International Systems and Standards

Siemens Rail Automation Pvt. Ltd (File No.: IND.B.04.17.
0057)
Indian RAIL WAY Station Audit by Bureau Veritas E&I
Auditors
ELECTRONIC INTERLOCKING SYSTEM
Date: 18/06/2018
Speaker : Mr. B. Saravana Kumar
© - Copyright Bureau Veritas

Training Objectives
1. Audit of Electronic Interlocking System of Railway signaling hardware

system.
2. Audit based on site installation check list
3. Equipment manufacturing and site installation check list refers to RDSO

(Research, Designs standard organization Specification No.
RDSO/SPN/198/2008).
TAN-STS-E-TAN 3012 Ver 2
© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 2

Check Points As Per Installation Check List
► Check the type of system installed at site.
Centralized System Or Distributed System

► Check the System Configuration.
(1+1, 2+2, 3+3 & 4+4 Configuration)

► Check the control Panel Type.
(CCIP+VDU or Dual VDU)

► Check the earthing arrangement followed as per RDSO Specification and
RDSO TAN.
► Check the Earthing Resistance or Verify The Test Report Jointly signed
by Railways
(Earth Resistance Should Be Less Than 1Ω)

► Check all the below Equipments and Fittings for any Physical Damage,
and no Forced External Installation e.g. Twisting, Bending. etc.
Check all cards properly aligned with top and bottom guide Rail.
Check all connectors physically.

► Visual Inspection of E.I modules and Relays
► Un pack all the modules and check the physical damages and
deformations.
► Check the modules are installed as per Vital Interface Circuit.
► Check RDSO Stamp and Hologram Stickers availability on all
modules and relays.

► WESTRACE Housing - Front cover and rear end cover plate
► Check correct type front & rear cover provided for WESTRACE
Rack.
► Whether blanker modules are fixed in unused slots.
► Check availability of screws of front and rear cover and tightness of
the same

► Westronics Housing - Front blank cover plate

1. Check whether Westronics blank front cover plate installed in the
unused slots.
2. Check whether Westronics front blank cover plate aligned with

adjacent S2 modules (If Applicable).
3. Check whether all the S2 modules tightened with screws (If

Applicable).

► Installation of EI racks and Relay racks
1. Check EI rack and relay rack installed as per Vital Interface Circuit.
2. Check whether racks are insulated from the floor by providing
rubber mats &Insulators to withstand the vibrations

► Ladders arrangements between the racks.
1. Check the ladders are insulated from racks and walls with 8 mm
Insulators.
2. Check whether cable trough [cable duct] fittings are provided as
per the vital interface circuits.
3. Check whether all the ladders are connected to nearest earth point

► CABLE ROUTING : Input and output, communication cable, Power Supply

cable routing.
 Check whether input, output, Communication and power supply cables are routed
in different cable trough (Cable duct) with a gap of minimum 6 to 8 inches.
 Check Vital I/O Cables are routed in seprarat cable trough (Cable Duct).
 Check whether AC & DC power supply cables, serial communication cables,

block instrument cable & axle counter cables & analog voltage monitoring cables
are separated.
 Check the FO Patch Cord length of INCL & IHCL communication between hot
stand by WESTRACE System (0.5 to 1.5 Mtrs Long ST-ST Patch Cord).
 Check the INCL & IHCL ST-ST Patch cord not bunched with cable trough. If need
the same to be bunched separately.
 Check whether single mode OFC cable lay in double ring architecture between
central relay room cabins to end cabins, as per the vital interface circuits? If it is
distributed interlocking configuration.

 Check whether single mode OFC cable lay in circuits. ring architecture between
Central Relay room cabins to SM room for CCIP and Dual VDU system
communication.
 Check whether single mode OFC cable 24 cores –FMS boxes are installed as per
the vital interface circuits.
 Check whether all the terminated OFC cores of cables have been tested through
OTDR and verify the test report duly signed by railways.
 Check OFC patch cord connecting FMS to Network Switches & Serial to OFC
converters] is limited to run inside the rack & not exceed more than 3m.
 Check the unused patch cord connectors are protected with capes and proper
identification provided.
 Check OFC patch cord should not bunched with other cables and bend on OFC
Cable.

