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(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

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REVIEW
OF

MAINTENANCE SCHEDULE FOR

OHE
TARGET GROUP: TRD Maintenance Staff

CAMTECH/ E/ 11-12/ OHE-Schedule/ 1.0

August, 2011

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Maharajpur, GWALIOR - 474 005
Review of Maintenance Schedule for OHE August, 2011
2 CAMTECH/E/11-12/OHE-Schedule/1.0

Review of Maintenance
Schedule for OHE

QUALITY POLICY

“To develop safe, modern and cost

effective Railway Technology complying
with Statutory and Regulatory
requirements, through excellence in
Research, Designs and Standards and
Continual improvements in Quality
Management System to cater to
growing demand of passenger and
freight traffic on the railways”.

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CAMTECH/E/11-12/OHE-Schedule/1.0 3

FOREWORD

To achieve high reliability and zero defects on Overhead Equipment (OHE), it is

necessary to maintain the OHE through proper schedule maintenance/checks on its geometry and
all other design parameters.

CAMTECH has prepared this handbook on “Review of Maintenance Schedule for

OHE” to achieve the above objective. This handbook contains details of various maintenance
schedules and the proformas used for these schedules. Newly developed current collection test
by OLIVER-G and Condition Based Maintenance through Thermo Vision Camera etc. have
also been covered.

I hope this handbook will prove to be useful for the maintenance personnel working in
TRD department.

CAMTECH, Gwalior S.C. Singhal

Date : 30th August 2011 Executive Director

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PREFACE

Overhead equipment (OHE) provides energy to electrically driven locomotives &

EMUs. OHE comprises of the electrical conductor over the track, together with their
associated fittings, insulators and other attachments. For utmost utilization of traction assets,
outage of overhead equipment should be minimum. For this proper maintenance of OHE is
essential to cater growing demand of passenger and freight traffic on the Railways.

This handbook on Review of Maintenance Schedule for OHE has been prepared by
CAMTECH with the objective of making OHE maintenance personnel aware of correct
maintenance procedure, upkeep records, proforma and repair techniques. Recent developments
in maintenance such as current collection test by OLIVER-G and Condition Based Maintenance
through Thermo Vision Camera are also included in this handbook.

It is clarified that this handbook does not supersede any existing provisions laid down
by Railway Board, RDSO or AC Traction Manual (ACTM). This hand book is for guidance
only and it is not a statutory document.

I am sincerely thankful to TI Directorate RDSO Lucknow and also all field personnel
who helped us in preparing this handbook.

Technological up-gradation & learning is a continuous process. Please feel free to

write to us for any addition/ modification in this handbook. We shall highly appreciate your
contribution in this direction.

CAMTECH, Gwalior ( Peeyoosh Gupta)

Date: 29th August 2011 Jt.Director Electrical
e - mail id : [email protected]

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CONTENTS

Item No. Description Page No.

Foreword III
Preface IV
Contents V
Correction Slip VIII
1.0 INTRODUCTION 01
2.0 FOOT PATROLLING OF OHE 01
3.0 TROLLEY / CAB OF LOCOMOTIVE INSPECTION OF OHE 07
4.0 CURRENT COLLECTION TEST 07
4.1 By Mirror 07
4.2 Current Collection by Oliver-G 08
5.0 SPECIAL CHECKS 08
5.1 Insulators 08
5.2 Section Insulator 09
5.3 Isolating switches at yards/ Loading siding 09
5.4 Bi- metallic clamps 09
5.5 Earth connections 09
5.6 OHE Support on steel girder 09
5.7 Bird nests 09
5.8 Pre- summer checks 09
5.9 Pre- monsoon checks 10
5.10 Monthly Maintenance of PTFE Type Neutral Section Make
Balfore Betty Power Corporation Ltd UK(BBPC) 10
5.11 Quarterly Maintenance of PTFE Neutral Section Make Arthur
Flury AG 11
6.0 MAINTENANCE 12
6.1 Annual Maintenance of ATD 12
6.2 Eighteen months Maintenance of Single Cantilever and Annual
Maintenance of Double & Triple Cantilever 15
6.3 Annual Maintenance of Isolator 18
6.4 Quarterly, Half yearly and Yearly Maintenance of
Motorised Isolator 19
6.5 Annual Maintenance of Level Crossing Height Gauge 20
6.6 Annual Maintenance of Cross/Along Track Feeder 21

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Item No. Description Page No.

7.0 ANNUAL MAINTENANCE BY OHE INSPECTION CAR 21

7.1 Maintenance of Turnout / Crossover 21
7.2 Maintenance of Section Insulator Assemblies 25
7.3 Maintenance of Over Lap OHE and RRA Clamp 26
7.4 Annual Maintenance of Overline Structure/Tunnels and
Clearances Under Overline Structure 27
7.5 Splices 28
7.6 Annual Maintenance of OHE by Inspection Car 28

8.0 PERIODICAL OVERHAUL 29

8.1 POH of Cantilever 29
8.2 POH of Regulating Equipment 31
8.3 Catenary and Contact Wire 35
8.4 Jumpers and PG Clamps 35
8.5 Insulated and Un- Insulated Overlaps 35
8.6 Overline Structure 35
8.7 Overhead Cross-feeder, Return Conductor and 25kV Feeder 35
8.8 Contact Wire & Catenary Wire Ending Clamp 35

9.0 RE-TENSIONING OF UNREGULATED OHE 36

10.0 CONDITION BASED MAINTENANCE THROUGH THERMO

VISION CAMERA 36

11.0 RECOMMENDED PROFORMAS OF MAINTENANCE SCHEDULES

FOR OHE 38

PROFORMA No. 03-01 Daily Progress Register 38

PROFORMA No. 03-02 Register for Foot Patrol 39
PROFORMA No. 03-03 Tower Wagon/ Cantilever Assembly
Maintenance Register 40
PROFORMA No. 03-04 Record of Contact Wire Wear and Splices
(Proforma 04 & 15 merged) 41
PROFORMA No. 03-05 Register for Features of Over Line
Structure 42
PROFORMA No. 03-06 Register of Earth Resistance
Measurements 42
PROFORMA No. 03-07 Record of Current Collection Tests 43
PROFORMA No. 03-07 ‘A’ (New) Register for Current Collection by
Oliver – G 44

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Item No. Description Page No.

PROFORMA No. 03-08 Record of Implantation & Foundation

(Proforma08– 013 merged) 45
PROFORMA No. 03-09 Register of Breakdowns / Accidents
Involving OHE 46
PROFORMA No. 03-10 Regulating Equipment 47
PROFORMA No. 03-11 Isolator Switches 48
PROFORMA No. 03-12 Turnout and Crossover 49
PROFORMA No. 03-13 Level Crossing Height Gauges 49
PROFORMA No. 03-14 (New) Maintenance Record of Insulated /
Un-Insulated Overlap 50
PROFORMA No. 03-15 (New) Maintenance Record of Section Insulator
Assembly 50
PROFORMA No. 03-16 (New) Maintenance Record of BBPC Make Neutral
Section 51
PROFORMA No. 03-17 (New) Maintenance Record of OHE by Thermo
Vision Camera 51

REFERENCES 52

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ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :

CAMTECH/E/11-12/OHE-Schedule/C.S. # XX date---------

Where “XX” is the serial number of the concerned correction slip (starting
from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. Date of Page no. and Item Remarks

issue no. modified

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1.0 INTRODUCTION

To achieve high reliability and zero defects on OHE, it is necessary to maintain the
OHE in perfect condition through proper schedule maintenance/checks on its geometry and
all parameters adopted in the design without compromising on safety of the equipment as well
as personnel.

The Over Head Equipment is subjected to dynamic oscillations due to the movement
of the fast moving pantograph and wind pressure. It comprises huge number of insulators,
fittings and accessories. The failure of any one may result in interruption of train services for
substantial period until the defect/ breakdown is rectified.

