Break Down Management SC, BZA Divn..pptx

In Indian Railways if OHE breakdown happens how to attend the Breakdown we have discussed in this PPT.

1. OHE Breakdown Management

2. Types of Breakdowns Snapping of catenary wire Snapping of contact wire Snapping of catenary/contact wire Failure of stay/ Bkt /9-ton insulator Failure at RT/steady arm Failure of SS wire rope Damage/uprooting of mast Failure of ending cones/other fittings Failure of Section Insulator Slewing/re-slewing of OHE Pantoentanglement

3. Duties of field supervisors Alert break down staff and vehicles on receipt of information Gather details of damages through available sources Move one person by first available means to get more details of damages Proceed with men & materials at the earliest Assess the work involved for quick temporary restoration Plan activities and distribute men & material activity wise Demand for additional resources of men & material if required Ensure proper communication between gangs and TPC Take necessary protection before commencement of work Do quick survey of site and decide action plan Assign work location wise among gangs Pass information to TPC or senior most official at TPC Ensure avoidance of unnecessary usage of cell phone at site Sr Supervisor to lead, coordinate and monitor activities for quick restoration Ensure Mega phone, walkie-talkie in working condition for extensive usage Ensure generator in working condition & keep adequate lighting arrangement

4. Duties of TPC Isolate the faulty section quickly Advise the SCOR for necessary protection Intimate the concerned section incharge & alert adjacent depots Inform CTPC/ADEE/ SrDEE about the unusual Other board TPC should assist the TPC of affected board to gather information Advise concerned ASM for opening Isolator to minimize the faulty section Coordinate with SCOR for quick movement of T/car Advise SCOR to issue Caution Order to the first train in the adjacent section and inform On arrival of TRD staff at spot collect full details and advise depots for men & matrial Coordinate with field staff for temporary restoration to facilitate early restoration of traffic Coordinate with SCOR for movement of traffic as situation permits Analyze for probable nature of fault based on sensitivity & selectivity of protective relays acted Take quick stock of Express trains likely to suffer punctuality Advise SCOR for imposition / cancellation of TSL working as situation permits Switch-off the section adjacent to faulty section

5. Duties of field supervisors 3. Observe the status of CB whether AUTO-RECLOSED / LOCKED OUT / BYPASSED Record alarms/indications of relays during faults displayed by SCADA system 4. Test charge CB once to confirm the status 5. On persistent fault CB does not hold then initiate fault isolation as per chart Fault Isolation & Efficient Train Operation 2. Visualize the nature of fault based on data of relays 6. Keep a log of switching operations to ensure systematic sequence of control

6. BM-1 BM-2 BM-4 BX-1 BM-3 FDR CB-2 FDR CB-1 DN UP 0101 0202 0301 0402 7. Charge subsector feeding to trains leaving TSS first to avoid panto-bridge-flashover For CB-2 charge 0301 first For CB-1 charge 0202 first

7. 8. Collect the details of trains likely to detain from train charting 9. Identify top priority trains like DURANTO / RAJADHANI 10. If restoration is likely to take longer advise SCOR for TSL working 11. TPC to apprise TLC and crew to make up the time lost to the possible extent 12. TPC to coordinate with counterparts of adjacent division to monitor punctuality

8. Preparatory work before reaching SPOT On available details of damages visualize to understand the work involved Carry full complement of working T&Ps, spares before proceeding Splice complete with both cones Splice complete with one cone

9. Suspension bracket with incomplete “U” bolt assembly

10. PG-clamp without copper spring washer

11. Stay sleeve bolt Dropper clip bolt Ensure correct bolt is provided in stay sleeve & dropper clip

12. Ensure Tirfor set is with correct rope

13. Keep Tirfor rope ready with pulley inserted

14. Plan the activities and distribute the same among staff Nominate incharge for gangs Distribute materials & tools among gangs Decide location of discharge rod location early Spares like steady arm,RT,ST,Insulators , droppers,etc ., to be kept ready Suitable catenary piece with splices on both ends to be kept ready Suitable contact piece and splices to be kept ready SED & LOP of effected section to be carried Keep staff ready for removal of discharge rods while work is about to finish Refer to the road approach of the section to reach quickly Preparatory work

