KEC INTERNATIONAL LTD

WORK METHODOLOGY
( S&T WORK )

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A: Work Instruction Electronic Interlocking Installation
The following flow chart explains about the sequence of work progress about EI Installation.The detailed installation
guideline shall be arranged by the respective OEM when onboard, however the general practice to be followed during
EI installation described here.

1.Major activity for EI Installation

a. Erection of EI racks applicable for each station

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b. Making of Cable support arrangement for I/O, Power, OFC cables & cables connecting the Relay
rack and the CT rack,

c. Wiring of interconnecting racks such as

i. Relay rack to EI rack wiring.
ii. Power supply wiring between various racks.
iii. OFC Cable splicing and termination in FMS.
d. Installation of Earth Arrangement as per OEM & RDSO specification.
2. Cable support arrangement shall be used to keep the interconnecting cables/wires between different
racks. Cable support arrangement will be isolated from Wall and rack. Isolator Pot shall be used for
isolation from wall and the racks.

3. Wiring of interconnection shall be done after installation of the racks, wiring shall be classified as follows:
4. I/O wiring between ET racks to relay rack using Male/Female Connector.
5. Relay rack to CT rack wiring
6. Power Wiring to various racks
7. Installation testing
8. Fiber Optic cable wiring
9. Simulation Wiring (for Site testing)
10. Dressing
11. Interconnection wiring between racks shall be done at site.
12. Based on the Interface circuit, wire/cable Conductor Size shall be used for all circuits.
13. I/O Cable wiring shall be done from EI rack to relay rack.
14. EI power supply system consists of 110/24V DC-DC Converters, which will be kept inside the rack. DC-DC
Converters will be in N+1 arrangement as per RDSO Specification. 110V DC Power supply shall be extended
from the Power supply system IPS to EI racks and ASM terminal.
15. 110V AC, 24V DC, 110VDC power supplies shall be extended from power supply system to Relay rack.
16. Operator VDU as a Control Console will be installed at ASM room.
17. Fiber patch cord will be used for Connecting rack to rack at the station.
18. For connecting EI, rack to ASM VDU OFC cables would be used.
19. In order to avail spare is in the OFC, Fiber cable will be terminated in the Fiber Management System (FMS).
From FMS, Fiber patch cord will be used for connecting respective systems.
20. Precautions: To maintain the better noise immunity, I/O wiring and Power wiring shall be separated.
21. Proper Crimp Contacts and Lugs shall be used for EI wiring as per interface circuits.
22. For crimping, proper tools shall be used.
23. Installation testing: After completion of all wiring, Internal Installation test will be done as shown in the flow
chart (Fig: Flow chart of Installation Process).
a. After rectifying all errors during the internal testing, the customer testing shall be carried out.

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24. Simulation wiring: For doing EI Functional test, simulation wiring will be done for field I/O relays done as shown
in the flow chart (Fig: Flow chart of Installation Process).
25. After rectifying all incidents errors in the EI Functional test, Simulation wiring will be removed and the entire sub
systems integration test shall be done.
26. Dressing:-Dressing of all wires will be done after completion of the wiring.

Instruction Relay Rack (RR) Installation

1. Check the relay rack arrangement drawing and mark on the floor to fix the relay racks.

2. Check that adequate space is available on all sides for maintainer.

3. Check for lighting arrangement and calculate for adequate light for reading relay particulars for both front and
back.

4. Mark the grouting points accordingly after measuring the relay rack bottom frame holes.

5. Punch the marks accordingly & sufficiently so that the drill bit doesn’t slip.

6. Fix the rack mounting brackets with self-grouting bolts (min 200 mm and if anti-vibration bad is used then 250
mm) grouting compound should be used if mortar quality is not good. If AVM is not used anti, vibration pads
should be provided between floor and mounting bracket.

7. Fix the relay bottom frames without tightening the nuts.

8. Calculate the scaffolding angle sizes and cut accordingly. Preferably, wall-to-wall scaffolding should be
planned.

9. Fix the relay frame to the base on insulators / anti vibration, mounting loosely and keep then erect by tying with
ropes. Fix the top frame on the relay racks.

10. Mark the fixing holes for the scaffolding after fixing insulators on top of relay rack top frame.

11. Mark the fixing holes on the walls and fix the wall fixing angles with grouting bolts preferably with grouting
compound.

12. Now for all the relay racks to the scaffolding with insulator.

13. Check for squareness of all the relay rack and tighten the bolts one by one.

14. Fix the relay mounting bracket or square rods.

15. Fix PVC cable channel mounting bracket.

16. Fix PVC cable channels behind the relays racks as per given size.

17. Fix the cable ladder on top of scaffolding ensuring that the edge matches with the relay frame from the front
side.

18. All bends and joints shall be covered with gasket so that wire is not damaged.

19. Cable ladder size should be determined according to wiring requirement (min150 mm).

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20. All angles and components should be painted with primer and enamel before fixing. After fixing, provide a final
coat of paint.

21. Fix the plug boards as per relay disposition chart. Ensure that contact configuration is also checked.

22. Paint relay position and function name from the back side and on the relay name plates.

23. Fix the relay name plates on the front side.

24. Check all the relay positions with function names as per relay disposition in contact analysis chart is LH from
front becomes RH from back.