► OPCR wiring/Relay rack wiring circuits:
 Check the OPC relay and repeater relay wiring one as per VIC.
 Check the correct type relay and relay base used, Twisted pair cable used for
relay wiring.
 Check the relays are fixed as per section specific relay disposition chart, relay
pins are properly locked in relay base and relays are securely locked with relay
retaining clip.
 Check Siemens point contractor relay mounted with proper guide rails.

► Fuse Terminals/Fuse ratings/Fuse fixing
 Check whether fuse terminals are fixed with proper fuse ratings as per the vital
interface circuits.
 Check whether Wago terminal blocks [‘’+ve & - ve’’] are fixed as per the vital
interface circuits.
► CON3 and CON4 wiring circuits & VSEV wiring Circuits:
 Check whether twisted pair cables used for CON3 & CON4 connector of
NCD PFM as per the vital Interface circuits.
 Check whether CON3 and CON4 polarity connection is done as per the
vital interface circuits.
 Check whether VSEV wiring circuits is done as per the vital interface
circuits

► EC2 & EC3 cable routing arrangements:
 Check whether backplane bus extension and power supply cables [EC2
& EC3] are routed through the PFM clean area.
 Check the length of EC2 & EC3 cable length (500 mm and 700 mm).
 Check the back plane extension cables are connected between housing
to housing as per VIC.
 Check whether securing clips of backplane extension cable [EC2-EC3]
connectors are locked in to the sockets.
► WESTRACE Power supply wiring:
 Check the 24VDC, 50VDC, 110VAC and 230VAC power supply wiring
circuits is done as per the vital Interface circuits.

► Earthing wiring connections:
 Check the Housing to housing earthing, EI earthing, network switch

earthing, S2 panel process housing earthing, surge protector, DC-DC
converter earthing wiring circuits is done as per the vital Interface circuits.
 Check whether copper tape provided vertically [top to bottom] for effective
star earth point connection in the WESTRACE rack as per the vital
interface circuits.
 Check whether all the equipements connected as star earth point
Connections & not in daisy connections.
 Check whether all earth connections are tightened with mounting screws
and star washers.
 Check whether housing to star earth point cable is less than 3 meters

EI Rack Earthing Connection WESTRACE Rack Vertical Earth Bus Bar

► Power supply board wiring and arrangements:
 Check whether individual 24VDC power supply connected for each

WESTRACE housing power supply and wiring of the same done as per
VIC.
 Check the housing to housing wiring done as per VIC.
► VPIM and VROM Interface wiring circuits:
 Check whether VPIM & VROM wiring is done as per the vital interface
circuits.
 Check whether twisted pair cables used for circuits VPIM and VROM
module wiring Circuits.

► Terminals / Lugs / connectors arrangements and Tightness:
 Check the wire ends are crimped with correct type and correct size lugs and
check the tightness of crimping and termination.
 Check the correct positive & negative short links provided on terminal blocks.
 Check the correct type terminals, lugs & wire gauges and used.
► Surge arrestor wiring and fitting arrangements:
 Check whether surge arrestors are fixed very near to the room earth bar.
 Check whether 230V AC, 110V AC and 24V AC surge arrestor wiring is done as
per the vital interface circuits.
 Check whether the earth terminal of the surge arrestor connected to the room
earth bar as per the vital interface circuits

