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MAINTENANCE HANDBOOK
on
CAMTECH/E/2008/BE/1.0
April 2009
Centre
for
Advanced
Maintenance
TECHnology
Excellence in
Maintenance
(A Unit of RDSO)
January 2006
CAMTECH/2005/E/REV-EMU/1.0
MAINTENANCE HANDBOOK
on
BONDING & EARTHING
for
25kV AC TRACTION SYSTEM
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.
Maintenance Handbook on Reverser/ Winding Change Over Switch
of AC EMU/MEMU
January 2006
CAMTECH/2005/E/REV-EMU/1.0
FOREWORD
Bonding and Earthing of rail plays a very important
role in safe and reliable working of TRD installations.
This maintenance handbook contains general
description, type of bonds, arrangement of bonding and
earthing at different traction installations, Rules applicable
to Permanent way staff, Rules for S&T installation,
maintenance schedule, working procedure for Permanent
way, TRD and S&T staff etc.
I am sure this handbook will prove to be very useful
for our field personnel working in Traction Installations.
CAMTECH, Gwalior
Date:
S. C. Singhal
Executive Director
January 2006
CAMTECH/2005/E/REV-EMU/1.0
PREFACE
In 25 kV AC, 50Hz Single Phase Traction System
bonding and earthing is very essential for overhead
equipment and associated railway track. Provision of
bonding and earthing at TSS, FP, SSP, ATs, S&T
equipments etc. complete the return circuit and also ensures
safety.
It is clarified that this handbook does not supersede
any existing provisions laid down by RDSO or Railway
Board. The handbook is for guidance only and it is not a
statutory document.
I am sincerely thankful to officers and staff of the
T.I. Directorate of RDSO/LKO for their valuable
suggestions and comments. I am also thankful to 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 his handbook. We shall highly
appreciate your contribution in this direction.
CAMTECH, Gwalior
Date:
Jaideep
Director Electrical
January 2006
CAMTECH/2005/E/REV-EMU/1.0
CONTENTS
Chapter No.
1.
2.
3.
4.
5.
Description
Page No.
Foreword
iii
Preface
iv
Contents
Correction Slip
vii
GENERAL DESCRIPTION
01
1.1
INTRODUCTION
01
1.2
02
1.3
03
TYPES OF BOND
05
2.2
08
WORK INSTRUCTIONS
19
3.1
19
3.2
22
MAINTENANCE SCHEDULES
24
4.1
FOOT PATROLLING
24
4.2
25
4.3
ANNUAL MAINTENANCE
25
4.4
TOOLS REQUIRED
25
27
5.1
DOs
27
5.2
DONTs
29
January 2006
CAMTECH/2005/E/REV-EMU/1.0
Chapter No.
Description
Page No.
ANNEXURE A
30
ANNEXURE B
32
ANNEXURE C
34
ANNEXURE D
35
ANNEXURE E
37
REFERENCE
38
January 2006
CAMTECH/2005/E/REV-EMU/1.0
Date
issue
January 2006
CAMTECH/2008/E/BE/1.0
CHAPTER 1
GENERAL DESCRIPTION
1.1 INTRODUCTION
Bonding and Earthing is an essential part of the
25kV AC, Traction System. Bonding is a solid electrical
connection between two or more conductors or noncurrent carrying metallic parts i.e. traction mast,
structure, support and rails. Wherever, earthing is a solid
electrical connection of an object to the earth electrode.
Bonding of rail facilitates passage for the traction return
current from rail to earth and vice-versa. The bonding
and earthing of the system connects the earth leg of
traction transformer at the TSS to the traction rail and
buried rail. Bonding of rails spread of flow of return
current into the earth and consequently reduces the
voltage between rail and earth to ensure safety of
personnel as well as provide low resistance path for
traction return current and signaling current.
In 25kV AC, Traction System, the traction current
is drawn from the contact wire of OHE by the electric
rolling stock and the return current flows through
traction rail to the earthed structures and to the buried
rail by means of bonds. Maximum amount of the return
current reaches to TSS/FP through the earth circuit and
rest of the return current flows through traction rail to
buried rail which is provided in front of TSS/ FP.
Maintenance Handbook on Bonding & Earthing
for 25 kV AC Traction System
April 2009
CAMTECH/2008/E/BE/1.0
April 2009
CAMTECH/2008/E/BE/1.0
ii.
v.
vi.
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x.
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CHAPTER 2
STRUCTURE BO ND
TRACK
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RAIL BOND
X -B O N D
DOW N
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Insulated joint
Impedance bond
Insulated joint
10
TRACTION MAST
10
EARTH PIT
CUT IN INSULATOR
WIRED TRACK
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10
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11
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12
350 m
CROSS BOND
350 m
350 m
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2.2.12
13
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14
FP
BURIED RAIL
1000 M
1000 M
RAIL BOND
CROSS BOND
300M
300 M
500 M
500 M
700 M
700 M
1000 M
1000 M
RETURN FEEDER
FP
BURIED RAIL
1000 M
RAIL BOND
TRACTION RAIL
TRACK
CIRCUITED
RAIL
TRACTION RAIL
300 M
500 M
700 M
1000 M
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15
CROSS BOND
TRACTION RAIL
CIRCUITED RAIL
100 M
100 M
TRACK CIRCUITED SECTION
50 M
50 M
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16
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2.2.15
17
B L O C K J O IN T
O IL D E P O T S ID E
U N W IR E D T R A C K
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18
******
Maintenance Handbook on Bonding & Earthing
for 25 kV AC Traction System
April 2009
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19
CHAPTER 3
WORK INSTRUCTIONS
3.1 APPLICABLE TO PERMANENT WAY STAFF
Precautions are required to be taken on account of the
following:
a.
b.
c.
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20
b.
c.
d.
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e.
21
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iii.
iv.
v.
vi.
vii.
viii.
22
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23
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24
CHAPTER 4
MAINTENANCE SCHEDULES
4.1 FOOT PATROLLING
An experienced OHE lineman (accompanied by a
khalasi if deemed necessary by local condition) should be
deputed to patrol the section on foot by day including
yards once a fortnight and suburban section once a week.
The lineman on foot patrol should be equipped with
signal flags (Red & Green), an emergency telephone
instrument and essential tools, nuts, bolts and washers
required for attending defects on the spot.
i.
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25
2.
3.
4.
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26
5.
6.
7.
8.
9.
******
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27
CHAPTER 5
5.1 DOs
1.
2.
3.
4.
5.
6.
7.
8.
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9.
10.
11.
12.
13.
14.
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29
5.2 DONTs
1.
2.
3.
4.
5.
6.
7.
8.
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30
ANNEXURE A
WORK INSTRUCTIONS FOR PERMANENT WAY,
TRACTION AND S&T STAFF FOR CHANGING THE
RAILS CARRYING OUT TRACK CIRCUITING AND
AUTOMATIC SIGNALLING WORKS
1.
2.
3.
4.
5.
6.
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31
7.
8.
9.
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32
ANNEXURE - B
JOINT PROCEDURE ORDER FOR ENSURING SAFETY
DURING TRACK RENEWALS
Since the working of relaying unit involves removal of
existing rails along with all the different types of traction
bonds, it is absolutely essential that temporary jumpers for
passage of return current are provided till such time the
permanent bonds are fixed to the new rails.
Following procedure shall be followed by the site in
charges of both the Engineering and TRD branches associated
with relaying work.
1.
2.
3.
4.
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33
5.
6.
7.
8.
9.
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34
ANNEXURE - C
WORK INSTRUCTIONS FOR PERMANENT WAY AND
TRACTION STAFF FOR CHANGING RAILS CARRYING
OUT IN FRONT OF TRACTION SUB-STATION, SSP & SP.
1. Before any changing the rails in front of Traction substation/feeding post, sub-station post and sectioning post
which bonds are connected to the traction rail to buried rail
in electrified track is commenced due notice of 48 hrs. in
advance shall be given to concerned TRD Depot Incharge.
2. A power block & traffic block must be obtained of that
track to be replaced. Temporary connections shall be
provided with the other rail of the track at both ends by
TRD staff. In case of replacement of both the rails of track.
Temporary connection shall be provided with in rails of
adjacent track both end by TRD staff, before disconnecting
bonds from rail or vise versa.
3. Before replacing the rails in front of TSS/FP, SSP and SP
(Bonds which are connected the traction rail to buried rail
and other bonds) of Traction bonds in electrified area, the
permanent way inspector will ensure that traction
distribution staff is available at site for removing the all
bonds and jumper/ bonding connections wherever required.
4. After completion of replacement of rail ensure reconnection
of all concerned bonds.
5. Permanent way staff shall be responsible to make hole in
new rails for reconnection of bonds.
6. Before canceling the power and traffic block, TRD personal
shall ensure with permanent way inspector that man and
material have removed to resume normal traffic.
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35
ANNEXURE D
NEW DEVELOPEMENT IN THE FIELD OF RAIL BONDING
APPLICATION
CADWELD aluminothermic
applications in the field of:
1
welding
has
following
Grounding
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2.
36
Bonding
WELDING TOOL
Welding tool with welder handle and graphite mould
complete set of LH & RH pair is suitable for jointing steel flat
40 mm x 6 mm on rail web as shown in figure on next page.
WELDING TOOL
MOLD
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37
ANNEXURE - E
SUGESSTIONS RECEIVED FROM VARIOUS RAILWAYS
DURING SEMINAR HELD ON 7TH & 8TH AUGUST 2008
AT CAMTECH.
1.
2.
3.
4.
5.
6.
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CAMTECH/2008/E/BE/1.0
38
REFERENCE
1. Manual of AC Traction Maintenance and Operation,
Volume II (Part-I), Fixed Installations (1994).
2. Catalogue no. IEEMA-20-2000 issued by IEEMA on
Surge Arrester Selection and Application Guide.
3. Field study and literature collected from various depots
on Indian Railways.
4. SMI & Specification issued by RDSO on Lightning
Arrester.
April 2009
CAMTECH/2008/E/BE/1.0
39
OUR OBJECTIVE
To upgrade maintenance technologies
and
methodologies
and
achieve
improvement
in
productivity
and
performance of all Railway assets and
manpower which inter-alia would cover
reliability, availability, utilisation and
efficiency.
Director Electrical
Postal address
Indian Railways
Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior,
Pin Code - 474 005
Phone
0751 2470740
0751 2470803
Fax
0751 - 2470841
April 2009