signalling -...

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

SIGNALLING

RESEARCH, DESIGN & DEVELOPMENT

Development of Multi Section DigitalAxle Counter

Development of Block proving by Axle Counter(BPAC)

Development of HighAvailability SSDAC

Design & Development of Electronic Interlocking(EI) System

Project for development of DAC (SSDAC & MSDAC) isin progress in collaboration with CSIR and CEL. SSDAChas been developed and being supplied to ZonalRailways on regular basis.

Field trial of Multiple Section Digital Axle Counter(MSDAC) developed by M/s CEL is undergoing atFaridabad (Northern Railway). After analyzing failures,certain modifications like software of SM reset panel,higher transmission level of modem module have beendone by CEL from time to time. To properly monitor theperformance in comparison to existing track circuits,approval was given vide letter dated 24.7.2008 to shiftthe track devices closer to insulation joints of trackcircuits. The same has been carried out by M/s CEL.Software validation has been completed. Type testinghas been completed in RDSO lab. Last phase of trials tostart at Jaitipur station in Kanpur-Lucknowsection.MSDAC system is installed at Jaitipur andperformance is being monitored.

Provision of BPAC will reduce dependence on humanelement in train operation and thus will improvesafety.The existing design of BPAC with Analogue axlecounter and MUX is not so reliable and therefore BlockProving by Axle Counter using UFSBI & SSDAC forsingle line & double line has been developed by M/sDeltron/Kolkata who is an approved vendor. One more

source(M/s Webfill,Kolkata ) isalso developed and approvedas per RDSO/SPN/188/2004specification under limitedsupply for Double line section.

Further, Solid State BlockProving by Axle Counter( S S B P A C ) i s u n d e rdevelopment by M/s Efftronicsas per RDSO/SPN/175/2005.In this system, the relay logichas been replaced by solidstate logic thereby reducingthe total number of relays fromabout 40 to 10 which isexpected to improve the reliability. Field trials ofprototype equipments, one each in double line & singleline section, are completed and system is ready forstandalone Fieldtrial. on Vijayawada division of S.C.Rly.Hardware/ software validation of the system has beencompleted. Standalone field trials shall be startedshortly. SC Railway is processing for CRS clearance fortrials

SSADC is used in block proving and other applicationswhere availability requirement is high. To increase theavailability, a system has been developed usingredundant architecture having duplicated electronicsand redundant communication channel. This systemwill remain operational even if one part of electronics orone communication channel has failed. In mostscenarios, the working system will automatically resetthe failed system without any intervention from operatoror maintainer. This system has been deployed for fieldtrial and will be approved shortly based on field trialresults.

With development of modern fault tolerant and fail-safety techniques, electronics and particularlymicroprocessors have found acceptance in the area ofRailway signalling world over including ElectronicInterlocking. The features like software basedinterlocking logic, less wiring, easy alterations, selfdiagnostic, in-built data logger etc. make it maintainerfriendly. Two types of indigenous EIs are beingdeveloped.

Indigenous 2 out of 2 EI with hot standby has beendeveloped by M/s. Medha Servo Drives Pvt. Ltd.,Hyderabad. After successful completion of functionaltesting of these types of modules and functional &acceptance tests on the field model, the field trials in

UFSBI & Relay rack of BPAC

Multi Section Digital Axle Counter Reset Panel of MSDAC

Block Panel of BPAC

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parallel with existing Panel Interlocking started fromJanuary 09. After receipt of feedback from SouthCentral Railway and validators, the parallel trials werecompleted in June 2009. After receipt of environmentaltests reports and scheme for Phase II series mode fieldtrial by RDSO, the field trials in standalone series modehave started in August 2009 and completed in January2010. After successful field trial, provisional approvalhas been given to the firm to supply 10 equipments inSept.10 for performance assessment.