Surge Arrestor and Its Earthing Connection

► DC-DC Converter for WESTRACE system power supply (24V DC):
 Check whether 110V DC-DC converter power supply cables are not routed
across with other cables in the relay room and segregated from other clean wiring
[ Internal Power supply wiring].
 Check whether RDSO approved V2 type 2410A model DC-DC converters are
installed in WESTRACE rack.
 Check whether 24V DC-DC converters are provided with N+1 configuration for
main & standby WESTRACE systems and S2 panel processor, CCIP system
Dual VDU equipments.
 Check whether DC-DC converter power wiring and current Sharing & NO and NC
contact [Electrical feedback] wiring is done as per vital interface circuits.
 Check whether DC-DC Input and output power supply connector are correctly
inserted & tightened in the DC-DC converters.
 Check whether DC-DC converters /modular type DC-DC converters are installed
above the WESTRACE housing arrangements as per the vital interface circuits.
 Check that, the line drop between DC-DC converters and PSU24 PFM should not
be more than 0.5volt.
► DC-DC Converter for WESTRACE I/O Modules (50V DC ):
 Check whether RDSO approved V2 type – 5005A model DC-DC converters are
installed.
 Check whether 50 V DC-DC converters are provided with N+1 configuration for
I/O modules power supply circuits.
 Check whether DC-DC converter power wiring and current Sharing & NO and NC
contact [Electrical feedback] wiring is done as per the vital interface circuits.
► Serial port wiring [ Data logger & S2 Panel Processor]:
 Check whether serial communication cable wiring is done as per the vital
interface circuits.
 Check whether Serial port 2 / serial Port 3 - DB9 female connectors in the NCD
PFM are tightened promptly.
 Check whether shield of each serial communication cable is connected to rack
earth at one end only.

Serial port Wiring of NCD PFM

► Network port and Ethernet cable wiring circuits:
 Check the type of cable used (CAT5 or CAT6) and length should be 0.5 Mtrs to
100 Mtrs.
 Check the Ethernet cable factory crimped or locally crimped.
 Check whether ethernet RJ 45 type connectors and M12 connectors are

tightened & locked in the network port & network switches respectively.
 Check whether RJ45 /M12 network cables are marked with labeling for easy
identifications with respect to the station specific system Configuration.
► Network switch Installation:
► Check whether network switches are installed as per the vital Interface
circuits.
► Check whether NO/NC contact [electrical Feedback] wiring is done as per
► Check whether network switch Power supply wiring is done as per the
vital interface circuits.
► Serial communication equipment fitting & Connections:
 Check whether serial to OFC converters / RS232<->485 Converters are

correctly placed and wired as per the vital interface circuits.
 Check whether different power supply source used for serial to OFC
converter and network switches? If DC-DC converters are not used for
Panel + VDU configuration equipments at SM room.
► Serial to OFC Converter & Serial to converter cum Isolator switch
settings:
 Check whether RS232 /RS485 serial configuration DIP & toggle switch
setting is done as per the vital Interface circuits.

► MoviolaW /WESTCAD Network Cable connection and Power Supply

Connection:
 Check whether factory crimped Ethernet cables are used for MoviolaW and
WESTCAD communication.
 Check whether standby ethernet cable laid between the network switch to
MoviolaW PC.
 Check whether power supply adaptors provided with 3A Power rating for
MoviolaW and WESTCAD – Industrial CPU’s.
 Check whether uninterrupted 24VDC power supply extended to industrial CPU
Power supply connection through DC-DC converters.
 Check whether 230V AC distribution switch box fitting and wiring is done as per
 Availability of 3 pin socket in 230V AC distribution box which provided for
WESTCAD and MoviolaW power supply connection.
 Availability of UPS with minimum rating of 1KVA for WESTCAD and MoviolaW.

► WESTRACE rack fan tray and exhaust fan arrangements:
 Check whether 24VDC Cooling fans are provided as per the vital interface
circuits.
 Check whether separate DC-DC converters power supply fed to fans? It should
be other than WESTRACE E.I power supply.
 Check whether individual fuse arrangements provided WESTRACE rack cooling
fans as per the vital interface circuits.
 Check whether NO/NC [electrical feedback contacts] of fans wired to data logger
for monitoring purpose.
 Check whether air dust filters correctly mounted and ensure no physical damage
and deformation in the air dust filters.
► IPS connections for E.I equipments:
 Check whether all the required power supply from IPS equipments is extended for
E.I equipments & supporting equipments as per the vital interface circuits

