Pre-Commissioning Checklist

of

SMPS based IPS

REFERENCE: SPECIFICATION NO. RDSO/SPN/165

SIG0101 (Revision 1)

Number of pages 13

RESEARCH, DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR

LUCKNOW - 226011
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

DOCUMENT DATA SHEET

Designation

SIG 0101 (Revision 1)

Title of Document

Pre-Commissioning Checklist of SMPS based

IPS

Authors: See Document Control Sheet

Name: Vipul Goel

Designation: Joint Director / Signal

Approved By

Name: Shri G.D.Bhatia

Designation: Sr.Executive Director /Signal, RDSO

Abstract

This document defines the guidelines for Pre-Commissioning Checklist of

SMPS based IPS.

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Document control Sheet

Designation Organization Function Level

Joint RDSO Member Prepare

Director/Signal

Sr.ED /Signal RDSO - Approval

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

PRE-COMMISSIONING CHECKLIST FOR SMPS BASED IPS SYSTEM

1. STATION DETAILS

Zonal Railway Number of main signals

Division Number of shunt signals
Station Name Number of point machines
IPS Make Number of Axle Counters
RE/Non RE Number of Track Circuits
No. of lines / Roads Type of Track Circuit
(AFTC/DC)
Power availability Number/Type of Indoor
hours / day relays
DG set rating Number/Type of outdoor
relays
Type / capacity of Interlocking ( RRI/SSI)
battery (LM/VRLA)

2. PRE-COMMISSIONING REQUIREMENTS

S ITEM Specified Measured Value Remark

.N. Value/provision / Observation (OK/Not
OK)
A Ambience of IPS Room

A1 Availability of working 1 m (min.) from sides and

space for maintenance. rear. 2 m (min.) in front of
the IPS
A2 Provision of flooring to Pucca floor/ Ceramic tiles
ensure proper cleaning.
A3 Provision of forced Fresh Air fans with
ventilation dampers
A4 Arrangement for (i) Tight closing of doors &
protection against dust. windows; use gaskets if
necessary.

(ii) Washable dust filters on

windows.

(iii) Provision of double

door or entry through
adjoining room to reduce
dust ingress
A5 Provision of Ventilators As per RE Drg. No.
RE/Civil/S-129-2001
(Annexure-I).

Signature of Manufacturer's Representative Signature of Railway Supervisor

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S ITEM Specified Value/provision Measured Remark

.N. Value / (OK/Not
Observation OK)
B Batteries

B1 Installation of secondary Installed in separate room /

cell as per para 16.6 of apparatus case.
SEM Pt. Acid proof flooring and tiles
Exhaust fan
Initial charging as per instruction
of battery manufacturer
Use of battery grade sulphuric
acid conforming to IS: 266.
Use of distilled or de-mineralised
water conforming to IS: 1069
B2 Storage period of VRLA Less than 03 months (If the
batteries for IPS battery is being stored for more
than 3 months, freshening
charge should be given once in
3 months as given below. The
charging current should be 10%
to 20% (max.) of rated capacity:-

Float Charge @ 2.25V/cell for

24 hours
Boost Charge - @ 2.30V/cell for
15 hours)
B3 Measured capacity of Rated AH
battery after capacity test
on batteries.
B4 Feeder cable from battery
to charger
120AH 10 sq.mm copper
200AH 16 sq.mm copper
300AH 25 sq.mm copper
B5 Availability of Spare cell in 05 Nos.
charged condition at site
C Commercial/AT Supply

C1 Availability of commercial More than 6 hours in 24 hours

supply (Ref: RB letter No. with least fluctuations
2002/SIG/SGF/3 dt.
24.6.03). (Note: Nominal incoming AC supply
shall be 230V, 50Hz single phase
AC. The specified AC voltage range
for IPS is 150V-270V.)

Signature of Manufacturer's Representative Signature of Railway Supervisor

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S ITEM Specified Value/provision Measured Remark

.N. Value / (OK/Not
Observation OK)
C2 Voltage drop in input feeder Less than 30 volts
at full load.
C3 Provision of sources of RE Area
power supply as per para Power supply drawn from AT
16.2 of SEM Pt. II. Up/Dn/ Commercial
supply/Genset with auto/
manual changeover facility in
the control panel.

On double/multiple line
sections, at least one AT is
available to ensure power
supply in the event of power
block.

