Brief on the

visit of

Shri AshwaniLohani

Chairman

Railway Board

23rd November, 2017

SIGNAL DIRECTORATE
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1 FUNCTIONS OF THE SIGNAL DIRECTORATE

 Design, development &standardisation of Signalling & Safety equipments.

 Adaptation & absorption of emerging software embedded technologies.
 Investigation, analysis & remedial measures of specific field problems
referred byZonal Railways / Railways Board.
 Improving reliability of signalling equipments.
 Providing technical assistance/guidance to Zonal Railways.
 Vendor development.
 Testing of signalling items for vendor development & investigation. Issue,
review & revision of specifications, Test formats & STRs.
 Issue of Pre-Commissioning Check Lists for vital signalling equipments.

2 ORGANISATION CHART OF SIGNAL DIRECTORATE

SANDEEP MATHUR
EXECUTIVE DIRECTOR (CO-ORDINATION)/SIGNAL

ANURAG GOYAL
EDSIG

S.N. RAM M.M. WARIS Vacant A.K.SINGH

JDSIG-I JDSIG-III DSIG-IV DSIG-VIII

AJAY G.PAWAN HARI OM

VERMA KUMAR KUSHWAHA
DSIG-II DSIG-V DSIG-VI

3. SIGNAL TESTING LABORATORY

 Signal Testing Laboratoryis fully equipped for development, testing

andinvestigations of most of the signalling equipments.

 Signal Testing Laboratory is equipped with full testing facilities for Power
Supply Equipment (Battery Charger, DC-DC Converter, Transformer etc.),
Signal lamps & Lenses, Relays (Metal to Carbon & Metal to Metal contact
type).

 The laboratory is also equipped for testing of electronic and

microprocessor based equipments like Electronic Interlocking, Data
Loggers, Axle Counters,Block Interface for optic fibre cable, LED Signals,
Audio Frequency Track Circuits, Electronic Timers, Electronic Flashers,etc.

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  Signal laboratory is also equipped for testing of all types of
electromechanical signalling equipments like Point Machines, Signal
Machines, Electric Point Detector, Electric Key Transmitters, SM’s Slide
Frames, Primary Cells, all types of signalling cables and track fittings
related to signalling gears.

 There is a small signalling yard adjacent to laboratory having four

turnouts including thick-web high-speed turnout. The laboratory is provided
with requisite facilities of conducting type tests including performance,
endurance tests on all above types of signaling equipment.

 A Signalling Equipment Development Centre has been set up in the

Signalling Testing Laboratory. Here working systems including EI, Digital
Axle Counter, Data Logger, AFTCs, Block Instruments, LED signal lamps
etc. are available. In addition, equipments developed by RDSO, such as
signaling relay, polycarbonate lenses, triple pole double filament lamps,
power supply equipment etc. have also been displayed. This centre is being
used for various testing at developmental stages and for further
improvements in the designs of various signalling systems. Training for
newly inducted inspectors is also imparted in this center.

Electronic Interlocking Signalling Equipment

Development Centre

4. On Going Developments

4.1 Development of Train Collision Avoidance System (TCAS):

 Train Collision Avoidance System (TCAS) is meant to provide protection by

 Preventing trains to pass signal at Danger (Red),

 Preventing trains to pass at excessive speed over turnouts / Speed

restrictions and

 To avoid the situation in which more than one trains are on the same
track to cause collision, in case operations are not able to control so.

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  Train Collision Avoidance System (TCAS) also provides assistance to Loco
Pilots by means of real-time display of signal aspects in Loco Pilot’s cab. It
is based on the determination of location of Trains through distance
traversed from RFID tags installed on track and transmission of signalling
related information from Stationary Unit such as Station Interlocking.

Brief History:

 The specification for the first phase i.e. Absolute Block System were
drafted as RDSO/SPN/196/2012 Version 3.1.1 through the process of EOI
in the year 2011-12.

 In the year 2012-13, the Concept Field Trial has been conducted (in Oct-
2012) in Secunderabad Division of SC Railway.

 Based on successful Conceptfield trial, tenderto undertake trials on 250

km. section, was opened on 15.01.2013 in which 08 firms participated. By
end of 2012-13, few agencies have been able to develop lab demo models.

 Trials in Lingampalli- Vikarabad- Wadi- Bidar Section of SC Railway

have been taken up for further development of TCAS.

 Initially two field trials were conducted, first trial from 29.08.2013 to
05.09.2013 and the
 Second trial from 24.09.2013 to 30.09.2013.

 During Trial basic inter-operability between two vendors was tested

successfully involving loco equipped of M/s Medha equipment could inter-
operated in the station provided with RFID tag and station equipment of
M/s Kernex and vice versa.

 It was also possible to test basic functionality of equipment developed by

both the vendors including display of signal aspect, movement authority,
target speed and distance etc. in the locomotive.

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  Purchase Order for Contract Package-A & B was placed in June 2013 to
M/s Medha and M/s Kernex and for Contract Package ‘C’, was placed in
November 2013 to M/s HBL for development of Train Collision Avoidance
System.

Current Status:
 Brake Interface Unit was developed by all the three firms and got certified
from the motive power directorate of RDSO.

 The field trials are underway in 250 KM section in Secunderabad division of

South Central Railway.

 The RDSO specification for Train Collision Avoidance System (TCAS) No.
RDSO/SPN/196/2012, Version 3.2 dated 17.05.2017was updated to
resolve the issues observed during these field trials.

 The final field trials are ongoing and the Independent Safety
assessment certification for all the three firms is expected by
February 2018.

Future Planning:
 TCAS field trials in South Central Railway are conducted with IRAB type
locomotives with maximum permissible speed of 100/110 KMPH.

 Railway board has permitted conceptual TCAS field trials with E70 & CCB
type brake interfaced Locos (WAP-5) with speeds up to 160 KMPH at
BAAD station in Delhi-Agra section of Agra Division of North Central
Railway.

