Final Handbook On OHE Inspection PDF

dsoy dk;Zky;hu mi;ksx gsrq
(For Official Use Only)
सत्यमे व जयते
Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS
HANDBOOK ON
OHE INSPECTION
TARGET GROUP: TrD OHE STAFF
CAMTECH/ E/17-18/OHE-Inspection/1.0
February 2018
Maharajpur, GWALIOR - 474 005

HANDBOOK ON ‘OHE INSPECTION
QUALITY POLICY
“To develop safe, modern and cost

effective Railway Technology complying
with Statutory and Regulatory
requirements, through excellence in
Research, Designs and Standards and
Continual improvements in Quality
Management System to cater to growing
demand of passenger and freight traffic
on the railways”.
FOREWORD
For ensuring reliability and defect free Over Head

Equipment (OHE), Inspections are required to be conducted by
Officers and supervisors in charge of operation and maintenance
of OHE.
CAMTECH has brought this publication “Handbook on

OHE Inspections” to spread awareness among the Inspectorial
Officials on the important aspects of OHE maintenance and
effective checks required to be conducted during such
inspections.
It is expected that this book will be very useful to the

Field staff in improving the reliability of OHE.
CAMTECH, Gwalior (D.Govinda Kumar)

February 2018 Principal Executive Director
PREFACE
To ensure reliability of OHE, it is essential to perform ample

inspection as per schedules specified.
CAMTECH has prepared this “Handbook on OHE Inspection”

based on the ACTM and instructions issued by RDSO/LKO. This will
disseminate technical information regarding inspections. The
photographs will help technicians to understand the defects in better
way.
It is clarified that this handbook does not supersede any existing

provisions/guidelines laid down by RDSO or Railway Board/ Zonal
Railways. The handbook is for guidance only and it is not a statutory
document.
I am sincerely thankful to all field personnel who helped us in

preparing this handbook.
Technological upgradation and learning is a continuous process,
hence feel free to write us for any addition/ modification in this
handbook. We shall highly appreciate your contribution in this
direction.
CAMTECH, Gwalior Peeyoosh Gupta

February 2018 Director Electrical
CONTENTS
No. Description Pg.No.
Foreword v
Preface vii
Contents ix
Correction slip xi
1. GENERAL 1
2. FOOT PATROLLING INSPECTION OF OHE 2
3. TROLLEY INSPECTION OF OHE 2
4. FOOT PLATE INSPECTION OF OHE 3
5. CURRENT COLLECTION TESTS 3
6. SPECIAL AND EMERGENCY INSPECTION 3
7. CHECKLIST FOR INSPECTION OF OHE 4
a) OHE Structures 4
b) Insulators 5
c) Regulating Equipments 6
d) Bonding and earthing 7
e) OHE conductors 8
f) Cantilever 9
g) In Span OHE 11
h) Isolator Switches 13
i) Section Insulators 13
j) Over line structures 14
k) Level crossing 14
l) Turn Outs and Cross-Overs 15
m) PTFE Neutral Section Assemblies 15
n) Overlaps 16
No. Description Pg.No.
o) Splice Fittings 17
p) Miscellaneous 17
8.INSPECTION OF TOOLS USED FOR OHE WORK. 20

 Discharge Rods 20
 Tirfors 21
 Pull-lifts 21
 D-shackles 22
 Slings 22
 Manila Ropes 23
 Ladders 23
 Pulley blocks 24
 Come along clamps 24
REFERENCE 25
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this
handbook will be numbered as follows:
CAMTECH/E/17-18/OHE-Inspection/C.S. # XX date---------
Where “XX” is the serial number of the concerned

correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. Date of Page no. and Item Remarks

issue no. modified
CAMTECH/E/17-18/OHE-Inspection/1.0 1
1. General
In order to achieve high reliability and ZERO
DEFECT OHE, and to ensure effective checks on the
maintenance work inspections of OHE is to be carried out by
the officers and Senior Subordinates in charge of operation
and maintenance of OHE and associated system.
The inspecting officials should programme their

inspections in such a manner as to cover the complete section
in their jurisdiction and so stagger the inspections as to avoid
over inspections of the same section repeatedly, in a very
short time while neglecting other areas.
By inspection of every part of the OHE (including