25. Submit for approval as built drawing for the relay rack arrangement to customer.

B: Work Instruction for Internal Wiring

1. Collect the following copies,

✓ Circuit diagram/Interface Circuits

✓ CTR termination chart

2. Check that wires are available for all colours as per colour code of the zonal railway. Usual color code is,

✓ Internal 24v DC positive – Gray

✓ Internal 24v DC negative – Blue
✓ Signal 110v AC – Black
✓ Indication 12v DC / 24v DC or AC – Yellow / Green
✓ indicator – Red

Note: Separate color may be used for 110v DC point.

3. Ensure that checking of relay function names with contact analysis chart and route control chart is done.
4. All relay wiring should be done by 16/0.2 mm tinned copper wire.
5. Wiring should be done as per colour code from one contact to other starting from the fuse up to the relay coil.
Complete wiring for all the positive side.
6. Tick all the wiring with a pencil on the circuit diagram one by one simultaneously as wiring is done.
7. Check the circuit diagram for any left-over wiring. If inter connection wiring, CTR wiring is to be done later
note down the sheet no. with remarks.
8. Next wire from R2 to negative with blue wire except for signal lighting. Tick all the wires on the circuit diagram
as above.
9. Extra care should be taken for inter connection wiring (if tag blocks are not used) to avoid any damage to wire
especially at bends.
10. Only after completion of all wiring start soldering after preliminary bunching.
11. Bunch the wires keeping sufficient loose wires at bends and ends. Tie between all the relays and bends.
12. Solder wire should not be thicker than 18 SWG and soldering iron of min 50w /65w rating.
13. Strip the wire around 4mm with a wire stripper without damaging the wires. All 16 strands should remain
uncut.
14. Contact surface should be clean and free from grease and dirt.
15. Fans should not be allowed while soldering to avoid dry solder. Check that power supply is available to the
soldering iron and it has attained full temperature.
16. In addition to soldering irons of adequate wattage for the type of work done, the following shall be at hand:
• A small file for dressing the soldering tip
• A fire proof pad for wiping the tip

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• A mica sheet of adequate size or a suitable stand for soldering iron.
17. Check for shine after soldering. Visually inspect for any signs of dry soldering before insertion into plug board.
18. Avoid blowing on the hot contact after soldering. Do not disturb the solder till it has thoroughly cooled.
19. After insertion make sure with a sudden pull that contact has locked properly and there is no dry solder.
20. While soldering tag blocks ensure that solder does not spill to contacts below causing short circuit. Never
solder a tag block after energization.
21. Proper crimping with crimping tool should be done using maximum 15 sq. mm lugs whenever used. (Fuses,
negative bus bar, CTR). Only ring type copper lugs should be used.
22. All bus bars should be copper and fixed on proper insulators.
23. Negative bus bars should be threaded with a tap and lugs fixed with brass screws. Bolted lugs in drilled holes
are not permitted.
24. Washers shall be used for all purposes.
25. Connections to all resistor and capacitors should be soldered properly. Preferably on a PCB.
26. After soldering continuity test should be done before handing over to rail ways for testing.
27. Reverse tick on the circuit diagram with a pen (not pencil) and sign the circuit.
28. Wireman must read aloud the relay function name while supervisor should call out relay position only for
testing.
29. During the course of continuity testing, wire count should also be done simultaneously to verify the number of
wires actually available in each contact.
30. Any changes in wiring, contact no. shall be noted down by Red ink in both circuit & contact analysis.
C: Work instructions for Power Supply-IPS Arrangement-

1. Check for the power supply scheme as per contract. Mostly integrated power supply console (IPS) is used
for small and complex stations.
2. Erection of the IPS has to be done in the power room as per markings given by client.
3. Switch the IPS after proper installation and wiring and adjust all the DC-DC converters for designed
voltages. Consult manufacturer’s manual for initial switching on procedures. All converters should be in
switched off position while switching on the IPS.
4. Make all the load connections carefully after checking continuity of all the wires. Please ensure that no
wrong connections (DC or AC, voltage) are made which may burn relays or even may cause fire.
5. Check for smooth functioning of the IPS. Measure voltages across the relay coils. For Q-series relay, the
voltage should be between 24.5 to 26 voltage measures at R1-R2. With IPS switched off the voltage should
not fall below the rated voltage.
6. Arrange for battery racks and equipment racks (as per approved drawings) then erection should be done as
per layout approved by client.
7. Battery racks should be painted with acid resistance black paint.
8. Put the batteries on the battery rack and pour the electrolyte unless otherwise mentioned specifically the
specific gravity should be 1200.
9. If solution is prepared from concentrated sulfuric acid, (specific gravity is 1800). Ensure that acid is added to
distilled water and never vice versa. Mix thoroughly and let the mixture cool down. Measure specific gravity
repeatedly till the designed value (1200) is reached. Before pouring in the batteries the solution should have
cooled down to normal temperature and specific gravity measured again before pouring. Add distilled water
/ acid as required for achieving the designed specific gravity. This procedure will not be required if VRLA
type battery used.
10. The batteries after pouring electrolyte should be left to cool down for 12 hours. Check the polarity with a
voltmeter or cell-tester. Check for the correct level of electrolyte with the floats after screwing it
COMPLETELY.
11. Connect the batteries in series as per voltage with cell connectors. For IPS, it is 55 or 56 batteries to get
110V DC. Iron / GI bolts should not be used for connections.
12. Connect the battery charger to the back and set it to initial mode (on boost if initial is not available). Voltage
per cell should be 2.40V.
13. Switch on the charger and check the current. It should not exceed 10% of the AH rating of the battery. I.e.
for a 200AH battery the maximum current is 20A. Adjust the current using the potentiometer of the charger.
14. The batteries should be charged non-stop for 72 hours.