 Preliminary interface scheme for WAP-5 locomotives equipped with

CCB/E70 have been decided in association with Loco directorate of RDSO
and OEMs.

 TCAS installation in loco no 30107/WAP-5 with CCB type brake interface is

completed at Electric Loco Shed/ Ghaziabad in coordination with NR &
NCR. Installation of Stationary TCAS at BAAD station has been completed.

 Exclusive field trials for Auto-section are to be planned.

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4.2 Development of Train Protection & Warning system:

 Train Protection & Warning System (TPWS) is a continuous supervision

system that –

 Provides safety in train operations by dynamically monitoring the

speed of the train against specified limits.
 Eliminates risks arising due to cases of Signal Passing at Danger
(SPAD) based on ETCS Level-1. The speed limits are specified
dynamically based on signal aspect, route to be followed,
sectional speed limits, permanent speed restrictions etc.
 Internationally proven system.

 Till Oct 2017, the system has already been commissioned on around 330
route kilometers of Chennai-Gumudipundi section of Southern Railway,
HazratNizamuddin -Agra section of North Central Railway and Metro
Kolkata.

 Technical Advisory Note for implementation of TPWS for newly

sanctioned works was issued on 30.03.2016.

 The existing specification of TPWS has been revised and finalized as

RDSO/SPN/183/2016, Version 3.0 based on the field inputs received
on 18.11.2016.

 As Per Action Plan 2022 issued by Railway Board, TPWS (ETCS-

Level1) is to be introduced on 10000 Route Kilo meters. Presently,
Zonal Railways are implementing the same on 3690 KM on Delhi-
Mumbai, Delhi-Howrah and Mumbai-Chennai Sections of IR. RDSO is
assisting Zonal Railways in pre-bid process.

4.3 Development of Advanced Auxiliary warning system (AAWS):

 Advanced Auxiliary Warning System(AAWS) provides following functions:

 Providing train protection functions similar to AWS system in use

in Mumbai suburban section.
 Be interoperable with existing AWS system in Mumbai suburban
section including use of same driver interface as existing.
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  It is a microprocessor based control system, which continuously monitors
the speed, direction of travel, distance travelled, aspect of the signal
passed and alertness of the motorman and thus increases the safety of
railway system.

 It is a safety device preventing the unsafe situation due to the human

failure.It compels the motorman to obey the aspect of the signal and
maintain the correct speed. If it is not well acknowledged with in time
AWS decelerates the train and applies brake to stop train.

 AWS (OEM M/s Siemens) is installed on Mumbai suburban section

for preventing SPAD. M/s Siemens informed that due to obsolescence of
some of the components, it will not be possible to support on-board
equipment. Thus, RDSO started working on development of Indigenous
Advanced Auxiliary warning system (AAWS) through EOI.

 The specification RDSO/SPN/213 Ver. (1.0) of AAWS was finalized in

2014.

 A new vendor M/s Medha has been approved for onboard system of
AAWS on 18.09.2015. For track side equipment, the process of approval
is also ongoing.

4.4 Failsafe Networked Multiplexer (FNmux)

 Failsafe Networked Multiplexer (FNmux) covers the technical and

operational requirements for exchanging both vital and non-vital signaling
information using dual redundant OFC/Primary radio communication
media to replace signaling cables. It shall have safety integrity level of
4 and will be used for vital signaling functions that can be used for
proving, control and interlocking.

 FNmux will reduce the copper cable used in signalling at station and
block and increase in redundancy due to availability of alternate path.
Reduction in cost and time of outdoor work shall be possible.

 RDSO is working on development of FNmux. In the meantimeit has been

observed that these are commercially available which are SIL4 certified
and meets the functional requirements of FNmux. Accordingly
specification has been modified and draft specification
RDSO/SPN/211/2017 Ver. d3 has been uploaded on website on
17.10.2017 for comments.

4.5 Modelling and validation of interlocking for railway signalling systems:

 Object is to develop tool to improve the reliability & safety aspect of

present EI systems.

 With this model, conversion and verification of safety rules for signalling
system based on yard plan, control table and generic signalling circuits
shall be possible.

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  Model for equations for given yard for use of application data for EI to be
generated and verification of above model to check safety aspect by
verifying parallel, conflicting movement and control of points etc. shall be
possible.

 Later in next phase, this tool will be used for generating verified
application data for EI. MoUhas been signed between RDSO & IIT/ KGP,
work is progressing in mutual discussions between IIT/KGP and RDSO.

4.6 Opto Ethernet based backup interlocked system:

 A fail-safe SIL-4 certified Electronic Interlocking backup system for

existing interlocking system has been developed. In case of main
interlocking system shuts off due to any inside or outside reasons as in
case of fire at Itarsi Junction, the standby system will take over.

 With the permission of Railway Board, one system has been installed at
Nishatpura ‘D’ Cabin of Bhopal Division on 27.12.2.16. In this entire
interlocking software is duplicated in an intelligent safety controller and
controlling of outdoor signalling functions on OFC.

4.7 Development of Capacity Optimization & Simulation Tool (COST):

 The development comprises of design of basic software tool for

computation of line capacity of any Indian Railway section taking into
consideration of various parameters like type of block working, block
length, signal spacing, speed restrictions, and other parameters that would
have an effect on line capacity. The tool would assess the extent to which
section line capacity could be increased and quantify the impact of each
capacity enhancement.

 The tool would be used for examining the effect on line capacity for –
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  Technological improvements like Intermediate Block Signalling,
introduction of new stations, doubling/tripling/quadrupling, etc.
 Changes in operational patterns like using mix of goods and
passenger trains, various loco load combinations, intelligent
speed adaptation, etc. The tool would assess the extent to which
section line capacity could be increased and quantify the impact
of each capacity enhancement.

 MoU has already been signed with IIT/ Mumbai and Basic model is
developed and the improvements are being incorporated in the tool.

5. Completed Developments

5.1 Indigenous development of Electronic Interlocking:

1. M/s Medha, Hyderabad has developed first 2 out

of 2 indigenous Electronic Interlocking with hot
standby with object controllers under the
guidance of RDSO model MEI 633.

