Page 1 of 7 SPECIFICATION NO.ETI/OHE/27 (8/84) Effective from …………………..

SPECIFICATION No. TI/SPC/OHE/SI/0000(09/2016)

GOVERNMENT OF INDIA
MINISTRY OFRAILWAYS

SPECIFICATION
FOR

SECTION INSULATOR ASSEMBLY WITHOUT SECTION INSULATOR

Sep, 2016

ISSUED BY

TRACTIONINSTALLATIONDIRECTORATERESEARCHDESIGNANDSTANDARDSORGANISATION

MANAK NAGAR, LUCKNOW 226 011(INDIA)

Revision Date of Revision Total pages including Amendment Revisions

drawings
1 Sep -2016 7 Revision-1

NOTE: This specification is property of RDSO; No Reproduction shall be done without

permission from DG (TI) RDSO. This specification is not for general use.

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25 KV AC TRACTION OHE-SPECIFICATIONS FOR SECTION INSULATOR ASSEMBLY WITHOUT

SECTIONING INSULATOR
0. FOREWORD
0.1 The specification for section insulator assembly was first issued by erstwhile Railway
Electrification Organization in 1968. This was last revised by RDSO in 1971. The Earlier revision
which has been made to update all the material specifications referred herein, excludes the use
of aluminum-bronze fasteners and incorporates routine and acceptance tests. The present
revision has been made to update procurement of Fasteners.
1.0 SCOPE
1.1 This specification covers requirements of section insulator assembly for use on
Conventional 25 kv ac single phase traction overhead equipment with single 107 sq. mm hard
drawn grooved copper contact wire conforming to RDSO specification No. ETI/OHE/42(11/83).
1.2 The section insulator provides electrical isolation between two elementary sections of
Traction overhead equipment. It is required to provide a smooth passage to pantographs of
electric rolling stock for current collection without any perceptible arcing in either direction upto
a speed of 60 km/h when installed in any position in a span of overhead equipment.
2.0 STANDARD SPECIFICATIONS:
2.1 Following Indian Standard and RDSO Specifications are applicable for various materials
and processes used in the section insulator assembly.
(i) TI/SPC/OHE/INS/0070(04/2007): Solid core porcelain insulators for 25 kv ac
traction Overhead equipment.
(ii) IS: 3091-1999 : Aluminum bronze ingots and castings for overhead
Fittings.
(iii) TI/SPC/OHE/Fittings/0130 : Specification for fittings for 25 kv traction.
(iv) IS: 1897-2008 : Specification for copper strip for electrical purpose.
(v) ETI/OHE/42(11/83) : Specification for hard drawn grooved contact wire
For electric traction.
(vi) ETI/OHE/13(4/84) : Specification for galvanizing of mast, tubes, fittings etc.
(vii) RE/OHE/25(3/66) : Standards for drawings for traction overhead equipment.
(viii) IS: 3658-1999 : Code of Practice for liquid reentrant flaw detection.
(ix) IS: 6745-1972 : Specification for determination of mass of zinc coating and zinc
coated iron and steel articles.
(x) IS: 2633-1986 : Specification for method of tasting, uniformity of coating on zinc
coated articles.
(xi) BS: 970-Pt-4, 1970 : Schedule for wrought steel.
(xii) TI/SPC/Fasteners/0120: Specification for galvanized steel & stainless steel Fasteners.
(xiii) IS: 2629-1985 : Recommended practice for hot dip galvanizing of
Iron and steel.
2.2 In case of a difference between this specification and the above specifications, this
specification will be referred to.
3.0 SERVICE CONDITIONS:
3.1 The section insulator Assembly may be used in area of medium marine or /and industrial
pollution. These are also subjected to vibrations caused by wind and the passage of trains under
them or nearby track. The section insulator assembly shall be designed for satisfactory
performance under the following atmospheric conditions:
(i) Maximum temperature of air in the shade = 4500C

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(ii) Minimum temperature of air in the shade = 00C