feeder line) any defects and abnormalities noticed are
recorded and reported to the maintenance gangs for attention.
Major defects noticed during inspection which

endanger safety shall be reported forthwith to TPC. Full
details should be given to enable the TPC to decide on the
course of action to be taken and if required to regulate train
movements in the affected section.
The Importance of OHE arises from the fact that it is

extensive, with a very large number of insulators, fittings and
other parts; failure of any one of which may result in
dislocation of train services for appreciable period until the
defect / breakdown is rectified. The adjustment work is
particularly important at cross-over and at overlaps spans
since any departures from the standards laid down could
cause entanglement of the pantograph with the OHE, with
serious repercussions.
Handbook on OHE Inspection February 2018

2 CAMTECH/E/17-18/OHE-Inspection/1.0
2. Foot Patrolling Inspection of OHE

The object of foot-patrolling is to make visual
inspection of every part of the OHE (including feeder line) so
that any defects and abnormalities noticed are recorded and
reported to the maintenance gangs for attention.
An experienced OHE
Linesman (accompanied by a
Khalasi) should be deputed to
patrol the section on foot by day,
so as to cover every part of the
section including yards once a
fortnight and suburban sections
once a week. The Linesman
should himself attend to and
rectify the minor defects (e.g.,
loose bond connections), which
can be rectified by him on the
spot without special assistance. To facilitate this, he shall
carry with him a few essential tools.
SSE and JE should foot patrol the section once in six

months. If this patrolling is done thoroughly, many of the
defects will be noticed at the incipient stage, before they
develop into major defects.
3. Trolley Inspection of OHE

Inspection of OHE by push trolley is essential except
in sections where use of trolley is prohibited. The object of
such inspection is to enable supervisors and officer’s in-
charge of OHE maintenance to observe closely the OHE
under their charge and should be carried out during day time.
The depot-in-charge (SSE or JE) should inspect his entire
February 2018 Handbook on OHE Inspection
section once a month. ADEE/TRD should inspect their

respective sections once in 6 months respectively by push-
trolley or motor-trolley as convenient. Sr.DEE /DEE/TRD
also should cover his entire section at least once a year by
push-trolley or motor trolley.
4. Foot Plate Inspection of OHE

Officers and senior subordinates shall travel by the
cabs of locomotives and EMU trains as often as possible but
at least once a month (to cover the complete section in their
jurisdiction) to observe the general condition of OHE and to
get first-hand knowledge of operating conditions.
5. Current Collection Tests

It is necessary to carry out periodic tests to detect
points at which contact between the contact wire and
pantograph is unsatisfactory resulting in sparking. Such
current collection tests are performed at night.
The current collection tests should be carried out by

the depot-in-charge (SSE or JE) once in 3 months over his
entire section. The ADEE (TrD) should accompany the
depot-in-charge during such tests alternately so as to cover
their sections once in 6 months respectively. DEE/TRD
should accompany the depot-in-charge so as to cover his
jurisdiction once a year.
6. Special and Emergency Inspection

A special inspection of the overhead equipment
should be carried out after severe wind/hail storms, quakes,
snowfalls, forest fires, floods or heavy rains. Such inspection
should be done after sabotage too. The purpose of such
inspection is to detect any damage or breakage on OHE and

to effect necessary repairs.
When an OHE is subject to fault often, it should be

inspected to ascertain the nature of fault, such as tree
branches touching the line, etc. and to find out remedial
measures required with a view to avoiding their recurrence.
7. Checklist for Inspection of OHE

OHE Structures
 Check rail level and setting
distance against markings on
the masts.
 Tilting of masts especially on

high banks and masts with
sand-core foundations.
 Condition of embankments
with respect to stability of
masts.
 Condition of location number

plate.
 Cracked or damaged muffs.
 Condition of foundation.
 Damaged OHE structures

Insulator
 Chipped or damaged insulators.
 Dust and dirt accumulated on insulators in polluted areas.

 Flash over mark on insulators.

Regulating Equipment
 Whether equalizing plate is tilted.
 Free movement of auto-tensioning device.
 Position of counterweight with reference to upper and lower

limits of movement marked on the mast.
 Check 'X' and 'Y' dimensions in the case of pulley block

type equipment and 'Z' and 'Y' dimensions in the case of
winch type equipment against prescribed values for the
temperature.
 Check condition of stainless steel wire rope for any signs of

corrosion and breakage of strands.