2. For bigger yards MEI 634 is also under initial field

trials by M/s Medha.

3. M/s HBL has applied for indigenous EI.

M/s Medha, Hyderabad has developing new

indigenous Electronic Interlocking with hot standby
with object controllers under the guidance of RDSO
to meet the requirement of big yard with high speed
controller and technology. Parallel trial is under progress at Bibinagar.

5.2 Indigenous development of Single Section Digital Axle Counter (SSDAC):

Indigenous development of Single Section Digital Axle

Counter (SSDAC) has been completed jointly by RDSO,
M/s Central Electronics Limited (CEL) &Deptt. of Scientific
and Industrial Research (DSIR). The development was
completed in Aug. 2005. M/s CEL is presently approved.
M/s CEL has also developed indigenous MSDAC and same
has been approved under list of RDSO Vendors for
developmental orders.

5.3 LED Signals:

Development of Integrated Type of LED Signal Lamps for Main Signals:

With a view to have more reliability and easy interchangeability of LED signals of
various makes, integrated type of LED signals have been developed. Reliability
improvement measures have been added in these newly developed signals.
Adequate field trials have been done after prototype evaluations. 4 vendors are
now approved.

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 As per 84th SSC recommendations integrated type LED cost benefit analysis was
sent to Railway Board. Railway Board has desired the analysis of failures of
Integrated LED signal compare to conventional LED. Letter regarding same has
been written to all Railways on 24.01.17.

5.4 Solid State Block Proving by Axle Counter (Digital):

This replaces conventional block instruments. SSBPAC (D) is a microprocessor
based system used for exchanging signaling information between two stations
forming a block section. It controls signaling of block section through a block
panel. Objective of the system is to provide interlocking functions of block
signaling according to approved method of working, ensuring high degree of
safety, availability & reliability. This system is suitable to work on OFC also. One
source M/s Efftronics, Vijayawada has approved under list of developmental
orders. In addition M/s Medha, Hyderabad is under process of approval, parallel
field trial has completed and report from ISA awaited.

5.5 Non Metallic Colour Light Signal Units for LED Signals:
Railways have been using cast iron based colour light signal units for long time.
These are quite bulky and are difficult to handle during installation and
maintenance. Light weight colour light signal units have been developed using
Fiber Re-enforced Plastic (FRP) materials which are much easier to handle as
compared to metallic units. Modifications to suit LED signals have been done in
the specification. Recently, specification for such housing for signals other than
main signals has also been developed and existing vendor has been approved
for revised specification after evaluation of their improved sample. Samples of 3
more vendors are under advance stage of evaluation.

5.6 Development of Fuse Auto Changeover System (FACS):

In any signaling installation, each relay circuit has a fuse which plays a very vital
role in the signaling circuit. While blowing a fuse in case of any short circuit
condition protects the circuit, a considerable no. of fuse blowing occurs due to
other reasons like transient etc. With the intention of reducing down time and to
monitor the status of various fuses, a new specification for Fuse Auto
changeover system has been developed. The system has one standby fuse for
every signaling fuse. The standby fuse automatically comes in signalling circuit in
case the main fuse is blown. Provision for status monitoring both for main as well
as standby fuse has been done in the system. Remote audio visual extension of
alarm is also extended for immediate attention of the maintenance personnel.
Provision for sending SMS separately for main and standby fuse blown events to
designated GSM numbers is also made.

So far 04 vendors have been approved and 07 vendors are in process of

registration.

5.7 Fog Pilot Assistance System (FogPASS):

This is low-cost, portable equipment (Tiffin-box size, 1.5 kg, Battery powered) to
be carried by Loco Pilot while taking over duty-charge. It provides on-board real-
time information (Display as well as voice guidance) to Loco Pilot regarding
Location of fixed landmarks such as Signals, LC Gates etc. in advance to be
used particularly in foggy weather. Driver has to watch the landmark as per

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 operating procedure. Driver has to get Signal Aspect (Red / Yellow / Green) etc.
from physical trackside signals.

It displays approach indications of

next three approaching fixed
landmarks such as Main Line
Signals, Level Crossing Gates,
Neutral Sections, Speed
Restrictions, Stations etc.
accompanied with voice message at
~ 500m on approach.

6. Reliability improvement measures

6.1 Digital Axle Counter (DAC):

 Trials for E1 based communication on OFC for CEL/SSDAC is under

implementation in SER & NR.
 Modified software for CEL make SSDAC to improve tolerance to intermittent
faults has been approved for uses over Indian Railways.
 Modified software for G.G. Tronics also under parallel field trial.
 New MODEM and high efficiency DC to DC converter card of M/s CEL has
been approved for use. This card has reduce Modem and power related
failures.
 For Thales make MSDAC AzLM, Software version 6.1.11 approved for use
which removes periodic replacement of Flash ROMs required in earlier
versions.
 Wiring Disciplines made into a Technical advisory Note no. 6001 and issued
for implementation.
 TAN 7005 for lightning protection measures issued.
 Strict compliance to Pre Commissioning checklist and OEM’s certification
requirement before commissioning made mandatory for all installations.
 Continuous technical audits of critical installations by OEM for identifying
deficiencies and rectification.

6.2 Electronic Interlocking:

 Guidelines issued regarding Technical System Application Approval (TSAA)

for Electronic Interlocking Installation for better reliability.
 Guideline is issued regarding minor modification /Alteration in the application
software of Microlock-II, VLM6 & MEI633 Electronic Interlocking’s.
 Up gradation to executive software version 3.2 for Microlok-II (stability
improvement).
 Up gradation to executive software version 4.0 for WESTRACE
(Communication improvement).
 Circulation of maintenance organization with details of persons to be
contacted.
 Complete maintenance and diagnostic handbook for all approved EIs.
 Technical approval for all new commissioning more than 100 routes by
RDSO.