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15. Specific gravity should be measured and recorded in Battery History Card at regular intervals (maximum 6
hours).
16. All the cells should be carefully observed for level of electrolyte and should be topped up with distilled water
if the level falls below the mark.
17. Care should be taken so that the battery voltage does not drop to less than 1.95V.
18. After 1st charge, connect it to the load. It should discharge at maximum 10% of all rating. Fine adjustment
can be made if heater coils are used and cut accordingly to achieve designed current. Adequate
precautions should be taken if heater coils are used prevent fire. Batteries should be protected from any
heat also.
19. The cycle is to be repeated twice and the battery is ready after the third charge to be connected to circuit.
Cable Termination Rack (CTR) Installation
1. Take the approved layout plan for relay room.
2. Shift the required materials from store to site. Take proper care during shifting, loading and unloading of
materials.
3. Shift the required Tools & Plants from store to site.
4. Mark the dimension of cable termination racks and equipment is as per the approved layout plan.
5. Install the cable termination rack and other equipment’s on floor of the relay room
D: Work Instruction for Installation of Axle Counter
1. Collect the Approved Interlocking Plan or DP disposition Plan from Planning section,
2. Verify the Digital Axial Counter (DAC) available at stores before taking delivery for the following, that each set
has
(i) 2 Nos of Axle counter units
(ii) 2 Nos of Track device
3. Install and commission the DAC in the presence of Client or his representative only. Follow the installation
procedures given in the manufacturer’s manual.
4. Cast foundations for EJB (Electronic Junction Box), L/V (Line Verification) Box etc.
5. Survey the Station Master room along with client or his representative and locate the place for fixing the
Reset Box.
6. In case of BPAC (Block Proving Axle Counter) wire the BPR (Block Proving Relays) as per approved circuit
diagram.
7. Correct the DAC and wire it accordingly. EVR and SUPR relay, L/V Box, SM’s reset box and the TPR relays
shall be wired as per circuit diagram.
8. In case of BPAC for two stations, check the following (station A & station B)
a. Check the counter with dummy wheel in the direction at ‘A’ station and go to ‘B’ station check the
counter with dummy wheel on same direction. Both the counter should show Zero and reset
automatically.
b. Repeat the test confirm the result and record.
9. In case of any problem in adjustment of normal axle counter, the dip in the negative field shall be checked
with a CRO. The graph should show one clean dip with no ripples.
10. Check for resetting using SM’s reset box. L/V box push button needs to be operated simultaneously.
11. After testing observe counter readings for passing of a few trains (minimum two) and conform that counter is
resetting properly.

E: Work Instruction for Installation of Block instrument

1. Collect the Block Instrument with accessories such as block bell, filter unit, DC polarized relay, Connected
Terminal rack ( CTR), Block Proving Relay ( BPR), ARA Terminal etc. it’s detail drawings, technical
specification and manual from Stores/ Planning/OEM .
2. Mark the location for Block instrument in Station Master’s (SM) room in consultation with open line staff,
Station Master and client or his representative.
3. Bring the required wooden plank from the stores, Make the wooden box for supporting the Block Instrument
as per the drawing or to suit the site requirement (should be approved by the Open line staff, Station master,
client or his representative).

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4. Fix the wooden box on the floor or as directed by client or his representative and provide necessary cable
entry point.
5. Fix the block instrument on the top of wooden box and support the cable entry point.
6. Fix terminals and relay inside the box. Ensure that all terminations are connected through as per the circuit
diagram.
7. Provide block bell & filter unit to protect from 25kv induction and connect the same to BPR through box.
8. Wherever there are more than one block instrument provide buzzers with different tones.
9. Check all the contacts are clean and free from pitting and springs are in good condition and adjust properly.
10. Check all the bolts, terminal screws, lock nuts are tight and provide all split pins.
11. Ensure the following before commissioning :
a. Measure the voltage and adjust to get the required voltage.
b. Use block filters in the entire block instrument since the immunity of PR relay is only up to 10V.
c. Check the time setting in the relays as per specification and Manufacturer’s instruction and scheme.
d. Check the polarized relay returning to its normal position when no current is flowing.
e. Check the batteries and record the values.
f. Measure the line current.
g. Test the synchronization with the connected other instruments.
h. Check that the last stop signal is automatically replaced to ‘on’ when the train enters the section and
continues to remain in the ‘on’ position until the train has arrived at the receiving station and a fresh
“line clear” is obtained.
F: Work Instruction for Simulation Testing

12. Connect all the power wires to the bus bars after confirming voltage and AC or DC.
13. Make sure all the negative bus bar connections are secure.
14. If tag blocks are used a non-conductor strip like a scale shall ideally be passed through all the columns and
rows to eliminate possibility of any cross-connections.
15. Make a quick final check at the back of relays for any mix up of color at the same contact except for cross
protection contacts. If a standard back contact is used for cross protection it is easier to locate any mix up.
16. Switch on the internal power only. Measure the voltage at the bus bar.
17. Connect the simulation panel and pick up locally all the TPRs, RECRs and NWKRs.
18. Check for any internal relay picking up. Ideally, all relays for station normal condition should pick up but can
be made possible only at wayside stations.
19. One by one check for all the normally pick up relays which should pick up. Trace the circuit for any wrong
connections. Any required alternations shall be made only in consultation with client.
20. After station normal is achieved check for point operation in manual mode.
21. Now it is ready for setting of routes. Though many try to avoid it, it is best to try the longest route first (usually
home signal to main line starter).
22. One by one set all the routes as per selection table. Check for signal clearance and all indications on the
control cum indication panel.
23. Initially route may be released by emergency cancellation or just by manual pick up of ASR but again it is best
to take one route and check for route release by passage of train, release by signal cancellation (EWYN) and
by emergency cancellation (EUYN).
1. Once all setting and release of all the routes is achieved start the cross test as per square sheet.
2. Each route shall be observed until signal goes to ‘OFF’. I.e. HR / DR pick up.
3. All indications shall be observed carefully and any anomaly should be corrected.
4. Any alternations (of the circuit) at any stage shall be done only in consultation with Railway representative
present.
5. Wait for N.I (Non-Interlocking) to be declared before connecting any outdoor gears. The moment N.I starts
disconnect the simulation panel and connect the outdoor gears one by one and check correspondence from
outdoor location along with Railway representative.
6. Do not connect any outdoor gears especially points without permission from railways. Derailment may
happen during non-interlocked movement unless a full traffic block is available.
7. In case Railways asks for disconnection of any newly connected gear, do it immediately without delay.

