15.

LINE PLANT - CABLING

15.1 TYPES OF CABLES:

Cables used for carrying Signalling circuits shall conform to relevant approved
Specification and shall be of approved size.

Power Cable used for carrying Power Supply for Signalling circuits shall conform to
relevant approved Specification. The size of Conductor shall be so selected as to suit
the Electrical Load.

Cable types shall be required to be selected for the Control & Monitoring of the following
outdoor Equipment:

(i) DC Point Machines.

(ii) 3-Phase AC Point Machines.
(iii) Signals – LED types as well as usual Bulb types.
(iv) Detection Devices – DC Track circuits, AFTCs (Feeding & Receiving
Ends) and Axle Counters (Wheel Detectors).
(v) Electrical Key Lock Units.

Signaling Cables with Solid Circular Cores are to be used, with individual Cores
arranged in Concentric Layers or with Star-quad arranged Bundles. As Axle Counter
Systems are sensitive against Middle and Higher frequency Electro-magnetic Fields, the
required Cables shall be essentially of Screened type with guaranteed Reduction Factor.
The Metallic Shielding Elements in such Cables shall have to be earthed on both sides.

For feeding Signals, Point Machines, Track circuits and Electrical Key Lock Units, the
Interference Calculations shall have to be carried out for determining the Maximum
Controllable Distances.

For Feeding Signals, located at a Distance beyond the Normal Permissible Limits,
additional Cores shall be required to feed Repeater Relays in the Location. For a 4-
Aspect Signal, Repeater Relays HPR, HHPR & DPR shall be required, each requiring 2
Cores.

For feeding Point Machines, multiple Cores can be used in accordance with the Feeding
Distance required for a specific Point. Instances are common of using 2 / 3 / 4 Cores
bundled together for feeding a Pont Machine. When 4 Cores are used to feed a Point
machine a total of 12 Cores shall be required, 4 each for NW, RW & CW. 4 Cores shall
be additionally needed to obtain Detection Contacts for Normal & Reverse Settings
respectively.

15.2 PLANNING:

While planning for Cabling on a Route, the Number of Conductors required, depending
upon the circuits should be first determined. Recommended core sizes as per
Specifications shall be used.
Adequate Spare Conductors to a minimum of 20% of total Conductors used shall be
provided for in each Main Cable up to the farthest Point Zone, beyond this there should
be a minimum of 10% Spare Conductors of the total Conductors used. No Spare
Conductors may be required if the total Number of Conductors used is 3 or less. The
Spare Conductors shall be provided on the outermost Layer.

Where a Number of Cables have been laid along a Route, the Circuits shall be so
distributed that Cables can be disconnected for Maintenance purpose with the least
possible dislocation to Traffic. To meet this requirement, it is advisable to segregate
Cables Line-wise (for example, separate Cables for UP & DN Lines) and if necessary
Function-wise. Auxiliary Signals (‘A’ Marker, Calling-on & Post Shunt etc.) may be taken
in different Cables. Similarly, Point Operation and Emergency Operational Control
through Crank Handle may be better taken in separate Cables. Cable Cores for TPRs
also can be preferably in different Cables.

An Example shall make the concepts clear.

Consider the part Plan of a Signalling Yard given in Figure 15.1.

Assignment of Cable Cores and Cables for various Signalling Functions may be planned
as under:

(i) Cables for UP & DN Functions shall be separate. See the Location
Boxes ‘M’, ‘P’ & ‘T’ for DN Line Functions & ‘N’, ‘R’, ‘U’ & ‘V’ for UP Line
Functions.

(ii) Cables on UP / DN side for Main Signals and for Auxiliary Signals
shall be separate. For Example, Signals ‘15’ & ‘115’ shall be assigned
Cores in different Cables. Similarly, Core Allocations for Signals ‘20’ &
‘C20’ shall be in different Cables.

(iii) Cables for Point Operation shall be separate. Cores for Point
Operations shall include Core Requirements for ‘NW’, ‘RW’ & ‘CW’ as
also for NWKR & RWKR. Cores for feeding the Point Machines could be
2 / 3 / 4 Nos. depending upon the distance of the Point from the Station
Equipment Room (SER).

(iv) Cable Cores for Crank Handle Control (CHC) of Points shall be in
different Cable. 4 Cores shall be required for releasing the Crank Handle
for each Point / Point Group.

(v) Cables for Track Circuits TPRs shall be separate. 2 Cores shall be
required for each TPR.

As an Illustration, Location ‘P’ shall contain:

(i) 8c for 17 RG, HG, HHG & DG (2 Cores for each Aspect).
(ii) 6c for 17 HPR, HHPR & DPR.
(iii) 2c for SH. 117 ‘Off’.
(iv) 2c for SH. 117 HPR.
(v) 2c for 203b TPR.
(vi) 12c for Points 203 ‘NW’, ‘RW’ & ‘CW (presuming requirement of 4
Cores for taking the Load).
(vii) 4c for Crank Handle Control (CHC) for Point 203.
(viii) 2c for 17 ’A’ Marker Lighting & 2c for 17 AMHPR, if the Station is in
Automatic Block Signalling Territory.
(ix) 2c for Maintenance Telephone.

Functions listed in Groups [(i), (ii)], [(iii), (iv), & (viii)], [(vi)], [(vii)] and [(v)] shall be
preferably allocated separate Cables.