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  The revision of speciation No. RDSO/SPN/192/2017, for Electronic
Interlocking is under finalization.
 M/s KYOSAN K5BMC Electronic Interlocking upgraded software without
journal module for improved interface to Data Logger.
 Improved power supply card of Siemens EI (PSU mod C) are being replaced
by OEM to mitigate C zero error reported by various railways.

6.3 Integrated Power Supply (IPS) Systems:

(i) Provision of Isolation transformer at the input is under trial to protect from high
voltages.
(ii) Dual distribution and supervisory arrangements are being monitored at 143
stations in NCR.
(iii)Low voltage disconnect switch is removed from the circuit to protect undesired
disconnection of output supply.

6.4 Metal to Carbon Relays:

(i) Brief history of High contact resistance

• The issue of high contact resistance in ‘Q’ series relays came up during
discussion in CSTE conference held at SC on 27/11/16.
• RDSO was directed by Rly. Board to submit remedial and mitigation solutions
to overcome the problem.
• The issue of high CR was also discussed in CSE’s conference held at Rly.
Board on 04/03/16 where in emphasis was laid to use imported SIG contacts.

(ii) Reasons for High Contact Resistance

• In ‘Q’ series relays, silver electro plating process is most vulnerable process
from the angle of injection of impurities.
• In silver electroplating process, potassium cyanide (KCN) is used as catalyst
for bonding of silver to graphite surface.
• Though RDSO instructions exist for thoroughly cleaning of SIG contacts after
silver electroplating process through three stages of cleaning in distilled water
vapour/hot air so as to completely remove the traces of KCN from SIG
contacts.
• The cleaning activity is purely a manual job which is left to the lowest qualified
employees of SIG manufacturers and there is likelihood that KCN traces over
a period of time give rise to insulating potassium carbonate (K2CO3) film of
very small thickness on the mating surface of SIG contacts causing high
contact resistance.

(iii) Action Plan

(a) Changing silver electroplating process to silver sputtering

• Silver sputtering process is done using pure silver in clean environment like
vacuum whereas silver electroplating process requires use of chemical like
potassium cyanide and effluent treatment with water.
• In silver sputtering as potassium cyanide is not used, the root cause of
formation of thin layer of potassium cyanide is eliminated.

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• SIG/Relay manufactures have been advised to manufacture 5000 nos. of such
SIG contacts by using this technique and the relays so manufactured shall be
sent to Zonal Railways for field trials and point wise position is as given
below–

a) SIG Contacts were submitted by M/s Advance Tech on 01/06/17

b) These SIG contacts were sent on dated 16/06/17 to Podanur Workshop and
M/S CG to make relays.

c) Podanur Workshop sent relays on dated 09/11/17 to RDSO for testing and
same was sent to Signal Lab of RDSO on dated 14/11/17 for endurance test
(10 lakh operations) which will be completed approx. in 3 months.

(b) Changing silver electroplating process to copper spraying process

• Instead of electroplated silver, hot sprayed copper is used on the back side of
SIG contacts that is subsequently soldered to the contact spring.
• This process only affects the back side of the contact and does not extend to
or near the mating surface of SIG contact.
• The process also eliminates any contact contamination from the plating
residues particularly potassium.
• SIG contact manufacturers have been advised to manufacture 5000 nos. of
such SIG contacts and thereafter relays will be assembled by relay
manufacturers for field trials to be supplied to Zonal Railways against their
existing purchase orders

(c)Use of SIG contacts of Morgan, UK Technology

• In our existing process of SIG contact manufacturing, silver impregnation in

graphite is done through vacuum impregnation process in 25 consecutive
cycles.
• On the other hand in Morgan technology, silver is impregnated through
pressure impregnation process in one go and the complete process is
automatic. Through this process, silver impregnation is restricted to 45 – 55%
of silver but the same is uniformly distributed.
• Also in this technology, copper spray is used in place of silver electroplating
process, thus eliminating possibility of impurities on the mating surface at a
later date.

Field Trial done with imported Morgan SIG Contact

 Permission was given to M/s CGL for 100 No. of relays with Imported
SIG Contact from M/s Morgan SIG contact (having 45-56% silver
percentage whereas asper IRS:S 67-85 Silver percentage 53-60% in
indigenous SIG contacts ) on dated 21.11.11.
 M/s CGL has supplied 90 No. relays in Western Railway and was
installed at Namali station/WR on 03.11. 2012.
 Two relays were taken out for joint inspection by SSE/Sig/RTM division,
SSE/QA/Mumbai and firm representative. Joint report was satisfactory.
 Two relays bearing S. No 464130 & AC 464082 were failed due to high
contact resistance problem.

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Current Status

 M/s. CGL have requested RDSO to allow them to import 10,000 no. of
SIG contacts (for 500 relays) from M/s. Morgan, UK as per the
specification of M/s. Morgan/UK in which silver content (by weight of
silver) is 45 to 55% as against specified 55 to 60% as per IRS:S 67/85 for
SIG contacts.
 Firm has given the rates of SIG contacts to be imported from M/s.
Morgan, UK which is almost three times higher than the existing rates of
indigenous SIG contacts.
 As decided in CSE’s Conference held at Rly. Board on 04.03.16, one
more lot can be imported and performance compared for conclusive
decision. The permission is yet to be given to M/s. CGL.
 M/s. CGL has also requested RDSO to give permission for 5000 relays
with SIG contacts of M/s. Assam Carbon, in which silver content (by
weight of silver) is 45 to 55% as against specified 55 to 60% as per IRS:S
67/85 for SIG contacts.
 All firms are advised to check 100% weight of SIG contact i.e. checking of
each SIG contact during manufacturing process to determine the
percentage of silver in SIG contact.
 M/s. Advance Technology has located the sources of silver sputtering &
copper spraying process and have developed few SIG contacts with silver
sputtering and subsequently sent to M/s. CGL for manufacturing relay
after ascertaining the soldering of finger spring with SIG contact, which
have been found satisfactory as discussed with representative of M/s.
CGL.
 Development of SIG contact with copper spraying is under process of
evaluation by M/s. Advance Technology, which shall be ascertained by
him within 15 days.
 Specification of Morgan SIG contact is different from IRS:S 67/85.