The following schedules of maintenance for OHE are being followed in the Indian Railways:
1. Foot Patrolling
2. Trolley Inspection/ Cab of locomotives
3. Current Collection Test
i. By Mirror
ii. By Oliver ‘G’
4. Special Checks
5. Annual Maintenance
6. Checks by OHE Inspection Car
7. Periodical Checks
8. Re- tensioning of Unregulated OHE
9. Condition Based Maintenance through Thermo Vision Camera

2.0 FOOT PATROLLING OF OHE

An experienced OHE technician (accompanied by an OHE staff if deemed by local

condition) should be deputed to petrol the section on foot by day. He should cover every
parts of the section including yards once a fortnight and suburban sections once a week.
SE/JE OHE should foot- patrol the section once in six month.

The technician on foot-petrol should be equipped with signal flags, emergency

telephone instrument and essential tools required for attending minor defects (without power
block) on the spot.

The technician should check the points given on next page.

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FOOT PATROLLING DIARY

1. Depot:
2. Date:
3. Name of the Technician:
4. Section:
5. From Km to Km:
6. Time of Starting:
7. Time of Ending:
8. Reporting time to TPC:

S.No Item Observation

1. FOUNDATION i) Damaged or cracked
ii) Water collection around foundation
iii) Side earth filling required
iv) Top of foundation cleaned or not
2 MASTS AND i) Mast deflected towards track
PORTALS
ii) Mast deflected away from track (other than those already under
observation & thus painted with yellow band)
iii) Hit mark or damage to the mast
iv) Number plate missing
v) Number plate damage
vi) HRL, IMP, Telephone socket marking etc.
3. ANCHOR i) Nut, check nut or lock plate pin missing from anchor ‘U’ bolt
ii) Nut, check nut or lock plate pin missing from guy rod
iii) Anchor bolt rusting
iv) looseness of guy rod
4. BRACKET i) Bracket insulator damaged
ASSEMBLY
ii) Stay Insulator damaged
iii) 9-Tone insulator damaged
iv) Any other defect noticed
5. SECTION i) Abnormal wear on runners
INSULATOR
ii) Core insulator cleaned or not
iii) Core insulator having flash mark/damaged
iv) Any grease accumulation noticed
v) Abnormal wear of contact wire under section insulator splice
6. AUXILIARY i) Drop out fuse found fallen
TRANSFORM-
-ER FOR CLS ii) Soundness of earth connection
SUPPLY iii) Any oil leakages noticed
iv) Core insulator having flash mark/ damaged

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S.No Item Observation

7. OHE SPAN i) Span droppers abnormally out of plumb.
ii) Span droppers damaged.
iii) Any other abnormality in respect of jumper.
iv) Catenary strand damaged
v) Excessive sagging or hogging of contact wire
vi) Excessive wear of contact wire under swivel clip, curve, splices,
PG clamps etc.
8. ISOLATOR i) Post insulator damaged
ii) Integral and pad lock missing/damaged
iii) Any signs of sparking/over heating
iv) Isolator number plate missing
v) Soundness of earth connection
vi) Proper closing of contacts
9. GENERAL i) Availability of danger and caution boards
CHECKING
ii) Height gauge at level crossing
iii) Emergency socket found damaged/out of order
iv) Earthing of platforms/Sheds etc.
v) Bonds found disconnected/missing or any sign of sparking
vi) Protective screens on FOB/ROB
vii) Tree branches near OHE.
viii) Birds nest and pieces of stray wires
ix) Defect in transformer secondary neutral connection to rail at FP
x) General conditioning of SSP/SP on route.
xi) Minor defects rectified if any during patrolling.
xii) Observe running train pantograph condition passing in section
for smooth current collection and any abnormality
xiii) Any other abnormal/ unusual situations noticed
10. REGULATING i) Guide tube should not be bent & all fasteners and fitting must be
EQUIPMENT intact
ii) a. Movement of counter wt. with 10 kg wt. for winch type.
b. Movement of counter wt. with 17 kg wt. for three pulley and
observe for restoration in original position.
iii) Check the alignment of drum pulley and anchor fitting

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S.No Item Observation

10. iv) SS wire rope over riding on drum grooves
v) SS wire rope rubbing with pulley/drum
vi) SS wire rope strands found cut and bird caging
vii) Whether equalizing plate is tilted or not
viii) Twisting of OOR contact wire
ix) ‘Y’ distance is abnormal i.e. beyond the temperature markings
x) Whether small pulley is horizontal ( for winch type ATD)
xi) Any flattening of wire rope observed near small pulley ( for
winch type ATD)
xii) Check for bend, deformation, missing guide tube, deformation
of eye of base counter weight
xiii) Hex pipe of suitable length is provided over hex tie rod
(anti- falling rod)

Signature of Technician
Checked By:

Signature of Depot In-charge:

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Pictures Related to Foot Patrolling

SS wire rope stand broken

Bird caging

Fig-1 SS wire rope strands broken and bird caging

10 kg

17 kg

Fig-2 Movement of counter weight

with 17 kg for three pulley &
10 kg weight for winch type.

Fig-3 Guide tube & eye

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Fig-4 SS wire rope rubbing with pulley/drum

‘Y’ Value

Fig-5 SS wire rope over riding on drum grooves

Fig-6 ‘Y’ distance

Fig-7 Hex pipe of suitable length and anti falling rod must have washer at ends and
straight

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Crow nests

Fig - 8 Crow Nests

3.0 TROLLEY / CAB OF LOCOMOTIVE INSPECTION OF OHE

Inspection of OHE by push trolley is to enable supervisors and officers in charge of
OHE maintenance to observe closely the OHE under their charge and should be carried out
during day time. The depot /OHE in-charge (SE/JE) should inspect his entire section once in
a month. SSE/ADEE (TRD) should inspect their respective sections once in 3/6 months.
Sr.DEE/DEE (TRD) also should cover his entire section at least once a year by push trolley
or motor trolley.

Apart from trolley inspection as above, officers and senior supervisors shall travel by
the cabs of locomotives and EMU trains at least once a month to observe the general
condition of OHE and to get a first hand knowledge of operating conditions.

4.0 CURRENT COLLECTION TEST

4.1 By Mirror
It is necessary to carry out periodic tests to detect points at which contact wire
between the wire and pantograph is unsatisfactory resulting in sparking. Such current
collection tests are performed at night. A mirror is fitted in front of look out glass of the rear
cab of a locomotive and adjusts so as to get a reflection of the rear pantograph which is
normally in service. A person traveling in the cab can then observe through the mirror any
sparking which may take place and note down the location.

The current collection tests should be carried out by the depot /OHE in-charge (SE/JE)
once in three month over his entire section. SSE/ADEE (TRD) should accompany the depot
/OHE in-charge (SE/JE) during such test alternately to cover their respective sections once in
3/6 months. Sr.DEE/DEE (TRD) should accompany the depot /OHE in-charge (SE/JE) cover
his entire section at least once a year.

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4.2 Current Collection by Oliver-G

The OLIVIR-G Plus is developed to assist Over Head Equipment (OHE) spark
detection using a video camera. The hardware unit consist of a GPS receiver which track
the current position of the locomotive in which the ‘OLIVIR-G plus’ is mounted.

The OLIVIR mate RT software supplied with the unit identity sparks in real time
and save them as images with locations, at the same time continuous video film is also
recorded in hard drive. These images can be analyzed to recognize the type of spark (mega
pixel) with their locations.

Fig- 9 OLIVER-G Plus

4.2.1 Procedure
a) Current collection and checking of OHE by OLIVER-G is carried out consecutively
for two to three trips at an interval of two days, covering entire section. Same cycle to
be repeated after every two months.
b) Current collection through OLIVER-G is conducted by rear most electric
locomotive of banker in ghat- section.
c) Current collection is carried out during night time only.
d) Limit of flashes in the unit of Mega pixel and the time frame for its attention will be
as follows:

More than 100 units (High Intensity) - Attend within a week

Between 60 – 100 units (Medium Intensity) - Attend within a fortnight
Between 40 – 60 units (Low Intensity) - Attend within a month

4.2.2 Schedule
The current collection tests should be carried out entire section by ADEE (TRD) level
every two months. Sr.DEE /TRD will cover entire section once in six months.