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8. Let Railways check all the gears and wait patiently until they declare re-connection. I.e. commissioning of
station.
G: Work Instructions for Cable Laying

1. Receive the approved copy of cable core plan and cable route plan.
2. Prepare the cable allocation chart with PE/ME based on cable core plan.
3. Check for any existing cable laid on the route, if located, sufficient clearance (approximately 300 mm) should
be given for the laying of cable.
4. Mark the cable route including track crossings with client or his representative.
5. Check the required depth as per contract agreement for cable laying and also for track crossing. Usually
cable laid at a depth of 0.8 m, in theft prone area must be 1m, 0.6 m if RCC trucking is used and 1m below
rail flange for track crossing.
6. If the cable laying is in exiting track involves track crossing, provided a FLAG MAN to signal / whistle during
the train movement and alert the working personnel to keep away from the track. Permanent way staff
should be informed and prior approval taken.
7. Insulate the crow bars above one meter from the bottom tip and up to the top. Do not use un-insulated crow
bars for excavation work.
8. Check for any power cable crossing, if any existing shut down the power in that route before taking up for
excavation.
9. Follow shut down guidelines during power shut down.
10. Excavate the cable trench as per the drawings
11. Ensure that the cable protection materials such as BRICKS/ PCC TRENCH COVER / HDPE PIPE (DOUBLE
CORRUGATED PIPE) are available before starting of cable laying.
12. Check and record the trench dimension along with client or his representative and give clearance for cable
laying.
13. Bring the cable Drums as per cable allocation chart from store. Before taking the drum, check each drum for
continuity using megger and the record the values.
14. Unload the cable drum as per the plan and near the trench.
15. Load the drum carefully on the cable jack; lay the cable in the trench carefully. It should be ensured that
cable is not pulled on the ground.
16. Protect the cable from any damages during the payout operation and lay the cable in the trench and protect
with protective materials
17. It is desirable that the excavation of the trenches is not done in long lengths and not remains uncovered for
long period. It is preferable that cables are laid and refilling done on the same day.
18. Backfilling of the trenches should be done properly. The earth excavated shall be put back on the trench,
rammed and consolidated.
19. During excavation, the earth of the trenches should not be thrown on the ballast. The side of the trenches
away from the track should throw the earth.
Cable laying – Crossing Railway Track
1. When a cable has to cross the track it should be ensured that –
• The cable crosses the track at right angles
• As for as possible the cable does not cross the track under points and crossings
• The cable is laid in RCC / GI / CI / HDPE pipes, suitable ducts or in any other approved manner while
crossing the track.
2. While laying the cables the following instructions should be adhered to for the safety of the track.
• Outside the station limits, the cables should generally be laid at not less than 5.5 m from the center of
the nearest track.
• Within the station limits, the trenches shall preferably be dug at a distance of not less than 3 m from
the center of the track, width of the trench being outside the 3 m distance.
• At each end of the main cable an extra loop length of 5 to 8 m should be kept.
• At the relay room end 10-15 m extra loop should be kept.
3. Cable laying on platform, the work includes removing / breaking of exiting RCC Slabs / brick work on the
passenger platform, trenching to a depth of sufficient to accommodate the additional cables laid, covering the

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trench after the cables are laid, replacing the slabs removed or re-plastering with cement mortar and restoring
to the original condition as per the instructions of the Engineer at site.
4. Check for any existing cable laid on the route, if located, sufficient clearance (approximately 300 mm) should
be given for the laying of cable.
5. Get permission from SSE / PWAY or concerned authorities for crossing of Railway tracks.
6. Follow RDSO guidelines for crossing of railway tracks.
7. Mark the cable route with client or his representative and track engineers.
8. If the cable laying is in existing track, provide a FLAG MAN on both sides to signal/ whistle during the train
movement and alert the working personnel. To keep away from the track.
9. Ensure that the CABLE DUCTING material such as HUME PIPE / GI PIPE / are available before starting of
cable laying.
10. Ensure that the cable protection materials such as BRICKS / PCC TRENCH COVER / HDPE PIPE (DOUBLE
CORRUGATED PIPE) is available before starting of cable laying.