(d) 6R silver contact in place of existing19R

 Permission was given to M/s CGL on 09.03.12 for manufacturing of 5000

relays with 6R silver contact in place of 19R silver contacts, which has
characteristic of high current density and low contact resistance.

 Firm was supplied relays to NER and after satisfactory performance

received from NER, Firm was approved for regular production of relay
with 6R silver contact on dated 05.08.14

(e) Welded Line contact in place of silver contact

 Fifty No. of QN1 relays manufactured by M/s WSF, Kolkata with welded
line contact supplied by M/s Pure Carbon Pvt.Ltd,Kolkata was installed in
Sealdah Division.

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  Dy. CSTE/HQ/ER vide letter No. SG.224/0/3/Vol.X dated 25.10.16
informed that the performance of relay is satisfactory since its installation
in 2011.

 Vide letter 28.03.17 M/s Pure Carbon Kolkata requested that firm agree to
install one manufacturing unit with following aspect:-

 Require confirmation from Railway to get minimum order of 8

lakh no.of contacts for 50000 nos. of relays.
 Relay manufacturing firm will supply Pb-spring and will weld
bimetallic silver contact on pb-spring.

(f) Some more instructions given to Relay Manufacturer

• All SIG manufacturers were advised to enhance the cleaning time of

second & third stage of SIG contact to remove the impurities.

• All SIG manufacturers were also advised to explore the possibility to

install automatic cleaning/washing machine to completely remove the
manual cleaning process.

• All relay manufacturers use emery paper during assembly of relay. It

creates impurities on contact surface of SIG contact & cause high contact
resistance. All relay manufacturers has been advised to not to use emery
paper for cleaning of relay contacts.

6.5 Signalling Cable:

• STR version 3 for signalling cable was issued.

• Issue of standard practice for laying of signalling cable.

• XLPE insulated Signalling cable developed and tested. Draft Amendment

no. 1to IRS S 63/2014 issued for purpose of trials in Zonal Railways. No
Railways have given a feedback on same.

7. Important activities in hand

7.1 Automatic Fire Detection and Suppression System:

Specifications for Automatic Fire Detection and Alarm System was approved in
November 2016. Four vendors have applied for registration. Draft type test and
acceptance test formats have been prepared.

Final draft specifications for Automatic Fire Detection and Suppression System
are developed. The specification will be finalized after approval in SSC.

7.2 Development of additional vendors for EI, Data Logger & DAC:

EI –under SPN 192 four Vendors (5 models) are presently approved and One
vendor is approved for supply of spares only.
Under 203 only one firm i.e. M/s Siemens MK-II is approved for field trial for Big
yard.

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 Two indigenous vendors (Medha [MEI-634] & HBL) under SPN 192 are under
process of approval.
Further 3 vendors under cross acceptance (Kyosan & M/s Safeconnect) for
Bigyard EI (SPN 203) and M/s Safeconnect for SPN 192 are under process of
approval.

Data Logger –Four vendors are approved and one existing vendor has been
temporary delisted (CGL). One more vendors i.e. VTL Electronics (under Type
test), is under process of approval.

SSDAC –Three indigenous vendors are presently approved. Two vendors (M/s
INsys Digital Systems & M/s HBL Power Systems, Hyderabad) have applied
under indigenous development and they have been given permission to
manufacture prototype sample. One vendor (M/s Frauscher India) has also
registered under cross approval.

MSDAC –Three vendorsare approved under cross approval. The indigenous

development in association with M/s CEL has been completed and approved for
list of RDSO Vendors in developmental items.

Five more vendors (Three Indigenous M/s Medha, M/s G.G. Tronics, M/s HBL
Power Systems, and Two vendors- M/s Siemens for other Variants, & M/s Vista,
New Delhi under cross approval) have also applied.
M/s Medha and M/s GG Tronics systems are under types testing.
M/s HBL Power systems has been permitted to submit prototype sample for type
testing.

7.3 Development of sources for BPAC using UFSBI:

M/s Deltronand Webfil are approved sources. M/s CEL, Signal Workshop and
M/s DCC systems have been tested and approved for limited supply.

7.4 Monitoring of indigenization status of vendors approved on cross

acceptance basis:

SSDAC –Based on request of M/s Eldyne and the revised cross approval policy,
M/s Eldynehad submitted prototype sample for type testing,which has been
completed recently.

MSDAC – M/s Siemens have informed that they have completed 100%
indigenization. The sample was tested but it failed in Climatic tests. New sample
is under type testing. Based on request of M/s Eldyne and the revised cross
approval policy, M/s Eldyne had been asked to submit prototype sample for type
testing. Submitted sample failed in Climatic test. Documents for new sample are
under scrutiny.

EI –M/s SRAPL (VLM-6) & M/s Ansaldo have done 100% indigenization & both
have been type tested. M/s Kyosan completed 55% indigenisation, M/s SRAPL
(MK-II) has completed 100% Indigenization.

Page 16 of 29
7.5 Development of in- sleeper point machine:

Development of In-sleeper point machine was decided in 82nd SSC meeting in

view advantage of tamping in the point machine portion. A functional requirement
was prepared for development of in sleeper point machine and Expression of
Interest was invited for finalization of its specifications and product development.
Received responses were shortlisted and a meeting of respondent firms has
recently been done.A draft specification document has been prepared and sent
to shortlisted vendors and track directorate of RDSO for comments.Signal
Workshop Gorakhpur advised for development of prototype sample and install in
premises of workshop, which is under progress at workshop.

7.6 IP-67 compliant point motors:

A draft specification has been developed for IP-67 compliant point motors for use
in point machines so that these may not be affected due to water. Vendors have
been asked to modify existing point motors to make them IP-67 complaint. One
vendor has developed it so far and the motor has been tested for proper
functionality after keeping it in submerged condition for 24 hours. 5 such motors
have been given to Western Railway for installation and performance
assessment. Performance feedback is awaited from Western Railway.