15. Panto -entanglement Likely causes Turnouts not confirming to standards Leaning of structures Improper alignment of Section Insulator Failure of SS wire rope Failure of stay/bracket/9-ton insulator Failure of RT eye, dropper ,drop bracket, Susp . Bkt.,RT hook Out of stagger locations Defects in pantographs Foreign bodies falling on loco roof / OHE Hogging of OHE at turnout due to G-Jumper in danger zone Obstructed movement of ATD

16. Damages to cantilevers Damages to insulators Damages to in-span droppers Damages to jumpers Damages to catenary / contact wire Likely Damages Damages to PG-clamps Damages to turn outs / overlaps Damages to Section insulator

17. Restoration – Panto-etanglement Tools Al Ext.Ladder 20/36’ -2 Earth Discharge rods-2 at Loco Tool box with complete Spanners, cutting plier Hammer, screwdriver, Hacksaw with spare blades Sling 1M -2 Sling 2M - 2 Manila rope ½” – 2 Manila rope ¾” - 2 Steel pulley-2 0.75 T pull lift -1 D-shackles 1” – 4 D-shackles 3/4” – 2 2/3 Ton tirfor-1 set Ton tirfor-1 set Earth Discharge rods-2 for affected loc. Step ladder with hook -1

18. Material Material Steady arm - 4 Catenary wire of Suitable length - 1 Suitable RT -2 Cat. Wire ending cones -2 9-T insulator-1 Spl . droppers-10 Jumper-1 PG-clamps-4 Cat. Dropper clip-10 Binding wire-1 Cat.wire splice - 2 Stay insulator - 2 Contact splice - 2 Bkt . insulator - 2 Contact Dropper clip-10 Suitable BT -2 Suitable ST -2 Dropper clips for RT&BT -2 each

19. Manpower required At Loco to secure pantograph Tech - 1 Kh - 2 Affected location # 1 Tech - 2 Kh - 3 Affected location # 2 Kh - 3 Tech - 2

20. 1. Move one gang with tools to locomotive for securing pantograph 2. Carry small step ladder with hooks for climbing on to loco roof Restoration

21. 3. Secure damaged pantograph duly isolating from HT bus

22. 7. Move one or more gangs with tools & material to affected loc. 4. Clear loco roof from all obstructions 5. Raise front pantograph and move the train 6. While Pantograph is being secured quickly survey affected locations 8. Plan for quick temporary restoration 9. Plan for permanent restoration subsequently

23. Breakage of stay insulator Likely Damages Stay insulator gets damaged RTdropper gets twisted A-droppers get twisted

24. Tools required Tools Al Ext.Ladder 20/36’ -1 Earth Discharge rods-2 0.75 T pull lift -1 Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Cutting plier Hammer-1 Manila rope1/2” - 2 Steel pulley-1

25. Men & Material Men Material Tech - 2 Kh - 4 Stay insulator-1 SS-Fasteners – 2Nos Cantilever-1 set Stay tube suitable length-1 Swivel clip and pin -1

26. Restoration procedure Step-1 Provide earth discharge rods after permit-to-work

27. Right Method Wrong Method GI bolt for pull lift Provide ladder from inside for tangent Track and inside curve Step-2 Bring OHE to position manually by lifting OHE through ladder Step-3 Release the damaged insulator with rope Bring tested insulator to top by rope and hook to top attachment Step-4