H: Work Instruction for Installation of Location Box

1. Collect the approved copy of Signal Interlocking Plan (SIP), cable core plan and cable route plan.
2. Survey the track with client or his representative and mark the locations according to cable core chart and
cable route plan for installation of location box.
3. Select the type of location box-Full single CASE-I, Half case, quarter case based on the approved copy of
cable core plan.
4. Excavate pit for foundation of apparatus case as per the standard drawings. Ensure that all materials like
cement, coarse aggregate, fine aggregate, foundation bolts with nuts, pre-fabricated standard shutters, and
template are available at site.
5. Prepare concrete for standard M10/M15 grade. Refer work instruction for concreting.
6. Provide piping for cable entry from ground level entry to inside of the box.
7. Align the template with required level and dimension, fix the foundation bolts and pour the concrete.
8. Fix the location box on the foundation bolt aligns properly and tighten the bolt.
9. Paint the location box with red oxide paint. Inside should be painted White / Aluminum / Black as per client’s
requirement.
10. Prepare termination schedule for each location box get it approved by client or his representative.
11. Prepare hylam sheet based on termination schedule and fix terminals and fuses properly as per the drawing.
12. Install the relay mounting brackets and equipment rack (as per client’s approved design) usually made of
hardwood 50 mm thick.
13. After all the signaling cables are taken inside the Location box the side opening (if any) shall be closed with
masonry work and plastered. The inner side is then filled with sand and finally the bottom is sealed with
sealing component.
14. Fix the terminals and install all the equipment and relays as per approved location particulars.
15. Terminate the cables as per termination chart carefully maintaining core series. The same series should be
maintained throughout the station.
16. Write the equipment and terminals details neatly on the hylam sheet and inside door of the box and paint the
outside of the box with Aluminum paint.
17. On completion of all termination for a yard, check the continuity and insulation by megger and record in cable
meggering register. Insulation testing should be done between locations with all terminals disconnected.
18. Wiring of the equipment and relays (if any) shall be done as per approved circuit diagram. Refer work
instruction for wiring.

I: Work Instruction for Installation of Signals

1. Collect the approved Signal Inter locking plan (SIP) from planning section.
2. Identify the Type of signal such as HOME, ADVANCE STARTER, STARTER, & DISTANT. Mark the signal
locations with client or his representative with paint.
3. Check the distance from signal post to track, from signal to track on both sides, if the signal locations are
provided in between the tracks as per the approved drawings.

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4. Excavate the pit as per the marking.
5. Get the appropriate standard template and shuttering (from store) for foundation.
6. Before starting of foundation, ensure that all materials required for foundation such as cement, aggregate,
sand, Shutters, template and fixing bolts are available at the location.
7. Fix the shuttering in the excavated pit and align the same to the requirement, provide cable entry
arrangement through a PVC / HDPE pipe of not less than 75 mm dia.
8. Fix the template on the shuttering and fix the foundation bolts in the template standard ratio.
9. Prepare the concrete as per the specification and pour the concrete.
10. The next day of casting open the shuttering and fill up the excavated pit with soil then rammed. Curing of
foundation should be done at least 7 days.
11. The signal pole shall be securely fixed to surface base and erected on signal foundation and proper plumbing
should be done with MS flats to avoid tilting. The gap between the signal pole and surface base shall be filled
up with putty or mortar after plumbing.
12. Check the signaling plan for subsidiary signals. Holes should be drilled for cable exit for subsidiary signal.
13. For signal having route indicator (any type) the main signal is mounted on an offset bracket. Depending on
the no. of aspects of the main signal, the distance of the hole should be properly determined. A rough
approximation is given below.
• 4 Aspects - 1.6 m
• 3 Aspects - 1.2 m
• 2 Aspects - 0.8 m

14. Ensure that after fixing the main signal the route indicator visibility is not affected.
15. Holes for other subsidiary signals like calling on, dependent shunt shall be drilled proportionately. Take
marking for all the holes from the client / authorized representative. Check illuminated ‘A’ marker for which
holes need to be drilled also.
16. All distant, home and main line starter should be fixed on 4.6 m posts. 5.6 m post is used for home signals
only when both multi lamp / stencil and junction type route indicators are used on there is a curve.
17. Verify height of home signal from client before installing.
18. For all loop line starters and other signals 3.6 m post shall be used unless specifically required by client.
19. Check for any markers P/G/C/A to be fixed. All distant signals will have ‘P’ markers. All signals having a
calling on signal will have a ‘C’ marker just below the unit. All signals outside station limit and before a LC
gate shall have ‘G’ marker. Signals in auto block section will have ‘A’ markers. Signals before LC gate in auto
block section will have ‘G’ marker and illuminated ‘A’ marker both. Semi-automatic signals within the yard will
have an illuminated ‘A’ marker. Except for ‘G’ marker, which is black letter on yellow background, all others
are black on white background.
20. Multi aspect colour light signal up to 2/3/4 aspect shall be properly mounted on signal post when without route
indicator.
21. Soon after installation, the pole shall be painted with two coats of Aluminum paint after giving a coat of primer
and the signal unit shall be painted with two coats of Black enamel paint outside and white enamel inside. In
case of double distant signal, alternate yellow and black (300 mm) shall be painted.
22. Necessary earthwork shall be made around each signal if required by Railway. The cables are to be taken
through the pole to the unit without damaging the insulation and Armor is then skinned and terminated.
23. Fix the signal lamps and wire it. It is best to fix and wire the CLS units before mounting it. Route indicators
must be wired first then mounted.
24. All the signal units are to be wired as per approved practice by railway. The wiring is to be tested jointly. The
signal visibility shall be jointly checked during daytime at bright light at 90% of rated voltage.
25. Signal number shall be painted on the Number plate. All the fittings are to be tightened properly and signal
unit shall be locked properly (Both terminal box and unit cover).
26. The back cover of the signal shall be crossed with white lines (50 mm thick) or shall be painted white as per
the practice of railway.
27. All the posts shall be earthed as per standard practice or as per the tender specification.
28. Approved diagram by PMC of concerned Railway Dept. or Client. Proportion of cement, Sand, Aggregate
should be as specified in drawing or 1:3:6 3: Aggregate size shall be less than 40 mm.