► No loose Conductors / Fittings in the EI systems and supporting

equipments:
 Check whether there are no loose conductors in any of the wiring circuits.
 Check that there are no loose connections in any of the fittings.
► Labels/markers/Ferrules and name plate:
 Check whether all terminations have markers / labels and ferrules for their right
connection and identifications.
 Check whether makers /labels /ferrules / text in paintings /stickers are provided
for WESTRACE rack, relay rack, Communication rack, S2 rack, FMS box
wherever applicable.
 Check whether rack name plate provided for WESTRACE rack and Relay rack,
S2 rack.
 Check whether relay name plate or relay name painted for each relays in the
relay room is done as per the vital interface circuits.

► Cable entry gland fittings:
 a. Check whether cable entry gland are provided on the cable entry cut
outs in the WESTRACE racks and relay racks? Sharp bend should be
avoided in the cable entry points & wherever applicable
 b. Check whether flexible hose provided for the Input and output cable,
Power supply, Communication cable based on cable entry provisions.
► End Stopper and Terminal Cover Plate:
 Check whether end stopper and terminal cover plate provided in the
WESTRACE rack, relay rack, Communication Rack, S2 rack, CCIP &
wherever applicable.

► WESTRACE Housing Earthing:
 Check whether WESTRACE housing to housing earth connection is done as per

 Check whether earth connection is done rear end of the housings & further
extended to the star point room earth bar.
► Equipments and Outdoor Cable Connection:
 Check whether each rack (WESTRACE rack and relay rack) in the equipment
room is individually connected to Room Earth Bar as per the vital interface
circuits.
 Check whether interconnection cable arrangements between Relay Room & SM
Control Room is routed in separate duct and ensure that interconnected cables
are not mixed together in the cable trench.
 Check whether Outdoor cable routing and earthing of outdoor cables earthing is
done in the relay room as per the railway authority practice? It should be ensured
by the railway and contractors. However in case of any outside work which not
connected to the Siemens scope of work, then if any inconsistency is observed
this shall be reported formally to railways and Siemens office.
► Sub Racks and IPS racks connected to Room earth bar:
 Check whether IPS rack and the sub racks in the power room are connected to the
power room earth bar.
 Check whether power room earth bar is interconnected to relay room earth bar.
► Class “A” Surge protection arrangements:
 Check whether Class ‘’A’’ Surge protection provided on top of the station building.
 Check whether separate earth pits provided for lightning protection and it should not
be connected to perimeter ring earth bar to prevent the return flow of heavy lightning
discharges.
 Check whether lightning arrestor height higher than VHF antenna.
 Check whether copper tape provided to cover the maximum area in the Equipment/
relay room and Power room.
 Check whether earthing lead terminations is readily accessible.
 Check whether earthing lead connections is mechanically sound and protected.
 Check whether earthing cables or copper tape are correctly welded or connected in
relay room perimeter copper bonding
► Analog Voltage & Digital wiring to Data logger:
► Check all the below voltage terminals have been wired to data logger analog module
to fulfill the E.I analog monitoring requirements.
a) Main System 24VDC.
b) Standby System 24VDC.
c) Main System 50VDC.
d) Standby System 50VDC.
e) Main System 110VDC.
f) Standby System 110VDC.
g) Main 230VAC.
h) Network Switch Power Supply.
i) Dual VDU- Monitor Power Supply.
j) Serial to OFC converter Power Supply.
k) 110VDC power Supply for Point machines.
l) 110VAC Power Supply for Signals.
m) 110V AC Power Supply for track circuits.
n) External Data logger Power supply.
o) External 24VDC Power supply.
p) External – 24VDC which used for E.I system Cooling Fans.
q) External Block circuit Power Supply.