On single line sections where

power supply is drown from a
single AT, a DG set of suitable
capacity has been provided

In big yards, a DG set of

adequate capacity in addition
to supply from AT's and local
source

Non RE Area
Power supply drawn from
commercial feeder. In addition
two standby diesel generators
have been provided
C4 Size of input feeder cable
as per TI Directorate's note
no. TI/PSI/Project/CLS/01
dt. 04.01.02.(Annexure II)
from Auxiliary Transformer
(AT ) / Distribution
transformer to IPS room for
5 KVA AT 2X25 sq.mm Al
10KVA AT 2x70 sq.mm Al
50KVA AT 2x300 sq.mm Al

Signature of Manufacturer's Representative Signature of Railway Supervisor

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S ITEM Specified Value/provision Measured Remark

.N. Value / (OK/Not
Observation OK)
C5 Sanctioned Commercial
feeder load (KVA)=S
General Electrical Lighting
load (KVA)=L
Balance available for
Signalling Load(KVA) = S-L

4 Line Non-RE 7.4 KVA

4 Line RE 6.25 KVA
6 Line Non-RE 8.1 KVA
6 Line RE 7.0 KVA
C6 MCB/ Changeover switch 63 Amp of Merlin Gerlin
(Telemecanique) / Siemens,
(Ref: RB letter No. Schneider or ABB.
2004/SIG/SGF/3 dt.
25.3.2004.
D DG Set supply
D1 Provision of adequate
capacity DG set (without
AFTC)
4 Line Non-RE 10 KVA
4 Line RE/6 Line RE 10 KVA
6 Line Non-RE 12.5/15 KVA

with AFTC in yard At least 25 KVA

D2 Checking of DG set at
5KW dummy load:
Waveform Sinusoidal
Voltage Regulation within 3%
Frequency 50Hz ± 5% from no load to full
load
D3 Proper termination of Good workmanship
earth and neutral.
E Earthing
E1 Earth resistance of Less than 2 Ohm (without
earthing arrangement. adding water prior to
measurement)
Preferably maintenance free
earth.
E2 Extension of earth to Provided
equipotential bus bar.

Signature of Manufacturer's Representative Signature of Railway Supervisor

S ITEM Specified Value/provision Measured Remark

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

.N. Value / (OK/Not

Observation OK)
E3 Connection of individual with individual copper insulated
equipment to cable of size
equipotential bus bar:
- IPS racks 4 Sq.mm
- DG sets 4 Sq.mm
-Surge protection devices 16 Sq.mm
F Lightning & Surge Protection
F1 Provision of lightning & One set
surge arrestors (As per
Cl. 3.12 of
RDSO/SPN/165/2004 Ver
2)
G. Instruction Manual
G1 Instruction Manual Two sets
consisting of Layout drgs.,
Circuit/ System diagram,
PCB Layout etc. (Ref: Cl.
7.1 of
RDSO/SPN/165/2004 Ver
2)
H Training
H1 Imparting on job training 3 days
to SE/SSE/JE and ESM

3. IPS LOAD DETAILS

N= Number of modules provided in hot standby

S ITEM Specified Measured Remark

.N. Value/provision Value / (OK/Not OK)
Observation OK Not
OK
1. Signalling Equipment load 80% of the DG Set
(KVA) capacity provided at
station
2. Relay internal 24-32V/5A 5 *(N-2) Amp
3. Relay external 24-32V/5A 5 *(N-1) Amp
4. Axle counter 24-32V/5A 5 *(N-1) Amp
5. Block local 12-28V/5A 5 *(N-1) Amp
6. Panel Indication12-28V/5A 5 *(N-1) Amp
7. HKT/magneto 12-28V/1A 1 *(N-1) Amp
8. Block UP 12-40V/1A 1 *(N-1) Amp
9. Block DN 12-40V/1A 1 *(N-1) Amp

Signature of Manufacturer's Representative Signature of Railway Supervisor

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Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Measured Remark

Value/provision Value / (OK/Not OK)
Observation OK Not
OK
10 Block Tele UP 3-6V/0.1A 0.1*(N-1) Amp
11 Block Tele DN 3-6V/0.1A 0.1*(N-1) Amp

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

12 Data logger 24-32V/5A 5 *(N-1) Amp

13 SSI 24-32V/5A 5 *(N-2) Amp
14 Load on each Signal Tx UP 500 VA
15 Load on each Signal Tx DN 500 VA
16 Load on Inverter
4 Line 1.5 KVA
6 Line 2.0 KVA
17 Load on Signalling AVR
4 Line 1.5 KVA
6 Line 2.0 KVA
18 Load on Track Tx
UP 500VA
DN 500VA
19 Load on Track AVR
4 Line 1.0 KVA
6 Line 1.5 KVA
20 High voltage disconnect 275 V
21 Low voltage disconnect 160V
22 Battery capacity 300/200AH
23 Battery charging current 30/20A =Y
24 Total Current drawn from 20* (N-2) Amp=X
FRBC at 110 V after one hour
of discharge.
25 Current drawn from FRBC at X-Y
110 V when battery is in float
condition
26 Input feeder current at full
load
4 Line Non-RE 32 Amp
4 Line RE 27.2 Amp
6 Line Non-RE 35 Amp
6 Line RE 30.2 Amp
27 Input feeder voltage at full 160 Volts (Minimum)
load
28 Functioning of dynamic Operational
current control
29 Supply fuse 63 A