5.0 SPECIAL CHECKS

Mostly OHE items require attention during annual maintenance and periodical
overhaul. Some items should require more frequent attention as follows:
5.1 Insulators
i. Normally insulator needs cleaning once a year along with the annual maintenance
schedule, where there is no pollution.
ii. Where pollution is not high, the interval may be three months or longer depending
upon the degree of pollution in the area.
iii. Where pollution is heavy, more frequent cleaning of insulators are required.
iv. The affected section should be divided into various zones based on the degree and
nature of pollution and periodicity of insulator cleaning may be fixed suitably.

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5.2 Section Insulator

Section insulators on the main lines neutral sections, passenger yards and sidings
should be attended to once in three months as follows:
i. Clean insulators and replace badly chipped or even slightly cracked insulator.
ii. Check runners for flash mark.
iii. Check level of the assembly and adjust as required.
iv. Check for excessive contact wire wear near anchor clamp.
v. Tighten the PG clamps of droppers and stiffener properly.
vi. Check that pantograph passes underneath the section insulator smoothly.

5.3 Isolating Switches at Yards/ Loading Siding

The continuity and soundness of earth connections should be checked once a month.

5.4 Bi- Metallic Clamps

These should be checked for tightness and sign of overheating once a three month.

5.5 Earth Connections

Apart from general inspection of bond and earthing connections during foot
patrolling, all such connections should be specially checked for continuity and soundness of
connections once in six months.

5.6 OHE Support on Steel Girders

OHE support on steel girder bridge should be examined as possible depending upon
traffic movement.

5.7 Bird Nests

Precaution should be taken during the nesting season and the nests removed as soon
as possible.

5.8 Pre- Summer Checks

i. Overhead : Check all power line crossing for broken & loose guard wire.
crossing
ii. Bird nest/Kite : Remove all kite threads and polythene from OHE, transmission
threads line and other nearby structure as FOB/ROB/platform sheds etc.
iii. ATD’s : Ensure free movement of ATD’s, replaced jammed/ over riding
ATD’s. Proper Z & Y adjustment should be done.
iv. Jumper : Excessive loose jumpers should be attended.
v. Anti- creep : Anti creep having excess sag should be re-tensioned.
Vi Turn out/Cross : All turnouts and crossovers should be checked.
over
vii. FOB/ROB : Clearance of the OHE under FOB/ROB should be checked.
Protective screen, cable/wires should be properly secured.

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5.9 Pre- monsoon checks

i. Check the condition of insulators specially that of section insulator at major yards
having mixed type of traction.
ii. Check the over line structure for any water leakage on the OHE.
iii. Trimming of trees branches near to OHE.
iv. Check the condition of embankments with respect to stability of mast.
v. Ensure that proper drainage of rain water surrounding the OHE foundation/ OHE
mast.

5.10 Monthly Maintenance of PTFE Type Neutral Section Make Balfour Beatty Power
corporation Ltd UK (BBPC)

1. Date of Inspection:
2. Section:
3. Location:
4. Line:

S.No. Observation Action taken

1. Check ceramic bead insulator Cleaned/replaced (if required)
2. Check complete bracket of PTFE for any Checked loose connections,
abnormality damages and cracks.
3. Check the burning of arcing horns and Attended
arc catcher tips
4. Check horizontally of arc catcher Adjusted by adjustable dropper, if
required.
5. Check flexibility of anti-torsion spring Free movement checked
dropper
6. Measure air clearance between arcing Examined it should be 320 mm min.
horn and arc catcher tips
7. Check earth jumper Flashing mark on nut & bolt, lug
and loose connection checked
8. Check flashing mark on the rail, lug and Checked or replaced nut & bolt (if
mast required)
9. Check bond between rail to mast and Checked flashing mark and loose
mast to earth electrode connections
10. Check any cracks on anti-torsion tube to No crack observed
messenger clamp
11. Check free movement of telescopic anti- Checked free movement.
torsion tube.

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Aanti - torsion tube

to messenger clamp.

Earthing lug

Telescopic anti-
-torsion tube.

Complete
bracket of
PTFE
Ceramic beads

Arc traps and

Arcing horns.

Fig – 10 Maintenance of BBPC Type neutral section

5.11 Quarterly Maintenance of PTFE Neutral Section of Make Arthur Flury AG

1. Date of Inspection:
2. Section:
3. Location:
4. Line:
S.No. OBSERVATION ACTION TAKEN
1 Check PTFE cover of the insulating Cleaned/rotate(if required)
rod
2 Check complete bracket of Neutral Checked looseness of screws, nuts,
Section for any abnormality damages and cracks
3 Check wear of insulating rod Checked, if wear max 2 mm, the rod
should be rotated by 2 marks(72 degree)
4 Check leveling of skid Checked level by sprit level
5 Check the length of skid’s bulb Checked, if length less than 2 mm, then
skid’s should be replaced immediately
6 Excessive wear at the intake point Checked readjusted of the skids
of skids
7 Check turnbuckles Checked and locked with counternuts
and secured with locking wire
8 Check earth cable Connection checked

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Neutral section
Arthur Flury AG
type

Fig – 11 Neutral Section of Arthur Flury AG

6.0 MAINTENANCE

6.1 Annual Maintenance of ATD

1. Location No
2. Section
3. Elementary Section
4. Half Tension Length
5. Type of ATD
6. Make of the Equipment
7. Make & batch/year of mfg. of 9 ton insulator
8. Make & batch/year of mfg. of SS wire rope
9. Make of cat. wire ending cone
10. Make of cont. wire ending cone
11. Date of maintenance
12. Checks the following and attend /replace wherever required:-
a) Condition of SS wire rope and lubricate
b) Free movement of regulating equipment
c) Rubbing of SS wire rope with side wall of the pulley
d) Alignment of wire rope with drum/pulley
e) Condition of check nuts and split pin of anti falling rod
f) Condition of 9 ton insulator
g) Condition of guide tube
h) Condition of 9 ton adjusters
i) Condition of eye of base counter weight, if found bent or broken
replace/provide with clamping ring suitably sitting in the guide tube
j) Counter weights for any crack
k) Alignment of drum, center to center distance of hole in bent arms

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13. Checks the availability:-

a) Base counter weight split pin
b) 9 ton adjusters split pins
c) Double strap split pin at counter weights
d) Anti falling rod check nuts, split pins
e) Split pins of guide tube at top and bottom
f) Check the fixing end of SS rope and secure, if required
14. Check the tightness:-
a) Guy rod
b) Check nuts of 9 ton adjuster
c) Check nuts of anti falling rod
d) Anti falling rod angle
e) Top and bottom attachments of guide tube
15. Check the clevis for free to swivel, cracks / blow holes and defects:-
16. Measure and record:-
a. X / Z value in meters .
b. Y value in meters
c. Temp.0 C
I. Before Adjustment
II. As per Temperature
III. After adjustment
IV. Type of adjustment by turn buckle or by cutting of contact/ catenary
wire
17. Check the appearance of counter weights paint, if required with white aluminum.
18. Lubricate the SS wire rope with BALMER LUBE-1000
19. Length of sleeve to be provided on
Hex tie rod (anti falling rod) : ---------cm
Sleeve actually provided : ---------cm
20. Felt & Grease seals of drum with correct grade of grease
21. Check the max, min & normal markings of temperature, if faded repaint
22. Stencil the tension length on the mast and date on the bottom counter weight
23. Deviations if any from SED
24. Remarks, if any

Signature of the technician Signature of the supervisor

Initials of depot in-charge

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Pictures Related to Annual Maintenance of ATD

Fig-12 Alignment of Drum, center to center distance

Fig-13 Drum grooves no damage of its wall Fig-14 Felt & Grease Seals must

Fig- 15 Clevis free to swivel

G I pipe sleeve

Fig-16 Anti falling rod sleeve

Fig-17 Mast anchor fitting

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6.2 Eighteen Months Maintenance of Single Cantilever and Annual Maintenance of

Double & Triple Cantilever
1. Date of Inspection:
2. Section :
i) Location No:
ii) Km
iii) Road Up/Dn
3. Insulator make & year batch no:
i) Stay
ii) Bracket
iii) 9 ton insulator
4. Implantation: Height: Stagger:
i) As per SED
ii) As recorded
iii) As adjusted

Sr. OBSERVATION ACTION TAKEN

5. Type of Location
6. Type of mast
7. Tangent/Curve
8. Check the verticality of the mast - Up to 3 cm permitted
(for leaning) measure leaning - Up to 5 cm keep under
observation. A yellow band is
painted at a height of 1.85 m from
rail level
- Above 5 cm attend it.
9. Check the condition of insulators Checked and replace, if required
for any chipping / flash over /
cracks /loose cementation at the
metal caps
10 Check the condition of structure Checked for any damages of catenary
bond, in case of flash over noticed wire inside the suspension clamp
at the bond fasteners
11 Check the register arm dropper for Checked for dropper clip tightness
any wear on the hook & dropper Slipping of dropper clip cause panto
clip for looseness entanglement
12 Check the plumbing of the Checked if required
cantilever and attend
13 Check the up drooping of stay tube Checked and use adopter, if possible
14 Check the diameter of contact wire Wear of contact wire appears
and record abnormal, location should be
specified
15 Check the projection of bracket Checked bracket tube/ RT projection
tubes & register arm tubes whether is more then 20 cm replace or cut the
infringing the clearances to the tubes
portals or to other elementary
section of OHE.