r) Check whether all the voltage details are mapped in the analog database and labeled
correctly in the data logger analog modules.
s) Check whether protocol converter OPCR status wiring is done as per the vital interface
circuits.
t) Check whether all the vital input and Vital output relays front contacts wired to Data
logger for external relay status monitoring.
► Location : E.I relay Room Status : System Power ON Type of inspection :
Measurement Voltages at IPS / WESTRACE:
 All measurements will take up after power up of WESTRACE System the same will be
covered in MK2 stage inspection.
► Check that voltage drop between the 24VDC DCDC converters to PSUPFM , it should
not be more than 0.5 Volt.
► PSU 24 PFM - Power Supply Measurements:
 All measurements will take up after power up of WESTRACE System the same will be
covered in MK2 stage inspection.
 Check that 110 VDC voltage drop between the IPS to DC-DC converter is restricted to
1 volt.

► Voltage Measurement With respect Earth:
 All measurements will take up after power up of WESTRACE System the same
will be covered in MK2 stage inspection.
► S2 Panel Processor Installation Checklist: Visual check of S2 Panel
Processor Modules:
 Unpack all the modules from their covers and check whether you have received
the right type board with respect to the non vital Interface circuits.
 Visually check all the modules for their neat finish and plug them in the card file
except scanner module.
 Check whether all the S2 Westronics modules are stamped with RDSO seal and
hologram.
 Note down all the non vital modules serial nos and Part nos with respect to the
RDSO inspection certificate.

► S2 panel Processor Installation/Earthing / Interconnection Wiring Circuits :
 Check whether Panel processor and control cum Indication panel earthing is done as
per the non vital Interface circuits.
 Check whether S2 rack installed with rubber mats as per the non vital interface
circuits.
 Check whether the B24 & N24 Power supply connection for MBD 45, MBD 50(1), and
MBD 50(2) is done as per the non vital interface circuits.
 Check whether HAS3 [S2 Address] link settings is done as per the non vital interface
circuits.
 Check whetherS2 Scanner modules link [Jumber] setting is done as per non vital
interface circuits.
 Check whether Scanner module – Daughter board link [Jumber] settings is done as
per non vital interface circuits.
 Check whether scanner card consists of U7 & U19 IC’S with 9600 Baud rate
Executive software loaded condition.
 Check whether U8 & U18 available for loading Station specific Standard
Interlogic.
► S2 Standard Wrapping PCB:
 Check Whether S2 Standard Wrapping PCB received as per the Station specific
requirements.
 Check whether RI-14 cable connection is done as per the non vital interface circuits.
 Check whether N24 power source given for unused Pins of RI40 PCB 33-40 also as
per the non vital Interface circuits.
 Check whether the entire RI40 pin Cable [FRC] Continuity test completed at site.
 Check whether RI-40 pin FRC cables which connected to S2 Mother Board with
labeling as per the non vital interface circuits.
 Check whether mother board interconnectivity & power supply looping connection is
done as per the non vital interface circuits.
 Check whether interconnectivity of RI-64 FRC cable connection of MBD 45 & MBD50
[1], MBD 50[2] is done as per the non vital interface circuits

► Vital Interface Circuits - As made Circuits Verification:
 Check whether each sheet of WESTRACE vital Interface circuits duly signed by
railway officers and project & test Engineers.
 Check whether each sheet of S2 non vital Interface circuits duly signed by railway
officers and project & test Engineers.
► Dual VDU & MoviolaW VDU Installation:
 Check whether industrial CPU & Monitors are installed in air ventilated area.
 Check whether industrial CPU not placed /fixed in closed wall unit / wooden box or
direct to sunlight.
 Check whether24VDC nominal range of power source extended to the Industrial CPU
as per the vital Interface circuits.
 Check whether operator VDU / Maintenance VDU not fixed near to Power distribution
Panel / Communication Filter unit / Wireless communication equipments.
 Check whether power supply cables and network communication cables not mixed
together in inside the Communication rack.
 Check whether free space available to carry out the maintenance activities for dual
VDU supporting equipments e.g. Network Switches DC-DC converters.
► Bunching and Dressing of Wires:
 Check whether bunching and dressing activities completed in the below mentioned
racks on prior to
a) Commissioning?
b) WESTRACE Rack.
c) Relay Rack
d) S2 Panel processor Rack
e) Cable Termination Rack
f) Control cum indication Panel