Signature of Manufacturer's Representative Signature of Railway Supervisor

S.N ITEM Specified Measured Remark

Value/provision Value / (OK/Not OK)
Observation OK Not
OK

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

30 Working of Status Monitoring

Panel (Para 4.10 of spec.)
DOD 50% RED & Audio alarm
60% RED & Audio alarm
70% RED & Audio alarm till
DG is started

GREEN & Audio alarm

Stop DG Set
31 Call S&T due to failure of any RED & Audio alarm
module
32 Changeover inv. 1 to 2 and Inverter failure
vice versa
33 Changeover inv. to CVT and Both inverter fail
vice versa
34 DC-DC Converter for spare 02 Nos.
cells 2-12V, 5Amp
35 Temperature compensation Provided for VRLA
battery

4. Performance Monitoring of IPS

S.N ITEM Specified Observation Remark

Provision
1 Monthly calculation of MTBF / As per Annexure-III
MTTR and sending it to Zonal
Railways for onward
transmission to RDSO.

Signature of IPS Manufacturer's Representative Signature of Railway Supervisor

Name Name
Designation Designation
Date Date

**********************

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Annexure-II

Telephone : 2451200 Extn. 42394 Government of India - Ministry of Railways

Tele Fax : 91-0522-2452332 Research Designs & Standards Organisation
E-mail : dsig4@rdso.railnet.gov.in LUCKNOW - 226011

No.TI/PSI/PROJECT/CLS/01 Dated 04.01.2002

The Chief Electrical Engineer

i) Central Railway, Mumbai CST-400 001.

ii) Western Railway, Churchgate, Mumbai-400 020.
iii) Eastern Railway, Fairlie Place, Kolkata-700 001.
iv) South Eastern Railway, Garden Reach, Kolkata-700 043.
v) Northern Railway, Baroda House, New Delhi-110 001.
vi) Southern Railway, Park Town, Chennai-600 003.
vii) South Central Railway, Rail Nilayam, Secunderabad-500 371.
viii) CORE, Nawab Yusuf Road, Civil Lines, Allahabad-211 001.

Sub: The cable sizes between Auxiliary Transformer and Distribution Panel.

The existing cable between auxiliary transformer and distribution panel is of 2x25 Sq.mm
Aluminium cable for 5 KVA and 10KVA auxiliary transformers. The problem of excessive voltage
drop and failure of fuse / tripping of MCB in distribution panel especially during low OHE voltage
have been reported by the Signal Directorate. The cable size has been accordingly reviewed
considering the voltage drop as well as energy loss in the cable.
Presently, 10KV ATs are being provided at the end of platforms at the stations for
signalling loads. 5KVA ATs are being provided at IBH stations and level crossing gates. The
signalling load for ¾ line station in double line section on 10KV AT is about 8.5KVA. The signalling
load at IBH and level crossing gate is about 2.0KVA. 50KVA ATs are presently planned for
Mumbai area under DC-AC conversion where the requirement of load is higher. The estimated
max. signalling load on 50KVA AT is about 40KVA. These 50KVA ATs may be used in future in
other areas depending on the requirement of load.
Due to provision of voltage stabilizer, the signalling load is normally of constant VA type
i.e. if the voltage decreases the current will increase correspondingly. The input voltage range of
the voltage stabilizer is 160-270V. Considering this the optimum cable sizes for different types of
ATs are worked out and are given as follows:

AT type Cable sizes

5KVA 2 x 25 Sq.mm Aluminium
10KVA 2 x 70 Sq.mm Aluminium
50KVA 2 x 300 Sq.mm Aluminium

The above cable sizes of 1100V, PVC insulated, PVC sheathed, Al-conductor, Armoured
Power cable as per IS: 1554-Part-I are to be provided for the respective type of ATs. The cable
lugs and connectors are to be suitably provided. The taps of ATs should be judiciously kept so
that the available voltage is maintained in the range of 160-270 V, which is the input voltage
range of signalling voltage stabilizer.
(B.P.Singh)
for Director General/TI

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 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Annexure-III

Suggested Format of field MTBF to be submitted by Zonal Railways

Make Total working hours Total number of failures MTBF

IPS SMR** Inv.** DC-DC IPS* SMR Inv DC-DC IPS SMR Inv. DC-
Conv** Conv DC
Conv
AMR
BSMC
HBL
Statco
n

*IPS failures shall be those failures which have affected the final performance of signalling
system i.e failures affecting signals, complete shut down, failure of complete function.

** Total working hours of SMR = ∑ number of SMR provided x working hours of IPS system

Total working hours of Inverter = ∑ number of Inverters provided x working hours of IPS
system

Total working hours of DC-DC Conv = ∑ number of DC-DC Conv. Provided x working
hours of IPS system

Total working hours

MTBF = Number of failures of sub system

Format of field MTTR to be submitted by Zonal Railways

Make Total number of failures Total duration of MTTR (hours)

failures (hours)

AMR
BSMC
HBL
Statcon

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Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

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