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Sr. OBSERVATION ACTION TAKEN

16 Check the availability and condition of split
pins at
i) Mast attachment for bracket fitting clevis,
ii) Bracket insulator snap head pin
iii) Rivet at catenary suspension clamp holding
RT dropper
iv) Catenary dropper clip bolts of in span
droppers
v) Contact wire swivel clip pin
( ‘U’ pin)
17 Check the condition of rivets of large bracket Checked for any
tube slackness
18 Check the tightness of All rusted / damaged
i) Mast fitting for hook insulator bolts bolts noticed shall be
ii) Mast bracket fitting replaced
iii) Anti-wind clamp
iv) Drop bracket assembly
v) Tubular stay sleeve
vi) Catenary suspension bracket
vii) Catenary suspension clamp
viii) Stay tube insulator fasteners
ix) Bracket tube insulator ‘U’ bolts
x) Check inclined dropper, its fitting & split
pins
19 Check the galvanization of the cantilever tubes If rusted replace /paint as
required
20 Check & tighten ACC (Cat, double susp. clamp.
U bolts)
21 Check the condition of ACA / FTA / BWA
22 Check the condition of foundation if it is on the bank
check for soil exposure
23 Check the condition of muffing for any breakage If it is found broken
repair the same
24 Check the condition of galvanization of the If it is rusted, painted
supporting structure/mast by cold galvanizing
paint
25 Check the rail level with respect to the marking If deviation is more then
on the mast 20 mm, inform
concerned SSE ( P.way)
26 Check the markings on the mast viz. rail level, Checked and painted, If
implantation, telephone socket direction, ATD faded
upper, normal & lower level etc.
27. Check the condition of catenary wire in the In case of abnormality
Suspension clamp and presence of lock plates attend it.

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Sr. OBSERVATION ACTION TAKEN

28. Check the jumpers condition in Normal sag, proper direction & spacing
the span including fixing of PG clamps

29. Check the condition of splices No abnormality

30. Check horizontally of RT Horizontal

31. Check steady arm dip It should be 25 to 30 cm

Remarks, if any

Signature of the supervisor Signature of the technician

Initials of depot in-charge

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6.3 Annual Maintenance of Isolator

1. Section:
2. Location:
3. .Line:
4. Date of Inspection:
5. Identification:

Sr. OBSERVATION ACTION TAKEN

6 Check the presence and condition of the number If missing provide, clean
plate with waste cotton
7 Check the tightness of operating rod, operating Tighten, if required.
rod handle base plate and isolator base frame
bolts
8 Check the condition of locking arrangements to Lock provide
the operating handle and provision of pad lock.

9 Check the isolator for smooth operation and Should be free movement
correct alignment of contacts.
10 Clean the fixed and moving contacts of isolator Apply petroleum jelly.

11 Check the fixed spring contact tension Tighten

12 Check the distance between fixed and moving Min 380 mm to 500 mm
contact in fully open position and record. max.
13 Clean the pedestal insulators with dry cloth and Cleaned and replace crack
check for any cracks or flash over of flash over insulator
14 Measure and record IR values of tie rod insulators Measure IR by 2500 V
with megger and check for any cracks or flash- megger & replace crack
over. of flash over insulator
15 Lubricate all moving parts of the isolator. Lubricated

16 Check the tightness of the connectors on the Replace rusted nuts, bolts
isolator and check for any over heating marks & washers and over
heated connectors
17 Check the alignment of guide ring and operating No infringement
pipe
18 Check flexible earthing between operating handle Intact
and fixed structure
19 Check arching horn if applicable Any abnormality

Signature of the Supervisor Signature of the Technician

Initials of depot in-charge

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6.4 Quarterly, Half yearly and Yearly Maintenance of Motorised Isolator

1. Section:
2. Location:
3. Line:
4. Date of Inspection:
5. Identification:

a. Quarterly Schedule

S. No. OBSERVATION ACTION TAKEN

1 Open the cover of control box. Check By using dry cloth or vacuum
the interior & remove the accumulated cleaner.
dust
2 If any part of the panel found rusted Find out the cause, plug the
indicating entry of moisture holes and repaint the rusted part.

3 Check weather proof gasket For their good condition.

4 Check the connection of terminal For tightness and corrosion
connector nut, bolt and washer.
5 Check clearance between blades in open It should be 500 mm. and adjust,
condition. Check the correct alignment if required.
of isolator for its firm grip while isolator
in closed condition.
6 Check the operation manually as well as Mechanism and operating rod
electrically in local and remote, keeping functions smoothly without any
the control door open condition rubbing or obstruction.
7 Check wiring connections Tighten and secured
8 Check healthiness of relays and working
contactors.
9 Check the working of heater Working
10 Check the earthing connections Proper tightness
11 Check locking arrangement. working
12 Grease and lubricate all moving parts Greased & Lubricated

b. Half Yearly Schedule

S. No. OBSERVATION ACTION TAKEN

1 In addition to quarterly schedule,
carry out following activities
2 Clean the male/female blade/Jaw of Cleaned with dry cloth and apply
isolator with kerosene oil vaseline lightly. Wipe off the jelly
to avoid accumulation of dust.
3 Check limit switches, auxiliary Overheating, looseness and proper
switches & contacts. working
4 Check correct setting and alignment Adjusted if required
of arcing horn

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c. Yearly Schedule

S. No. OBSERVATION ACTION TAKEN

1 In addition to quarterly and half yearly
schedule, carry out following activities
2 Check the winding resistance of the 110V In permissible limit
DC motor.
3 Clean the commutator Cleaned
4 Check carbon brushes Measured length
5 Lubricate the operating mechanism and main Lubricated
contacts

Signature of the Supervisor Signature of the Technician

Initials of depot in-charge

6.5 Annual Maintenance of Level Crossing Height Gauge

1. Level crossing gate no:

2. Between location no:
3. Line reference:
4. Gate particulars:

S.No OBSERVATION ACTION TAKEN

5 Measure the height of contact wire It should be 5.50 m min.
from level crossing
6 Measure the gradient of contact wire
7 Measure the height of height gauge It should be 4.67 m max.
form road level
8 Check the condition of height gauge Checked for damaged of
boom, foundations, upright
etc.
9 Check the level of road below rail
level
10 Check the danger board Checked for availability
11 Check and tighten the Level Checked for availability
crossing barrier board
12 Check and tighten the cross bond Checked for availability
with in 5.0m of level crossing
13 Check the earthing of level crossing Intact
barrier

Signature of the Supervisor Signature of the Technician

Initials of depot in-charge

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6.6 Annual Maintenance of Cross/Along Track Feeder

1. Date of Checking:
2. Section:
3. Location:
4. Line:

S.No OBSERVATION ACTION TAKEN

5. Check the drop jumper - Tighten the PG clamps
conditions (OHE) - Replace overheated nuts, bolts & washers and PG
clamps
- Replace damaged, overheated and strand broken
jumper
6. Check bi-metallic pipe - Checked for availability
(Strip) between feeder - Replace overheated/ damaged bi- metallic pipe
PG clamp and copper (strip)
jumper
7. Jumper between - Tightened
Gantry to Gantry
8. Check insulator - Checked for cracked & chipped
9. Check the strain - Checked for cleaness, tighten and any deficiency
clamps and PG clamps

Signature of the Supervisor Signature of the Technician

Initials of depot in-charge

7.0 ANNUAL MAINTENANCE BY OHE INSPECTION CAR

7.1 Maintenance of Turnout / Crossover

Point and crossing are one of the most important locations which need special
attention in respect of erecting as well as maintenance because mal adjustment of OHE may
lead the panto entanglement.

Sr. DESCRIPTION STD. VALUE

1. Particulars of Turn-out / cross-over (Give the
number i.e.1:8½, 1:12 etc.)
2. Point no
3. Section
4. Location No.
5. Date checked
6. Type of Arrangement - Crossed /Overlap type
7. Height of contact wire above rail level at Main line contact
support at obligatory Structure Wire (m), (H)
Turnout contact wire (mts)
H+50 mm

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Sr. DESCRIPTION STD. VALUE

8. Height of contact wire towards turnout Main line contact Wire m (H)
up to 10 mtrs Turnout contact wire mts H+50 mm
9. Turnout span (m) 54 m (Max)
10. Height of contact wire in overlapping Main line contact
zone Wire (m), H
Turnout contact wire (mts) H+50 mm
11. Pantograph should not touch the turn Turnout/ crossover contact wire (m)
out/cross over contact wire while train H+50 mm
passing main line
12. Stagger of contact wire at obligatory Mainline contact wire (mm)
structure 200 max.
Turnout contact wire (mm) 300 max.
13. Sag of section insulator of Height same as at support zero
Turnout/Crossover
14. Sag of contact wire As per RDSO’s standard dropper
schedule
15. Movement of tower wagon from main 650 mm to720 mm from centre line of
line to turnout pantograph
a.Take off
b. Point of take off (in m from o/s) ------
16. Movement of tower wagon from 650 mm to 720 mm from centre line of
turnout to main line pantograph
a)Take on
b) Point of take on (in m from o/s) -----
17. Observation on obligatory location Resister arm tube horizontal
bracket plumbed deep 25-30 mm
18. Vertical distance between register arm With drop bracket – (300 mm)
axis and contact plane With steady arm clamp – (250 mm)
19. Stagger of section insulator of +/- 100
Turnout/Crossover
20. Track separation at the location of
section insulator (m)
(a) Runners towards the centre of turnout 1.65 m min
(b) Runners away from the centre of 1.45m min
turnout
21. Condition of ATD of turnout/mainline Free to move
OHE
22. Length of pipe provided in hex tie rod of As per SMI No.TI/MI/0035Rev.1
limiting device to bridge redundant length
of hex tie rod.
23. Setting distance (implantation) of 3.0 min
obligatory structure (m)
24. Distance of 'G' jumper from obligatory 5.6 m
structure (m)
25. Track separation at obligatory structure 150 to 700 mm
(mm)

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Sr. DESCRIPTION STD. VALUE

26. Length of ‘G’ jumper. (m) 4.0 m
27. Deviations from SEDs
28. Adjustments done, if any
29. Remarks
30. Name of supervisor and designation
31. Signature of supervisor

Signature of supervisor Signature of technician

Initials of Depot In-charge

Picture Related to Turn Out /Cross Over

Fig-18 Diamond Crossing

Fig- 19 Pantograph of tower wagon takes up the contact wire of main line OHE

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Fig- 21 Horizontal & vertical separation

Fig- 20 Obligatory Structure &
Implantation

Fig-22 Mainline stagger of turn out OHE

should not exceed than 300 mm

Fig-23 Clearance & Level of runners

Fig-24 Stagger of section insulator

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7.2 Maintenance of Section Insulator Assemblies

1. Section:
2. Location:
3. Line:
4. Date of Checking:
5. Identification with tag:

S. OBSERVATION ACTION TAKEN

No.
6 Clean the insulators and replace badly chipped or Cleaned by cotton waste
even slightly chipped insulators
7 Check the runners for flash marks Attended
8 Observe for hit marks on the runners Attended
9 Check the for excessive contact wire wear near Find the reason and attended
anchor loops
10 Check the level of section insulator cross beam Checked by sprit level and
assembly adjusted if necessary
11 Tighten the PG Clamps of the droppers and Tightened
stiffeners
12 Check and record clearance between runner to Checked runners to runners
runner and contact wire should be 460 mm max.
contact wire to runner 230
mm
13 Check the pantograph passes smoothly under the Smooth passes
section insulator
14 Measure and record the IR Values of section More then permissible limit
insulator and 9 ton insulator
10 Height of SI from rail level measured
15 Core insulator and cut -in- insulator make Noted
16 Encumbrance at S.I Not less then 450 mm
17 Adjust the runners for level a smooth passage of Adjested
pantograph
18 Measure the Stagger of section insulator It hould be zero

15 Remarks.

Signature of Supervisor Signature of Technician

Initials of Depot In-charge

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7.3 Maintenance of Over Lap OHE and RRA Clamp

1. Section between:
2. Date:
3. Line Reference:
4. Type of Over Lap:
5. Span:

Sr. OBSERVATION ACTION TAKEN

6 Check the distance between parallel 200 mm for UIOL
contact wire 500 mm for IOL
7 Stagger of in running contact wire ±200 mm (tangent)
±300 mm (curved)
8 Overlapping of contact wire 2 to 9 m
9 Cut-in–insulator of catenary and contact It should be zero
wire not to have longitudinal shift
(Eccentricity)
10 Proper seating and tightness of Tightened, if loosen and seating
connections at PG clamps of ‘G’ & ‘F’
jumper
11 Make adequate looping in jumper and Checked length of jumper, if
ensure 8 nos. of PG clamp in ‘G’ jumper short replaced it,
If PG clamp is less then 8 nos.
provide it
12 Make a proper shape of jumper Shaped
13 Check the contact wire in RRA clamp Checked by hair crack by
magnifying glass
14 Check for crack/damage to the contact Checked with the help of
wire and sharp edges/ defect in the magnifying glass
clamp fitting.
15 Check for deformation of RRA clamp If defective, replace it
16 Check for crack/damage to the contact Change the contact wire/
wire in the vicinity of RRA clamp providing splice/ Contact wire
ending clamp

Signature of Supervisor Signature of Technician

Initials of Depot In-charge

“JAHAN MILE DO TENSION LENGTH,

WAHAN HO ‘G’ JUMPER WITH DOUBLE (P G
CLAMP) STRENGTH”

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7.4 Annual Maintenance of Overline Structure/Tunnels and Clearances Under Overline

Structure
1. Date of Checking:
2. Section/ Station:
3. Between OHE Location:
4. Span Length:
S.No. OBSERVATION ACTION TAKEN
5 Check horizontal and vertical clearances Adjust if required
6 Check for flash marks on the under side of the
bridge structure
7 Check the gradient of contact wire on either side Checked it should not
exceed 3 mm/m
8 Check the clearance of catenary or contact wire Checked both ends
whichever is nearest to structure both ends
9 Check that false catenary (contact wire) is Checked for availability
provided
10 Check that insulated sleeve is provided
11 Check that smoke screens are properly Checked and these should
secured and have adequate clearance be attended by Engg.
Dept.
12 Check the condition and availability of 25000 Checked for damaged or
V danger board on screen missing
13 Check the condition of under side of the bridge Checked for any foreign
material hanging
14 Check the side gap on FOB/ROB for water or Checked and rectified
foreign material
15 The minimum height of ROB headroom from As per SOD (Schedule of
rail level should be maintain Dimension)

16 The minimum height of FOB headroom from As per SOD (Schedule of

rail level Dimension)