Development of 2 out of 3 EI with Object Controller isbeing done by M/s HBL Power Systems, Hyderabadagainst a sanctioned project. The field trials for the EIwere started at Falaknuma station of S.C. Railway inMay 2007. The trial of EI in parallel to existing RRI wascompleted during September 2008. Field trials instandalone series mode have been completed in April2009. Also, Labmodel has beencommissioned inR D S O d u r i n gMarch 2009. Thee x t e n d e dstandalone seriest r i a l has beencomp le ted andreports are beinganalysed.

New specificationof EI for big yards (more than 200 routes) has beendiscussed in SSC and approved by Railway Board asper SSC recommendations.

A Hand Signal Lamp is a hand held device which is veryuseful for various categories of railway staff to properlydischarge their duties related to safe train running.Display of either red or green light can be done toexchange safety related information among variousrailway staff. Hand signal lamp can also be used as atorch at night. Existing HS lamps suffer from poorillumination, low visibility and low battery life besidesother quality related problems. Hence, development ofbattery operated LED based torch cum hand signallamp was taken up by RDSO. Specification No.RDSO/SPN/195/2008 Revision: 2.0 (draft) has beenissued. Based on new RDSOSpecif icat ion, prototypes a m p l e s h a v e b e e ndeveloped and evaluated byRDSO. The developedBattery operated LED BasedTorch Light-cum-Hand SignalLamp is a lightweight, rugged,maintenance-free and user-friendly device with betterv i s ib i l i t y and ease o f

operation. This is powered by commercially availabledry cell batteries. After successful passing of type tests,four vendors have been cleared for field trial. Trials areundergoing for equipments from 3 vendors andperformance feedback for one vendor has so far beenreceived from railways and is generally good.

Tail lamp used at the last vehicle is to alert any vehicle inrear of a train. Development of an improved version offlashing tail lamps with improved visibility and better lifewas undertaken by RDSO and RDSO specification no.RDSO/SPN/200/2010 (draft) was issued fordevelopment of LED based flashing Tail Lamps. Basedon new RDSO Specification, prototype samples havebeen developed and evaluatedby RDSO. The developed TailL a m p i s p o w e r e d b ycommercially available dry cellbatteries and is better inconstruction quality, visibilityand is user friendly. Aftersuccessful passing of type tests,two vendors have been clearedfor field trial.

Existing main LED signals suffer from the limitation thatLED signal of one make/ version is not replaceable byanother make/ version due to discrete modules of LEDlighting unit, current regulator and HMU. Also reliabilityof current regulators is a concern.

To overcome existing limitations and improve reliability,development of the improved LED signal lamp withintegrated current regulator for main colour light signalto enable one to one replacement of lamp irrespective ofmake/ version with improved reliability was taken.Prototype samples of LED signal lamp with integratedcurrent regulator for main colour light signal have beendeveloped and evaluated. Three vendors are clearedfor trial at one station each of Central, North Westernand Eastern Railways. Performance feedback has sofar been obtained from Eastern Railway which issatisfactory.

Several design improvements like inclusion of line filterto suppress power surges, diodes and capacitors ofbridge rectifier circuit in series-parallel combination forredundancy, replacement of external load resistance bystandard SMD resistances in series-parallelcombination for redundancy and better heat dissipation,improvement in design of body for better heatdissipation, removal of jumper selection/ separate unitof current regulator/ connectors have beenincorporated based on failure analyses and feedback

Development of Battery Operated LED Based TorchCum Hand Signal Lamp

Development of battery operated LED based TailLamp

Review of present design ofL E D s i g n a l s f o rinterchangeability amongvarious makes and enhancement in reliability

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from railways and vendors over the period to improvereliability. HMU is removed. Instead, terminal blocks ofinternational standard with fuse link of 400mA and aMOV are provided. LED signal lamps are designed foruse with AC LED ECR only to avoid unnecessary powerwastage, confusion at site and for simplification ind e s i g n a n d i m p r o v e m e n t i n r e l i a b i l i t y.Recommendations of a working group formed for thispurpose have been sent to Railway Board for approval.