(iii) Maximum temperature of on object exposed to sun = 650C
(iv) Daily average ambient temperature = 350C
(v) Maximum relative humidity = 100%
(vi) Maximum wind pressure = 216 kgf/m2
(vii) Altitude = 1000m (max)
4.0 GENERAL CONSTRUCTION:
4.1 The section insulator assembly consists of a solid core porcelain insulator (Ref. RDSO
Specification No. TI/SPC/OHE/INS/0070 designed to secure a contact wire through a link at one
end. At the other end the insulator shall be connected to a cross beam supported on two runners
made of hard drawn copper through articulated links. The other contact wire shall be clamped
directly at one end of the runners joined together, so that the runners take the full tension of
the contact wire and ensure a rigid assembly.
The ending clamps for the contact wire at the runner and insulator ends shall be of the
toothed type, designed to grip the contact wire firmly. The entire assembly shall to such that it
provides means of easy adjustment during erection and permits smooth passage of pantograph.
The complete section insulator assembly shall be suspended from the stranded 65 mm 2
cadmium-copper catenary wire and maintained in proper level by means of 5 mm dia droppers
made of hard drawn copper wire attached to lugs , provided at the two ends of the runner cross
beam. Suitable lugs are also provided on the cross beam and the contact wire link to permit
suspension of the section insulator from the cross span wire(s). A schematic diagram of the
section insulator assembly indicating the main components is attached.
4.2 The air gap between the runners and the metallic parts of the insulator or the contact
wire belonging to a different electrical section shall not be less than 160 mm.
4.3 The distance between the axis of the runners shall not exceed 466 mm.
5. MATERIAL SPECIFICATIONS:
5.1 The cross beam, the contact-wire-end-link and the end-clamps of the runner-end and
insulator-end shall be die-cast aluminimum-bronze conforming to IS: 3091. The clamps shall
comply with TI/SPC/OHE/Fittings/0130.
5.2 The runners shall be made of 40mm x 8 mm hard drawn copper strip (Grade FRHC) to
IS: 1897.
5.3 All the fasteners including bolts, screws, nuts, locknuts, and pins shall be made of
stainless steel and conform to RDSO specification No. TI/SPC/Fasteners/0120. It shall be
manufactured in house or outsourced from CORE approved source.
5.4 Hot dip galvanized parts shall conform to RDSO specification No.ETI/OHE/13 (4/84). The
coating of zinc shall not be less than 610 g/m2.

6.0 MANUFACTURE AND QUALITY CONTROL

6.1 RDSO’s drawings for components and the assembly of the section insulator are for
guidance only. The manufacturer shall prepare his own manufacturing drawings incorporating
the closest tolerances attainable by him consistently on all dimensions. Closer tolerance are
required on holes, hole centers, wall thickness etc. The drawings shall be prepared in accordance
with RDSO specification No. RE/OHE/25(3/66).

6.2 The section insulator assemblies shall be manufactured strictly in accordance with the
manufacturer’s drawings approved by RDSO/CORE.

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6.3 All components shall fully interchangeable between different assemblies.

6.4 The aluminium bronze components shall be produced by die casting process, i.e. by
gravity or pressure die casting.
6.5 The galvanizing of ferrous parts shall be carried out in accordance with IS: 2629-1985.
6.6 The manufacturer shall provide identification mark indicating his name or trade make,
railways part number, melt and year on each of aluminimum bronze casting. From one melt
xxxx only one type of castings shall be made. Three test bars shall also be cast from each melt.
The fittings shall be used in assembly only if the test bar meets the requirements of IS: 3091-
1999 in respect of physical properties and chemical composition, otherwise the entire lot shall be
re-melted. Record of the tests carried out shall be maintained and offered to the Inspector at the
time of inspection for each type of fitting. The remaining two test bare of each lot shall be
carefully preserved.
6.7 The manufacturer shall prepare a Quality Assurance Standard to ensure that all
Component and assemblies provided conform to the specification. The Quality Assurance
Standard shall be got approved from RDSO/CORE.
7. TESTS:
7.1 The manufacturer shall arrange for tests at his works. The test, for which facilities do not
exist with the manufacturer, may be carried out at any reputed laboratory after specific approval
by RDSO/CORE.
7.2 Type Tests
7.2.1 Type tests shall be carried out to assess capability of the manufacturer to produce the
section insulator assembly to this specification and approved drawings. These tests may be
repeated any time on any of the sample by RDSO/CORE or the inspector of purchaser.
7.2.2 The manufacturer shall first manufacture prototype sample product type tests and send
test reports to RDSO/CORE. The Type test than shall be witnessed by representative of RDSO.
The manufacturer shall manufacture minimum or three assemblies in presence of RDSO
representative for the type tests.
7.2.3 The following test shall be made on the components/assemblies manufactured as per
clause-7.2.2:
SN Tests Type Routine Acceptance Refer
Test tests test Clause
1. Visual examination of components Yes Yes Yes 8.1
2. Dimensional verification of components Yes No Yes 8.2
3. Examination of assembly Yes No Yes 8.3
4. Inter-changeability of components Yes No Yes 8.4
5. Physical and chemical tests on aluminum- Yes Yes Yes 8.5
bronze test bars
6. Tests-on fasteners Yes No No 8.6
7. Radiographic examination of casting Yes No No 8.8
8. Liquid dye penetration test on castings Yes Yes Yes 8.7
9. Galvanizing test Yes No Yes 8.10
10. Test on runner strips Yes No Yes 8.9
11. Proof load test Yes Yes Yes 8.11

7.24 In the event of the tests not being carried through to completion at one stretch for
any reason attributable to the successful manufacturer and it is required for the representative
of Director General (Traction Installations), Research Designs and Standards Organisation,
Manak Nagar, Lucknow, to go again or more number of times to the works of the

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manufacturer or other place(s) for continuing and/or completing the tests on the prototype
(s) of the equipment. The guide line of ISO documents No. ISO9001:2008 Document No: QO-D-
7.1-10 Version No: 3.0 Date Effective: 07/05/2015 for Vendor sample type testing and
ISO9001:2008 Document No: QO-D-7.1-14 Version No: 6.0 Date Effective14/08/2015 for
Vendor registration schedule of charges shall be followed.
7.3 Acceptance Tests:
7.3.1 The manufacturer shall offer section insulator assemblies in lots of not more than 50
assemblies. Only those assemblies and their components which have already been subjected to
routine tests, as per clause-7.4, shall be offered for inspection. The results of routine tests shall
be presented to the inspector, who will record these in the inspection certificate.
7.3.2 Components of two assemblies shall be selected at random for acceptance tests.
7.3.3 Acceptance Criteria:
Provided routine tests results are satisfactory and the samples selected in accordance
with 7.3.2 are found conforming to the specification when tested as per clause-7.3.4, the lot
may be accepted. If any component fails in any test four more samples, taken at random, shall
be subjected to the test. If, there is no failure in the retest, that lot of the component may be
accepted otherwise not. If a component fails in more than one test, lot………. Of the component
may be rejected.
The assemblies shall be accepted only if all the components are acceptable and
interchangeable and the assemblies pass proof load test.
All accepted fittings and components shall be punched with the Inspector’s seal giving the initials
of Inspector and date of inspection. Alternatively, a lab carrying the initials of inspection and
date of inspection may be fixed indelibly on the each fitting/component.
7.4 Routine Tests:
7.4.1 The manufacturer shall carry out routine tests on all components and assembly. Records
of the tests shall be examined by the Inspector.
8. TEST METHODS:
8.1 Visual examination of components:
8.1.1 All the components shall be examined for visible defects, deformation, flaws and surface
finish. Particular attention shall be paid to smooth surface finish of contact surfaces of the
runners. The galvanizing of ferrous parts shall be examined for a visible defect as defined in IS:
2629.
8.1.2 As a routine test this test shall be carried out on all the components. The components not
found satisfactory shall not be utilised and offered for acceptance tests.
8.2 Dimensional verification of components:
8.2.1 The manufacturer shall check dimensions of all the components using gauges, approved
by the Inspector, on the entire lot before offering for inspection.
8.2.2 The Inspector shall check dimensions of the components of two assemblies selected in
accordance with Clause 7.3.2 for acceptance of the lot and for the purpose of type tests. In type
tests, all dimensions shall be checked. In acceptance test, important dimensions such as wall
thickness, hole diameters, hole centers, runner profile and runner thickness only may be
checked. The inspector, at his sole discretion, may check all dimensions. The dimensions shall be
within the tolerance indicated on the approved drawings.
8.3 Examination of assembly
Two assemblies shall be made and clearance as specified in 4.2 and 4.3 shall be checked.
It shall be possible to adjust the assembly so as to obtain proper level. The level of an assembly