Signature of Supervisor Signature of Technician

Initials of Depot In-charge

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7.5 Splices
1. Date of Checking:
2. Section:
3. Line:
4. Location:
5. Make:
Sr OBSERVATION ACTION TAKEN
6 Check for cracks, other casting defects and Checked and replaced
abnormalities
7 Tightness of the stainless steel stud Checked for tightness
8 Check that any slipping of the ends of two There should be no gap
contact wire has take place when viewed through between the two contact
the top window wire ends
9 Normally contact wire splices should not re-used
10 In case of catenary splice fitting tightness of the
right-hand and left-hand joint sockets
Signature of Supervisor Signature of Technician
Initials of Depot In-charge

7.6 Maintenance of OHE

1. Date of Checking
2. Section
3. Line
4. Location From----To----
5. Make of Contact Wire

SN OBSERVATION ACTION TAKEN

6 Check the stager of contact wire & centenary As per SED
wire
7 Check the contact wire height by height gauge As per SED
8 Check the all nuts & bolts, ‘U’ pins, split pins Tighten if loose, missing item
provided
9 Check the kinks in contact wire Kink remove by kink remover,
if observe
10 Check the ‘G’, ‘C’, ‘F’ jumpers Any deformation, strand
broken, shaping, PG clamp
tightness, Rusting of nuts,
bolt & washers
11 Contact wire diameter vertically Measured by micrometer
12 Check hogging of contact wire Adjust by one end dropper
13 Check the height of contact wire in mid span Calculate pre sag
14 Check gradient of contact wire profile 3mm/m
15 Check the twist of contact wire Twist remove by twister

Signature of Supervisor Signature of Technician

Initials of Depot In-charge

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8.0 PERIODICAL OVERHAUL

The object of POH is to recondition and restore the installation in the condition it was
when it was first commissioned, whereas preventive maintenance has for its objective to take
care of the wear and tear during normal service and forestalling possible failures by regular
inspection and quick attention. The POH should be thorough and cover every part of the
installation.
The POH of OHE should be intended on a programmed basis at an interval of 4 years.
The aim of POH is to make a thorough inspection of the OHE and to replace such of the
worn out or damaged parts by those which have been reconditioned earlier in the
maintenance depots and kept ready. The parts removed are sent to the maintenance depots
for dismantling, through inspection, re-conditioning.
In addition to the items detailed under annual maintenance, the following items should
be attended to during POH.
8.1 Cantilever
1. Date of Inspection:
2. Loc No:
3. Road (Up/ Dn):
4. Section:
5. Type of Loc:
6. Type of Mast:
7. Insulator Make & Year Batch No (Stay, Bracket and 9t Insulator):
8. Tangent/ Curve:
9. Implantation:
10. Height and Stagger:
i. As per SED
ii. As recorded
iii. As adjusted
11. Record the following parameters as shown in figure- 25 and compare with SED values.

Sr. SYMBOL DESCRIPTION

i. a ( dimension) Distance between mast stay arm fitting and the center of
catenary suspension bracket.
ii. b ( dimension) Distance between the axis of the vertical swivel and the
axis of catenary suspension bracket.
iii. c ( dimension) Distance from the bottom cap of bracket insulator to the
axis of register arm hook.
iv. d ( dimension) The horizontal distance between the center of the hook of
register arm hook and the axis of catenary suspension.
v. e ( dimension) Encumbrance the distance between the axis of catenary
and contact wire.
vi. f ( dimension) The distance between contact plane and mast bracket
fitting.
vii. r ( dimension) Distance between contact plane and register arm axis.
(Assume r is horizontal)
viii. h ( dimension) The vertical distance between top fitting and bottom
fitting.

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f
d

Fig – 25 Single bracket

a

c
h

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12. At least one complete cantilever assembly per 10 track- km should be removed and
taken to the depot/workshop for dismantling and detailed examination of various
components after through cleaning. This test check would reveal the extent to which
other cantilever assemblies have to be examined.
13. All GI fittings pipes should be examined for deterioration of galvanization. Minor
chippings may be repainted by using cold galvanizing paint.
14. Aluminium bronze fittings, bolts and nuts should be cleaned and carefully checked.
Care should be taken to see that the threads are in good condition. Fittings which
have developed cracks or any deformation should invariably be discarded.
15. As the bracket is articulated, check the position with reference to the axis of the
mast. The position will vary with temperature and distance from anti-creep. The
register arm and steady arm should be in the same plane as the bracket.
16. Check adjustments of cantilever assemblies, their slope and displacements at every
structure for compliance with the ‘as erected SED’s.

Signature of the supervisor Signature of the technician

Depot in-charge initials.

8.2 Regulating Equipment

In periodical overhaul Schedule complete set of Drum / pulley is removed from the
mast & new overhauled set is replaced instead of the old one. Periodical maintenance
schedule is carried out at each location after every 4 years. The POH schedule must be done
very carefully to avoid the failure on line.
1. Location No:
2. Half tension length:
3. Type of ATD:
4. Make of the equipment:
5. Make & batch/year of mfg. of 9 ton insulator:
6. Make & batch/year of mfg. of SS wire rope:
7. Make of cat. wire ending cone:
8. Make of cont. wire ending cone:
9. Date of maintenance:
10. All regulating equipment should be replaced by previously overhauled/new ones and
the removed equipment should be sent to the depot/workshop for overhaul.
11. The regulating equipment should be dismantled and every part should be checked and
cleaned.
12. Cleaning must be done by using kerosene & cloth.
13. The bearing should be replaced after each POH with a new bearing procured from the
manufacturer or its authorized representative.
14. Bearings must be removed using bearing puller jig with due care. Hammering with
local arrangement must not be done it may damage the housing & bearings.
15. Rubber washer/rings should be replaced where necessary.
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16. Any grazing or rubbing on pulleys should either be repaired if possible or the damaged
equipment should be replaced.
17. All lubricating holes should be free for passage of grease.
18. The stainless steel rope should be closely checked for damage to the strands.
19. Particular attention should be given to the end fittings on the stainless steel rope.
20. Ensure that use approved type of lubricant for regulating equipment components.
21. Check thoroughly the condition of stainless steel wire rope through magnifying glass
for loose wires/strand; broken wires/strands, rusting, pitting/corrosion and bird caging.
If any of these defects is observed, the wire rope should be replaced immediately with
new lubricated wire rope.
22. Check the pulley, bent arms & bearing housing for any change in dimension and if
found deformed, if should be repaired/replaced.
24. Aluminium bronze fittings, bolts and nuts should be cleaned and carefully checked.
Care should be taken to see that the threads are in good condition. Fittings which have
developed cracks or any deformation should invariably be discarded.

8.2.1 Replacement of ATD at Site

After getting power block with proper message confirmation & testing & putting
discharge rods on OHE. Following steps is carried out:-
1. Measurement of X, Z & Y values & analysis of X, Z & Y value for adjustment
during the schedule.
2. Putting cum- along clamps of contact & catenary wire.
3. Using pulley arrangement putting tirfor 3- tons for OHE & 1.5 -tons for balance
weight.
4. Taking load so as to lift the balance weight & pull the catenary to enable to release
the ATD drum/pulley set.
5. Remove the old set & fix the new overhauled set.
6. Setting the OHE & balance weight in its original position.
7. Measurement of X, Z & Y values.

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Picture Related to Regulating Equipment POH

Fig- 26 Checking for damage of groove using GO - NO -GO Gauge

Bent arms Nuts

Fig –27 Bent arms & nuts

Fig-28 Checking of housing with GO -NO -GO gauge

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Fig-29 Bearing jig and damaged housing & bearings

Fig-30 Bearing of NBC 6305 LLU or SKF 6305 2RS1

Fig-31 Fitment of drum/pulley after POH

Broken Strands

B
Caging at bend
B

Fig-32 Damaged SS wire rope

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8.3 Catenary and Contact Wire

i. Dismantle all jumpers, clip connections etc. and clean the conductors with the help of
emery paper in case of copper or bronze conductor and metallic brush in case of
aluminium conductors.
ii. If wire shows sign of overheating, because they are not tightened properly or the clips
are deformed contact surface is insufficient. Clip should be replaced.
iii. In the case of contact wire, groove has to be cleaned with either a fine metallic brush or
emery paper.
iv. The use of scraper or file is forbidden.
v. Remove kinks if found.