Train Protection & Warning System (TPWS) provides a

safety aid to train drivers by dynamically controllingspeed of the train within specified limits & preventsSignal Passing at Danger (SPAD). The speed limits arespecified dynamically based on signal aspect, route tobe followed, sectional speed limits, speed restrictionsetc. By use of this system, required train speed can bemaintained in all weather conditions while visibility ofline side signal is hampered adversely due to fog. Use ofthis system will facilitate running of trains safely in allweather conditions.

The system has been commissioned on 51.75 routekilometers of Chennai-Gumudipundi section of SR. Thesystem is under commercial trial in Mathura -Agrasection of NCR.

The existing specification of TPWS has been revisedincorporating the experience of commissioned systemof SR & trials on part ofNew Delhi-Agra section.

Train Collision AvoidanceSystem (TCAS) is a

network of loco & station TCAS units communicatingwith each other within certain range of communication,to avoid collision between the trains.

Trials of Anti Collision Device (ACD) of KRCL withoutGuard & LC Gate units were recently carried out onS.Rly. In Sep. 2010 & again in Jan. 2011. Furthermodification in ACD software is being done by KRCLbased on these trials.

RDSO has revised existing specification of TCAS in thelight of removal of Guard & LC gate units and theexperience gained during the ACD trials. The draftspecification was uploaded on RDSO's website. Thecomments received have been examined & draftspecification has been modified. EOI has been floatedfor finalizing the specification & developing the vendorsfor TCAS.

Based on analysis of failures given by Railways,approved firms and technical audits conducted byRDSO, following steps have been taken to furtherimprove reliability of IPS as per RDSO/SPN/165/2004 -

Provision ofAlarm & indication as and when 110Vbattery gets disconnected from the circuit.

Provision of changeover arrangement ofInverters using Static switch instead of relay/contactor based changeover arrangement withreduction in changeover time from 250ms to<60ms.

To reduce / rationalise types of DC-DC convertermodules used in IPS, development of 12-40V/5A,10A and 40-100V/1A Converters donefor overall reduction in types of modules from 15nos. to 06 nos.

Separate wall mountable output distribution boxd e v e l o p e d f o rterminating all AC &DC supplies from IPSalongwith suitableclass C/D SPDs.Drawing has beeni s s u e d f o rstandardisation.

Several Railways in therecent past have reportedfailures/ complaints relatedto frequent poor strength ofexistingAl boom. The booms were getting damaged/ outof shape due to vehicles crossing beneath the gate aswell as due to wind pressure. In order to improve thestrength and reliability, RDSO has developed astandard drawing RDSO/S 11600 of boom of GI materialin Octogonal shape with tapering cross section and

Development of Train Protection & Warning System

Development of TrainCollision AvoidanceSystem (TCAS)

Reliability improvement of IPS

Reliability improvementof Electric LiftingBarrier

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Front view

Back view

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telescopic jointing arrangement. The weight of the boomis approx. same as that of present Al boom for ease ofreplacement. 05 firms have been given approval forsupply of improved GI booms.

Other major failure reported by Zonal Railways inElectric Lifting Barrier was related to magnet proximityswitch for boom detection and locking lever & solenoid

based locking/ unlocking arrangement. In order toimprove reliability, motorized locking/ unlockingarrangement with limit switches has been developed. 05firms have been given approval to supply improvedmotorized locking /unlocking arrangement.

Further, the specification of Electric lifting barrierRDSO/SPN/180/2005 has been modified to incorporatethe above two improvements including following other

improvements and the modified specification shall beissued shortly -

Powder coating of all the mechanism cases andboom made mandatory to ensure quality of

painting.

Use of stainless steel nuts and bolts mademandatory.

Provision of rubber grommats at cable enterancein mechanism cases to prevent chaffing ofinsulation of cables.

Sheet thickness for mechanism casestandardized as CRC of 1.6mm thickness.

Use of hard chrome electroplated or powdercoated main shaft to prevent rusting/ worning out.

Provision of adequate spares and tool kit witheach set of Electric lifting barrier.