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29. Mixing must be done in a mixing trough or a M.S. Sheet which should not be more than half full at the time of
mixing
In order to avoid mis-reading of signals by drivers, provide X’ marks with white painted wooden reaper in front of
signal units till the station is commission

J: Work Instruction for DC Track circuits

1. Collect the Approved copy of Signal Interlocking plan (IP), Track bonding plan and outdoor termination charts
from planning section.
2. Mark the insulation joints with client or his representative as per approved Track bonding plan.
3. Mark the Track Feed (TF) and Track Relay (TR) in rail using paint as per approved Track Bonding Plan.
4. Collect the required material like Rail Drilling machine (manual cycle type or electric), G.I. wire, channel pin
and Track Lead Junction Box / Bootleg.
5. Dig the pit to the required dimension at specified location (keeping in mind the track clearance and cable
requirement) and insert the TLJB and grout. Check whether foundation is required as per contract agreement.
6. Drill the hole as marked in the web of the rail horizontally and clean the same free from burr. Two holes in
each rail.
7. Check whether GI wire, PVC insulated wire rope or 2X2.5 Sq. mm cable shall be used for jumper.
8. Measure the distance from TLJB / TLD box to near and far rails. Calculate the length of jumper wire required
at the rate of double the distance.
9. Connect the middle point making a neat loop to the TLD terminals or Aluminum angle piece connected to the
terminal as specified by the client.
10. Insert both ends of jumper wire from TLJB to holes in the corresponding rails and lock the wire rope with
channel pin by hammering. The wire should always be inserted from within the track.
11. Terminate cables in the termination board as per termination chart.
12. Fix and wire resistance, choke and track relay (QT2 or QTA2) in relay end location as per circuit in the
location box. Check for relay coil resistance whether 4 Ohms or 9 Ohms. In RE area choke and QTA2 relay (9
Ohms) can only be used.
13. Note that for 9 Ohms relay minimum 2 Nos (usually 3) battery shall be used. In case of long track circuit no. of
batteries shall be increased to achieve minimum 125% (200% shall usually be maintained) voltage at relay
coil.
14. Fix and wire the battery & track feed battery charger in feed end location.
15. Energize the track circuit and check the voltage at relay coil end. Adjust using the variable resistance to
achieve desired value.
16. Check for train shunting with 0.5 Ohms resistance shorted between rails. Relay should drop.
17. Measures pick up and drop away currents and voltages with charger both ON and OFF condition.
18. Approved Track circuit Plan is required. Bonding of rail joints, which shall be made with 8 SWG soft solid GI
wires, 7.2 mm holes are to be drilled close to fish plates on the web of rail and the bond wires are fixed by
driving Channel bond pin, tightly.
19. In point track circuit parallel jumpers bond wires/cables shall be provided.
20. Two TLJ boxes one at track feed end and another at relay end shall be fixed clear of Infringement and the
respective track circuit tail cable 6/2 x 1.5 Sq.mm PVC copper Conductor from the Location Box shall be
terminated.
21. The connection from the TLJB boxes to the rail should be through the jacketed wire, which should be fixed to
the Rail by channel Bond pin both at feed and relay ends. The G.I. wire from TLJ boxes to sleepers should be
covered with suitable PVC colored sleeve and there upon neatly clipped on the sleepers to prevent shorting
with rails

K : Work Instruction for Installation of Point Machine

1. Collect the approved circuit containing point machine wiring diagram from planning section.
2. Collect the point machines with all accessories, WILLIAM STRETCHER ASSEMBLY and other required
materials from stores

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3. The point machine shall be installed after cleaning both inside and outside the machine, after greasing / oiling
to all moving parts.
4. The point machine shall be hand operated and detection and motor-controller contacts shall be adjusted
before taking to site. All unwanted openings shall be covered with MS sheets.
5. Check whether the point crossing switch portions are assembled to the requirement and accepted. If any
variations observed, inform P-WAY gang to correct and accepted.
6. Do not proceed without correction and acceptance of assembly.
7. For new lines fix the William stretcher bar in switch portion.
8. Fix and adjust the tongue rails along with P-WAY staff on new line. On existing line, fix and adjust the tongue
rails along with open line staff (PWAY and S&T STAFF).
9. The point shall be adjusted by operating the machine first by crank handle. The insertion of hand crank should
disconnect the power supply to the machine. When the machine has been fastened down, the through bar
connections shall be set up and the point machine hand cranked to one end of the stroke positioning the
locking blades so as to allow the appropriate locking dog to pass through notches.
10. The closed switch shall be adjusted to just in contact with the stock rail. Then the connections shall be
tightened further by 2 mm to 3.5 mm to impart a springing action to the tongue rail. The machine should be
hand cranked to the opposite end of the stroke and the setting repeated for the other switch.
11. The machine shall be hand cranked to the end of the stroke to close the tongue rail. Insert 1.6 mm test piece
between stock rail and switch rail at 150 mm from toe of the switch and operate the point. Ensure detector
contacts just make. A test gauge of 3.25 mm shall be inserted between the switch rail and stock rail at a
distance of 150 mm from the toe of the switch.
12. The detector connection of the closed switch shall be adjusted till the appropriate detector contacts are just
broken. The same shall be repeated at the other end of the stroke. All the relevant nuts shall be tightened.
13. The point driving rod and the lock connections of the machine must be so adjusted that with 5 mm thick test
piece obstruction placed between the switch and the stock rail at 150 mm from the toe of the switch:-
14. The point cannot be locked,
15. The point detector contacts should not assume the position indicating point closure &Friction clutch should
slip.
16. The point machine shall be fixed with proper bolts, nuts and flats/spring washers with correct size of holes
through the special sleepers to avoid lateral /longitudinal play, on extended Gauge Tie Plate.
17. All point connecting rods shall be connected to point machines without any strain and with min. offset. All
connecting rods shall be in level and correct size of bolts and nuts shall be used to avoid longitudinal play.
18. Separate junction box shall be installed clear of infringement near the point machine and the respective
cables shall be terminated. The leading in wires from the boxes shall be taken through flexible pipes and
securely fixed.
19. The wiring inside the point machine for motor and detector circuit shall be carried out neatly and meggaring of
cable to be carried out before charging the circuit.
20. Point machines and junction boxes shall be painted and point numbers shall be painted neatly. Wiring
diagram shall be painted on the inside of the point machine cover.
21. Wire the point machine as per approved circuit diagram and seal the cable entry to protect entry of water or
dust.
22. Check the connections and sequence of operation as per circuit diagram.
23. Check the tightness of bolts and nuts in assembly and provide lubrication of all gears in the point machine
and in assembly.
24. Measure the voltage & current at motor terminals for both normal &reverse operation and compare the
readings with the specified limits of the different types of point machines.
25. Check the electrical operation, If found satisfactory offer for client or clients representative’s Inspection.
L: Work Instruction for Earthing

1. Prepare a hole of 100 mm to 125 mm dia manually or with the help of ‘Earth auger’ to a
2. depth of about 2.8 meters.
3. Place the earth electrode into the center this hole.
4. Gently drive on the top of the rod to penetrate it into the soil so that minimum 150 mm of the electrode shall
be inserted in the natural soil

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5. Now fill the Earth enhancement material (min. approx.30-35 kg) into the augured/dug hole in slurry form and
allow it to set. After setting, the diameter of composite structure (earth electrode + earth enhancement
material) shall be of minimum 100 mm dia. covering entire length of the hole)
6. Cover the remaining portion of the hole by backfill soil, which is taken out during auguring/digging.
7. A copper strip of 150 mm X 25 mm X 6mm shall be exothermically welded to main earth electrode for
taking the connection to the main equi-potential earth bus bar in the equipment room and to other earth pits,
if any
8. The main earth pit shall be located as near to the main equi-potential earth busbar in the equipment room as
possible
9. Prepare a hole of 300 mm dia manually or with the help of ‘Earth auger’ to a depth of about 2.95 meters
10. 50 mm dia Light Class GI pipe of thickness 3 mm, with 5 mm dia hole drilled at staggered pattern, with
minimum 02 nos of hole per 305 mm length shall be centrally inserted inside 300 mm dia hole.
11. Bottom 1.5m height shall be filled up by using Charcoal and Salt as an alternate layers ,remaining 1.15 m
shall be filled up by using soil
12. Exposed 300 mm pipe shall be encased by using concrete chamber of size 450 x450 mm
13. Clamp shall be welded at the top of the pipe, followed by fixing with CI threaded cap Earth Resistance shall
be measured and painted on the earth piped with date. The Earth resistance shall not be more than 10 Ohms.
M: Work Instruction Cable Termination & Wiring

1. Approved Location Particular detail required to complete this activity.

2. Hylum sheet of P3 grade 10mm thick shall be used and planned for fixing ARA Terminal /Wago /fuse block.
3. The underground Signaling cable shall be taken into the Location Box/battery boxes and properly secured by
wooden clamps/cable gland plates. The cables shall be neatly skinned, bunched and terminated. All cores of
cable shall be terminated on the terminal board at locations as per approved Location particular Details and in
Relay rack at the required places as per approved design. All the power cables (Aluminum) shall be provided
with Aluminum lugs using crimping tool.
4. The wiring shall be carried out in a neat manner with 3/0.75mm PVC copper wires or by 1 x 1.5 sq. mm cable
conductor and terminated, bunched and tested. The relays wherever fixed shall be fixed in such a manner
that they cannot be easily removed or tilted. Details of cable terminations and wiring particulars shall be
painted inside the Location Boxes door in addition to documentation the inner side of location boxes filled with
sand and finally the bottom is sealed with sealing compound.
5. Charged Secondary Cells installed inside Location Boxes, shall be fixed firmly leaving working space for
taking Specific Gravity reading and distilled water topping. Anti-corrosive black paint shall be coated inside
the Location Box.
6. For each track circuit, secondary cell 80 AH shall be charged and installed in the apparatus case as per
practice of ZONAL RAILWAY. The No. of cells and chokes to be used for each track circuit as per approved
circuit.
7. Choke, chargers, and adjustable resistance suitably fixed on Plank shelfs and wiring as per circuit diagram.
Battery links (lead) with suitable bolts and nuts shall be used for connecting cells. Petroleum jelly is to be
applied on terminals immediately after connection

Frequency of calibration of equipment’s

Sr. Name of the Elements for Calibration Frequency of
No. equipment calibration Agency calibration
1 Earth tester --- External Yearly
2 Insulation Megger --- External Yearly
3 Multi meter --- External Yearly
4 Clamp on meter --- External Yearly

Note: These frequencies are indicative. In case of intermediate deviations or repairs, immediate calibration shall be
undertaken.

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Check List
&
Formats

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No :

Date :
CABLE LAYING VERIFICATION REPORT

Name of the Project : Chainage/KM/Station:

Name of contractor:

Approved Drg. No :

SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified
1 Availability of approved core plan and cable
route plan

2 Marking completed

3 Ducting materials, protective materials

4 Flag man is available caution sign is put and

cable jack also available & erected

5 Checking of trench dimensions

6 Permission of crossing of track

7 Laying completed properly

8 Protection of cable done properly

9 Back filling and compaction done

10 Record the measurements of cable

11 Meggering of all cables completed and

recorded jointly Before laying & After laying

Verified By: _________________________________

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No :
LOCATION BOX VERIFICATION REPORT
Date:
Name of the Project : Chainage/KM/Station:

Name of contractor:

Approved Drg. No :

SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

1 Location Box No, Size and Km

2 Distance from nearest track

Condition of :
a. Location Box
b. Foundation
c. Plastering
3 d. Foundation Bolts with nuts & washers
e. Earth Around the location box
f. Stone pitching around the location
box
g. Closing of cable entry

4 No. of cables in the LB

Condition of cable armour Soldering &

5
Earthing

6 Bunching

7 Fixing of ‘E’ type lock and ward No.

8 Back door locking arrangement

9 Fixing and arrangement of terminal blocks

10 Fixing and arrangement of fuses

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SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

11 Fixing arrangement & painting of relay frame

12 Fixing of relay plug boards

13 Condition of soldering of relay wires & clips

14 Condition of relay contact clip locking

15 Relay particular painting

Power cable lugs arrangement

16
(25 / 35 sq. mm)

17 Condition of 16/0.2 lugs

Earthing of location
a. Providing earth wire in the LB
18 b. Earth wire connection to LB (GI wire /
Cable)
c. Earth value inside the location

Painting :
a. Inside Painting (White)
19 b. Outside Painting (Silver)
c. Location Box No.
d. Location Particulars painting

Verified By: _________________________________

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No :
Date:
SIGNAL VERIFICATION REPORT

Name of the Project : Chainage/KM/Station:

Name of contractor:

Approved Drg. No :

SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

1 Signal No and Km

Position of signal (LH Side / RH Side) if the

2 signal is located on RH side reason may be
mentioned

3 No. of Aspects and Colors

4 Height of the Signal from the rail level

Distance from the nearest track LH Side (Min.

5
2.36 Mtr.)

6 Distance from the nearest track RH Side

7 Distance of the OHE masts in rear

8 Distance of the OHE masts in advance

9 Staggering of the contact wire near the signal

Condition of the screen and Earthing

10
arrangement

11 Ladder arrangement

12 Route indicator (Stencil type / Jn. type)

In case Jn. Type Route Indicator (1/2/3/4

13
way)

Condition of the signal foundation with

14
plastering

Condition of the ladder foundation with

15
plastering

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 KEC INTERNATIONAL LTD

SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

Calling on signal unit :

a. Condition of the offset bracket and
16
fixing arrangement
b. ‘C’ marker provision

17 Foundation bolts

18 Earth around the foundation

19 Stone pitching around the foundation

20 Condition of the cable entry

21 Signalling cable from LB No

Back door locking arrangement (Universal

22
Locks)

23 Intactness of the back door

Fixing and arrangement of ladder, signal

24
hoods & number plate
Earthing of signal :
25 a. Earth wire connection
b. Earth value
Painting :
a. Post (White)
b. Fittings (Hood and Mechanism box –
Black)
26
c. Inside Painting (White)
d. Outside Painting (Aluminium)
e. Signal Surface base and ladder
(Black)
27 Focussing of Signal
Painting of signal No. on Number Plate and
28
outside of door
Back cover of the signal shall be crossed by
29
white lines (X)
Mesh protection for signal units as per RE
30
std.

Verified By: _________________________________

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 KEC INTERNATIONAL LTD
No :

Date:
POINT MACHINE VERIFICATION REPORT

Name of the Project : Chainage/KM/Station:

Name of contractor :

Approved Drg. No :

SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

Engineering Side :

1 Point layout (Wooden / PSC / Steel)

2 Size of the rail

Layout of the point (1 in 8 ½, 1 in 8 ½ SS, 1

3
in12, 1 in16)

Point
4
a. Gauge b. Level c. Opening

5 Condition of rail joints in the layout

6 Condition of ballast

7 Condition of backing

8 Provision of creep level pillars

9 Condition of lengthy sleeper

10 Condition of the fittings (Chair Plates)

11 Condition of the gauge tie plate

12 Condition of William stretcher bar

13 1st following stretcher bar

14 2nd following stretcher bar

15 3rd following stretcher bar

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SI. Verified Not

Points for Verification Remarks
NO OK NOT OK Verified

16 Fixing of SOD of TW layout

Measurements :

1 Distance of the point machine from center line

Distance of the point machine from controlling

2
panel

3 Squareness of the point machine

The inner distance of 3rd and 4th sleeper on

4
which the point machine is fixed

5 Squareness of the tongue rails

Distance of throw rod to tip, tip to center line

6
of 1st sleeper

7 Distance

8 Ground gear connection and alignment

9 Intactness of pins with split pins

10 Spring and flat washers on lock rods

11 Spring and flat washer on detector rods

12 Wiring in the point machine

13 Cross protection arrangement

Cut out key crank handle grouping and cut

14
out floppy arrangement

Verified By: _________________________________

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