7.7 400V AC immunized point motors:

So far, point motors with 160 V AC immunizations are in use over IR. In view of
requirements of higher AC immunity in point motors for long rage operation,
increase in immunization level of point motors is under consideration. All existing
vendors were advised to work in this direction. One vendor M/s. Globe Scott has
submitted sample which is under finalstage of testing at RDSO lab. M/s. Globe
Scott approved for supply of 400V AC immunized point motors.

Page 17 of 29
 ANNEXURE-I
SIGNAL TESTING LABORATORY FACILITIES

1. Environmental Testing

The following test chambers are available to carry out testing as per requirement of
IS: 9000: -
 Programmable Environmental
Test Chamber (Temp. &
Humidity)
 Dry heat chamber
 Cold chamber
 Rain chamber
 Salt mist spray chamber
 Dust chamber
 Mould growth chamber
 Recovery chamber

Programmable Environmental
Test Chamber
2. Test and Measuring instruments
Important test and measuring instrument used for testing of various signalling items
available in the lab are as under:-

 Chromameter
 Power Harmonics analyzer
 Digital Storage Oscilloscope
 Automatic Relay Testing Jig
 Electrical & electronic load
 High voltage tester
 Insulation resistance meter
 Cable testing equipments
 High Precision Digital Multimeters
 Power supplies
 Tensile Strength testing machines
 Automatic Pneumatic based life testing equipment for DLBI & EKT

3. LED Signals
Testing facilities are available for measurement of
colour coordinates and luminance by using
Chromameter setup of all aspects of LED signals.

Chromameter

Page 18 of 29
4. Relay Performance and Endurance Testing

Facilities for testing of all types of

signaling relays including line relays,
track relay, lamp proving relays and
point contactor relays area available.
Test benches for measurement of all
operating parameters like pickup,
drop-away, voltage/time, contact
resistance, contactpressure, contact
bounce time etc. areprovided for
expeditious completion oftype
tests.Endurance test set-ups for
testing of relay for 10 lakh operations
are also available for all types of plug- Endurance Test Setup for Relays
in type relays.

5. Power Supply Equipment Testing

Facilities for High voltage test, induced high

voltage test, performance test, endurance test
are available for all types of power supply
equipment like Battery Charger, DC-DC
Converter, Transformer etc. used in Railway
Signalling

Power Supply Section

6. Cable Testing

The following test facilities for underground Signalling cables (including axle
counter cables) and indoor PVC cables/wires are available: -
i) Elongation and tensile strength
testing,
ii) Thermal stability test.
iii) Ageing test.
iv) Melt flow index test.
v) AC/DC High voltage water
immersion test.
vi) Measurement of insulation
resistance (dry & wet),
conductor resistance, specific
gravity etc.

Page 19 of 29
7. Electro-Mechanical Equipment Testing

The type test facilities including set up for endurance/performance test for the
following electromechanical safety signalling equipment are available:-

i) Point machine
ii) Signal machine
iii) Electrical point detector
iv) SM’s slide frame endurance
v) Lever locks
vi) Circuit controllers
vii) Block instruments
viii) Electric signal reversers
ix) Electric key transmitter
Automatic Life Cycle Tester (Mechanical)
8. Miscellaneous items

Other signalling items like PBT terminals, electric filament switching unit, choke etc.
are also tested regularly in the laboratory.

9. Performance
The following number of tests have been carried out at Signalling Lab during the period
mentioned in the table:-
2015-16 2016-17 2017-18
(upto 20.11.2017)
Initial/Development 28 21 10
Maintenance Type Test 1 0 1
Investigation Tests 6 9 13
Acceptance 2 2 0
Climatic Test 22 19 16
Total 59 51 40

70
59
60 Initail/Development
51
50 Maintenance
40
40 Investigation
30 Acceptance
20 Climatic
10 total
0
2015-16 2016-17 2017-18

Page 20 of 29
10. Consolidated List of Type Test Charges w. e. f. 01/04/2017
(Excluding taxes, if any)

