shall be repeated with the point set in normal position, attempt being made to operate it to the reverse position. (ii) With the obstruction in the points, the point shall be operated from normal to reverse and reverse to normal and it shall be checked that the over-load relay where provided gets energised and the feed to the motor is cut off immediately. Where over load relay is not provided, the feed to the motor shall be cut off after the lapse of a prescribed time. (iii) The out of correspondence test shall be carried out by opening cut out contact of one end of point machine and the point lever/knob/button operated. The other end of the point may operate but the point indication relay shall not energise. (h) Point Indication Circuit (i) The point shall be operated from normal to reverse and reverse to normal and the position of point detection relay as well as the indication of the point in the cabin/panel shall be checked for correspondence with the position of the points at site. It shall also be checked that with the obstruction in the point, the detection relay is de-energised and both normal and reverse point indication in the cabin/panel are extinguished in case of electromechanical signal and flash in case of PI/RRI installations. (ii) The operation of the detection relay to the correct position as well as its de-energisation should be checked by making and breaking the relevant point detector contacts at site. (i) Crank Handle Interlocking It shall be checked that when the crank handle is removed from its normal position in Electric Key Transmitter/other approved Relay interlocking arrangement, the signals reading over the concerned route/zone cannot be taken 'OFF' nor the points can be operated from the cabin/panel. It shall also be checked that when the signal reading over the concerned route/zone is taken 'OFF', the crank handle cannot be released from its normal position in Electric Key Transmitter/other approved Relay interlocking arrangement. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 403 of 530 19.8.10 Testing Procedure for Panel Interlocking/Route Relay Interlocking Installations It shall be ensured that the interlocking system as per approved plans and drawings. Typical testing procedure for a Relay interlocking installations is given below with an example for a two line station for an understanding. (The actual testing at site shall be as per station layout) 19.8.11 Testing of Relay Interlocking LOCKS Sl. SIGNAL CONTROLLED LOCK & DETECTS ROUTE ROUTE HELD BY ROUTE REMARKS No. NO. BY TRACKS POINTS POINTS 1. 2W 2WBI APPROACH BACK LOCK 2WT, A2ET NORMAL REVERSE 4EB 2E Controlled TRACKS TRACK 2T, 2BT,BT 1 2 by closed A2WT 2WT A2ET IBT position of (120 Sec 2T 2BT LC gate time delay) 2. 2W 2WBII A2WT 2WT A2ET 2WT, A2ET 1,2 4EB 2E Controlled (120 Sec 2T 2BT 2T, 2BT, BT - 3WB by closed time delay) IBT, IT A1 WT position of LC gate (a) Point Locking Operate point No. 2 to reverse position and clear the signal route No. 2WBI by operating signal switch/button. Operate point knob 2 to normal. The point should remain locked. Restore the point knob to reverse. De-energise 2RWKR. Signal 2WBI shall go to 'ON'. Restore the signal switch/button to normal. When point No No.. 2 is free, shunt the track 2T. Turn the point knob 2 from reverse to normal. The point should remain locked. (b) Approach Locking: Take 'OFF signal for route No. 2WBI by setting the points in required position. Normalize the signal switch/button with A2WT clear. The signal assumes 'ON' position. Try to alter the route, it should be free. Again take 'OFF' signal for route No. 2WBI. Shunt the approach Track A2WT. Normalize the signal switch/button. Try to alter the route. Route should be held till the route is cancelled and 120 seconds time delay has lapsed. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 404 of 530 (c) Interlocking of Signals: Clear the signal route 2WBI after setting the route. Try to clear the signal 4EB by operating the relevant switch/button. Signal 4EB should remain in 'ON' position and signal 2W should continue to display 'OFF' aspect. Similar tests shall be carried out for signal 2E also. (d) Track Circuit Controls: (i) Clear the signal route 2WBI again. Shunt the track 2WT. Signal should go to 'ON'. Remove the shunt, the signal should not re-clear. Normalize route and re-clear again. Shunt A2ET and other controlling track circuits one by one. Signal should go to 'ON' in all cases. Remove the shunt. Normalize the route. (ii) Where track circuits provided with redundancy, its proper working shall be thoroughly tested for redundancy and effectiveness in the signalling circuits. Detailed instruction and precaution for testing and fault rectification shall be issued by Zonal Railway. (e) Back Locking: (i) Clear the signal 2W for route 2WBI again. Shunt the track 2WT. The signal should go to 'ON'. Normalize the signal switch. The route should be held. Shunt and clear all the back locking tracks as per selection table in sequence. The route shall be released by sequential proving of tracks as per the provisions of para 4.3.3 of Relay interlocking specification IRS: S 36-87. (ii) Clear the signal route 2WBI again and de-energize the Level Crossing Gate control relay. The signal should go to 'ON'. Re-energize the relay, the signal should assume 'OFF' aspect. (f) Conditional Locking: Wherever conditional locking is provided (for alternate overlap/parallel movements etc. for yard flexibility), the points setting and its route holding, correct proving in the signal circuits shall be thoroughly checked. (g) Datalogger Circuits: The data loggers connected to various power supplies, relays of internal/ external circuits, block instruments, battery chargers and other applications like open/close status of relay room, battery charger/IPS/Invertors monitoring etc. shall be regularly checked/tested. Also ensure the nominated JE/SSEs/ staff are receiving the various exception reports generated from the data logger to aid their day to day works/ maintenance/fault restorations in coordination with Fault control JE/SSEs/staff incharge of Datalogger monitoring. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 405 of 530  (h) Miscellaneous Circuits: (i) Miscellaneous arrangements like effectiveness of Station Master’s key, cascading of signals on the route, Red lamp protection on the route etc. shall be thoroughly tested for the independent signal/routes. (ii) The protection arrangements like Lightning arrestors, Surge protection devices and its associated Fuse/Earthing arrangements shall be regularly tested and Maintained. (iii) The relay contacts shall be paralleled, if spare contacts are available. 19.8.12 Precautions during Testing Following precautions shall be taken during testing and checking so that (a) No signal taken 'OFF' for a train movement is thrown to 'ON' in the face of the train. (b) No signal which will create a conflicting or unsafe movement is taken ‘OFF’. (c) No point and isolation in a route set for a train movement is disturbed. (d) No track relay of an occupied track circuit is energised. (e) No voltage higher than permissible levels is applied to the equipment. (f) There should be no risk of electric shock to testing or operating personnel. Section 9: Maintenance of Outdoor Signalling 19.9.1 Insulation tests on Cables shall done as per Chapter 15 of SEM. 19.9.2 Maintenance of Colour Light Signals (a) Cleanliness of LED Lenses (i) Polycarbonate Lenses of LED lamp shall be kept clean. A dry soft cloth free from lint and abrasives shall be used for cleaning. (ii) Housing shall be kept clean and opening in inclement or stormy weather avoided. The condition of the gasket shall be checked to ensure that rain water does not have access to the interior of lamp unit. (b) Replacement (i) Defective LED lamps must be replaced immediately. (ii) The LED lamps shall be replaced as per prescribed codal life. (c) New lamp shall be pre-tested as per approved instructions before putting into use. Chapter 19: Installation, Testing & Maintenance of Signalling Equipment Page 406 of 530