 Tilting of anti-falling device.

 Over riding of stainless steel wire rope.
Bonding And Earthing

 Defective bonds

 Open or loose bonds.

 Bond missing.
 The continuity and soundness of earth connections.
OHE Conductors
 Condition of contact wire, particularly for kinks and twists.
 Thickness of contact wire.
 Damaged strands of catenary or any other stranded wire.
 Condition of PG clamps and jumpers

Cantilever Assembly
 Rusted/damaged fittings, tubes etc.

 Height and stagger of contact and catenary wire.

 Check that the drain holes in the tubes are free and not
clogged.
 Out of Plumb Cantilever Assembly

In Span OHE
 Displaced fittings and damaged droppers.

 Excessive sagging or hogging of contact wire.

 Gradient of contact wire.
 Check for sufficient length
and adequate looping to
provide flexibility of
jumpers.
 Check for adequate cross-

section of jumper conductor
to carry the normal currents
and possible overloads due
to shut-downs on adjacent
line as well as faults.
 Check for proper bonding and tin soldering of the ends of

jumper wire.
 Check for proper seating and tightness of connections at PG

clamps.
 Condition of Jumpers and PG clamps.

Isolator Switches
 Isolator’s blades being fully in.
 For signs of sparking or overheating of isolators
 Condition of locks/interlocks.
 Correctness of operation.
 Alignment of contacts and arcing horns.
 Adequate distance between male and female contacts in
open position. (380 - 500 mm) depending upon the type of
isolator.
Section Insulators

 Badly chipped or slightly cracked or dust and dirt

accumulated on insulators.
 Flash-marks on runners.
 Level of the assembly.
 Excessive contact wire wear near anchor clamps.
 Condition of PG clamps of droppers and stiffeners.
 Pantograph passes underneath the section insulator
smoothly.
Over line Structures

 Condition of protective screens,
 Condition of caution and warning boards
 Water leakage on the OHE
 Horizontal and vertical electrical clearances
 Any flash-marks on the underside of the bridge structures.
 Availability of prescribed height of contact wire.
 Bonding and earth connections.
Level Crossing
 Structural soundness of height gauges at level crossings;
 Height of contact wire.
 Condition of caution and warning boards.
 Bonding and earth connections.

Turn Outs and Cross Overs

 Check stagger of both the OHE at turnout.
 Check that the main line OHE of overlap type turnout is

about 50mm below that of the turnout OHE.
 Condition of cross contact bar, if any, for displacement and

distortion.
 Rail level and setting of the obligatory mast.
PTFE Neutral Section Assemblies

 State of cleanliness of insulators

 Condition of arcing horns and arc traps
 Pantograph hit marks
Overlaps
 Height and stagger of OHE in the overlap section,
 Clearance of 500mm is available between the two

OHEs is an insulated overlap and 200mm in an
uninsulated overlap.
 Out of plumb insulators in IOL
 Whether the lifting of out-of-run OHE is correct.

 Parallel running of contact wires in the overlap for a
minimum 2m in the panto sweep region.
Splice Fittings
 Careful examination for cracks or other casting defects or
abnormalities.
 In case of catenary splice fitting tightness of the right hand
and left hand joints sockets.
 Check to see if any slipping of the ends of two contact wires
has taken place. When viewed through the top window, there
should be no gap between the two contact wire ends.
 In case of contact splice, tightness of stainless steel studs.
Miscellaneous
 Bird-nests and pieces of stray wire likely to cause short

circuits.


 Branches of trees likely to infringe the OHE.
 Any other obstructions including tree branches in the way of

free movement of pantograph and trains.
 Signs of heavy sparking when trains pass.
 General condition of switching stations en-route.
 Check Emergency telephone sockets.
 Check position of drop out fuse of auxiliary transformer.
 Any other abnormal/unusual situation.

8. Inspection of Tools used for OHE work.

 Discharge Rods
 Damaged strand of cable.

 Defective clamps.

 Tirfors
 Damaged strands of steel rope.

 Defective hook.
 Defective jaws of tirfor.
 Pull-lifts
 Defective chain
 Defective hooks.