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shall be checked by moving a straight flat copper strip of approximately 500mm length below
the assembly in a manner similar to movement of pantograph. Alternatively, arrangement can
be made to suspend the assembly over a plain table to check the level. The sectioning insulator
for the test shall be provided by the manufacturer.
8.4 Interchangeability of components
Al components shall be freely interchangeable. If the components selected in a random
manner permit assembly without any further machining of forming operation and the assemblies
s made meet the requirement of 8.3, the requirement of this test shall be deemed to have been
complied.
8.5 physical & chemical tests on aluminum bronze test bars.
8.5.1 The manufacturer shall test one of the three test bars cast for each melt for physical
properties and chemical composition. Only if the test results are found conforming to IS: 3091
the lot of the components cast from the melt shall be utilised and offered to the Inspector.
Otherwise the lot shall be re-melted.
8.5.2 one second test bar shall be tested by the Inspector for the each lot of components from
each melt for physical properties only. If the requirements of physical properties are not met,
the particular lot shall be rejected and components broken or re-melted by the Inspector in his
presence.
8.5.3 The third test bars of each lot shall be preserved for five years for testing in future if
need arises.
8.6 Test on fasteners
8.6.1 The fasteners shall be tested in accordance with RDSO’s specification No.
ETI/OHE/18(4/84) both for type tests and acceptance tests.
8.6.2 The stainless steel pins shall be tested for chemical composition and Inter crystalline
corrosion bend test as per BS: 970 (Part-4) of the test shall be made on one sample only both
for type test and acceptance tests.
8.7 Liquid dye-penetration test on castings
8.7.1 All castings shall be tested for cracks, blow holes porosity etc. by liquid dye penetrate
flaw detection method in accordance with IS: 3658-1981. The defective fittings shall be
rejected. The test shall be carried out as routine test by the manufacturer and as acceptance
test by the purchaser’s Inspector. Records of routines tests shall also be examined by the
inspector.
8.8 Radiographic examination of castings
8.8.1 Radiographs of three samples of each casting shall be taken. These will be evaluated by
the Purchaser for inclusions, blow holes, cavities, cracks porosity etc. the accepted radiographs
shall be retained by manufacturer and RDSO for reference and record. Manufacturer shall
subject castings to radiographic tests from time to time to ensure that the accepted standards
are maintained.
8.9 Tests on runner stripes
8.9.1 For the purpose of type tests, chemical analysis, mechanical test and electrical resistivity
tests shall be made on three samples. The test results shall conform to IS: 1897.
8.9.2 For acceptance tests, only physical properties and electrical resistivity shall be tested.
8.10 Galvanising tests on ferrous parts.
8.10.1 The galvanized ferrous parts shall be tested in accordance with IS: 2629 for visible
defects and adherence; IS: 2633 for uniformity of Zinc coating; and IS: 6745 for weight of zinc

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coating. The samples shall meet the requirements of respective specifications. The uniformity of
zinc coating shall be ascertained by seven one minute dips in the Preece Test.
8.10.2 For acceptance test only weight of zinc coating shall be checked by magnetic
method or by stripping method.
8.11 Proof load test
8.11.1 The complete section insulator together with end links will be tested for a proof
load of 3 tone for one minute for type test and 2 tonne for one minute for acceptance and
routine tests.
The position of contact wire shall be marked suitably prior to the test. There shall not be any
slipping of neither contact wires nor any deformation to any component of the assembly.
8.11.2 A suitable dummy steel plate with ends shaped exactly as the tongues of
sectioning insulator may be use in lieu of the sectioning insulator for proof load test.
9. PCKING AND MARKING:
9.1 The components and fittings of section insulator assembly shall be packed either in fully
assembled conditions or in knocked down condition in strong wooden boxes. Every, box shall
contain a list of components giving quantity of each component packed in the box.
9.2 Every box shall carry, in legible and indelible lettering, the following information:
i) Manufacturers trade name and brand mark.
ii) Number of assemblies/component packed.
iii) Contract/ Order number.
iv) Consignees address.
v) Date of Inspection and Inspecting Authority.
vi) Any other particulars specified by the Purchaser.

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