8.4 Jumpers and PG Clamps

i. All jumpers and PG clamp should be replaced by previously overhauled/new ones and
the removed jumpers and PG clamp should be sent to the depot/workshop for
overhaul.
ii. All jumpers and PG clamp should be checked for detailed examination of damaged or
frayed and through cleaning of jumpers.
iii. Proper bonding and tin soldering of jumpers end.
iv. Check and clean oxide from PG clamp surface with the help of emery paper in case of
copper or bronze item.
v. Bolts, nuts and washers should be replaced in POH, if rusted.
vi. Apply corrosion inhibiting compound.

8.5 Insulated and Un- Insulated Overlaps

i. Check the position of contact wire with respect to tracks to comply with SED’s.
ii. Ensure that insulators of anchoring wires are crossing the plane of OHE in correct
position as per plan.

8.6 Overline Structure

i. Check the height and gradient of the contact wire adjust the same with drawings.
ii. Check the long time and short time clearances

8.7 Overhead Cross-feeder, Return Conductor and 25kV Feeder

i. Check wire for frayed strands, overheating, pinching or corrosion, especially at
suspension clamps and PG clamps.
ii. Ensure that all joints are properly coated with vaseline during tightening PG clamps.
iii. Check tension in wire and adjust if necessary.
iv. Other overhead wire such as bypass feeders and earth- wire should be checked. The
insulator attachments should be dismantled and cleaned, overhaul and put back in
poison.

8.8 Contact Wire & Catenary Wire Ending Clamp

i Visual inspection should be done during POH (Once in four year).
ii. Replace the fitting once in eight years (alternate POH) and carried out necessary
adjustment

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9.0 RE-TENSIONING OF UNREGULATED OHE

The re-tensioning of unregulated OHE in accordance with the tension-temperature

chart should be done normally at the end of 6 months from the date of erection and again at
the end of 12 months. There after the tension should be checked up once in 2 years and re-
tensioning done as required.

10.0 CONDITION BASED MAINTENANCE THROUGH THERMO VISION CAMERA

Failure of electrical & mechanical devices is because of component failure or

electrical loose connections. Failures such as overhead line problem, problem in electric
connections, overheating, hidden faults and insulation defect etc. results in thermal heating.

Thermal imaging infrared camera identifies electrical and mechanical problems like
hot spots, heat development on loose connections etc. before they result in failures. It is a
non-contact device which detects infrared radiations and converts it into electronic signals.
These signals are then processed to produce thermal image of the object.

The main advantages of thermal imaging infrared camera are:

i. It helps to find out electrical hot spots and faulty equipments in incipient conditions.
ii. It is an ideal means to monitor electrical connections for its healthiness and reliability
when conducting routine surveys of electrical systems, switchgear and electrical
components.
iii. It is a light weight, comfortable and sensitive test instrument with touch screen, text
features.

The following items are to be checked by thermal imaging infrared camera in 25kV
AC OHE as follows.

i) All types of jumpers and their PG clamps

ii) Catenary splice, ‘U’ clamps and bulldog clamps
iii) Contact splices
iv) Isolators contacts, connectors, jumpers and their PG clamps
v) Feeder wire jumpers connected with OHE and their PG clamps

Schedule

The depot /OHE in-charge (SE/JE) should inspect his entire section (OHE) once in
a year and should also OHE Ghat section in a six months.

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Photograph of overheating jumper/ splice connections

Fig –33 Over heating loose connection

Fig –34 Over heating temperature chart

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11.0 RECOMMENDED PROFORMAS OF MAINTENANCE SCHEDULES FOR OHE

PROFORMA No. 03-01

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Daily Progress Register
Ref : Rly Bd’s L.No. 2004/RE/161/1 Pt- III (ACTM) Corr. Slip 13
1. Power Block on sub-sector / Elementary section: Date:
i. Time asked: ii. Time received:
iii. Time returned: iv. Remarks:
2. Staff utilized:
i. Skilled: ii. Semi skilled: iii. Un skilled:
3. Details of work carried out in power block:
S Type of work Locations Staff/Supervisor
No.
3.1 Cleaning of Insulator – ST,BT & 9T

3.2 Section Insulator

3.3 OHE checking & adjustment
3.4 Height & stagger of contact wire
3.5 Dia of contact wire measured in mm
3.6 Clearance checked at locations in mm
3.7 i. Checking of gap insulated overlap
locations
ii. Checking of gap un-insulated
overlap locations
3.8 ATD Locations
4. General report on OHE of the section. Preventive action suggested ____________
5. Report on catenary/jumper damage in the section. Preventive actions suggested _____
6. Details of work carried out under non-power block
SNo. Type of work Locations Staff/Supervisor
6.1 Muff cleaned
6.2 Bond checking
6.3 Rail level and implantation checked
6.4 Repainting of RL and implantation
6.5 Tree trimming

7. Report of foundation/muff condition,, Leaning of masts Preventive action suggested_

8. Report on changes in RL/Implantation, preventive action suggested________
Station:
Signature of Supervisor Signature of Technician
Name & Designation
Initials of Depot In-charge

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CAMTECH/E/11-12/OHE-Schedule/1.0 39

PROFORMA No. 03-02

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION

Register for Foot Patrol

Ref : Rly Bd’s L.No. 2004/RE/161/1 Pt- III (ACTM)

Corr. Slip 13

Patrolling section:
Km.:--------- To-------

Supervisor’s
remarks
Date of noticed

proposed with

Date attended
CategoryA/B

Name/Sign
Noticed by
Location

Action
S. No.

PDC
Date

Category ‘A’ means defect related to safety and train operation

Category ‘B’ means all other excluding ‘A’
Note: Each page should be allotted for every Km.

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PROFORMA No. 03-03

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Tower Wagon/Cantilever Assembly Maintenance Register

Ref : Rly Bd’s L.No. 2004/RE/161/1 Pt- III

(ACTM) Corr. Slip 13

Insu. Make
Attention

Contact
/ Batch

wire

Condition of fitting

Name & Signature

Type of location

Sch/ Un sch
Work done

Clearance.
No.of C/L

Sup./Staff
checking

Due date

Remarks
Dt. of
S.No.

Stg.
BT

Ht.
ST
9T

Note - 1. Each km should start with a fresh page

August, 2011 Review of Maintenance Schedule for OHE

 S.No.

Type of Location(Specify if stop

signal/hard spot
location/tunnel/ROB/FOB/Label
crossing gate or any other location)
CAMTECH/E/11-12/OHE-Schedule/1.0

Location No.

Review of Maintenance Schedule for OHE

Thickness At
support
Wear since last check

Thickness At mid
span
Wear since last check

Dt of provision of CW splice
PROFORMA No. 03-04

................ DIVISION
................ RAILWAY

Observation

No. of catenary strands cut

TRACTION DISTRIBUTION SECTION

Dt of provision of catenary splice

Sup./Staff
Name & Signature
Pt- III (ACTM) Corr. Slip 13

Remarks
Ref : Rly Bd’s L.No. 2004/RE/161/1
Record of Contact Wire Wear and Splices (Proforma 04 & 15 merged)

August 2011
41
42 CAMTECH/E/11-12/OHE-Schedule/1.0

PROFORMA No. 03-05

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Register for Features of Over Line Structure

Ref : Rly Bd’s L.No. 2004/RE/161/1

Pt- III (ACTM) Corr. Slip 13
FOB/ROB------------------- Between Locations --------------------
Station/Section-------------
Clearance
Contact wire height in mtr.

Feature
present
in cm.