S. Description of Item for testing Type test

N. charges
(inRs.)
1 ALL TYPES OF Block Instrument 231403
2 SIGNALLING RELAYS (All Groups) 214479
3 SIGNALLING RELAYS (Group "0") 12535
4 SIGNALLING RELAYS (Group"I") 19911
5 SIGNALLING RELAYS (Group"II") 49845
6 SIGNALLING RELAYS (Group"III") 115102
7 SIGNALLING RELAYS (Group “IV”&“V”) 23839
8 SIGNALLING RELAYS (Group “VI”) 8673
9 SIGNALLING CABLES (EXCEPT SINGLE CORE) 120322
10 SINGLE CORE INDOOR SIGNALLING CABLES 35113
11 ELECTRIC POINT/SIGNAL MACHINE 211000
12 ELECTRO MECHANICAL SIGNALLING ITEMS 112291
(Motor for Electric Point Machine, Motor for Electric Lifting Barrier, Electric
Point Detector, Lever Lock, Circuit Controller, Electric Signal Reversor,
Electric Key Transmitter, Arm & Light Repeator, S.M.’S Control Frame,
Signal Motor etc.)
13 POWER SUPPLY ITEMS 140303
(Battery Chargers, Invertors, Ferro Resonant Voltage Regulator, Static
Transformer, Transformer Rectifier Set, Primary Cell Etc.)
14 POWER SUPPLY ITEMS 73265
(Testing of Transformer & 'B' Type Choke, TFBC & Other Small Electrical
Signalling Items)
15 Nylone/PBT Material (PBT/Backlite Terminal Blocks, PBT 8 Way Terminals, 76175
LB Joints, Copolymer Bush, San Jar Ad Cells, Track Lead Junction Box,
Boot Leg, IRJ/Top& Bottom Roller etc.)
16 Signal lenses & Roundels 8005
17 EARTH LEAKAGE DETECTOR 147202
18 SOLAR PANELS AND CHARGE CONTROLLER 145533
19 SIGNAL LAMPS 67109
20 FILTER UNIT 130951
21 AC METAL CAN CAPACITOR 83911
22 BUMP TEST (1000 Bump in each direction) 12029
23 DRY HEAT TEST (ONE CYCLE of 16 hrs.) 20368
24 DAMP HEAT TEST / HUMIDITY (ONE CYCLE of 24 hrs.) 21851
25 DAMP HEAT TEST / HUMIDITY ( SEVEN CYCLE ) 32955
26 DUST TEST (ONE CYCLE of two hrs.) 12268
27 COLD TEST (ONE CYCLE of two hrs.) 12390
28 COLD TEST (ONE CYCLE of 16 hrs.) 20493
29 SALT - MIST TEST (2 hrs. + 22 hrs. damp; 3 cycles) 15225
(Test for corrosive atmosphere)
30 SALT - MIST TEST (2 hrs. plus severity of 7days damp: 3 cycles i.e. 21days) 29615
(Test for corrosive atmosphere)
31 SALT - MIST TEST( 2 hrs. plus severity of 7days damp: 4 cycles i.e.28 32821
days)( Test for corrosive atmosphere)
Page 21 of 29
32 SALT - MIST TEST ( 48 hrs. continuous) 20916
(Test for corrosive atmosphere)
33 SALT - MIST TEST ( 96 hrs. continuous) 21832
(Test for corrosive atmosphere)
34 MOULD - GROWTH TEST ( 28 days) 36671
(Test for fungus effect)
35 RAIN TEST (ONE CYCLE of two hrs.) 12151
36 CHANGE OF TEMPERATURE TEST (Three cycles) 21911
(One cycle of 8 hrs.)
37 SMPS BASED IPS 233600
38 DATALOGGER 305022
39 UFSBI 277133
40 BPAC Using UFSBI 344995
41 BPAC WITH UFSBI & Multi-Combiner 427384
42 Indigenous UNIVERSAL AXLE COUNTER SYSTEM 251698
43 Indigenous SSBPAC( Solid State block proving with Axle counter) 1421219
44 SSDAC/MSDAC (Single/Multi Section Digital Axle Counter 1432592
45 LED CLS SIGNALLING LAMP 113265
46 LED SEMAPHORE LAMPS 60397
47 AFTC EQUIPMENT, INCLUDING TRANSMITTER, RECEIVER, TUINING 224702
UNIT, POWER SUPPLY BONDS ETC.
48 IMPEDANCE BOND OR LINE MATCHING UNIT 76275
49 ELECTRONIC INTERLOCKING INDIGENIOUS 2087125
50 Battery operated LED Torch Lighting/Flashing Hand Signal Lamp 30070
51 FOGPASS 154958
52 ENDURANCE TEST FOR TELECOM ITEMS 168 hrs. 30334
53 FUSE AUTO CHANGEOVER SYSTEM 90643
54 BATTERY OPREATED LED FLASHING TAIL LAMP 40901
55 DOMINO TYPE CONTROL PANEL 66630

Page 22 of 29
11. Summary of Time required for Type Test in Signal Lab

S.N Items Time duration for Time Tentative Remarks

. various Tests (Working time
days) including
waiting time
and other
factors
(in months)
1. Data logger Visual test -03 days 52 4½ -
Function test – 12
days
Climatic test – 37
2. SSDAC/MSDA Visual test -04 days 69 6 -
C Function test – 26
days
Climatic test – 39

3 Electronic Visual test -04 days 70 6 -

Interlocking Function test – 27
days
Climatic test – 39
4. BPAC Using Visual test -02days 47 4 -
UFSBI Function test – 07
days
Climatic test – 38
5. UFSBI Visual test -04 days 61 6 -
Function test – 20
days
Climatic test – 37
6. Signaling/Pow Physical -03 days 39/36/42 3 -
er/ Quad Electrical – 03 days
Cable PVC Parameters- 11
days
Misc. Parameters- 22
days
7. Electric Key Physical & Elect. – 01 101 5 Life cycle test consists
Transmitter days 50,000 operations.
Life test- 96 days
≈4months
Climatic test- 04 days
8. Point machine Physical & Elect. – 02 244 10 Life cycle testconsists
days 10 lac operations.
Life test- 242 days≈
9months

Page 23 of 29
9. Double line Physical & Electrical – 211 10 Life cycle test consists
Block 02days 10,000 operations.
Instrument Life test- 200 days≈
7months
Climatic- 09 days
10 Motor (for Physical & Electrical – 16 2 -
. Point 02days
Machine/Electri Functional test- 02
c lifting barrier) days
Climatic test- 12 days
11 Relay Group-0 (05 days) 365 12 Maximum time taken for
Group-1 (12 days) Group-6 test for
Group-2 (59 days) Storage. Measurements
Group-3 (82 days) taken every 03 months.
Group-4 (30 days)
Group-5 (06 days)
Group-6 (365 days)
12 Timer Group-0 (08 days) 95/140/18 05/07/09 Maximum time taken for
(60/90/120 Group-1 (23 days) 5 Group-3 test Endurance
seconds) Group-3 (95/140/185 test for 10 lac operations
days)

13 Group-0 (08 days) 93 4½ Maximum time taken for

Flasher Group-1 (23 days) Group-3 test Endurance
Group-3 (93 days) test for 10 lac
operations.