28. Step-5 Align stay tube to insulator cap with rope /ladder and provide bolts

29. Restoration procedure - summary 1. Provide earth discharge rods after permit-to-work 2. Bring OHE to position manually by lifting OHE through ladder 3. Release the damaged insulator with rope 4. Bring tested insulator to top by rope and hook to top attachment 5. Align stay tube to insulator cap with rope /ladder and provide bolts 7. Adjust RT dropper and A-dropper 6. Fully tighten stay insulator bolts. & release rope, ladder, etc,. Staff Tech-2 Kh-4 Tools & material Al Ext.Ladder -1 Earth Discharge rods-2 ½” manila rope – 2 0.75 T pull lift Stay insulator-1 Hammer-1 Time – 20 Min Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Stay tube-1 Steady arm-1 Cutting plier-1 Swivel clip & pin-1 SS-Fasteners – 2Nos Steel pulley-1

30. Breakage of bracket insulator Likely Damages Bracket insulator gets damaged RT dropper gets twisted A-droppers get twisted

31. Tools required Tools Al Ext.Ladder 20/36’-1 Earth Discharge rods-2 0.75 T pull lift -1 Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Cutting plier Hammer-1 Manila rope1/2” - 2 Steel pulley-1

32. Men & Material Men Material Tech - 2 Kh - 4 Bkt insulator-1 SS-”U” – 2Nos Steady arm-1 Bracket suspension-1 Swivel clip and pin -1

33. Restoration procedure Step-1 Provide earth discharge rods after permit-to-work

34. Bring OHE to position manually by lifting OHE through ladder Step-2

35. Step-3 Release the damaged insulator with rope

36. Step-4 Bring tested insulator by rope & insert into Bottom attachment swivel with snap head pin

37. Align Bracket tube to insulator with rope and ladder Step-5 Provide “U” bolts to secure BT into insulator Fully tighten “U” bolts & release rope, ladder, etc,. Step-6 Step-7

38. Restoration procedure - summary 1. Provide earth discharge rods after permit-to-work 2. Bring OHE to position manually by lifting OHE through ladder 3. Release the damaged insulator with rope 4. Bring tested insulator by rope & insert into bottom attachment swivel 5. Align Bracket tube to insulator with rope and ladder 6. Provide “U” bolts to secure BT into insulator 7. Fully tighten “U” bolts & release rope, ladder, etc,. Staff Tech-2 Kh-4 Tools & material Al Ext.Ladder -1 Earth Discharge rods-2 ½” manila rope – 2 0.75 T pull lift Bkt insulator-1 Hammer-1 Time – 20 Min Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Bkt Susp-1 Steady arm-1 Cutting plier-1 Swivel clip & pin-1 SS-” U”bolts – 2Nos Steel pulley-1

39. Tools required Al Ext.Ladder 20/36’ -1 Earth Discharge rods-2 Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Cutting plier Manila rope1/2” - 2 Replacement of RT and steady arm

40. Men & Material Men Material Tech - 2 Kh - 4 Register tube-1 Drop Bkt-1No Steady arm-1 Antiwind clamp-1 Swivel clip and pin -1 Spl . dropper-1 RT dropper clip-1set

41. Replacement of RT and steady arm Open register arm hook near BKT insulator and release the RT eye from hook Step-2 Remove swivel clip by securing the contact wire with rope Step-1

42. Remove RT dropper clip at suspension clamp end Release the RT assembly with drop bracket, steady arm & dropper clip Pickup the new the RT assembly with drop bracket, steady arm & dropper clip Step-3 Step-4 Step-5

43. Provide steady arm into swivel clip to secure contact wire Step-6

44. Step-7 Fix the RT dropper clip with pin at suspension clamp

45. Step-8 Assemble the RT eye with hook and tighten to required stagger

46. Replacement of RT - Summary 8. Assemble the RT eye with hook and tighten to required stagger 7. Fix the RT dropper clip with pin at suspension clamp 6. Provide steady arm into swivel clip to secure contact wire 5. Pickup the new the RT assembly with drop bracket, steady arm & dropper clip 4. Release the RT assembly with drop bracket, steady arm & dropper clip 3. Remove RT dropper clip at suspension clamp end 1. Remove swivel clip by securing the contact wire with rope 2. Open register arm hook near BKT insulator and release the RT eye from hook Tools required Al Ext.Ladder 20/36” -1 Earth Discharge rods-2 Spanners-16x17 DE&ring-2 sets Spanners-24x27 DE&ring-1 set Cutting plier Manila rope1/2” - 2 Time – 20 Min Men Material Tech - 2 Kh - 4 Register tube-1 Drop Bkt-1No Steady arm-1 Antiwind clamp-1 Swivel clip and pin -1 Spl . dropper-1 RT dropper clip-1set