Name& Signature
Protective screen
Span in mtr.

double CW
Sup./ Staff
Crossing

Earthing

Ins.Cat./

Remarks
Caution
END 1

END 2

Board

Pr. of
Pipes
Date
Line

PROFORMA No. 03-06

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Register of Earth Resistance Measurements

Ref : ACTM Pt-III Para no. 20349

Station/Section :
Nearest location:
Earth pit No.:

S.No. Date of test Resistance Overall Initial of Remarks if

in ohms Resistance supervisor any

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PROFORMA No. 03-07

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Record of Current Collection Tests

Ref : Rly Bd’s L.No. 2004/RE/161/1

Pt- III (ACTM) Corr. Slip 13
Date:
Timing:
Train Number:
Section From………….To…………

S.No. Location Observation / Corrective Date of Supervisor / Remarks

category action Corrective staff Name
action Signature
Medium
Heavy

Light

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PROFORMA No. 03-07 ‘A’ (New)

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Register for Current Collection by Oliver - G

a) Date:
b) Timings:
c) Train Number:
d) Train Departure: Ref: i. Central Railway CSTM Latter no.L/
e) Train Arrival: 574/TRD/Policy dated 14.11.06
f) Section ii. 28th MSG TRD at SCR on Feb 2011
item no. 28.19
From………….To…………

g) Loco Number & base:

Date of attend high intensity (with

Mega Pixel

Date of attend low intensity (with

the unit of
Flashes in

Date of attend medium intensity

(with in a fortnight)

Reason for flashing

units) White color
Medium Intensity

(between 40 – 60
(between 60-100
units) Blue color
units) Red color
By whom done

(more then 100

High Intensity

Low Intensity

in a week)

in a moth)
Location

Remarks
S.No

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CAMTECH/E/11-12/OHE-Schedule/1.0 45

PROFORMA No. 03-08

................ RAILWAY

................ DIVISION

TRACTION DISTRIBUTION SECTION

Record of Implantation & Foundation ( Proforma 08– 013 merged)

Ref : Rly. Bd’s LNo. 2004/RE/161/1

Pt- III (ACTM) Corr. Slip 13
Section:

Amount of leaning

Amount of leaning
in mm at 1.85 mtr
in mm at cont.
Implantation

from HRL
wire level

Supervisor name & Signature

HRL mark height above rail level

Reason for leaning

Foundation type & condition

Staff / Signature
Action taken
Away from track

Away from track

Dt. of checking

Towards track

Towards track
Step distance
Location No.

As per SED

Actual
S.No.

Note: One page in the register to be allotted for each location

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46 CAMTECH/E/11-12/OHE-Schedule/1.0

PROFORMA No. 03-09

................ RAILWAY

................ DIVISION

TRACTION DISTRIBUTION SECTION

Register of Breakdowns / Accidents Involving OHE

Ref : ACTM Pt-III Para no. 20349

S.No. DESCRIPTION OBSERVATION

1. Date of accident / breakdown

2. Station

3. OHE Locations affected

4. Detail of damages

5. Probable cause

6. Brief description and remedial

action taken

7. Reference to detailed reports sent

8. Remarks if any

Note : One page in the Register to be allotted for each case

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CAMTECH/E/11-12/OHE-Schedule/1.0 47

PROFORMA No. 03-10

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Regulating Equipment

Section:
Line:
Location no:
Type of location other end: Ref : ACTM Pt-III Para no. 20349

Whether replacement of ATD done

Adjustment Final
Noted Value Adjustment done
Required Value

with the over hauled one

Date of Adjustment

Wire cut
Date of checking

Whether greased
X/Z mm

X/Z mm

BY turn buckle
Tension length

Y mm

Y mm

Catenary
Temp 0c

Temp.0c

X/y mm
Contact

Y mm
S.No.

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48 CAMTECH/E/11-12/OHE-Schedule/1.0

PROFORMA No. 03-11

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Isolator Switches

Isolator Switch No…….

Section/Station…………
Make & Batch No…..
Elementary section….
Integral lock Key No…….
Pad Lock Key No……. Ref : ACTM Pt-III Para no. 20349
Elementary section

Particulars of work
Isolator switches
Date checked

Gap between
Particular of

done, if any
connected

Condition
Location

Remarks
contacts
S. No

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CAMTECH/E/11-12/OHE-Schedule/1.0 49

PROFORMA No. 03-12

................ RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Turnout and Crossover

Turnout/Crossover No………… Ref: ACTM Pt-III Para no. 20349

Location between ………..
Section/Station……….

Height of Stagger of

Adjustment done, if any

Whether cross type or
Particular of Turnout/

Turnout /Crossover
Main line contact

Turnout/ crossover

Mainline OHE mm
contact wire, m
Date of check

overlap type

OHE mm
crossover

Remarks
wire, m
S. No.

PROFORMA No. 03-13

............... RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Level Crossing Height Gauges

Ref: Rly Bd’s L.No. 98/Elect (G) 113/7/ACTM

Location of Level

gauges from road

Height of contact

Whether manned
Date of checking

Height of height

or un-manned
height gauge
Condition of

Remarks
crossing
SNo.

level
Line

wire

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PROFORMA No. 03-14 (New)

............... RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Maintenance Record of Insulated /Un-Insulated Overlap

Ref: ACTM Vol. II (pt-1) para 20326

Section:

Condition of

Condition of
between two

RRA clamp
parallelism
Clearance

Length of

Remarks
Type of
overlap

jumper
S. No.

OHE
Date

Line

PROFORMA No. 03-15 (New)

............... RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Maintenance Record of Section Insulator Assembly

Section:
Location between:
Identification no: Ref : ACTM Vol. II (pt-1) para 20326
Anchor clamp
Condition of

Condition of

Condition of

Condition of
droppers &
Insulators

stiffeners
Leveling

Remarks
Runners
Stagger
S.No.

Date

Sag

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PROFORMA No. 03-16 (New)

............... RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Maintenance Record of BBPC Make Neutral Section

Ref: OEM’s Instruction manual

S. Date of Stagger Height Condition Any grease Action Remarks

No. Checking of PTFE of PTFE of beads collection taken

PROFORMA No. 03-17 (New)

............... RAILWAY
................ DIVISION
TRACTION DISTRIBUTION SECTION
Maintenance Record of OHE by Thermo Vision Camera

Ref: i. Central Railway CSTM Letter no.

L/ 574/TRD/Policy dated 14.11.06
ii. 28th MSG TRD at SCR on Feb 2011
item no. 28.19
Section……..
Line……..
Temperature of Catenary

Temperature of Isolators
Temperature of Jumpers

with OHE and their PG

wire jumpers connected
Temperature of Contact

Temperature of Feeder
their PG clamps in °C
contacts, jumpers and
and PG clamp in °C

clamps and bulldog

Temperature of ‘U’
By whom done

clamps in °C

clamps in °C
splice in °C

splice in °C
Location

Remarks
S.No.

Date

NOTE: The temperature of hot spots shall be compared with adjacent/ nearby similar components.
The variation of temperature shall be taken as follow:
i) Variation more then 20°C - To be attended within 24 hrs.
ii) Variation more then 10°C and less then 20°C - To be attended within 10 days.
iii) Variation more then 5°C and less then 10°C - To be attended within a month.
iv) Variation less then 5°C - Normal

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52 CAMTECH/E/11-12/OHE-Schedule/1.0

REFERENCES

1. Manual of AC Traction Maintenance and Operation Volume II (Part–I) Fixed

Installations 1994

2. RDSO’s Specifications no. TI/MI/ 0018 REV-3, TI/MI/ 0028 REV-2, TI/MI/ 0029
REV-3, TI/MI/ 0034 REV-0,TI/MI/ 0035 REV-1, TI/MI/ 0037 REV-2,

3. Indian Railways Institute of Electrical Engineering NASIK.

4. Study of maintenance practices in the field.

5. Maintenance Schedules received from various Railways WR, CR, and SCR, SR etc.

6. Manual of OLIVER-G plus M/s. Total Solution, Bhopal

7. Details of Thermo Vision Camera 28th MSG TRD at SCR on Feb 2011 item no.
28.19

8 Railway Board latter no.2004/RE/161/I Pt-III (ACTM) Correction Slip no. 13 dated
01.07.2005

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CAMTECH/E/11-12/OHE-Schedule/1.0 53

OUR OBJECTIVE

To upgrade maintenance technologies

and methodologies and achieve
improvement in productivity, performance
of all Railway assets and manpower
which inter-alia would cover reliability,
availability, utilisation and efficiency.

If you have any suggestions and any specific

Comments please write to us.

Contact person : Director (Elect.)

Postal Address : Indian Railways

Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code – 474 005

Phone : 0751 – 2470740

0751 – 2470803

Fax : 0751 - 2470841

Review of Maintenance Schedule for OHE August 2011