Introduction of certificate of fitness of installationby OEM for each Electric lifting barrier beingcommissioned.

Signalling equipments with solid state components aremore susceptible to damage due to surges, transientsand over voltages being encountered in the system dueto lightning, sub-station switching etc. These signallingequipments include Electronic Interlocking, IntegratedPower supply equipment, Digital Axle counter, Datalogger etc.

An effective, low resistance earthing & bonding systemis essential to efficiently dissipate fault currents andelectrical surges to protect equipment being damagedand to also protect the personnel who work within thearea from electrical shock.

Hence, Code of Practice RDSO/SPN/197/2008 forEarthing & Bonding system for signalling equipmentshave been issued. After successful field trial at fewlocations on Zonal Railways, 02 vendors have beenapproved for supply of material and installation as perspecification.

In the existing design of plug-in type (Metal to Carbon)relay, dome shaped silver contacts are being used, inwhich point contact is made with SIG contact. To avoidthe problem of high contact resistance silver line contacthaving more area of contact are being tried out. Samplerelays with line silver contact have been tested for 6lakhs operations and results are encouraging. Further,50 sample relays have been manufactured and installedfor observing performance in the field.

With a view to increase the reliability and performance oftrack circuits, weld material for track circuit applicationsto make reliable & permanent electrical bondconnection between two conductors as per IRS:S103/2004 is being used by Zonal Railways. Properinstallation of bonds with rail using weld material is also

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Code of Practice for Earthing & Bonding System forSignalling Equipments

Development of Line Silver Contact

Guidelines for Using Weld Material for Track CircuitApplications

Present Al boom

Improved GI boom

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very important aspect for reliability of track connections.Therefore, the "Guidelines for using weld material fortrack circuit applications" have been issued for thebenefit of users in the field.

Proper installation of exothermic/pin brazing bonds withrail using weld material is very important aspect forreliability of track connections as well as integrity of rail.Welding technicians of the firms doing the welding in thefield are trained by the RDSO recommended firmsthemselves. However, a competency certificate towelding technicians trained by these firms shall beissued by RDSO. The procedure for ascertainingcompetency of welding technician for track circuitapplication has been finalized with M&C Directorate.The competency of welding technicians of 6 firms havebeen completed.

Increase of 41% in no. of tests completed is recorded inlast two years. Appreciably, large no. of test reports i.e.404 of vital signalling safety items submitted during theyear 2010-11. The rigorous testing of these itemsincludes life test and all type of climatic/ environmentaltests apart from performance tests. The tests includinginitial/ developmental test, maintenance type test,investigation tests and climatic tests.

Initial/Developmental Test 65 51 81

Maintenance Type Test 135 174 168

Investigation Tests 25 60 71

Climatic Test 61 85 84

Total 286 370 404

Earning of Rs.110 lakhs realized against testingcharges of signalling items as against Rs.56 lakhs in2008-09.

With the upcoming of advance signalling itemslike SSI, Digital Axle Counter, AFTC, LED Signallamp etc., it is necessary to provide testingfacilities in Signal Lab for testing of theseadvance signalling items in addition to theexisting signalling safety items. Work ofmodernization of signal lab at the cost of Rs.2.73Crores is prepared and included in Pink Book2008-09.

Detailed estimate has been sanctioned at thecost of Rs. 3.34 crores.

Indents of Rs.2.17 Crores have been forwardedto Stores for the work of 'Modernisation of SignalLab'. Technical suitability of 112 cases completedand submitted to Store. Purchase Order of 108items of value Rs.165 lakhs have been issued. 86equipments of value Rs.105 lakhs have beensupplied so far.

Type of Tests 2008-09 2009-10 2010-11

Procedure for Competency Certificate of WeldingTechnician for Track CircuitApplication

IMPORTANTACTIVITIES IN SIGNAL LAB

Increase of 41% in no. of Tests Completed in TwoYears

Earnings increased by 100% over last two years

Modernization of Signal Lab

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