47. SS wire rope failure Likely damages SS wire rope cuts Pulley gets damaged Counter weight gets grounded Turnout gets disturbed Overlaps gets disturbed SI alignment changes Counter weight guide tube ring gets broken

48. Tools required Tools Al Ext.Ladder 20/36’ -1 Earth Discharge rods-2 Slings 1M - 3 3/5 Ton tirfor-1 set 2/3 Ton tirfor-1 set Tool box with all spanners Cutting plier , hammer, screwdriver, Hacksaw with spare blade D-shackles 1” – 4 D-shackles 3/4” – 1 Manila rope1/2” - 2 Steel pulley-2 Cat. / contact come along clamps-1 each

49. Men & Material Men Material Tech - 2 Kh - 6 SS rope-1 Counter wt. eye rod-1 Reg. Eqpt.-1set SS rope ending cones -2sets 9-T insulator-1

50. Replacement of SS wire - Procedure 2. Put ladder on to OHE near compensating plate 1. Provide earth discharge rods after permit-to-work

51. 3. Provide sling & two 6’ pullies one each for OHE and counter weights

52. 4. Provide catenary & contact come along clamps slightly away from compensating plate

53. 5. Provide 5 ton tirfor for taking OHE load 6. Provide 3 T tirfor for lifting counter weights

54. 7. Secure 9-T insulator & regulating eqpt ., to tirfor rope with manila rope

55. 8. Take OHE load with 5-T tirfor 9. Lift counter weights up to bottom attachment

56. 10. Release damaged SS wire rope from

57. 12. Terminate new SS wire rope to counter weight 13. Release counter weight tirfor & OHE tirfor respectively 11. Provide new SS wire rope and terminate to regulating equipment 14. Release sling & come along clamps to ground 15. Remove ladder & clear men from OHE

58. Replace ment of SS rope - Summary 15. Remove ladder & clear men from OHE 14. Release sling & come along clamps to ground 13. Release counter weight tirfor & OHE tirfor respectively 12. Terminate new SS wire rope to counter weight 11. Provide new SS wire rope and terminate to regulating equipment 10. Release damaged SS wire rope from 9. Lift counter weights up to bottom attachment 3. Provide sling & two 6’ pullies one each for OHE and counter weights 8. Take OHE load with 5-T tirfor 1. Provide earth discharge rods after permit-to-work 2. Put ladder on to OHE near compensating plate 5. Provide 5 ton tirfor for taking OHE load 4. Provide catenary & contact come along clamps slightly away from compensating plate 7. Secure 9-T insulator & regulating eqpt ., to tirfor rope with manila rope 6. Provide 3 T tirfor for lifting counter weights

59. Snapping of contact wire Likely damages Cutting of contact wire Twisting /damage to adjacent droppers Breakage of cut-in insulators if present Turnout / overlap gets disturbed Displumbing of adjacent cantilevers SI gets out of alignment Cutting/damages to Jumpers, PG-clamps if present Damage to RT, steady arm, antiwind clamp

60. Tools required Tools Al Ext.Ladder 20/36’ -1 Earth Discharge rods-2 Slings 1M - 3 3 Ton tirfor -2 set Tool box with all spanners Cutting plier , hammer, screwdriver, Hacksaw with spare blade D-shackles 1” – 4 D-shackles 3/4” – 1 Manila rope1/2” – 1 Manila rope ¾” - 1 Steel pulley-2 Contact come along clamp-2

61. Men & Material Men Material Tech - 3 Kh - 6 Con.wire splice - 2 Contact wire of Suitable length - 1 RT -1 Con. Wire ending clamps -2 9-T insulator-1 Spl . droppers-5 Jumper-1 PG-clamps-4 Con. Dropper clip-5 Binding wire-1

62. Restoration Procedure 1. Provide earth discharge rods after permit-to-work 2. Lift counter weights at ATD location 3. Provide come along clamps

63. Permit trains if required with caution order of LOWER PANTO BEFORE THIS LOC. RAISE PANTO AFTER THIS LOC. 4. Take load of wire with tirfor and secure to normal height

64. 5. Cut contact wire vertically for correct splice

65. 6. Provide splice with hand splicing jig & tighten the splice bolts uniformly 7. Release tirfor & smoothen the level of bottom surface of contact wire under splice

66. Snapping of catenary wire Likely damages Cutting of catenary wire Twisting /damage to adjacent droppers Breakage of cut-in insulators if present Turnout / overlap gets disturbed Displumbing of adjacent cantilevers SI gets out of alignment Cutting/damages to Jumpers if present Damages to PG-clamps

67. Tools required Tools Al Ext.Ladder 20/36’ -1 Earth Discharge rods-2 Slings 1M - 3 3 Ton tirfor -2 set Tool box with all spanners Cutting plier , hammer, screwdriver, Hacksaw with spare blade D-shackles 1” – 4 D-shackles 3/4” – 1 Manila rope1/2” – 1 Manila rope ¾” - 1 Steel pulley-2 Catenary come along clamp-2

68. Men & Material Men Material Tech - 3 Kh - 6 Cat.wire splice - 2 Catenary wire of Suitable length - 1 RT -1 Cat. Wire ending cones -2 9-T insulator-1 Spl . droppers-5 Jumper-1 PG-clamps-4 Cat. Dropper clip-5 Binding wire-1

69. Restoration Procedure 1. Provide earth discharge rods after permit-to-work 2. Lift counter weights at ATD location 3. Provide come along clamps

70. 4. Take load of wire with tirfor and secure to normal height 5. Trains can be permitted after securing wire & tirfor above contact plane

71. Splicing of Catenary Wire 7. Provide binding wire & cut damaged catenary wire 8. Provide two endpieces of splice with cone inserted

72. 9. Provide catenary splice, tighten & release men and material

73. At ATD location Provide sling for tirfor Lift the counter weight At cat/contact cut loc. Provide come along clamps Cut the damaged wire Provide tirfor and secure the wire Keep new wire to be spliced ready with splices Release damaged jumpers,droppers,other obstruction Tech-2 Kh-3 Tech-1 Kh-2 Ladder/ladder trolley Provide discharge rods after permit-to-work Restoration - Summary Dos Cut contact wire vertically for correct splice Smoothen levels under contact splice to avoid hitting Remove kinks if any after splicing Provide binding wire before cutting catenary Provide splice with hand splicing jig

74. At ATD location Provide sling for tirfor Lift the counter weight At cat/contact cut loc. Restoration Procedure – activity wise Provide come along clamps Cut the damaged wire Provide tirfor and secure the wire Keep new wire to be spliced ready with splices Parallel activities Release damaged jumpers,droppers,other obstruction Splice the damaged wire – exclusive activity Release the tirfors at ATD & catenary Replace the damaged droppers,jumpers,etc ., if req. & time permits Tech-2 Kh-3 Tech-1 Kh-2 Ladder/ladder trolley/T-car Release come along clamps,slings,ladder,etc. Provide discharge rods after permit-to-work Remove earth discharge rods after clearing all men & material --– cancel permit-to-work Parallel activities 15 Min. 10 Min. 5 Min.

75. Temporary Restoration 1. Lift the counter weight with tirfor 2. Secure the damaged OHE/SI with tirfor & clear physical obstruction 3. Ensure that the T/out OHE is 50mm above that of main line 4. Declare X-over unfit for electric trains Breakage of SI Core Insulator

76. Temporary mast erection Tools Al Ext.Ladder 20/36’- 1 Earth Discharge rods-2 Slings 1M - 3 3Ton tirfor-1 set Tool box with all spanners-1 D-shackles 1” – 4 D-shackles 3/4” – 2 Manila rope3/4”-3 Steel pulley-2 Empty drum-1 Anchor plate-1 Showels -3 Punjas-2 Sledge hammer-1 Time-40 Min

77. Men & Material Men Material Tech - 2 Kh - 6 Temporary mast assebly 1 set Spikes– 18Nos Steady arm-1 20x50x37 GI bolt- 30 16x37x50 GI bolts -30

78. Erection procedure Step-1 Decide suitable location and level surface for placing the base plate Step-2 Place the base plate and fix with spikes

79. Step-3 Hinge the bottom piece of mast to base plate

80. Step-4 Assemble the balance pieces to the bottom member

81. Step-5 Arrange tirfor for lifting the mast Step-6 Provide sling to the assembled mast and fix tir for rope for lifting Step-7 Lift the mast manually to possible height for further lifting by tirfor Provide two manila ropes for balancing while lifting with tirfor Step-8

82. Step-8 Lift the mast by tirfor balancing with ropes

83. Step-9 Lift mast to complete vertical and fasten to base plate through bolts

84. Step-10 Lift parkona with manila rope to top for support to lift cantilever

85. Step-11 Erect parkona on top of temporary mast

86. Step-12 Tie cantilever to be erected to manila rope Step-13 Erect cantilever to temporary mast

87. Slewing of OHE for crane working on track

88. Tools required Tools Al Ext.Ladder 20/36’- 1 Earth Discharge rods-2 Slings 1M - 2 2/3 Ton tirfor-1 set Ton tirfor-1 set Tool box with all spanners Cutting plier,hammer,screwdriver D-shackles 1” – 4 D-shackles 3/4” – 1 Manila rope3/4” - 2 Steel pulley-1 Fibre pulley-1 Staff / loc. Tech-1 Kh-4

89. 2. Fix pulley to top step bolt of ladder 3. Tie catenary near suspension clamp with manila rope & pass through pulley 1. Provide ladder on catenary near suspension clamp Slewing Procedure

90. 4. Remove swivel clip & suspension clamp “U” bolts

91. 5. Release catenary from suspension clam by taking load with rope 6. Lower the OHE to ground and secure

92. 136/15 136/15 Wrong Method Correct Method If the lifting pulley is placed on BT, while lifting the catenary /contact wire downward load will be on ST which will bend and ST will part Alluminuim ladder to be placed. Chain pully / cuppy to be put on Ladder and than catenary /contact to be lifted. Re-slewing Procedure 1. Lift the ladder with manila rope with pulley on top 2. Secure catenary wire with rope on ground 3. Pull the rope to take OHE upto bracket

93. 4. Provide catenary into suspension clamp and tighten “U” bolts

94. 5. Provide swivel clip with pin 6. Clear all T&P and men

95. Dos Visualize and understand the damages to the extant possible before reaching spot Plan & distribute activities before commencement of work on reaching spot Distribute full materials exclusively activity wise & location wise Understand & council staff for correct sequence of activities Ensure clear communication between gangs Prioritize activities for quick and temporary restoration for minimal or no detention Plan permanent restoration after clearing traffic detention Follow safe working and standard methods Take load of catenary/contact wire on ladder with pull lift Secure catenary/TF wire with binding wire before providing splice/ending cone During temporary restoration ensure T/out OHE is 50mm above Main line Secure OHE on either side before cutting

96. Don’ts Do not plan activities after commencement of work Avoid usage of same tools by different gangs Do not adopt own and unsafe methods If loss of communication and plan alternative course of action Do not leave designated spot unless instructed Do not cut catenary/contact wire without securing Do not provide excess length of catenary/contact which may disturb T-out/IOL Do not use release spares Do not take load by fixing pulley to stay tube Do not cut OHE without locking ATD

97. THANK YOU