After deciding the Size and the Number of Conductors in the different types of Cables to
be used on a Route, a Foot Survey along the Track should be done to determine the
best Route for the Cable. Routing shall be decided in close cooperation with the
Providers of Cable System for Telecommunication and Power Supply.

The Route shall be shown clearly on a Cable Route Plan showing the actual Alignment
of Track, giving Offsets from Permanent Way or Permanent Structures. The Diagram
should indicate the various Road and Track Crossings, Crossing with Power Cables,
Water & Sewage Mains and other points of importance. It is preferable to chart the
Route on a Route Plan on which the existing Routes of Power Cables, etc. are shown.

Cable Route Plan should be got approved by Civil Engineering and Electrical
Engineering Departments as well.

As far as possible Low Lying Areas, Platform Copings, Drainages, Hutments, Rocky
Terrains, Points & Crossings should be avoided.

Preferably, separate Cables shall be laid for Point Operation.

15.2.1 Laying the Cables above Ground:

Signalling Cables for outdoor circuits should not normally be laid above ground. In
exceptional circumstances, where it becomes unavoidable, the following Precautions
should be taken:

(i) The Cable should be suspended in Wooden Cleats, from Cable

Hangers or in any other approved manner so that no mechanical damage
occurs to the Cable even under exposed condition.

(ii) The Cable Supports shall be so spaced as to avoid Sag.

(iii) In Station Yards, Cable shall be laid in Ducts suitably protected.

(iv) Indoor Signalling Cable should normally be laid on Ladders, Channels

or in any other approved manner. The Cables should be neatly tied /
laced.

Note: In AC Electrified Areas Cables shall be laid underground only.

15.2.2 Laying the Cables Underground:

Cables may be laid underground, either in the Trench, in Ducts, in Cement Troughs, in
Pipes or in any other approved manner.

15.2.3 Laying the Cables in Ducts:

RCC, Masonry or other approved type of Ducts may be used for laying the Cable.

The Ducts shall have suitable Covers.

The Ducts shall be of such Design as to prevent water collecting in the Duct.

The Ducts used shall be UV-stabilised, fully recyclable as well as not hazardous to the
Environment.

When Cables are laid in Rocky Area, it is desirable to protect them with split RCC Ducts
of suitable Design.

Where it is necessary to take the Cable between the Tracks, it shall be carried in
Trunking kept sufficiently below the Ballast Level.

Where several Cables of different Categories have to be laid in the same Trench, they
shall be placed as far as possible in the following order starting from the Main Track
side, so that in the event of failures, the Maintenance Staff may easily recognize the
damaged Cables:

(i) Telecommunication Cable.

(ii) Signalling Cable.
(iii) Power Cable.

Cables belonging to Post &Telegraph Departments or the Electrical Department must

not be laid in the same Trench along with Signalling & Telecommunication Cables. A
distance of approximately 10 cms. must be maintained between the Telecommunication
Cable and Signalling Cables. The Signalling Cables must be separated from Power
Cables by a row of Bricks between them.

15.3 STORING & TRANSPORTATION OF CABLES:

Cable Drums shall not be stacked on Flat side. Suitable Stoppers shall be placed for
Stability.

Cable Drums shall have easy Access for lifting and moving.

When rolling the Cable Drum either for unloading or Transportation, the Drum shall
always be rotated in the direction of ‘Arrow’, which is marked on the Drum.

The Drums shall not be rolled over Objects that could cause damage to the protecting
battens of the Cable.

When unloading is carried out from the Vehicle, the Drum shall not be dropped on the
ground directly to avoid damage due to impact. Fork Lifter or Ramp shall be used.
During all stages of Storage, it is essential that the ends of the Cable are effectively
sealed by end cap or in any other approved manner to avoid water entry in to the Cable.

It is desirable that Cable Drums are stored in Covered Shed to protect against direct
exposure to Sun.

15.4 PAYING OUT AND TESTING THE CABLE:

For paying out Cables, the Cable Drums shall be mounted on Cable Wheels. It should
be ensured that no Kink is formed, while paying out the Cable.

The Drum on the Wheel shall be brought to one end of the Trench and the end of the
Cable freed and the Cable shall be laid along the Trench.

A party of Labourers shall move along the Trench carrying Cable at suitable intervals so
that Cable is not damaged due to dragging along the ground or bent unduly.

Before the Cable is laid in the Trench, a visual Inspection of the Cable shall be made to
see that there is no damage to the Cable. It shall be tested for Insulation and continuity
of the Cores. Thereafter the Cable shall be laid in to the Trench. Insulation and Loop
Resistance measured shall be recorded.

In cases where the Wheels are not available, the Drum shall be mounted on an Axle at
one end of the Trench and Cable paid out and carried by Labourers.

In no case, shall the Drum be rolled off on to the Road for laying the Cable and the
Cable dragged on the ground for laying purposes.

Whenever Mechanised Equipment is used, the work shall be carried out by a trained
Operator under the Supervision of the Supervising Engineer incharge of the Work.

Where the Cable Drum is in damaged condition, the Cable may be placed on a
horizontal revolving Platform and the Cable paid out in the same manner as described in
Paras above.

Paying out of Cable should be done by rotating the Cable Drum and NOT by pulling the
Cable with excessive Force.

15.5 LAYING:

Cables laid parallel to the Track shall be buried at a depth of 0.80 m minimum from the
ground level. While those laid across the Track must be 1.0 m below the Rail Flanges.
However, in case of Rocky Soil, the depth may be reduced suitably. When it concerns
the laying of Tail Cables which serve the Track Apparatus etc., the depth should not be
less than 0.50 m. In Theft prone Areas the Cables may be laid at a depth of 1.2 m with
Anchoring at every 10 m.

The Width of manually made Cable Trenches should commensurate with Number of
Cables. The minimum Width shall be kept as 0.3 m. The Bottom of the Cable Trench
should be leveled and got rid of any sharp materials. In the Soft Ground, the Cable
should be laid at the Bottom of the Trench previously leveled. In the Rocky Ground, the
Cable should be laid on a layer of Sand or sifted Earth of 0.05 m thickness previously
deposited at the bottom of the Trench. In both the above cases, the Cable should be
covered with a layer of Sand or sifted Earth of 0.10 m thickness and thereafter a
protective cover of Trough or a layer of Bricks should be placed.

Cable Markers should be placed at suitable Interval and at Diversion points.

Cable Markers shall be made from Concrete or other approved Material.

15.5.1 Cable Crossing:

When a Cable is to cross the Track, it should be ensured that:

(i) The Cable crosses the Track at Right Angles.

(ii) The Cable does not cross the Track under Points & Crossings, and
(iii) The Cable is laid in Concrete / GI / CI / PVC Pipes, suitable Ducts or in
any other approved manner.

Whenever practicable, the Cable may be taken underground across the Drain Bed at a
suitable depth for crossing small culverts with low Flood Level.

When Cables have to cross a Metallic Bridge, they should be placed inside a Perforated
GI Pipe or Metallic Trough which may be filled, as an anti-theft measure, with sealing
Compound. The Cable should be supported across the Bridge in a manner which would
involve minimum Vibrations to the Cable and which will facilitate the Maintenance Work.
Adequate Cable Length to the extent of 2 to 3 m shall be made available at the approach
at either end of the Bridge.

While laying the Cable in accordance with above Instructions, the following Instructions
should be adhered to for the Safety of the Track:

(i) Outside the Station Limits, the Cable should generally be laid at not
less than 5.5 m from the nearest Track.

(ii) Within the Station Limits, the Trenches shall preferably be dug at a
distance of not less than 3 m from he centre of the Track, the width of the
Trench being outside the 3 m distance.

(iii) At each end of the Main Cable an extra Loop length of 6 to 8 m should
be kept.

It is desirable that the Excavation of Trenches is not done in long lengths and does not
remain uncovered for long period. It is preferable that the Cables are laid and refilling
done on the same day.

Back filling of the Trenches should be done properly. The Earth excavated shall be put
back on the Trench, rammed and consolidated.

During Excavation, the Earth of the Trenches should not be thrown on the Ballast. The
Earth should be thrown by the side of the Trenches away from the Track.
In places where Cables are to be laid within 1 m from the Sleeper end, digging beyond
0.50 m shall be done in presence of an Official from Engineering Department, and the
laying of the Cable and refilling of the Trench should be done with least delay, preferably
on the same day.

Cable Joints of approved type only shall be used.

The Work shall be supervised at Site personally by an Official of the Signal &
Telecommunication Department not below the Rank of Junior / Senior Engineer (Signal).

15.6 CABLE TERMINATION:

Cable laid in the Yard is required to be terminated on the Cable Termination Rack (CTR)
in the Relay Room or in the Equipment Room in case of Solid State Interlocking.

A possible arrangement is shown in Figure 15.2. A Photograph of the Entry of the Cable
in to the Relay Hut / Equipment Room may be seen in Figure 15.3.

Layout of the Terminations shown in Figure 15.2 provides for 7 Terminal Strips ‘A’ to ‘G’.
Cables coming from one end of the Yard, say East end, can be terminated on Strips ‘A’
to ‘C’ and that coming from West end on Strips ‘E’ to ‘G’, Strips ‘A’ & ‘G’ earmarked for
Signalling Cables, Strips ‘B’ & ‘F’ earmarked for Quad Cables (for AxC), and Strips ‘C’ &
‘E’ earmarked for Power Cables.

Cable coming from SM Room and Platforms can be terminated on the Strip ‘D’.

Care should be taken to terminate Power Cable from each side of the Yard on same
Rows on Strips ‘C’ & ‘E’.

Refer to Figure 15.4 for the Photograph of the Cable Termination Rack (CTR) in a Relay
Interlocking Installation. Notice the Tag Blocks above the Termination Links. Incoming
Cable is first terminated on the Tag Blocks and then from there is taken to the Terminals.

Figures 15.5 to 15.8 display the Photographs of the Interiors of Relay Rooms in Relay
Interlocking Installations to have a feel of the Indoor Cabling, Terminations and Fixtures.

15.7 LOCATION BOX / JUNCTION BOX:

The Location Box / Junction Box of suitable Capacity and approved Design shall be
used to terminate the Cable in the Yard and for keeping some of the Outdoor
Equipment.

Each Location Box shall have Lock & Key arrangement for locking the Location Box to
prevent Theft & Interference. Common Key must be there for all the Location Boxes in
the Yard.

The Location Boxes must be fitted on suitable Foundation so that they do not fall with
the external Force. Drawings for the Foundations shall be got approved by the
Competent Authority.

The Entry Point of the Cable in the Location Box must be sealed suitably.
The Location Box must be provided with the Lighting arrangement so that the Staff can
work even in night. The Lighting Arrangement must be provided with ON / OFF Switch.

Cables terminated inside the Location Boxes should be fixed by Clamp or nay other
approved Method to give it a neat and ordered look.

Terminal Blocks provided at Locations as also at other places shall be provided with
suitable links to facilitate Isolation of the two sides of the circuits, which are connected to
the Terminal Links. The links shall be of a Design which prevents the Cable in one pole
short-circuiting to that of other pole.

Crimpled eyelet Terminals shall be used for terminating flexible wires.

Refer to Figures 15.9 to 15.11 for the Photographs of Location Boxes. Notice specially
the Fixing Position of the Location Boxes in the Yard, which is perpendicular to the Track
Layout. Such a Position is a desirable one to take care of the Safety of the Working Staff
on the Location Boxes.

15.7.1 Naming of Location Boxes:

Location Boxes in the Field can be located in different Zones of concentration of

Signalling Gears and geographically numbered as ‘A’, ‘B’, ‘C’ ----- in incremental order
from left to right, with description of Location Box – ‘F’ for Full Location Box, ‘H’ for Half
Location Box and ‘Q’ for Quarter Location Box.

Zones could be ‘Distant Signal Zone’, ‘Home Signal Zone’, ‘Loop Starter Zone’,
‘Advanced Starter Signal Zone’, ‘Emergency Crossover & Back Shunt Zone’ and ‘LX
Gate Zone’ etc.

A specific Location may require more than one Box and those multiple Boxes could be
named as ‘A1’, ‘A2’, ‘A3’ ----- etc.

15.8 MAINTENANCE:

All Cables Termination Devices, Pillar Boxes, Cable Heads and Glands shall be kept
Clean and dry. These parts shall be frequently inspected and any tendency of moisture
or water leak shall be immediately attended to.

No Excavation in the vicinity of underground Signalling Cables shall be undertaken

without a representative of the Signal & Telecommunication Department being present
and without taking suitable precautions for the Safety of the Staff.

The Protective Works provided for the Cables at places like Track Crossings, Culverts,
Bridges etc. shall be regularly inspected by the Maintenance Staff, special attention
being paid to these protective works soon after the Monsoon.

15.8.1 Earth Leakage Detectors:

The use of Earth Leakage Detectors is desirable in all Electrical Signalling Installations,
such as Route Relay Interlocking, Panel Interlocking, Centralised Traffic Control and
Solid State Interlocking Systems.

15.8.2Testing of Cables:

All Conductors in Signalling Cables must be tested for their Insulation in dry weather
every year. A comparison of the Test Results between Test Results between successive
Tests carried out on a Cable under similar conditions will give an Indication of the trend
towards deterioration of the Insulating Material over a period of time. If a sudden fall in
Insulation is observed, the Cause should be investigated and immediate steps taken up
to repair or replace the Cable.

In addition to the regular Testing of the Cables in dry weather, Random Tests in Wet
weather may also be carried out, where considered necessary, to localize sudden
deterioration in Insulation of Cables.

15.9 INSULATION RESISTANCE TESTING OF SIGNALLING

CABLE:

15.9.1 General:

Insulation Resistance Tests should be made in such a manner that safe Operation of
Trains is not affected. It should be ensured that no unsafe conditions are set up by the
application of Test Equipment.

All Conductors in Signalling Cables must be tested for their Insulation at the time of
Commissioning and thereafter in dry weather every year preferably during the same part
of the year.

Insulation Resistance Tests should be made when Conductors, Cables and insulated
parts are clean and dry.

In addition to regular testing of Cables in dry weather, Random Tests in wet weather
may also be carried out, where considered necessary.

The Conductors of the Cables possess appreciable Electrostatic Capacity and may
accumulate Electrostatic Charge. The Cable Conductors should be shorted or earthed to
completely discharge any accumulated Charge (a) before connecting the Insulation
Tester while commencing the Test, and (b) before the Insulation Tester is disconnected
when the Test is completed. This is in the interest of Safety of Personnel and Protection
of the Equipment.

A 500 V Insulation Tester should be used for Insulation Testing. The fact that the Cable
has Capacitance means that it has to be discharged before a measurement of the
Insulation Resistance can be made. The Insulation Resistance should, therefore, be
recorded after the Test Voltage has been applied for 1 minute or so when the Indicator
of the Insulation Tester shows a steady reading.

Any Metallic Sheath or metal work of any Rack or Apparatus Case should be bonded to
Earth during Test.
15.9.2 Test Procedure:

Disconnect all Cores of the Cable at both ends. The disconnection may be made
through links of ARA Terminals.

Connect one Terminal of the Insulation Tester to the Conductor under Test and the other
Terminal to all the other Conductors bunched together and connected to Earth. Similarly
test remaining Conductors of the Cable one by one.

Insulation Resistance so measured should not be less than 5 Mega Ohms per Km. at
buried temperature. If the Insulation Resistance is found to be lower than 5 Mega Ohms
per Km., the cause should be investigated and immediate steps taken to repair or
replace the Cable to prevent any malfunctioning of the Equipment and Circuits.

The Results of the Insulation Resistance Tests should be recorded in the following
Proforma. A Comparison of the Test Results between successive Tests carried out on a
Cable under similar conditions will give an Indication of the Trend towards deterioration
of the Insulation Resistance of the Cable. If sudden fall in the Insulation Resistance is
observed the Cause should be investigated and immediate steps taken to repair or
replace the Cable.

Cable Insulation Resistance Test Sheet

Main / Tail Cable

1. Location: From ------------------------------- to -------------------------------.

2. Cores: -------------------------------.
3. Size: -------------------------------.
4. Grade: ------------------------------- V.
5. Length: -------------------------------.
6. Type: Unscreened / Screened / Power.
7. Type of Insulation: -------------------------------.
8. Date of Installation / Commissioning: -------------------------------.
9. Name of the Manufacturer: -------------------------------.

Core No. Date of Test & Weather Value of Insulation

(Dry / Wet / Damp) Resistance.

Temperature: ---------------------------------.
Remarks:
--------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------
--------------------------------------------------------------.
 Testing Official
Name: ---------------------------------.
Designation: ---------------------------------.

15.10 EARTHING:

15.10.1 Earthing Objectives:

Earthing shall be provided for all Indoor & Outdoor Signalling Installations to achieve the
following Objectives:

(i) To provide Safety to the Operating & Maintenance Personnel against the
Electric Shock on account of any High Potential (Voltage) appearing on
exposed parts with respect to Earth or due to Electromagnetic /
Electrostatic Induction.

(ii) To ensure Safe & Reliable Operation by limiting or eliminating the

Induced Voltages and Transients in the Signalling & Train Control
Equipments.

(iii) To protect the Equipment against build up of unduly High Voltages, which
can cause Dielectric (Insulation) Breakdown or Damage to the Equipment
or their parts?

(iv) To serve as Common Voltage Reference Point, wherever required.

15.10.2 Earthing Policy:

(i) Earthing and other Protection Devices shall be designed to

accomplish the following minimum requirements:

(a) Protect Operating & Maintenance Personnel and

Equipment from Electrical Hazards, including
Lightning.

(b) Reduce Potential to System Neutrals.

(c) Reduce or eliminate the effects of Electrostatic and

Electromagnetic Interference arising from within the
System on account of Traction Voltages, Traction
Return Current, Rolling Stock Characteristics and
other extraneous Sources.

(d) Provide a proper Earthing method for all Equipment

Enclosures, Cabinets, Drawers, Assemblies and
Sub-assemblies.
 (e) Provide a clean Zero Volt Reference Point, where
required.

(ii) The Earthing System shall be so designed so as to give Earth

Resistance with in the stipulated limits at all locations and under
all climatic conditions.

(iii) Any Electrical Joints in the Earthing System shall be protected

from moisture ingress by using proper wrapping, sealing with
waterproof tapes, or such other measures.

(iv) For the purpose of measurement of Earth Resistance, a small

interconnecting copper strip of appropriate cross-section shall be
provided in the Ring Earth in a small manhole chamber so that the
Ring Earth can be broken from the loop.

15.10.3 Architecture of Earthing System:

The Architecture of the Earthing System at each Installation shall be based on following
four Major Elements:

(A) Perimeter Earthing System:

A Perimeter Earthing System shall be created for each Equipment Housing Room.
Usually Operating Panel Room, Station Equipment Room (SER) and Battery Equipment
Room (BER) are located in the same Premises. As such a common Perimeter Earthing
System can be planned for all the Equipments housed in these three Rooms.

The Perimeter Ground will be created by bonding a Network of Earth Electrodes

together using GI Strip – 5 mm x 50 mm. The Number of Earth Electrodes will depend
on the Soil Resistivity and the depth to which Electrodes can be buried. The GI Strip will
be Cad-welded to each of the Earth Electrodes to form a Ring. The GI Strip is to be
approximately 0.5 m below Ground Level.

Refer to Figure 15.12 for a Graphical Representation of the Perimeter Earth

Architecture. When a Perimeter Earthing System has been installed, the Earth
Resistance shall be measured. Should the Resistance be too high, additional Earthing
Electrodes shall be driven and bonded to the Perimeter Earth. Suitable Markers to
identify Perimeter Earth Electrodes shall be provided.

Perimeter Earthing System shall provide a Path for conducting of Surge Voltages and
Currents into the Earth Mass.

Maximum Value of Earth Resistance of the Perimeter Earth System shall not exceed 1
Ohm and Impedance offered to Surge Currents shall not be more than 30 Ohms.

(B) Main Earth Busbar and Main Earth Link:

In each Equipment Housing Room, there shall be a Main Earth Busbar. Main Earth
Busbar can also be named as Room Earth Busbar. This Busbar shall be mounted
directly onto the Wall and shall be insulated from the Wall. The Main Earth Busbar shall
be approximately 300 mm x 6 mm x 70 mm Copper Bar. The Busbar shall be predrilled
for 10 mm Nuts and Bolts. All Earthing Cables will be fastened to the Main Earth Busbar
using soldered ‘Eyelet’ or ‘Lug’ type Connectors fastened with a Brass Nut, Bolt and
Washer above and below the Lug. All Secondary Busbars within the Installation shall be
connected to the Main Earth Busbar in a Star Configuration using 5 mm x 50 mm GI
Tape.

The Main Earth Busbar shall be mounted no more than 300 mm above Floor Level and
as close as possible to those Cables that could introduce Surges and EMI to the
Equipments in the Equipment Housing Room. The Main Earth Link, from the Perimeter
Earth to the Main Earth Busbar shall be Cad-welded to the Closest Earth Electrode
using 5 mm x 50 mm GI Tape. The Link shall be bolted to the Main Earth Busbar using a
Locknut -. two Nuts on a Bolt.

(C) Earthing Inside Equipment Rooms:

All Secondary Earth Busbars shall be bonded to the Main Earth Busbar. All Connections
to the Main and Secondary Busbars shall be via 10 mm Brass Nuts and Bolts. The Nut
shall be a ‘Locking’ type - two Nuts on the one Bolt, to prevent loosening due to external
vibration.

Figure 15.13 provides a General Schematic for the Secondary Earth Wiring inside a
Station Equipment Room. The Cable Termination Rack must be located as close as
practical to the Main Earth Busbar. Where required, Cable Shields shall be bonded to
the Secondary Earth Busbar on the Cable Termination Rack.

(D) Rack and Cable Tray Earthing:

Internal Racks shall be bonded to one another and to the Cable Trays to form an Equi-
potential Zone (Figure 15.14). The Metal to Metal contact shall be via an Overlap of
Metal Structures and Fastenings (Nut, Bolt and Washers). Serrated washers shall be
used to ensure adequate Metal to Metal contact.

Each Rack will have its own Secondary Earth Busbar directly bolted to the Rack Metal
Work. The Secondary Earth Busbar shall be positioned at the bottom of the Rack, as
close as possible to the Main Earth Busbar. The Secondary Busbar shall be attached
using Brass Nuts and Bolts. The Protective Coating on the Rack must be removed to
provide an effective Metal to Metal Surface. Cable Trays shall also be bonded to the
Racks that they join using Short Bonds. The Bonds will consist of ‘Eyelets’ crimped to 10
mm2 Copper Cable at each end. The Bond shall be bolted to the Tray and the Frame.

15.10.4 Labels of Earth Bonding Conductors:

For Identification purposes, all the Bonding Conductors must be labelled to indicate their
Source point and Destination.

15.10.5 Earthing of Equipments Mounted in Racks:

Card Files and Chassis of the Equipments mounted in a Rack must be earthed via the
Rack. Connecting the Earthing Stud on each Card File or Chassis to the Rack using 4
mm2 insulated Copper Wire can do this. Terminate this Wire on the Rack Frame. When
no Earthing Studs are provided on he Cardfiles / Chassis, ensure good contact between
the metallic ears of Cardfiles / Chassis and the Rack via the use of Mounting Screws
and Star Washers.

15.10.6 Earthing of Miscellaneous Equipment Frames:

The Metallic Covers of equipment such as Power Supplies and Transformers that are
not located on Racks shall be bonded directly to the nearest Secondary Earth Busbar
using 10 mm2 insulated Copper Cable. Operating Equipment such as Mechanical Lever
Frames, Block Instruments and Operating Panels also need to be bonded to the nearest
Busbar using 10 mm2 insulated Copper Cable.

15.10.7 Cable Shields:

Shielded Cable shall be earthed to a Main or Secondary Earth Busbar at one end only.
(Note: Cable Armour is not Shielding and shall not be treated as Shielding.) The Shields
shall be earthed at the end farthest from the Equipment Room, if the Cable is run
between an Equipment Room and another Building or Installation.

15.10.8 Metallic Scaffoldings and Safety Screens:

External Scaffolding and Personnel Safety Screens shall be earthed to the nearest Main
Earth Busbar or an Earth Electrode by a 16 mm 2 insulated Copper Cable. Such Cable
must be protected from Theft.

15.10.9 Way Side Equipment Earthing:

Wayside Equipment, apart form Points Machines and associated Rodding, shall be
provided with Earthing to protect the Installation from Lightning related Surges and
possible fallen Overhead Traction Conductors. If the Equipment is isolated (no other
equipment within 30 m), the Equipment shall be provided with its own Earthing Electrode
(s). Where Wayside Equipment is located within 30 m of the next piece of Equipment, a
Local Earthing Network can be created by bonding the Equipment to a Common
Earthing Electrode.

15.11 TRANSIENT & SURGE PROTECTION:

Occurrences of Transient High Voltages, Lightning & Surges are of temporary nature,
and are usually of short duration & limited energy. Electronic Equipment with a High
Input Impedance is inherently susceptible to these Transients & Surge Voltages.
Physical distance from the Transient Source does not necessarily guarantee their
immunity from Transients. An effective Transient & Surge Protection System is,
therefore, essentially required for protection of the Electronic Equipments.

15.11.1 Architecture of Surge Protection System:

The Surge Protection System Architecture inside the Equipment Rooms and Location
Cases is based on the concept of ‘Zoning’. Zoning is based on the concept of limiting the
Area of an Equipment Room that can be ‘Contaminated’ by conducted EMI. Thus Wiring
is classified as either ‘Dirty’ or ‘Clean’. Restrictions are placed on where Clean and Dirty
Wiring can be run in the Equipment Rooms. The Restrictions are based on identified
Zones within the Room.

The three Zones that shall be used when designing a Surge Protection System are:

(i) Z0: The Outside Environment.

(ii) Z1: The area adjacent to the point of Entry for ‘Dirty’ Wiring coming in from Z0.
(iii) Z2: The area where ‘Clean’ Wiring can be run.

Wiring passing from ‘Z1’ to ‘Z2’ must be ‘Cleaned’ through the use of Surge Arrestors
and / or Filters before allowing it to be conducted to ‘Z2’.

The Cable Termination Rack (Z1) is adjacent to the side of the Room containing the
Cable Point of Entry from the Outside (Z0). The Main Earth Busbar is also adjacent to
the Cable Point of Entry. The Equipment Racks containing Equipments Susceptible to
Stray EMI are mounted in Zone ‘Z2’. It is not permissible for Cables to run directly from
‘Z0’ and be terminated in ‘Z2’. They must be terminated on the Cable Termination Rack
and suitably ‘Cleaned’ before Electrical Inputs can be conducted to ‘Z2’.

The application of Surge Protection Devices (SPD) is one method for cleaning ‘Dirty’
Wiring. A second method is the use of Relays to galvanically isolate ‘Z2’ circuitry from
the Wiring originating in ‘Z0’.

Surge Arrestors are basically Variable Resistance Devices, whose Resistance is a

Function of the Applied Voltage. They are designed so that they provide a Clamping
Effect when Voltage across them exceeds a certain Level. A good Surge rotection
Device should have High Surge handling Capability, Fast Response Time, and Low
Clamping Voltage. Suitable SPDs are to be incorporated in the Electronic Equipments
and Sub-systems, to ensure that the latter withstands the conditions obtainable, without
any Damage or Permanent Degradation in Performance throughout the System Life-
time.

15.11.2 Types of Surge Protection Devices (SPD):

(i) Gas Discharge Tube (GDT), Slow but can handle very High
Power.
(ii) Metal Oxide Varistor (MOV), Fast and available in a wide range of
Energy Ratings.
(iii) Avalanche Devices, Semi-conductor Devices with Zener type Action,
very Fast but not very High Power.
(iv) SCR Devices, another type of Semi-conductor Devices, Slow but can
handle high Currents.

Figure 15.15 shows Voltage –Time Curves for various types of SPDs when exposed to
leading edge of Surge Waveform. It shows GD Tubes and SCR Devices are slow to start
the Suppressing Effect. They have to reach a Trigger Voltage before they begin to
conduct and during this time they let the Surge Voltage pass to the Protected
Equipment. MOV and Avalanche Devices act like Zener Diodes with a Knee Voltage
where they start to draw current. As the Current increases, their Clamping Voltage also
rises but slowly.
15.12 LIGHTNING PROTECTION:

Station Buildings prone to Lightning shall be provided with the Lightning Protection
Arrangements.

Protection against Lightning Surges travelling through Conductors into Equipments’ side
shall be done, using appropriate Surge Protection Devices.

15.13 POWER SUPPLY PROTECTION:

15.13.1 Integrated Power Supply (IPS):

In order to ensure a sufficient Protection against any EMI, the Power Supply of the
Signalling Systems shall be separated to the Mains Supply by Galvanic Insulation, e.g.
by using separating Transformers.

Between the Overhead Catenary System and the UPS, an Isolation Transformer shall
ensure Galvanic Insulation, so that no Interference will be transmitted to Signalling and
Telecommunication Systems.

The Input Stage of the IPS receives Power from two different Auto-transformers
(Automatically Switched). As an Auto-transformer has only one Winding, the Output
Stage of an Auto-transformer is not galvanically isolated from the Input Traction Earthing
System. Thus, a 1:1 Isolation Transformer is required between the Traction Auto-
transformers and IPS.

In order to minimise Capacitive Coupling between the Primary and Secondary Coils, the
Isolation Transformer shall be provided with an Electrostatic Shield (on the Primary Coil).
The Shield Earthing connection MUST NOT be connected to the Signalling Earthing
System. It shall be connected to the Traction Earthing System.

The IPS shall be fitted with Surge Protection Devices to protect sensitive ‘Z2’ Equipment
from Surges and EMI that could interfere with System Reliability. The Input Stage of the
IPS is provided with a Lightning and Surge Protection Unit. Within the IPS, Type 2
Surge Protection is provided at the Input to the SMPS Charger Unit.

15.14 INTERFACE CIRCUIT PROTECTION:

Interface circuits are the hardwired circuits that link Equipment at one Location with
Equipment at a second Location. As Interface circuits are run parallel to the Overhead
Traction System, Voltages will be induced into the Signalling Cables, 116 V AC / Km. on
Single Lines and 95 V AC / Km. on Double Lines. The Induced Voltage will effectively
limit the distance the circuits can be run under the 25 KV Overhead Wiring. The Vital
Relays that are used in such circuits must be AC Immune.

Immunisation Limits for the various Safety-critical Line circuits are given in the following
Table:

Circuits Maximum Distance

Filament Signal Lighting Circuits. 180 m for Single Track and 220 m for
Double Track.
 LED Signal Lighting Circuits. 400 m.
IRS Points Control Circuits. 910 m for Single Track and 1100 m for
Double Track.
Three Phase Points Control Circuits. No Limit.
AC Immune DC Track Circuits. Maximum length of 35 m from Rail to
Track Relay.

Immunisation Distances

15.14.1 Vital Relay Circuits:

Vital Relays (AC Immune) are used to provide Galvanic Isolation between Field
Equipment and the Equipment housed in the Station Equipment Room (SER), for both
Inputs and Outputs.

15.14.2 Equipment Interface Circuits:

(A) Audio Frequency Track Circuits:

Each Interface between either a Transmitter or Receiver and the External Environment
shall be protected by Surge Protector Unit. This Unit shall be mounted as close as
possible to the point where the Tx and Rx Cable leave the SER or LSC.

(B) DC Track Circuits:

The DC Track feed Units are supplied by 110 V AC that is distributed from the closest
SER or LSC. The 110 V AC supply is fed via Step-down Transformers (600 VA, 230 /
110 V AC) from the IPS. The Track Relays are QTA2 Relays. The Track Relay is
repeated in SER by QSPA1 Relays to provide Galvanic Isolation. The Wiring (Z0 to Z1)
for such Relays will not usually be fitted with Surge Protection.

(C) Axle Counter Circuits:

The Axle Counter Evaluation Unit (ACE) and Detector Units contain adequate Surge
Protection. No additional Surge Protection is required.

(D) Level Crossings:

The Level Crossing Installations are supplied with 110 V AC from an IPS. No additional
Surge Protection is required for the Level Crossing Units as the Equipment is robust.
The 110 V AC Supply is fed via Step-down Transformers (600 VA, 230 / 110 V AC) from
the IPS. The interface to Level Crossing Equipment is provided through AC Immune
QNA1 Relays which provides Galvanic Isolation.

(E) LED Signal Control Circuits:

The LED Signals are fed via Step-down Transformers (600 VA, 230 / 110 V AC) from the
IPS. The Output Stage of the IPS is provided with Differential Mode Metal Oxide Varistor
(MOV) Protection. The Interface to LED Signal is provided through Q-series and LED
ECR Relays which provide Galvanic Isolation. No additional protection is required on the
LED Signals.
(F) Block Instrument Circuits:

The Interface to Block Instrument is provided through AC Immune QNA1 Relays which
provides Galvanic Isolation. No additional Surge Protection is required to protect the
Block Instrument Equipment.

(G) Points Control Circuits:

The Point Machines shall be isolated from the Rail. The Points are fed directly from the
IPS 110 V DC Batteries. Back to back MOVs are provided in the IPS circuitry to provide
Differential Mode Protection. The Interface to Point Machine is provided through AC
Immune QBCA1 and QNA1 Relays which provide Galvanic Isolation. No additional
Surge Protection is required for Points Control Circuits.

(H) Serial Interface (RS-232) Protection:

Surge Protection is required where Copper Conductors are used to implement Serial
Communications between Equipment Rooms.

A serial Opto-isolator can be used to provide the required Isolation between ‘Z0’ and ‘Z2’
Electronic Equipment.

The Controller’s Workstation (VDU) is located in the Station Master’s Office. The
Workstation RS-232 Serial Ports shall provide a Serial Link to the ‘Z2’ Electronic
Interlocking Equipment. If the distance between the Workstation Computer and
Interlocking Equipment is less than 15 m, no additional Data Communications
Equipment (DCE) (MODEM) is required other than the Opto-isolators. For Stations
where, the Serial Link between the Workstation Computer and the Interlocking
Equipment Room is 15 m or more, the RS-232 Serial Data is converted to RS-485
Standard which supports a Longer Transmission Distance. In such cases, RS-232 to
RS-485 Isolation / Converter should be used as the Interface. Wherever such
Converters are used, provision of Opto-isolators are not necessary as the Converters
provide for in-built Isolation & Surge Suppression between its Input & Output.

15.15 CABLE SEGREGATION

Cables shall be classed into 4 Classes as follows:

(i) Class-4: ‘Dirty’ Cables from Z0.

Examples: Power Cables for Auto-transformers, Power from Local

Electrical Authority, Low Power (24V - 48V AC / DC) Cables, Telephone
and Communication Lines, Fibre Optic Cables with Metallic Armour.

(ii) Class-3: Cable in Z1 that has Type 1 and / or Type 2 Surge Protection
(e.g. GDT, MOV).

Examples: Power after a Secondary Shunt Type SPD (MOV based),

feeding into a Z2 area, Power to Fluorescent Lighting, Power to
Mechanical Loads (e.g. Air-Conditioners).
(iii) Class-2: Clean, non-communications Cable within the Z2.

Examples: Power Cables located within Z2 area, Signal Cables leading to

or from Z0 areas that have passed through a SPD at the Z1 area, and are
now within the Z2 area, 48 V / 24 V / 12 V DC Low Power Cables within
Z2 areas, Signalling Cables to or from Z0 areas that are Galvanically
Isolated using Vital Relays in Z1, and are now within the Z2 area.

(iv) Class-1: Clean Communications Cable within Z2.

Examples: Communication Cables from Z0 areas that have passed

through a SPD at the Z1, and are now within the Z2 area, Optical Fibre
Cables from Z0 areas that have had their Metallic Armour removed at Z1,
and are now within the Z2 area.

Within SER / LSC, separation of 0.2 m shall be applied for each of the above Classes of
the Cables.

15.16 ELECTRO MAGNETIC SHIELDING

Shielding can assist in reducing the adverse effects of fast transients, especially for
highly Sensitive Electronic Equipment. Shielding can be addressed at the Room, and
Equipment Levels.

At the Equipment level, all Sensitive Equipment shall be housed in Metallic Enclosures
(Cardfiles or Racks) to provide protection from Radiated EMI.

At the Room Level, Cladding the Room with Mesh or expanded Metal and bonding it
with Main Earth Busbar can provide quite acceptable values of Shielding Effectiveness.

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