 D-shackles
 Defective D shackle pin.
 Slings
 Broken strands
 Damaged loops

 Manila Ropes
 Old and damaged rope
 Ladders
 Damaged steps
 Defective lock

 Pulley blocks
 Damaged grooves
 Defective hooks
 Defective axle
 Come along clamps
 Damaged jaws.

REFERENCE
1. ACTM Volume II, Part I.

2. ACTM Volume II, PartII.
3. Treatise on Electric Traction Distribution

OUR OBJECTIVE
To upgrade maintenance technologies and methodologies

and achieve improvement in productivity and performance
of all Railway assets and manpower which inter-alia would
cover reliability, availability, utilisation and efficiency.
CAMTECH is continuing its efforts in the documentation and up-

gradation of information on maintenance practices of electrical assets.
Over the years a large number of publications on electrical assets have
been prepared in the form of handbooks, pockets books, pamphlets &
video films etc. These publications have been uploaded on the internet
as well as rail net.
For downloading these publications please do following:
1. On internet visit : www.rdso.indianrailways.gov.in
Go to Directorates  CAMTECH  Publications for download
Electrical Engineering
2. On Railnet visit RDSO website at 10.100.2.19
Go to Directorates  CAMTECH  Publications for download 
Electrical Engineering
For any further information regarding publications please contact:
Director (Elect.) – 0751- 2470740 (O) BSNL, 9752447030 (CUG)
SSE/Electrical - 9755549297 (CUG)
E-mail at direlcamtech@gmail.com
Fax to 0751- 2470841
Write at: Director (Electrical)
Indian Railways
Centre for Advanced Maintenance technology,
In front of Hotel Adityaz,
Airport Road, Maharajpur,
Gwalior, Pin code – 474 005

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dsoy dk;Zky;hu mi;ksx gsrq

(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

Maharajpur, GWALIOR - 474 005

“To develop safe, modern and cost

For ensuring reliability and defect free Over Head

CAMTECH has brought this publication “Handbook on

It is expected that this book will be very useful to the

CAMTECH, Gwalior (D.Govinda Kumar)

To ensure reliability of OHE, it is essential to perform ample

CAMTECH has prepared this “Handbook on OHE Inspection”

It is clarified that this handbook does not supersede any existing

I am sincerely thankful to all field personnel who helped us in

CAMTECH, Gwalior Peeyoosh Gupta

8.INSPECTION OF TOOLS USED FOR OHE WORK. 20

Where “XX” is the serial number of the concerned

CORRECTION SLIPS ISSUED

Sr. No. Date of Page no. and Item Remarks

The inspecting officials should programme their

By inspection of every part of the OHE (including

Major defects noticed during inspection which

The Importance of OHE arises from the fact that it is

Handbook on OHE Inspection February 2018

2. Foot Patrolling Inspection of OHE

SSE and JE should foot patrol the section once in six

3. Trolley Inspection of OHE

section once a month. ADEE/TRD should inspect their

4. Foot Plate Inspection of OHE

5. Current Collection Tests

The current collection tests should be carried out by

6. Special and Emergency Inspection

inspection is to detect any damage or breakage on OHE and

When an OHE is subject to fault often, it should be

7. Checklist for Inspection of OHE

 Tilting of masts especially on

 Condition of location number

 Cracked or damaged muffs.

 Damaged OHE structures

February 2018 Handbook on OHE Inspection

 Dust and dirt accumulated on insulators in polluted areas.

Handbook on OHE Inspection February 2018

 Free movement of auto-tensioning device.

 Position of counterweight with reference to upper and lower

 Check 'X' and 'Y' dimensions in the case of pulley block

 Check condition of stainless steel wire rope for any signs of

February 2018 Handbook on OHE Inspection

 Tilting of anti-falling device.

Bonding And Earthing

Handbook on OHE Inspection February 2018

 Open or loose bonds.

 Condition of contact wire, particularly for kinks and twists.

 Thickness of contact wire.

 Damaged strands of catenary or any other stranded wire.

 Condition of PG clamps and jumpers

February 2018 Handbook on OHE Inspection

Handbook on OHE Inspection February 2018

 Height and stagger of contact and catenary wire.

February 2018 Handbook on OHE Inspection

 Displaced fittings and damaged droppers.

Handbook on OHE Inspection February 2018

 Excessive sagging or hogging of contact wire.

 Check for adequate cross-

 Check for proper bonding and tin soldering of the ends of