LED CLS Visual Inspection-02 61 4½

SIGNALLING days
14
LAMP Performance-22 days
Climatic-37 days
Battery Visual Inspection-02 71 5½ Performance test
operated LED days include Life cycle test of
15 based Hand Performance-59/54 600 hours for battery
Signal Lamp & days and switch operation.
Tail Lamp Climatic-10/14 days
Visual Inspection-02 34 3
FUSE AUTO days
16
CHANGEOVE Performance-12 days
R SYSTEM Climatic-20 days
Visual Inspection-01 20 1½
EARTH days
17
LEAKAGE Performance-4 days
DETECTOR Climatic-15 days
Power Supply Visual Inspection-02 44 4½ Transformer, ‘B’type
18 Equipments days Choke, TFBC &other
(Category –1) Performance-11 days small electrical

Page 24 of 29
 Climatic-31 days
Power Supply Visual Inspection-02 59
Equipments days
(Category – 2) Performance-06 days
19 Endurance- 42 days
Climatic-09 days
PBT/BAKELIT Visual Inspection-01 31
E Items days
Performance-4 days
20 Climatic-26 days
Filter unit Visual Inspection-01 16
days
21
Performance-6 days
Climatic-9 days
signalling items
5 Battery Chargers,
Invertors, Ferro
Resonant Voltage
Regulator, Static
Transformer,
Transformer Rectifier
Set, Primary Cell etc.
3 Terminal Blocks, PBT 8
Way Terminals, IB
Joints, Copolymer Bush,
San Jar Ad Cells, Track
Lead Junction Box, Boot
Leg, IRJ/Top&Bottom
Roller Etc.
1½
Page 25 of 29
 ANNEXURE-II

IMPORTANT ACHIEVEMENTS OF SIGNAL DIRECTORATE

DURING LAST FIVE YEARS
(Updated Oct. 2017)
SN Financial Broad Area Title of Description of Likely Current Status
Year of Achievement Achievement Benefits of
Achievement Implementation
1 2013-14 Safety Indigenous Train Collision Avoidance Improvement Under
development of Train System (TCAS) in safety implementation
Collision Avoidance
System (TCAS)
2 2012-13 Safety Specification No. Train Protection & Improvement Implemented.
RDSO/SPN/183/ Warning system in safety Zonal Railways
2012 Ver. 3.0 are floating
tenders.
3 2012-13 Safety Indigenous Multi Section Digital Axle Improvement Implemented
development of multi Counter (MSDAC) in safety
Section Digital Axle
Counter (MSDAC)

4 2012-13 Reliability Revised Integrated Power Supply Improvement Implemented

Specification in reliability
RDSO/SPN/165/2012

5 2012-13 Safety Block Proving by Block Proving by Digital Improvement Implemented

Digital Axle Counter Axle Counter (BPAC) in safety
(BPAC) using UFSBI using UFSBI

6 2012-13 Reliability Integrated for main Integrated for main LED Improvement Implemented
LED Signal (with Signal (with integrated) in reliability
integrated)
7 2013-14 Reliability & Modelling and Modelling and validation Improvement Under
Safety validation of of interlocking for railway in Reliability & implementation
interlocking for signalling systems Safety
railway signalling
systems
8 2013-14 Safety LED based Flashing LED based Flashing Hand Improvement Implemented
Hand Signal Lamp Signal Lamp in safety

9 2013-14 Safety LED Tail Lamps for LED Tail Lamps for Guard Improvement Implemented
Guard in safety
10 2013-14 Efficiency Capacity Line capacity optimization Improvement Under
Optimization and in line capacity implementation
Simulation
Tool(COST)
11 2014-15 Safety Fog Pilot Assistance Improvement in Improvement Implemented
System for Safety specification of Handheld in safety
Device which can guide
loco pilots about land
marks enroute.
12 2014-15 Efficiency Fuse auto Monitoring of signalling Improvement Implemented
changeover system fuses in validation
13 2015-16 Reliability iP-67 for Motor Improved Point motor Improvement Under
Electric Point in reliability implementation
machine (Trial ongoing)

Page 26 of 29
14 2015-16 Reliability Stainless steel Improved fabricated Improvement Under
apparatus case apparatus case stainless in reliability Implementation
drawings steel (Trial ongoing)
15 2015-16 Safety Indigenous Advance Auxiliary Improvement Implemented
development of warning system in reliability
Advance Auxiliary
warning system
16 2016-17 Fire safety Automatic Fire Detections and Alarm Improvement Specification
Detection and Alarm Systems in fire Security developed.
Systems for of signalling Vendor approval
signalling installations. under process.
installations.
17 2017-18 Fire Safety Automatic Fire Clean agent based fire Improvement Specification
Suppression System suppression system. in fire Security developed
for signalling of signalling
systems installations.

Page 27 of 29
 ANNEXURE-III

SIGNAL DIRECTORATE- YEAR WISE CASES PENDING FOR

VENDOR REGISTRATION
(As on 17.11.2017)

YEAR Total No Total No Initial Advise for Advise to Under Misc.

of of Scrutiny Capacity Firm for Type
Applicati Cases Capability Prototype Test
on pending Assessme sample
received for nt submissi
approva on
l

Before 4 4 - NIL NIL 2 2

2013 At
appro
val
stage

2013 1 1 - NIL NIL 1 -

2014 15 15 - 1 6 8 -

2015 11 11 - NIL 4 7 -

2016 16 16 - 8 6 2 -

2017(upt 19 19 8 11 - NIL -
o Sept.
17)
After
Sept. 17 2 2 - 2 NIL NIL -

Total 68 68 8 22 16 18 -

Page 28 of 29
 ANNEXURE-IV

POSITION OF GAZETTED CADRE OF RDSO INCLUDING SIGNAL, TELECOM, QA &

RESEARCH DIRECTORATES AS ON 31.10.2017

Post Permanent Work charged TOTAL

Sanctioned

Sanctioned

Sanctioned
Strength

Strength

Strength
Working

Working

Working
Vacant

Vacant

Vacant
SAG 04 04 - 04 04 -
JAG 17* 17 - 02 02 0 19 19 0
Sr. SCALE 02 01 01 04 01 03 06 02 04
JR. SCALE 13 13 00 06 06 06 19 19 00

* One number of JAG post has been transferred to SHRESTHA as per Railway
Board’s letter No. ERB-I/2016/23/54 dt.10.02.17.

Page 29 of 29