► Bell test of wiring circuits:
 Check whether bell testing has been completed and duly signed by railway and
project Engineers prior system power up.
► Simulation board bell Testing:
 Check whether simulation board is wired with respect to station specific vital input
chart assignment & Signal /Point / Crank handle/ Axle counter /block proving circuits.
► Prewired rack assembly and wiring Checklist:
 Check whether duly filled checklist received at site without any remarks

Topics Learning objectives Speakers Key content
9:05-9:30Hs Introduction Open the session, Welcome Mr. Viswanath Welcome- Golden Rules- Objectives-
Participants and set the stage Patil VB agenda- participant’s presentation
9:30 -10:45 Bureau Veritas TQR- Quality Alerts, Individual Network Offices, Organization,
Customer Complaints/Issues Services
Feed back Siebel reporting issues Surveyor
T&E reporting and Delays
10:45-10:55 Break TEA

Safety at Site
10-55- 11-30 Personal Attributes RAVIKUMAR Organization
and Time Management
11:30-12:30 Bureau Veritas Customer Complaints Individual Network Offices, Organization,

Services
Surveyor
12:30-1:30 INDUSTRY Discover the IND/CTC Business VSS Organization, Main Services and
Line Expectation For 2017
13:30 Lunch Re-energize, Relax and Disperse


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Siemens Rail Automation Pvt. Ltd (File No.: IND.B.04.17.

© - Copyright Bureau Veritas

1. Audit of Electronic Interlocking System of Railway signaling hardware

2. Audit based on site installation check list

3. Equipment manufacturing and site installation check list refers to RDSO

TAN-STS-E-TAN 3012 Ver 2

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 2

► Check the type of system installed at site.

Centralized System Or Distributed System

(1+1, 2+2, 3+3 & 4+4 Configuration)

(CCIP+VDU or Dual VDU)

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 3

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 4

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 5

► WESTRACE Housing - Front cover and rear end cover plate

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 6

► Westronics Housing - Front blank cover plate

2. Check whether Westronics front blank cover plate aligned with

3. Check whether all the S2 modules tightened with screws (If

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 7

► Installation of EI racks and Relay racks

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 8

► Ladders arrangements between the racks.

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 9

► CABLE ROUTING : Input and output, communication cable, Power Supply

 Check whether AC & DC power supply cables, serial communication cables,

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 10

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 11

► OPCR wiring/Relay rack wiring circuits:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 12

► Fuse Terminals/Fuse ratings/Fuse fixing

► CON3 and CON4 wiring circuits & VSEV wiring Circuits:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 13

► EC2 & EC3 cable routing arrangements:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 14

► Earthing wiring connections:

 Check the Housing to housing earthing, EI earthing, network switch

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 15

EI Rack Earthing Connection WESTRACE Rack Vertical Earth Bus Bar

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 16

► Power supply board wiring and arrangements:

 Check whether individual 24VDC power supply connected for each

► VPIM and VROM Interface wiring circuits:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 17

► Terminals / Lugs / connectors arrangements and Tightness:

► Surge arrestor wiring and fitting arrangements:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 18

Surge Arrestor and Its Earthing Connection

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 21

Serial port Wiring of NCD PFM

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 22

 Check whether ethernet RJ 45 type connectors and M12 connectors are

► Network switch Installation:

► Serial communication equipment fitting & Connections:

 Check whether serial to OFC converters / RS232<->485 Converters are

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 24

► MoviolaW /WESTCAD Network Cable connection and Power Supply

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 25

► WESTRACE rack fan tray and exhaust fan arrangements:

© - Copyright Bureau Veritas SRAPL-Webinar Session June 2018 26

► No loose Conductors / Fittings in the EI systems and supporting

 Check that there are no loose connections in any of the fittings.

► Labels/markers/Ferrules and name plate: