Electronic Interlocking 4p642

S 18 ELECTRONIC INTERLOCKING

Issued in November 2009

INDIAN RAILWAYS INSTITUTE OF SIGNAL ENGINEERING & TELECOMMUNICATIONS SECUNDERABAD - 500 017

S-18 ELECTRONIC INTERLOCKING CONTENTS S. No

Chapter

Page No

1

Introduction to Electronic Interlocking

1

2

MICROLOK-II EI system

14

Annexure-I

Electronic Interlocking Spec. No: RDSO / SPN / 192 / 2005

49

Annexure-II

Items of Microlok-II EI system (Centralised version) for a typical 4- Road Station

65

Annexure-III

Items of “ All Indoor Works for provision of Microlok-II EI system (Distributed version with OFC) at Stations of Indian Railways”

70

Annexure-IV

Technical Specifications of E.I.

72

Annexure-V

Failure summery of Electronic Interlocking system at Stations of Indian Railways

81

Annexure-VI

Factory Acceptance Test and Site Acceptance Test of Microlok II

85

Annexure-VII

SIMIS S EI system

101

Annexure-VIII

ESA11- IR Electronic Interlocking System Manufactured by AZD Praha

122

Annexure-IX

GE system of Electronic Interlocking

131

Annexure-X

Pre-commissioning Checklist

136

Annexure-XI

Review Questions

144

Drafted By

P. Raju, IMS-2 , S.V.K. Hanuman, IES-5

Checked By

Jyotirmoy Ray, Asst Prof /Sig

Approved By

Ch. Mohan, Sr. Prof / Sig

DTP and Drawings

P.V. Surya Narayana, JE I (D)

No. of pages

145

Date of Issue

November 2009

Version No

A4

© IRISET “ This is the Intellectual property for exclusive use of Indian Railways. No part of this publication may be stored in a retrieval system, transmitted or reproduced in any way, including but not limited to photo copy, photograph, magnetic, optical or other record without the prior agreement and written permission of IRISET, Secunderabad, India”

http://www.iriset.ac.in

INTRODUCTION OF ELECTRONIC INTERLOCKING

CHAPTER 1 : INTRODUCTION 1.1

Introduction of Electronic Interlocking :

The era of interlocking started with mechanical lever frames. As the size of yards & train movements increased, size of lever frames also increased. These lever frames not only increased in size occupying more space but also required intensive maintenance. With the advent of Electro-mechanical relays, these lever frames gave way to relay interlocking based installations. This development resulted in relatively faster operation, fail safety in operation and reduced size of buildings required for housing of interlocking installations. With further increase in traffic and expansion of railway network, large number of Route Relay Interlocking and Interlocking installations were commissioned. Route Relay interlocking (RRI) and Interlocking (PI) installations use Electromechanical relays requiring complex wiring and Inter-connections. The wiring diagrams for such installations run into hundreds of sheets. Individual relays, wiring and interconnections along with thousands of soldered ts are required to be physically examined and certified. This exercise requires traffic blocks of long durations and large manpower to manage the traffic during blocks. Even for small yard re-modeling like addition of a loop line, all the above activities are required to be redone. Therefore, the advantages of relay based interlocking installations are being nullified. With development of modern fault tolerant and fail safety techniques, electronics and particularly microprocessors have found acceptance in the area of railway Signalling world over. Railways in advanced countries of Europe, North America & Australia have gone for large scale introduction of microprocessor based Electronic Interlocking system (EI). This system occupies considerably less space, consumes less power, is more reliable and is easy to install and maintain. Also, initial commissioning & changes due to yard re-modeling can be carried out in negligible time requiring skeleton manpower for traffic management during the blocks. EI is a computer based electronic interlocking system, used for controlling points, signals, level crossing gates etc, through a centralized control or through VDU, like existing relay based/ mechanical interlocking systems. (Microprocessor or Micro controllers are used in EI’s.) . Based on a proposal for development of Electronic Interlocking System, submitted by IIT Delhi to DOE, a project was started at IIT Delhi in July 1983. Two Officers from Railways were posted on this project to IlT, Delhi. Two industries (M/s DCM & CGL) were also associated in development and fabrication of the prototype. A design of the system was evolved in March 1985. The design was evaluated through software simulation at IIT Delhi and a prototype based on this design was fabricated in 1987. RDSO and DOE funded the project for design, development and prototype fabrication tly. The prototype was installed at Brar Square Station of Northern Railway for field evaluation. Based on field trial results, it was decided by Railway Board to manufacture four engineering models incorporating necessary improvements. Railways and DOE funded these tly on 50:50 basis. Thereafter, design and fabrication of SSI Mark-II system was taken up by RDSO in association with lIT, Delhi. Brief history of EI s in Indian Railways is follows. (a) First EI (Microlok I ) is installed at Srirangam (SR) in 1987. (b) First indigenous EI – Installed at Brar Square (NR) – (Parallel operation)-1987-88 (c) First indigenous EI – Installed at Dushkheda (CR) – Stand alone – October, 1995 DCM. (d) Second indigenous EI – Installed at Bhadli (CR) – Stand alone – March, 1997 CGL. (e) Third indigenous EI – Installed at Uppugunduru (SCR) – Stand alone – Warm standby - April, 1998 - RPIL. More than 350 EI have been installed in Indian Railways so far of various makes and 75 more in various stages as on 2009-10.

Page 1

(S18) ELECTRONIC INTERLOCKING

INTRODUCTION

1.2 Advantages of Electronic Interlocking System: (a) System can be tested at factory level using simulation s. (b) Non-Interlocking period is less (Typically few hours instead of few days.) both for initial installation and also for yard alterations (which can be done using application software compiler which is friendly.) (c) Modular in design and easy for maintenance, thus requiring less staff . Expertise of hardware and software is not much needed for maintaining the equipment at initial stage. (d) Requires less number of relays - vital EI replaces interlocking circuits Thus less space required for signal equipment room (Relay rooms). (e) Less power supply as compared with existing PI/ RRI’s. Less failures, less wiring, less soldering, less complexity in the circuit. (f) Enables usage of OFC (with Object Controller) which reduces requirement of Copper cables , their cost & maintenance. (g) Remote operation of signals, points, and level crossings controls is feasible. Thus Compatible with centralized traffic Control. (h) All EI’s are designed and manufactured as per the international safety committees – such as CENELEC STANDARDS (European countries). (i)

Standard of safety and reliability is higher as compared with existing relay interlocking systems (PI/RRI).

(j)

Datalogger / Event logger is an integral part of EI.

(k) Self-diagnostic in feature: i.e. error code/ alarm code messages will be displayed on display cards or on the front of printed circuit boards. Hence easy for rectification of failures and reduces the failure duration.

Policy on type of Interlocking to be adopted : Board has decided the following policy to be adopted on IR vide Board’s letter Nos. 2003/Sig/G/5 dt. 10-09-2003 and 2003/Sig/G/5/Pt. Dated 30th January, 2006 Up to 50 routes

Relay based interlocking of Metal to Carbon or Metal to Metal type according to the expertise available on the railway. (In special cases, EI may also be adopted in installations below 50 routes on a case to case basis. Such proposals for EI at signalling installations below 50 routes have to be justified on a case to case basis based on life cycle cost including capital cost, annual maintenance cost, depreciation provision, saving due to avoidance of repeated relay wiring due to anticipated yard remodeling etc. and concurrence of the associate finance obtained.)

50 to 200 routes

Electronic interlocking.

Above 200 routes

RRI with relay based interlocking of Metal to Carbon or Metal to Metal type according to the expertise available on the railway. ( Note : Bd has directed RDSO to finalise new Specification for EI for above 200 routes also vide Lr No .2008/SIG/SGF/4 /EI /GEN dt 29/07/09)

Note :- The above policy will be applicable to all new works and such of those sanctioned works where detailed estimates are not yet sanctioned.

IRISET

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VARIOUS USED IN E I

1.3 Various used for EI’s:(a) U – Central Processing Unit ( Micro processor or Micro controller) (b) RAM – Random Access Memory (used for vital data processing and event / error logs) (c) EPROM –Erasable Programmable Read Only Memory. (used for storing Executive and Application software) (d) EEPROM – Electrically Erasable Programmable Read Only Memory. (used for storing Executive and Application software) (e) OBJECT CONTROLLERS (OC): (i) Object controller is the equipment which drives the field function through conventional Relay or directly through its own electronic circuitry. It also takes inputs from the field. (ii) Object Controllers drive the field gears (Points, Signal etc.,) through relays and take (input) from various field gears (Track, Point Indication, Aspects etc) through concerned relay s. (iii) Object Controllers are used as slave unit of Main system . (iv) Object controller and Main system can be connected by copper cable or Optical Fiber Cable (OFC) or wireless. (v) By using Object Controllers Main signalling cables between Equipment Room (Relay Room) and Location Box of field functions can be eliminated.

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INTRODUCTION

Different types of Electronic Interlocking Systems currently used in Indian Railways.

Manufacturer

MODEL

RDSO/SPN/ 192/2005 clause No

Hardware Redundancy

Software Diversity

Standby arrangement HotWarm standby standby

US & S

MICROLOK-II

7.1 (a)

NO

YES

NO

YES

SIEMENS

SIMIS S (See Annexure-VII)

-

NO

YES

YES

YES

WESTING HOUSE

WESTRACE

7.1 (a)

NO

YES

YES

YES

AZD-PRAHA

GE ALSTOM KYOSAN

IRISET

ESA 11- IR (See Annexure-VIII)

VHLC (See Annexure-IX) ASCV SMARTLOK

-

2 out of 2

YES

At control level Processor

At command level and I/O cards level processor cold stand by

7.1(b)

YES

YES

NO

YES

-

NO

YES

YES

YES

2 out of 2

NO

KB-5

Page 4

Some of the installations ECoRly, Walter division of Kottavalsa - Vizianagaram Palasa section, Pundi, Naupada, Kotabomalli, Tilaru, etc., SCRly, Mahaboob Nagar (HYB division); WRly, Rajkot Division of Sabli Road, Leelapur Road, Lakhtar, Bala Road, Vani Road, etc., SERly, CKP division, Mahalimarup station.

SC division, BZA-BBQ Section SCRly,-12 Nos

CRly, PA division, KOP-KRD section, SNE, Shirwade, etc., DMRC On BRC Division, Western Railway, 7 Kyosan Systems of have been installed in 2005-2008

CLASSIFICATION OF EI’S

1.4 Classification of EI’s: Depends on redundancy EI’s are classified as : (a) Software Redundant. (b) Hardware Redundant. 1.4.1

Single Hardware with software redundancy. Ex: (i)

MICROLOK -II US&S.

(ii)

WESTRACE – WESTING HOUSE

(iii)

VPI – Vital Processing Interlocking – ALSTOM.

(iv)

ASCV (SMARTLOK) – ALSTOM.

(v)

SIMIS S - SIEMENS EI

With this configuration hot standby or warm standby with auto changeover arrangement is required. 1.4.2 Dual Hardware with Hardware redundancy – 2 out of 2 system. Ex: (i) VHLC – GE Transportation (ii) SICAS S5 – SIEMENS EI (iv) ESA 11 – AZD Praha (vi) ESA 12 – AZD Praha (vii) EBI LOCK 850 – Bombardier Transportation. With this configuration hot standby or warm standby with auto changeover arrangement is required. Software used in both hardware may be identical or diverse. 1.4.3 Triple Modular redundancy - Hardware redundant - 2 out of 3 system Ex: (i)

ALSTOM – SSI

(ii)

SIMIS –W - SIEMENS

(iii)

SICAS – SIEMENS

(iv)

ESTWL90 – ALCATEL

In this TWO out of THREE hardware (identical) system Software used in hardware may be identical or diverse.

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INTRODUCTION

1.5 TYPICAL HARDWARE USED IN EI 1.5.1 Any computer-aided systems require the study of both hardware and software of the system. Study of hardware involves the study of components; printed circuit boards (PCB’s) provided in the computer aided Signalling system. Software (Program) is a set of instructions given to a microprocessor (computer). A brief description of common hardware features for different Electronic Interlocking Systems are discussed as follows. 1.5.2

Common Features of Hardware: (a)

Electronic Interlocking System is a microprocessor based electronic device with fail-safe information processing used in place of conventional relay interlocking systems.

Fig.No.1.1 (a) Input Cards : All the field conditions (i.e. Field relay s) are connected to these input cards of EI system. The maximum inputs capacity of each RI card will depend on design of the RI cards by different manufacturers. The total number of inputs will depend on the yard layout. Total inputs means: (i) Field inputs (ii) inputs

:

ECRs, TPRs, NWKR etc.

:

GNs , UNs, NWNs, RWNs, etc.

(iii) Read back inputs :

HR, DR, WNR, WRR etc

Opto couplers are provided to isolate field optically from the system in Input cards. These cards will read the conditions of inputs and es the information to EI system.

IRISET

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COMMON FEATURES OF HARDWARE

(b) Processor card: This card is also called as central processing unit card of the System. This is provided with microprocessor, RAM, ROM, EPROM, EEPROM Memory IC’s. These EEPROMS or EPROM’s (ROM’s) are programmed with software required for executing the system commands. System software consists of the following: -

Executive software programmed in system EPROM’s

-

Application software programmed in DATA EPROM’s.

Executive Software

Application Software.

This software is common to all EI’s for the This software is specific to each station. same company manufacturing. Different for different stations. Factory installed software

This is as per table of control of specific station

Performs all operations

Can be installed at site by signal engineers.

Cuts off vital supply voltage to output Logic installed through Boolean expressions relays, in case of unsafe failures. or -friendly equations. In all EI installations, DATA EPROM’s are to be replaced with new DATA EPROM’s at the time of yard alteration works. i.e. yard data as per new table of control software is to be programmed in the EPROM’s For doing yard alterations as per the new table of control (interlocking) EI compiler software is used. Some manufacturers are providing EEPROMs, in which program can be erased electrically and reprogrammed with new software as per new changes using a debug port. Function of U Card : This card will execute the commands given by the (station master/ operator). Whenever the operator operates the push buttons, the relevant push buttons will be operated. Processor card will sense the operation of the operation of the operator (through inputs cards) and process according to the program available in EPROMS and finally gives output if the conditions are favorable (i.e., field condition relays are favorable as per principle of interlocking). The output voltage generated by the U card will be connected to Relay output cards. Before sending the output-to-output relays safety checks will be done internally. Output card (Relay Drive Card): This card receives the output of U card as input and picks up relevant output relay as per the operators’ request. The output of this card is terminated on phoenix terminals from there the output relays are connected.

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INTRODUCTION

1.5.3

Basic Principle of Hardware design :

The Basic principle of design is shown in Fig.No.1.2. Input/output cards, and U card with RAM and ROM are inter connected.

Fig No: 1.2 System Bus for information (data) exchange. Input cards gives information of all inputs to system Bus. U card will read the status of inputs and output cards are connected to output relays for operating the circuits (i.e., signal lamp circuit, point operation circuit, CH slot circuit etc). U will execute the commands as per the program stored in the memory chips. During execution of commands it reads the status of all inputs and writes on the RAM. After processing the interlocking logic the output is written in RAM and then according to a fixed program, these are written to the output s of the output cards through which output relays are actuated. 1.5.4

Safety and Reliability of Hardware :

Prime objective of EI design for Railway Signalling shall be, to obtain fail safe features similar to that obtainable in relay interlocking systems which are already existing. Microprocessor based equipment cannot be designed to work on fail safe principle at all times. Therefore, reliability has a much more importance role to play which is achieved by redundancy. Fail-safe EI system can be obtained only when it is made possible to detect any fault in the system instantly on occurrence to apply remedial measures. The output of the system should be cut off whenever the system detects any unsafe condition. So, all the EI’s should have self-diagnostic features so as to achieve fail to safety condition. To ensure safety and reliability there are three approaches to the hardware (redundancy) design of EI’s globally. (a) Single processor system – with extensive safety checks. (b) System with redundancy (two out of two) – failsafe (c) System with redundancy (two out of three) failsafe and failure tolerance.

IRISET

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TESTING AND VALIDATION

1.6

TESTING AND VALIDATION

Testing and validation of a microprocessor based safety system is carried out in four stages as described below: Stage-1 Theoretical design of the hardware and program structure of the software are examined for reliability and fail-safety at the initial design level. Stage-2 Each card or the circuit module of the hardware is tested under normal as well as fault conditions. In the case of software, each routine is tested with diverse test data. Stage-3 Overall system, after integration of hardware and software is tested under different input data conditions. Testing at this stage can be carried out by simulation for accelerated testing using computers. Stage-4 Exhaustive field trials of the equipment is conducted under the field conditions.

1.7

REQUIREMENTS FOR ORDERING OF ELECTRONIC INTERLOCKING SYSTEM

While ordering EI, purchaser is required to furnish the following documents to the supplier: (a) Approved Interlocking Plan (b) Approved / Front Plate Diagram (c) Selection table. After installation at the station, functional testing shall be done by the purchaser as per the Selection table.

1.8 CRITERIA FOR THE SELECTION OF EI SYSTEM The main criterion for the selection of EI System is its reliability, availability, maintainability & safety apart from meeting full functional requirements. The main features are: (a) System should meet functional requirements and have future expandability. (b) Meet the requirements of environmental conditions, electromagnetic interference, etc. (c) System should be friendly and economical (example – object controller for yards). (d) System architecture should be such as to give very high overall availability while ensuring high degree of safety. (e) System validation to international standards to meet safety integrity level 4 (defined in CENELEC Standards). To meet above main requirements, various architectures have been suggested in Para 7.1 of the specification No. RDSO/SPN/192-2005.

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INTRODUCTION

1.8.1 Block diagrams of various available systems is given below: (a)

Single Hardware with software redundancy:

Fig : Single Processor without any Standby

SINGLE PROCESSOR WITH STANDBY (TWO EI’S CONNECTED IN PARALLEL) Fig No :1.3 (b) Dual Hardware with Hardware redundancy – 2 out of 2 system:

DUAL HARDWARE WITHOUT STANDBY Fig No : 1.4

IRISET

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BLOCK DIAGRAM OF VARIOUS AVAILABLE SYSTEMS

DUAL HARDWARE WITH WARM STANDBY Fig No : 1.5

DUAL HARDWARE WITH HOT STANDBY Fig No : 1.6

DUAL HARDWARE WITH OBJECT CONTROLLERS Fig No : 1.7

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INTRODUCTION

c) Triple Modular Redundancy (TMR) - Hardware redundant - 2 out of 3 system:

TMR WITH RELAY INTERFACE Fig No : 1.8

TMR WITH OBJECT CONTROLLERS Fig No : 1.9

IRISET

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VARIOUS DESIGN ASPECTS OF SYSTEM

1.8.2 Various Design aspects of the System to achieve viability & safety: Design of electronic Railway Signalling Equipment based on processor and/or software has to ensure that safety integrity of whole system/sub-system is maintained through out the life of the equipment. Safety integrity is specified as one of 4 discrete levels by IEC/CENELEC Standards. Level-4 has highest level of safety integrity. For Safety Integrity Level - 4, dangerous failure rate per hour for continuous mode of operation should be less than 10-10. Safety integrity of any system covers mainly two components: (a) Systematic failure integrity. (b) Random failure integrity. It is necessary to specify both the Systematic & Random failure integrity requirements of the system if adequate safety is required to be achieved. 1.9 European Committee for Electro technical Standardization (CENELEC) has come up with several Standards, out of which, the following are to be considered for any Electronic component – based Railway Signalling equipment. EN 50121

--- Electromagnetic Compatibility (EMC).

EN 50126

--- Railway applications - The Specification & Demonstration of Reliability, Availability, Maintainability and Safety (RAMS).

EN 50128

--- Railway applications - Software for Railway Control and Protection Systems.

EN 50129

---

Railway applications - Safety Related Electronic Systems for Signalling.

Besides these Standards if Communication Line is used in Railway Signalling as in the case of Block Signalling or Axle Counter, another Standard. EN 50159 --- Signalling and Communications — Safety-related Communication -- is also to be considered. EN50126 for RAMS fail-safe systems like EI, ATP, AFTC are verified and validated to SIL- 4 standard of EN50129 and EN50128.

***

Page 13


MICROLOK - II : EI SYSTEM

CHAPTER 2: MICROLOK - II - EI SYSTEM 2.1

Introduction:

Microlok is a trade name of US&S currently known as Ansaldo STS India Pvt Ltd. Initially Microlok I was introduced in early 1990 s . The current version is Microlok II , which is a multipurpose monitoring and control system for line side interlocking equipment. With this system we can have Direct control of wayside signals, Control and monitoring of Point Machine, Control and monitoring of track circuits Vital communication to other compatible interlocking systems and Cab signalling. The hardware used in Microlok II (MLKII), various aspects of design, installation, testing, commissioning and maintenance of MLKII with the update post commissioning changes in yard is detailed as under :-

2.2

Hardware used in this system: Microlok II equipment consists of : (a) (b) (c) (d) (e) (f) (g) (h)

2.3

Card file. U PCB. Power Supply PCB. Vital Output PCB. Vital Input PCB. Non-Vital-Input / Output PCB. VCOR- Vital Cut Off Relay. Wiring hardware

Software used in this system:

2.3.1 Executive Software: Executive software used in this system does the following functions. (a) Monitoring all Vital and Non-vital cards. (b) Processing inputs, decision making and issuing commands. (c) Continuous internal and external diagnostics. (d) Management of serial data ports. (e) Execution of application software. All Microlok II U boards are shipped with executive software loaded in memory. Upgrade is possible using Maintenance Tool. 2.3.2 Application Software: develops Application Software based on Interlocking requirement and Yard Size.

IRISET

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HARDWARE USED IN THIS SYSTEM

FRONT VIEW OF MICROLOK-II SYSTEM Fig No : 2.1

REAR VIEW OF MICROLOK-II SYSTEM Fig No : 2.2

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2.4

Hardware:

2.4.1 Card File:

Power Supply card

1

2

U card

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Vital Input, Vital Output, Nonvital I/O cards.

CSI card

20

Microlok-II Card file layout Fig No: 2.3 Each card file is like a shelf having 20 Slots to accommodate various PCBs that are used in a system. Slot nos.1 to 15 and 20 are used to accommodate Non-vital Input-output or Vital Input or Vital Output PCBs. Slot no.16&17 are used to accommodate Power supply PCB. Slot no.18&19 are used to accommodate U PCB. In this cardfile a mother board is available in the rear side connecting all the 20 Slots. This cardfile is suitable to mount on a 19” rack. 2.4.2 U PCB Each card file to have one U PCB and always placed in slot no.18&19. In this card Micro Controller used is Motorola 68332 and its speed is 21 MHz. In this card, 4 nos. of flash EPROMs of 8 MB are used to store executive and application software, Two nos. of fast Static RAM (each 64KB) are used to process the vital data and Four nos. of Static RAM (each 64KB) are used to store events and errors. It has Five serial ports to communicate with peripheral devices. Ports 1 & 2 are RS 485 types to interface with vital control system such as MLKII. Port 3 is RS 432 type for other Nonvital control systems such as operators PC. Port 4 is RS 232 type for other Non-vital control systems such as indication / Genesys. Port 5 is used to interface with Maintenance PC provided with maintenance tool software, exclusively for diagnostic purpose. The main functions of U is described as under: It monitors continuously status of Vital Boards. It also monitors system internal operation for faults and responds to detected faults. It processes application logic based on inputs received and deliver outputs to drive external gears. It records system faults and routine events in -accessible memory. It monitors and controls the serial communication ports. It controls power to vital outputs through external VCOR relay.

IRISET

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U PCB

U Board Front Layout Fig No : 2.4

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Various indications/buttons available on front side of the U card is tabled below. U Printed Circuit Board ( Refer Fig : 2.4 )

Fig No:2.2

LABEL

DEVICE

1,2

(None)

4 – Character alpha numeric displays

3

A,B,C,D,E

Yellow LED s

4

1,2,3,4,5,6,7,8

Red LED s

5

ON LINE

Green LED s

When lit , indicates normal system operation (successful diagnostics)

6

VPP ON

Yellow LED

When Lit , indicates FLASH + 5 V or +12 V programming voltage enabled (via board jumper)

7

RESET

Red LED

8

RESET

Momentary Push Button

When Pressed , RESETs the U. Also used to replace the U in the RESET mode.

9

MENU

3 – Position (Return to Centre) toggle switch

Used to search main program menu items shown on displays.

3 – Position (Return to centre ) toggle switch .

Used to select main program menu items shown on displays.


Used to cycle through configuration values to be selected with ACTION switch.


Executes or Cancels configuration value selected with ADJUST switch.

L-R 10

MENU UP- DOWN

11

ADJUST UP-DOWN

12

IRISET

ACTION ACCEPTREJECT

Page 18

PURPOSE

On site Configuration programming menus and options Reserved for serial link status - defined in application software

When Lit , Indicates that the system is in RESET mode.

POWER SUPPLY PCB

2.4.3

Power Supply PCB:

Each card file to have one Power Supply PCB and always placed in slot no.16&17. Power supply PCB is basically a DC-DC converter that converts 12V DC input supply is +12V, -12V and +5V required for various board functioning. Based on diagnostic check by U, Power Supply Card receives 250Hz signal from U and extends supply to VCOR relay. This card provides isolated supply to internal circuit. System Operating Power Power Input to System Cardfile Voltage Range

Nominal Voltage

9.5 to 16.5 12V dc VDC

Min. Sys. Maximum Start-Up Ripple

Current Draw

11.5V dc

Determined by Installation (No. of signal lamps, cab carrier frequency, etc.)

0.5V P-P

Cardfile Power Supply Printed Circuit Board Outputs* For System Cardfile PCB 5V Internal Circuits

For System Cardfile PCB 12V Internal Circuits

To VCOR Relay

+5V @ 3A

+12V @1A, -12V @ 1A

+12V into 400 Ω Coil

* Not used to power vital or non-vital external devices or circuits

The table below is a list of the worst-case current draws for Microlok-II system boards:

BOARD

CONDITION

+ 5V

+ 12 V

- 12 V

IN16 N17061001

16 LEDs

170 ma

-

276ma

OUT16 N17060501

16 LEDs

155 ma

6 ma

-

IN8.OUT8 N17061601

16 LEDs

150 ma

4 ma

147ma

U N17061301

No serial links ON 840 ma

4 ma

12 ma

U N17061301

Serial link ON

1000 ma

4 ma

12 ma

NV.IN32.OUT.32 N17000601

64 LEDs ON

576 ma

-

-

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POWER SUPPLY CARD Fig No : 2.5

IRISET

OUTPUT CARD Fig No : 2.6

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VITAL OUTPUT PCB

2.4.4 Vital Output PCB: Each Vital Output PCB has 16 Outputs. It is available in 12V and 24V DC applications. Each Vital Output can drive an output device such as any Q-series relay. This output relay in turn controls signals, points, crank handle, siding control, level crossing etc. Since Vital Output drives the relay, which controls important outdoor gears, all the Vital Output boards are continuously diagnosed by a U. Any abnormality in any of the outputs will shut down the system to ensure safety. The status of vital output is known from LEDs available in front of the PCB. Vital Output PCB

VCOR Relay

Standard Vital Output card (24V)

B 24

Output “X”

Controlled External Relay

Poly switch Protected Output “”

N24 Analog Ground

U Control Standard Vital Output Fig No : 2.7

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2.4.5 Vital Input PCB: Each Vital Input PCB has 16 Inputs. It is available in 12V and 24V DC applications. Each Vital Input is assigned to read the status of outdoor gears such as Track circuits, Point detectors, Crank handles, Siding controls, level crossing etc. Since the Vital Inputs read the status of outdoor gears, they are normally configured with double cutting arrangement using relay s. The status of Vital Input is known from LED indications available in front of the PCB.

INPUT CARD Fig No : 2.8

IRISET

Non-Vital Input-Output Card Fig No : 2.9

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NON-VITAL INPUT/OUTPUT PCB

2.4.6 Non-Vital Input/output PCB: Each Non-vital I/O has 32 inputs and 32 outputs in one PCB. It is available in 12V and 24V DC applications. Non-vital inputs are push buttons and keys. Non-vital outputs are indication LEDs, counters and buzzers. The status of Non-vital Input/output is known from LED indications available in front of the card. 2.4.7

Vital Cut off Relay- VCOR:

Each card file will have one VCOR to ensure the healthiness of the system. VCOR has 6 F/B dependent s each rated for 3 Amps. When system is healthy the coil receives voltage from PS PCB, which in turn controlled by U. Power to Vital output board is controlled by VCOR, thus ensuring safety.

Vital Cut-Off Relay (VCOR) Fig No : 2.10 2.4.8 Lightning & Surge protection arrangements in MicrolokII •

The interfacing of CCIP with I/O gatherer cardfile is on PIJF cable. GD tubes have been provided at T1 rack for protection of Non-vital Input /output boards against surge, transient / lightning. GD tubes (EPCOS EC90) have been connected at non-vital input from and non-vital output to and grounded with system equipotential earth.

•

Microlok Non Vital Output Filter is a surge protective device which protects the non vital output board from electrical surges caused by lightning or power faults in Microlok system.

•

An augmented surge protection arrangement (external protection box) introduces surge suppression for the Non Vital Board output lines safeguard the system against lightning surges & other switching surges:

Page 23



•

Every Non Vital Board output line is provided with 30V Tranzorb (1.5KE30A) and MOV (V36ZA80). The Tranzorb is connected to the +24V DC signal line & MOV is connected to the 24V DC Common line.

•

Every Non Vital Board output line is provided with GD Tube (CG2 145L) and MOV (V36ZA80). GD Tube is grounded to the earth & MOV connected to the 24V DC Common line. The RS-5 Resistor is provided in each of the output lines which is capable of withstanding 5 joules energy.

•

The external protection box also provides protection to the 24V common line for every Non Vital board. Every 24V common line is provided with 30V Tranzorb (1.5KE30A) and MOV (V36ZA80). The Tranzorb connected to the +24V DC signal line & MOV connected to the 24V DC Common line. The RS-5 Resistor is provided in each of the output lines which is capable of withstanding 5 joules energy.

(* Extract of RDSO Guidelines vide L.No.STG/IH/ML dt.10.07.09) Consequent to damage of Microlock-II EI due to lightning at a few stations on ECoR, implementation of an earthing improvement scheme comprising of following three stages was decided. Zonal Railways and the firm were accordingly advised vide this office letter of even no. dated 14.03.2008. Stage 01 -

Shielded cable between Termination Rack and Control is to be properly grounded at the Termination side. Microlock-II Racks which are having epoxy coating will be provided with copper foil. Separate DC 24V supply to be used for Microlock-II cooling fan. Ensuring proper copper connection of Room Earth Bar and Earth points Ensuring earth resistance value <1 ohm.

Stage 02 -

the serial port of one Microlock-II to another Microlock-II will be isolated (using optoisolators) if the stations is located in high hazard lightning area (having more than 50 Average thunder Storm days per year)

Stage 03 -

IRISET

Provision of augmented surge protection arrangement for the non-vital output board lines in case the operating room (SM’s room) and the equipment room (EI room) are located in two different buildings.)

Page 24

WIRING HARDWARE

2.5

Wiring Hardware:

48 Pin Address select PCB and Connector assembly is provided for Vital Input and Vital Output cards. 96 Pin Address select PCB and Connector assembly is provided for Non-Vital I/O cards. 48 Pin Connector Assembly is provided for PS and U PCB. EEPROM PCB which is provided on rear side of the U connector to configure various serial communication ports. Keying plugs are provided in the cardfile to ensure coding to each type of cards.

PCB Wiring Connector Mounting and Address Select PCB Fig No : 2.11

Page 25



2.6

Address Select PCB

It is used to address particular slot of the card file. Each address select PCB consists of 6 nos. of Jumpers. These jumper settings are unique and shall match with the definition of cards in application program. 48 Pin address select PCB is used for Vital Input and Output boards. 96 Pin address select PCB is used for Non-vital I/O boards. PCB Jumper selection Table is given below : Board Order

2.7

Non – Lamp Board Jumpers 1

2

3

4

5

6

1

0

0

0

0

0

1

2

0

1

0

0

0

1

3

0

0

1

0

0

1

4

0

1

1

0

0

1

5

0

0

0

1

0

1

6

0

1

0

1

0

1

7

0

0

1

1

0

1

8

0

1

1

1

0

1

9

0

0

0

0

1

1

10

0

1

0

0

1

1

11

0

0

1

0

1

1

12

0

1

1

0

1

1

13

0

0

0

1

1

1

14

0

1

0

1

1

1

15

0

0

1

1

1

1

16

0

1

1

1

1

1

Connector Assembly

Each connector assembly consists of connector receptacle (i.e. cover), guide pair to fix the connector on the cardfile & crimp s. Connector Assemblies are used to connect MLKII cards with Relays, relay s and with help of pre-wired cables. The 48 Pin Connector assembly is used for Vital Input and Output boards. The 96 Pin connector assembly is used for Non-vital I/O boards.

IRISET

Page 26

KEYING PLUG

2.8

EEPROM PCB

The EEPROM PCB is placed on the 48 Pin connector assembly of the U PCB. The purpose of EEPROM PCB is to store Site-specific configuration data.

2.9

Keying Plug

The purpose of the keying plug is to avoid insertion of wrong type of board in card file slot. Each slot requires of 6 Nos. of keying plug and to be inserted according to type of the board. In principal keying Plug is similar to the index pin of the relays.

CARDFILE SLOT KEYING PLUG INSTALLATION Fig No : 2.12 Card File Mother Board Keying Plug Locations : Printed Circuit board U Power Supply (with out ) Standard Vital O/P (24 v) Vital I/P (24v ) Code System interface Non- Vital I/O ( N17000601 ) Non-Vital I/O (N17061501)

3

4

Keying Plug Location 5 6 7 8 9 10 √ √ √ √ √ √

1 √ √

2 √ √

√

√

√

√ √

√ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Page 27

12 √

√ √ √

√

11

√

√ √

√ √



2.10

Design :

Microlok II Design consists of : (a) Interface Design: Wiring diagram of relays, s, CT racks, Power supply, Microlok II card file etc. (Mainly external to MLKII). (b) Application Program Design: Complete Interlocking program, further converted in conventional circuit, which is easy to understand.

2.11

Inputs for Design

To start design of MLK II based Interlocking system, Inputs required are: (a) Approved Signal Interlocking Plan. (b) Approved Front Plate Drawing. (c) Power supply scheme. (d) Relay room building layouts. (e) CT rack termination details. (f) Details of any additional interlocking equipment to be interfaced with MLKII.

2.12

Process of Interface Design (a) Vital and Non-vital I/O bit calculation. (b) Vital and Non-vital board calculation. (c) System configuration and serial communication. (d) Power calculation. (e) Interconnection of various racks and interlocking equipment. (f) Manuscript of complete wiring diagram.

2.12.1 Calculation of I/O Bits Gather following information from Interlocking plan: (a) Type of signals, direct/indirect feed. (b) Points/Cross over and type of control/operation. (c) Motor points/Hand operated points. (d) Level crossings, siding control and crank handles. (e) Track circuits. (f) Axle counters. (g) Type of block working with adjacent stations. Gather following information from Front Plate Drawing: (a) Number of push button controls and key controls. (b) Number of indications, counters, buzzers, bells etc. The Information gathered from “Signal Interlocking Plan” and “Front plate Drawing “ is used to calculate Vital I/O and Non-Vital I/O respectively.

IRISET

Page 28

DESIGN

Example of I/O Bits Outdoor Gear 3A Signal (HOME)

3A Signal

Vital Output

Vital Input

Non-vital Input

Non-Vital Output

Relays

DR HR Co HR UHR

DECR HECR RECR Co HECR UECR

GN

DGKE HGKE RGKE UGKE AJKE COKE

ECR- 5

DR

DECR HECR RECR

GN

DGKE HGKE RGKE AJKE

ECR- 3

HECR

GN

HGKE RGKE AJKE

ECR- 2

HR

2A Signal

HR

RECR

WNR

NWKE RWKE WLKE ACKE ACKRE ANKE ANKRE BCKE BCKRE BNKE BNKRE

QN1-4

QN1-2

QN1- 1

QN1-2

WRR

NWKR RWKR

WN

Track Circuit

-

TPR

-

TKE TKRE

Crank Handle

CHYR

CHLR

CHN CHR

CHKE CHKRE

QN1-2

Siding Control

KLR

KLCR

KLN KLR

KLKE KLKRE

QN1-2

LXYR

LXCR

LXN LXR

LXKE LXKRE

QN1-1 QNA1-1

-

LR TOLR

Points

Level Crossing Block Inst.

QNA1-2

QNA1-1

2.12.2 Calculation of Board & Relays After finding out final quantity of Vital and Non-vital I/O bits, quantity of various boards is derived as below: (a) 16 Vital Inputs per one Vital Input Card. (b) 16 Vital Outputs per one Vital Output Card. (c) 32 Non-vital Inputs and 32 Non-vital Outputs per one Non-Vital card.

Page 29



(d) 8 Vital Inputs and 8 Vital Outputs per one Mixed Vital I/O Card. (e) Calculate various relays on the basis of above table and decide ,the size and design of relay rack. (f) Per Card file, allocate 16 cards either Vital or Non-Vital. 2.12.3 Estimation of MLK II Hardware (a) 48 pin Connector Assembly: Sum of Vital I/O Boards, U and Power Supply PCB. (b) 48 Pin Address select PCB: Sum of Vital I/O Boards. (c) 96 Pin Connector Assembly: Sum of Non-vital Boards. (d) 96 Pin Address select PCB: Sum of Non-vital Boards. (e) Each cardfile will have one U, one PS PCB and one VCOR. (f) Each U will have one EEPROM PCB.

2.13

Configuration of MLK II

Place maximum of 16 nos. of either vital or Non-vital cards per Cardfile. Arrive at final quantity of card files. On the basis of requirement of installation/site, MLK II is connected with the peripheral equipments such as VDUs and another MLKII units. All the peripherals are connected with MLK II with serial communication cable. Inputs and Outputs from / to control are connected through multi core cables.

Configuration of MLK II CONTROL CONTROL

OP. VDU

To Adjacent Station

To Adjacent Station P1

P1

MLK-II MLK II UNIT-A -A P5

P4

OP VDU Link NV

MLK-II -B UNIT-B

P4

P3

P3 P5 Maint . VDU Link NV Diagnostic Link

MAINT. VDU

DOUBLE DECK TERMINALS (PHOENIX TERMINALS)

RELAY RACK

CABLE TERMINATION RACK

MLK II UNIT

Fig. No: 2.13

IRISET

Page 30

CONFIGURING MLK II

2.14

Configuring MLK II : (a) Operator VDU and Maintenance VDU are connected to MLK II- U through “NonTwisted pair-communication” cable. (b) Communication between A and B MLK II are wired with Twisted Pair-communication cable. (c) Control Inputs and Outputs are connected to MLK II with help of “Single strand Multi core” cable. (d) Relay rack and CT racks are connected to MLK II with “Single Strand Multi core “ cable. (e) Vital Input and Vital Outputs are wired with help of “Twisted Pair” wires. (f) Relay wiring is done with the help of “Multi strand, Single core” wire.

2.15

Design of Relay Room Floor Plan

Once calculation of boards, relays and MLK II configuration is finalized Design of Relay Room Floor Plan is taken up with following criterion: MLK II Rack: Relay Rack: Termination Rack:

2.16

Size: Capacity: Size: Capacity: Size: Capacity:

2100mm X 800mm X 600 mm 2 Card files 2100mm X 1120mm X 300 mm 96 Relays 2100mm X 700mm X 300 mm 12 Non-vital boards

Interface Design

All the required details now available to design interface drawings. Interface Drawings consists of: (a) Index. (b) Signalling Layout Plan-Replica of Signal Interlocking Plan. (c) Front Plate drawing. (d) Route control chart. (e) Relay Room Floor Plan. (f) Configuration drawing. (g) Serial Ports wiring details. (h) Address select PCB, Jumper settings and keying plug details. (i) U&PS PCB wiring detail. (j) I/O Bit Charts. (k) Non-Vital & Vital board wiring. (l) All field gear driving circuit. (m) Power supply distribution drawing. (n) Fuse chart. (o) Rack assembly drawings. (p) Interconnection details. (q) analysis.

Page 31



2.17

Application Program Design

Application Program is nothing but another form of Interlocking Circuit. The design is based on Signal Interlocking Plan, Route Control Chart & Front Plate Drawing. Application Program is written in form of equations called Boolean equations. All the relays used in conventional circuits are called as BIT when referred to Application Program. Program is divided in various parts : (a) Local I/O bit definition section. (b) Boolean bit definition section. (c) Serial bit definition section. (d) Timer Section. (e) Log bit definition section. (f) Logic section.

2.18

Conventional PI Logic

GNR, UNR

GN,UN

Pressed

GNCR, UNCR

UP

WKRs

UP

NRR

Down

UCR

ALSR

UP

Down

UP WLR

NNR

WNR, WRR

Down

UP HR

Down

Up

TPRs

UP

RECR

RGKE

Down

Down

HECR

HGKE

UP

UP Fig No : 2.14

IRISET

Page 32

CONCEPT OF MLK II APPLICATION LOGIC

2.19

Concept of MLKII Application Logic:

Fig No : 2.15

Page 33



2.20

Non-vital Section:

It consists button relay logics and indication logics. The relays such as GNR, UNR and indications such as RGKE, HGKE, WLKE etc. are defined in Non-vital I/O board definition section. Rest of the relays GNCR, UNCR are defined in NV Boolean bit definition section. These logics are written as “NV ASSIGN “ statement.

2.21

Vital Section

It consists complete interlocking logic except button relay and indication logics. The names of Vital relays such as HR, DR, RECR, HECR, TPR etc. are defined in Vital I/O board definition section and rest of the relays such as ASR, UCR, TLSR etc. are defined in Vital Boolean bit definition section. These logics are written as “ASSIGN” statement.

2.22

Timer Section

“Slow to Pick “or “Slow to Release” time delay for any function are defined in this section. The definition works as Condenser-Resistor combination generally used in conventional installation. “Slow to Pick” is defined as “SET=1 SEC”. “Slow to Release” is as “CLEAR=1 SEC”.

2.23

Serial Section

This section is required to communicate the STATUS of any bit to other compatible system like VDU, MLKII etc. Output BIT from one system becomes Input BIT to other system and vice a versa. Output BIT and Input Bit definition sections are different. The order of BIT definition shall be same in both systems.

2.24

Symbols Used in Application Program * SERIES + PARALLEL ( START OF PARALLEL PATH ) END OF PARALLEL PATH ~ BACK , BIT SEPARATION ; END OF STATEMENT/ SECTION // SINGLE LINE COMMENTS % MULTI LINE COMMENTS - - - - - - - - - - - - - TYPE 1 \ /* MULTI LINE COMMENTS - - - - - - - - - - - - - TYPE 1 */

2.25

Conversion of Circuit to Equation A

B

C

D

E .

ASSIGN

IRISET

A * B * (~C* D+E)

Page 34

To

XYZ ;

XYZ

CONVERSION OF CIRCUITS TO EQUATIONS

Examples:Typical examples are given below :

Fig No : 2.16

Fig No : 2.17

Page 35



2.26

Compilation of Application Program

Program shall be stored as “PROGRAM.ML2” file name. Compilation is carried out with help of Microlok II Compiler. Result of compilation will be two files viz. ‘PROGRAM.MLL” & “PROGRAM.MLP”. “MLL” file is a listing file, which gives any errors, warnings, no. of BITs used, no. of time one bit used and so many other important information. This also gives unique identification numbers called as “CHECKSUM” & “CRC”. “MLP” file is a data file, which is loaded in memory of U of MLK II using MLK II Maintenance tool.

2.27

Concept of Hot Standby

Any Signal Interlocking System needs to be uninterrupted as it deals with safety. Train detentions shall be minimal. MLK II being an Electronic System, it is mandatory to duplicate entire system. All the Vital and Non-vital boards, U, Power Supply PCB, VCOR are in duplicate. Duplicated MLKII systems are identified as “SYSTEM-A” and “SYSTEM-B”. When one system fails due to any reason, it is ensured the other system is available to take care of Station Interlocking.

2.28

Evolvement of Hot Standby Logic

Both systems shall work all the time. Inputs are read by both the systems independently and compared continuously. Processing application logic simultaneously and comparison at various stages. Parallel delivery of Output by both the systems after comparison. Any mismatch in the STATUS of bits between the system will KILL the system ensuring other unaffected. 2.28.1 Design Concept: a)

Vital Output:

Vital output will be delivered only when status of the BIT is same in the both the systems. Both the systems’ outputs are connected in parallel to one interface relay through a DIODE to avoid back feeding. Once output is delivered, any change is STATUS of other system will not affect status of delivered bit. In case of MISMATCH no outputs will be delivered by either system. MISMATCH indication will appear on Control and VDU. b)

Vital Input:

System-A read Input as HIGH and that in B as LOW. Input LOW is most restrictive state, it is considered to be valid. MISMATCH is generated in the system which has Input in HIGH state and System-A will be KILLED. c)

Non-vital Output:

Outputs are not compared before delivery as it is difficult to compare status of Flashing Output. Output is delivered only by one system. When system which is delivering Non-vital Outputs is KILLED, the control will be shifted to other system. Interruption of visual indications on control for few seconds. d)

Non-vital Input:

The inputs are compared for its STATUS in both systems. Mismatch will be generated in as system that has not read Input and it will be KILLED. Concept of Vital Output, Vital Input and Non-vital Output is same as above. Nonvital Input is ANDed with its corresponding bit from other system. Further process is negated in the system, which has not read the Input, MISMATCH is generated and system will be KILLED. When one system is KILLED, it needs human intervention to restore back ONLINE. System need to be RESET manually. When RESET, it will not update itself from already ONLINE system.

IRISET

Page 36

CONCEPT OF HOT STANDBY

2.28.2 Disadvantages: Momentary button inputs cause Disabling/Shutting down of one system or some time both the systems. Remedy: Intermediate bits are compared to generate MISMATCH. This intermediate bit is nothing but next level steady bit(which has its own holding path). Incase of MISMATCH indication will appear on control and VDU and further process in the both the systems will be negated. Killing incidences are then reduced and system is made STABLE. In stations both the systems are working on actual Hot Standby logic is most satisfactorily and stable.

2.29

Warm Standby Logic:

Hot Standby Logic working in some stations, though having stable design, due to climatic instability / lightening caused failure of cards and both the systems were shut down which has interrupted train movements. In these stations warm standby logic is introduced i.e. external change over circuit is developed to switch on second system, when first has failed due to some reasons. Both the systems’ cards are kept inserted in slots and in ready condition to switch ON when intended. MLKII power supply is controlled by “External Changes Over” circuits, which proves back of VCOR relays. Only one system is ONLINE and other is power OFF. This is a Worm Standby Logic and working satisfactorily in stations. The main advantage of this warm standby logic is to maintain only one Application Program and its testing is easy and time saving. The disadvantage is the system which is Powered OFF, integrity of the cards and whole system cannot be ascertained unless Powered ON next time. Traffic interruption for 3 to 5 Minutes.

Page 37



2.30

Maintenance:

MLK II based Interlocking System is provided with Windows based Maintenance Tool package. Maintenance tool is loaded in Maintenance VDU Using the tools provided in this Maintenance tool program, maintenance personnel and application engineers can perform a wide variety of Microlok II system maintenance, configuration, and diagnostics functions. The program provides these tools as selections on the Microlok II Maintenance Tools main menu, as shown in Figure below.

This main menu displays the selection buttons that activate the primary functions of the program. These selection buttons are grouped into four main categories. (a) (b) (c) (d)

IRISET

Run-time Monitor Historical Data System Adjustment/Setup Other Tools

Page 38

MAINTENANCE

2.30.1 RUN-TIME MONITOR These buttons lead to display data about an operating MICROLOK II and its application. This group of tools enables you to view the current status of equipment and related systems. (a) System Information: It views system events and appears as shown below.

This display shows the current version number of the executive software and an abbreviated "snap-shot" of the most recent system events. Where appropriate, the display defines the action taken in response to an event. The system information display lists the time and date when the following types of events last occurred: (i) System resets (ii) System errors (iii) Unit configuration (iv) Clearing of the system log clear (v) Clearing of the data log clear (vi) Time changes (vii) Clearing of conditional power supply (S) trips Since some of these events occur infrequently, the displayed date also includes the year in which the associated event occurred. (b) Board Information: It displays the status information about Input – Output interface cards (Printed Circuited Boards) of a Microlok II or Serial link. It displays the current status of each enabled PCB in the Microlok II cardfile. Each board type is dynamically updated. (c) Free-run Variable Display and Dynamic Bit/Variable Display: These two tools enable you to view the real-time status of Microlok II system variables. These tools list the current values for selected variables and bits as well as a real-time list of changes. These two displays provide the same information in different ways. The free-run display presents the status information in a text mode, while the dynamic bit/variable display represents the indications graphically in strip-chart view of bit and variable changes.

Page 39



2.30.2 HISTORICAL DATA: These buttons lead to views which display data which an operating Microlok II has collected and stored. The Microlok II system logs and reports information of critical errors, warnings, and operational events. This section contains four tools that enable you to review the logged system information in several ways. (a) Data Log: The data log records only those events that the specifies. It displays changes of selected bit and numeric variables as requested by the application or configuration. This log is capable of recording up to 90,000 of the most recent specified Boolean changes, or at least 64,000 Boolean and/or numeric changes. (b) System Event Log: The system event log records up to 5000 of the most recent critical errors, warnings, and events. Any system critical error or warning will be logged in the system log. Events are used to relay miscellaneous system information and may be limited by use of the configuration. (c) System Error Log: The system error log is limited to critical errors. Since the older events may be lost in system event logger, the system error log contains a list of the last 50 time stamped critical system errors. (d) Merged Events Log: The merged events log enables you view errors, warnings, and events as in the Data, System Event, System Error log and Dynamic variable changes merged onto the same time axis. This log also provides graphic displays of parameters and events as specified in the data log. 2.30.3

SYSTEM ADJUSTMENT / SETUP

These buttons lead to views which modify parameters of the Microlok II. (a) Set Time of Day Clock: This function displays the date and time settings for both the Microlok II system U and the laptop computer and sets the Microlok II on-board clock. (b) Software : This tool is used for ing a custom-designed application software program from the laptop PC to the Microlok II U. This tool interacts with Windows-based files; therefore, you should be familiar with application software and Windows file navigation to use this feature. (c)

Reset Microlok II:

This tool enables you to reset the Microlok II U from the laptop computer. The reset function is used mainly to clear system faults and return the system to normal operation.

IRISET

Page 40

OTHER TOOLS

(d) System Configuration: The configuration tool provides a wide variety of options for checking and modifying the configuration of the Microlok II system hardware and software. Three types of options are provided within this tool: (i) System configuration options enable you to modify the general system parameters and the parameters, and to assign specific parameters to the data log. (ii) Board configuration options enable you to enable/disable and configure the individual Microlok II system PCBs (Printed Circuit Boards). (iii) Link configuration options enable you to configure the Microlok II system communication links. 2.30.4

OTHER TOOLS:

These buttons lead to views which allow special diagnostic functions to be performed. (a) System Memory Dump: Allows Ansaldo STS personnel to provide specialized debugging assistance. The system memory dump tool enables Ansaldo STS system developers and maintainers to perform debugging operations when a customer encounters a software problem. (b) Program Settings: The Program Settings dialog is used to modify the way in which the system stores and displays data. These options can also change the general appearance of the screens. (c) Serial Message Monitor: This tool enables you to monitor serial message traffic on a selected active serial link. (d) Save Comma Delimited : This tool lets the the data a comma-delimited format. This file can be viewed in Microsoft Excel. The file can be saved via the diagnostic port link, or directly from the PCMCIA card in the card reader on the individual PC. (e) Application : This tool lets the the application image from the EEPROM on the Microlok II unit. As a default, the file is stored with a filename.mlp extension so it can be easily ed to the system, if necessary. It is for to present working application program.

2.31

Microlok II as a Distributed Interlocking System : (Working in Kottavalsa - Vizianagaram Palasa section of ECo Rly ) (a) Object Controllers (OCs) are used as slave unit of Central Interlocking Unit (CIU) through duplicated serial communication.

Page 41



(b) As on date, Object Controllers drive the field gears (Points, Signal etc.,) through relays and take (input) from various field gears (Track, Point Indication, Aspects etc) through concerned relay s. (c) The medium of communication between CIU and OC shall be Optical Fiber Cable (OFC) provided on a ring basis. (d) Any error in any OC or hardware fault leading to unsafe condition shall immediately withdraw all output commands. (e) In place of Control cum Indication , two number of VDU with LCD monitor of 22’ (One working & one standby) are provided. VDU have the auto change over facility as well as manual change over facility. (f) OC and CIU have been interfaced by OFC with ring by providing Optical modem (OSD-1250). (g) Although system has inbuilt Data logger system, the system has been provided with external data logger for networking purpose with other station. (h) All vital outputs are drive to field through relay only. (i) Here OC and CIU are represented by each Microlok II. (j)

Communication equipment used : (i) 422 CFCR Used as interface between Microlok and Redundant modem(OSD1250LC) (ii) OSD 1250LC -

Redundant optical modem ( 2ch-OFC) Communication between Microlok-II to Microlok-II

(iii) 485 LDRC -

RS232 to RS485/422 converter cum Isolator. Used between Microlok to Operator’s PC / Maintenance PC.

(iv) OSD 136L -

2.32

Advantages of Distributed Interlocking System : (a)

2.33

Optical modem without ring protection. Used for communication between Microlok-II to Datalogger.

As Main Signalling Cable is totally eliminated, -

Main Cable Maintenance and testing is Reduced.

-

Main Cable failures are prevented.

-

Damage of equipment due to short circuit of main cables is prevented.

-

Damage of main equipments under short circuit condition of traction supply (OHE catenary wire broken and fallen on the rails) is minimised.

-

Expenditure has been reduced considerably.

(b)

Deg and modification has become more easier.

(c)

Simulation can be more simplified.

General Maintenance of MLK II:

System must be protected from the dust. Wires should be properly inserted of wires in terminals. All the terminals should have tightness. Battery shall be maintained properly. data log shall be ed regularly.

IRISET

Page 42

DO’S & DON’T’S

2.34

DOs & DON’Ts of MICROLOK II System:

√ DOs - Keep the Microlok II room free from dust. - Finger Tighten the boards after insertion. - Ensure all terminations are fully tightened. - Place the removed boards with a tag into a conductive shielding bag. - Maintain Minimum 13.5 V to 16.5 V DC at the power supply board terminals. - Maintain 24V to 28V DC at the Microlok II Input /Output power Modules. - Check Microlok II system fuses at regular intervals. - Take back up of Data Log / Event Log / Error Log data files weekly. - Ensure synchronization of Microlok II clock time with Maintenance PC after the System changes over. - After completion of diagnostics, Reset that system and enable S in up mode (Ref: ”S CLEAR FUNCTION” details). - During Maintenance changeover of one system to other system, SGE block Instrument must be kept in TOL Condition. -

Use Vacuum for the externally accumulated dust and dirt.

X DO NOT

-

Don’t attempt Troubleshooting if you do not have proper Microlok II training.

-

Don’t switch ON Radio Equipment within the vicinity of Microlok II.

-

Don’t use non-conductive materials such as Styrofoam cups, Plastic ashtrays and Cell phone wrappers in the vicinity of Microlok II.

-

Don’t reset the system using Maintenance Tool/U front Reset push button when working.

-

Don’t remove boards, VCOR relays, fuses / Links and 48/96 pin

-

Connectors when the system is ON.

-

Don’t force boards into the Slots during insertion.

-

Don’t change jumper settings in U board & Address select PCBs.

-

Don’t touch the board components.

-

Don’t repair boards on your own.

-

Don’t alter Microlok II system, Maintenance PC & Operator PC settings without authorization.

-

Don’t delete/Modify Application logic programs without authorization.

-

Don’t apply blower for cleaning dust.

-

Don’t use any kind of Solvents, Detergents or Abrasive cleaners on the Card file or internal components.

-

Don’t use vacuum cleaner inside the Card file. ***

Page 43



2.35 Cost Saving for a 4-road Station with Distributed Interlocking over Centralised Interlocking: In case of Distributed Interlocking system Object Controllers and Optical Fiber Cable are used in place of Main Signalling Copper Cable between Relay/Equipment Room and Location Boxes/ Goomties. (a)

All the items with Centralised EI are same with Distributed EI except:

(b)

-

Copper cable from Central Interlocking Unit to Goomties is replaced by OFC by ring path.

-

Modems are required for interfacing.

-

At both end Object Controllers, U and Power supply cards are required. (All other cards are remain same)

In case of Centralised EI, Cost of Copper cable from Central Interlocking Unit to Goomties: Sl. No

Cable Size

Length in KM.

Cable Cost per KM in Rs. Lakhs

Total Cost in Rs. Lakhs

1

30 Core

1.4

2.59

3.62

2

24 Core

5.6

2.16

12.09

3

18 Core

9.8

1.88

18.42

4

12 Core

5.6

1.19

6.66

Grand Total

40.80

Cable Trench size = 1400m X 0.3m X 1.2m Workmanship cost for trenching, cable laying, termination of cable at both ends, location boxes, freight, transport, storage space, cut and theft of cable and maintenance cost all tighter the total cost shall be approximately Rs. 10 Lakhs. Total cost = Rs 40.80 Lakhs + Rs 10 Lakhs (c)

=

Rs 50.80 Lakhs

In case of Distributed EI, Cost of OFC cable, modem and other cards: -

Cost of OFC 3 Km

= 3 X 0.4 Lakhs

= Rs 1.2 Lakhs

-

Laying of OFC 3 Km

= 3 X 0.5 Lakhs

= Rs 1.5 Lakhs

(Inclusive of HDPE pipe in ring path also) -

Optical modem 6 nos.

= 6 X 0.4 Lakhs

= Rs 2.4 Lakhs

-

Other cards at OCs

= 2 X 1 Lakhs

= Rs 2 Lakhs

Total cost

= 7.1 Lakhs only

Thus, there is a net saving of Rs 50.80 Lakhs – Rs 7.1 Lakhs = Rs 43.7 Lakhs per station. ***

(Disclaimer : Cost shown in this notes is for general information only and may vary . Readers have to from relevant sources for accurate information.)

IRISET

Page 44

TESTING

2.36 Testing: Testing of Microlok II electronic interlocking system is carried out in two phases. 1. System testing at factory premises called as Factory Acceptance Test. 2. System testing at site called as Site Acceptance Test. 2.36.1 Factory Acceptance Test •

Factory Acceptance Test (FAT) for Microlok-II EI system shall be tested in Factory environment with simulation setup to validate application software.

•

The purpose of Factory Acceptance Test is to: o

Ensure that the Microlok II Interlocking system fulfils the station Interlocking & Rout Control Chart requirements and working in safe manner even if any false inputs / information received.

o

Minimises the site errors & risks and reduces the corrections at site. This results in saving of time at site testing.

•

FAT is carried out through simulation set up (using Simulator with toggle switches or Simulator PC with Microlok Interlocking Simulation Setup - MISS software) in which all field inputs are simulated.

•

FAT is carried out for each station interlocking separately.

•

After deg the Application Software, designer issues it to the validation department for carrying the Factory Acceptance Test.

•

It is carried out only through VDU , whereas Site Acceptance Test (SAT) is carried out through CCIP and VDU s, if both the options are available at site.

•

Application logic is modified for the FAT testing for Timer values used for signal, point, overlap and cancellation are reduced from 120 secs to12 secs to speed up the testing. It is essential that the original times are reinstated and validated at the completion of testing.

•

In FAT setup, the I/O boards are not physically present and the same is simulated using the test setup (MISS). Therefore, field inputs and outputs delivered by Input and Output card will be disabled and will be directly delivered into simulation VDU. However this will not affect the interlocking part of the application logic. To carry out FAT, the following inputs are required: • • • • •

Signal Interlocking Plan (SIP) Route Control Chart (RCC) Control cum Indication Diagram Cross Table Microlok II Station Interlocking Application Software files as designed (.ML2, .MLL, .MLP)

After carrying out FAT, the following are the outputs: • • •

Microlok II Station Interlocking Application Software files as tested (.ML2, .MLL, .MLP) Ansaldo STS Total Management System (TMS) Forms FAT Certificate

For detailed testing procedure of FAT please Ref: Annexure •

If Railways/Customer testing is completed, then the Checksum and CRC values of the FAT simulated application logic will be recorded as per the Application Logic and it is to be tly signed by Ansaldo STS and Railways representative.

Page 45



2.36.2 Site Acceptance Test •

Site Acceptance Test (SAT) defines the procedure for Site testing of Microlok II Station Interlocking System, where tests are executed at site environment.

•

SAT mainly involves the System integrity and functional testing of all equipments and interlocking testing also shall be carried out with full setup except the trackside equipments.

•

SAT is carried out for each station separately.

•

Results of the tests are observed and documented in a Test Report.

•

The Site Acceptance Test ensures that all the equipments installed at site i.e. Microlok II, Communication equipments, Power supply equipments, Relays and Control cum Indication are functioning correctly as per approved system configuration & station interlocking requirements and working in safe manner and failsafe even if any equipment fails / false inputs/information received.

•

SAT ensures the overall system safety and error free system is being delivered to the client.

•

To carry out SAT, the following inputs are required:

Microlok II .ml2, .mll & .mlp file (Hardcopy & Read-only Softcopy) Station SIP Station Route control chart Station Control cum indication diagram Cross tables Wiring circuits

•

All the equipments involved for station working is being installed before proceeding SAT, so there is no need of separate set up is required except to simulate the field inputs with Simulation .

•

All the field inputs are simulated by using simulation through toggle switches and inputs are sending to Microlok II via relays and the field outputs are sending to lamps through relays.

The following testing shall be carried out while doing SAT • • • • • • • • • • • •

Visual test Wire count test Bell test Insulation resistance test Earthing test Power On VCOR Communication testing Correspondence Test System Integrity Test Interlocking testing Change over test

For detailed testing procedure of SAT please Ref: Annexure -VII.

IRISET

Page 46

ALTERATIONS TO SIGNALLING -APPLICATION LOGIC MODIFICATION

2.37

ALTERATIONS TO SIGNALLING -APPLICATION LOGIC MODIFICATION: “Microlok II Interface Design Modification” and the steps involved in implementing the modifications are briefly described here. Steps involved in implementing the modifications: •

Compare New SIP with old SIP and find out the changes

•

List out the additional gears

•

List out the gears which are removed

•

System configuration for Information purpose

•

Additional hardware required.

•

Implement this changes in Route control chart

•

Implement these changes in Bit chart

•

Implement this changes in all Interface circuits ( see below for detailed steps)

•

Implement changes in VDU

•

Implement changes in Application Logic. ( edit plus software is required. Application software needs to be amended and Application version No. has to be changed)

•

Compile the Application software (Compiler software is required)

•

Factory Acceptance Test -- for Application Software.

•

Site Acceptance Test – for application software with actual gears.

•

UP LOAD the Application program.

•

Keep one updated version of application software in CD at Site, Head Quarters and also at Company.

Steps involved in implementing the changes (Deletion of Shunt Signal and addition of Crank handle) in all Interface circuits: •

Control cum Indication layouts

•

Microlok II Non-Vital I/O Bit chart – A1/B1

•

Microlok II Vital I/O Bit chart – A2/B2

•

Microlok II Non-Vital Input circuits

•

Microlok II Non-Vital Output circuits

•

Microlok II Vital Output circuits

•

Microlok II Vital Input circuits

•

Signal Repeater relay & Lighting circuit – Shunt signal

•

Crank Handle Control circuit

•

Relay Rack Layout – R2

•

Terminal chart – (R2 rack & T1 rack)

•

Fuse & Terminal chart

•

analysis

•

Control LED Identification layout

Page 47



2.38

PROBLEMS REPORTED IN MICROLOK II

•

It has been noticed that data in internal data logger of EI is stored in raw form which is difficult to interpret. It necessitates the requirement of external data logger for maintenance friendly interpretation. In absence of external data logger, the propose of provision of internal data logger or data storage is defeated due to unsuitable maintenance diagnostic software loaded in Maintenance Tool. In view of above, maintenance diagnostic software loaded in Maintenance Tool needs to be improved. In connection with this problem M/s Ansaldo STS has already developed friendly software and same shall be installed in all future installations of Microlok-II.

•

The checksum at the time of FAT varies from the checksum at the SAT due to hard wired testing not done at FAT. To avoid the duplication of testing, there is need of modification in testing procedures / devising of suitable arrangement including software changes so that there is no change in checksums. The possible solution is the checksum at the time of FAT matches with checksum at the site is creating the similar conditions as exists in the field. i.e. testing with fully hardwired test zig and keeping all timers at their standard value. Even alter that to keep the checksums same there should not be any last minute changes in interlocking logic by the railways.

***

IRISET

Page 48

RDSO / SPN / 192 / 2005

Annexure – I Specification No. RDSO / SPN / 192 / 2005 ELECTRONIC INTERLOCKING INDEX S.No

Item

Clause no.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Foreword Abbreviation Scope Terminology General requirements Requirement of Electronic Interlocking Interlocking Requirements System Composition Hardware & fail safe System Architecture Maintenance and diagnostic aids Software Requirement Power supply requirements Information to be furnished by the manufacturer / supplier Test and Requirements Type test Acceptance Test Routine tests Test Procedure Quality Assurance Packing Information to be furnished by the Purchaser

0 0.3 1.0 2 3 3.13 4 5 6 7 7.2 8.0 9 10 11 11.3 11.4 11.5 12 13 14 15

Page no. 6 7 8 8 8 9 9 9 11 12 13 13 14 15 16 17 17 17 18 20 20 20

0.

FOREWORD :

0.1

This specification is issued under the fixed serial No. RDSOI SPN/192/2005 followed by the year of original adoption as standard or in case of revision, the year of latest revision.

0.2

This specification requires reference to the latest version of following specifications: — 1 2 3 4 5

IRS : S 36 Relay Inter Locking Systems IRS : S 23 * Electrical Signalling and interlocking equipment RDSO / SPN /144 Safety and reliability requirement of electronic signaling equipment IS : 9000 * Basic environmental testing procedures for electronic and electrical items IS :2147 – 62 * Degrees of protection provided by enclosure for low voltage switch gear and control gear.

Page 49


SPECIFICATION OF ELECTRONIC INTERLOCKING

6

ISO :9001

Quality Systems- model for quality assurance in design, development, production, installation and serving. EN 50126 Railway applications - specification and demonstration of reliability , availability , maintainability and safety. EN 50128 Railway applications- signaling and communication Software for Railway control and protection system. EN 50129 Railway applications- Safety related electronic systems for signaling EN 50159 – 1&2 Railway applications Signaling and Communication Safety related communication in closed and open transmission system. IEC 529 / EN Specification for degree of protection provided by 60529 enclosures.(IP code) EN 61000.4.2 Electromagnetic compatibility (EMC) - testing and measurement techniques- electrostatic discharge immunity test and basic EMC EN 61000.4.4 Electromagnetic compatibility - testing and measurement techniques - electrostatic fast transient/burst immunity test and basic EMC publication. EN 61000.4.5 Electromagnetic compatibility - testing and measurement techniques – surge and immunity test. IRS : S – 99 Data logger system RDSO / SPN /186 Domino Type Control for Railway Signalling

7

8 9 10

11 12

13

14 15 16 *

Or equivalent Recognized International standard. The supplier shall submit a copy of the same for verification.

Whenever, reference to any specification appears in this document, it shall be taken as a reference to the latest version of that specification. 0.3

IRISET

ABBREVIATIONS: SNO.

ABBREVIATION

EXPANDED FORM

1

ABS

AUTOMATIC BLOCK SIGNALLING

2

ATP

AUTOMATIC TRAIN PROTECTION

3

CA

CROSS ACCEPTANCE

4

CCIP

CONTROL CUM INDICATION

5

CD

COMPACT DISC

6

CENELEC

EUROPEAN COMMITTEE FOR ELECTRO TECHNICAL STANDARDISATION

7

CIU

CENTRAL INTERLOCKING UNIT

8

CMU

CNTRAL MONITORING UNIT

9

CTC

CENTRALISED TRAIN CONTROL

10

EI

ELECTRONIC INTERLOCKING

Page 50

RDSO / SPN / 192 / 2005

SNO.

ABBREVIATION

EXPANDED FORM

11

EMU

ELECTRICAL MULTIPLE UNIT

12

EPROM

ERASABLE PROGRAMMABLE READ ONLY MEMORY

13

IBS

INTERMEDIATE BLOCK SIGNALLING

14

I/O

INPUT / OUTPUT

15

ISA

INDIPENDENT SAFETY AUDITOR

16

MTBF

MEAN BETWEEN FAILURE

17

MTBWSF

MEAN BETWEEN WRONG SIDE FAILURE

18

MTTR

MEAN TIME TO REPAIR

19

MT

MAINTENANCE TERMINAL

20

OC

OBJECT CONTROLLER

21

OFC

OPTICAL FIBRE CABLE

22

PC

PERSONAL COMPUTER

23

PCB

PRINTED CIRCUIT BOARD

24

QA

QUALITY ASSURANCE

25

QAP

QUALITY ASSURANCE PROGRAM

26

SEM

SIGNAL ENGINEERING MANUAL

27

SIL

SAFETY INTEGRITY LEVEL

28

STR

SCHEDULE OF TECHNICAL REQUIREMENTS

29

TOT

TRANSFER OF TECHNOLOGY

30

UV

ULTRA VIOLET

31

VDU

VISUAL DISPLAY UNIT

32

VGA

VIDEO GRAPHIC ARRAY

1.0

SCOPE:

1.1

This specification covers the technical requirements of Electronic Interlocking.

1.2

The El covered in this specification shall be a microprocessor based equipment used for the operation of points, signals, level crossing gates, block working with adjacent station, releasing of crank handle for manual operation of points and other controls like slots etc. through a control cum indication or VDU based control . It shall be capable of future interfacing with ATP & CTC systems. In case of End Cabin / Multi Cabin working, it shall be possible to interface more than one CCIP or VDU control terminal or both with the El.

1.3

Page 51



2

TERMINOLOGY:

2.1

For the purpose of this specification, the terminology given in latest version of IRS: S 23 and RDSO/SPN/144 shall apply.

3

GENERAL REQUIREMENTS:

31

The system shall provide all the interlocking, control and indication functions as per approved interlocking plan, selection table and diagram of the station. The system shall have facility of monitoring of internal variables as well as status of I/O.

3.2 3.3

The system shall be suitable for working on sections having 25 kV AC traction and where enger/freight trains hauled by single phase thyristor controlled or three phase induction motor controlled AC locomotives or chopper controlled EMU stock are operated.

3.4

The system shall be capable of working in conjunction with the control cum indication or a VDU or both as per clause 5.3 as required by Railways.

3.5

The system should have capability to interface with Block Working. It should also be capable of interfacing with IBS, ABS including interfacing with outlying yards and sidings. Supplier shall submit interface details.

3.6

The system shall be capable for working in non air-conditioned environment and ambient temperature range between –10 0 C to 70 0 C and Relative Humidity unto 95% at 40 0 C.

3.7

The system shall be provided in a dust protected cabinet. If forced cooling is required, the cooling fans shall operate on system power supply with over current protection arrangement. The failure of any one of the fans shall give an alarm to the operator.

3.8

The equipment shall be so constructed as to prevent unauthorized access to the system.

3.9

Necessary provision shall be made in the hardware and software for modular expansion of the system. For large stations, which cannot be covered by one El, it shall be possible to connect more than one El preferably through a serial channel. The communication channel provided between various El shall comply with the requirements for transmission of vital safety information as laid down in relevant clause of latest version of RDSO/SPN/144/2004.

3.10

El shall have -friendly graphic based design tool to generate station specific application software to carry out future yard modifications.

3.11

For all vital inputs! outputs, double cutting arrangement shall be provided.

3.12

Either OFC or twisted pair cable shall be used for all vital connections.

3.13

REQUIREMENT OF ELECTRONIC INTERLOCKING:

3.13.1 Both hardware & software of El must meet SIL-4 as defined in CENELEC Standards. If the system is developed using any equivalent International standard other than CENELEC, a copy of standards followed shall be submitted with application. The certificate of validator certifying that the system is equivalent to SIL-4 compliant shall also be submitted. 3.13.2 The El system software as well as warm/hot standby changeover software should have been independently verified and validated including its offered configuration by third party. Railway shall application software pertaining to yard data. IRISET

Page 52

INTERLOCKING REQUIREMENTS

3.13.3 The firm manufacturing El, when applying for type approval or cross - acceptance approval shall submit documentary proof of independent validation as per CENELEC Standards or equivalent standard along with complete safety case. 3.13.4 The firm shall give details of all modifications carried out in the system after initial validation! approval. Date of each modification with brief reasons for undertaking modifications shall be given. All modifications must have got approval of original validating agency! approving agency. 3.13.5 The next level Signal control circuits like Cascading of Signal aspects, Red lamp protection etc. shall be achievable through Software only. 3.13.6 The audio-visual alarm shall be available for Approach locking, Button stucking etc. in El.

3.13.7 CIU shall have log of all counters provided at like Emergency Route cancellation Calling on signal, Emergency Point operation, Overlap release operation etc. so that in case, operation commands are given through VDU in place of CCIP, then proper working of counters shall be possible and readings of all counters can be read as and when required. 4.

INTERLOCKING REQUIREMENTS:

4.1

The system shall meet the interlocking requirements as specified in Cl.4.0 of IRS: S 36.

5.

SYSTEM COMPOSITION:

5.1

The El system shall consist of the following:

5.1.1

Microprocessor based interlocking equipment to read the yard and inputs, process them in a fail-safe manner as per the selection table and generate required outputs.

5.1.2

Cycle time and response time to read and process the input shall be fast enough to ensure safety and avoid any apparent delay. Cycle time and response time of the system shall be clearly indicated. Requirement of spare parts of each type for the first line maintenance shall be indicated to meet system availability with Mean time to repair (MTTR) being not more than 6 hours.

5.1.3

5.1.4

Domino type Control Cum Indication (CCIP) with processor having standby processor or VDU control terminal as required by purchaser.

5.1.5

Maintenance terminal (MI) with display, keyboard, printer and event logging facility for minimum 10,00,000 events. The system shall have facility for automatic serial data transfer to a central monitoring unit through data logger. The protocol for this communication shall be as per Data Logger specification No. IRS: S-99.

5.1.6

Relay rack along with required number of approved type of relays or OCs.

5.1.7

OBJECT CONTROLLER:

5.1.7.1 OC shall be a Processor based system having similar architecture as of CIU. It shall work as slave unit of CIU through duplicated serial communication and placed within 15 Km. radius from CIU. The OC shall drive the field gears (Points, Signals & Relays) and take (Inputs) from various field gears without any modification! change in the design of outdoor Signalling equipment.

Page 53



5.1.7.2 OC shall be normally placed in field locations. 5.1.7.3 The medium of communication between CIU and OCs shall be OFC provided on a ring basis. In case of communication failure between CIU & OC, all the outputs shall be brought to safe state whenever two consecutive telegrams are not received in stipulated time period. 5.1.7.4 All the inputs and outputs of OCs shall be isolated. 5.1.7.5 OC shall carry out the supervisory function to check the proper level of system voltages at critical points to ensure proper working of the system and sf4alI also check the health of the complete system. 5.1.7.6 Occurrence of any error in any OC or hardware fault leading to unsafe condition shall immediately withdraw all output commands and remove the source supply to outputs. Functionally, each OC should be independent from other OC. Error in one OC should not affect the working of other OCs.

5.1.7.7 If the system is developed using OCs, then it shall be developed in following two phases: (I)

(ii)

In first phase, the object controller shall have only Relay driver cards duly validated and meeting all safety requirements to drive Points, Signals and other field gears. The approval shall be given to provide system with this arrangement over the stations of Indian Railways. In second phase, after successful testing & working of above mentioned system for specified time as decided by RDSO, Solid State Point and Signal lamp modules shall be developed to the satisfaction of validators and RDSO.

5.1.7.8 In case of Cross Acceptance, El with OCs may be directly accepted provided these have performed satisfactorily for the quantity and period as specified in Cross Acceptance procedure of RDSO. 5.2

CCIP shall conform to relevant clauses of IRS: S 36 and RDSO/SPN/186. It shall be provided with push buttons/control switches for individual operation of points, clearing of signals, releasing of crank handle/ground lever frame, gate controls, cancellation of routes and other functions as covered by IRS: S 36 including block signalling, auto signal, lB signal, adjacent yard layout, to facilitate indication or operation aim indication as per requirement.

5.3 CONTROL TERMINAL WITH VDU DISPLAY: 5.3.1

If required by the purchaser, a control terminal with VDU display in lieu of or in addition to conventional CCIP shall be supplied. This will consist of: i) ii) iii)

A latest PC, colour VDU monitor with minimum size of 17”(43 cm.) as specified by purchaser. A Key Board & mouse and Suitable interface to continuously display the current position/status of various field equipment and track circuits.

A flashing indication shall be provided on the VDU to indicate healthy condition of the main system, communication channel and processor. Three dot markers in Red, Blue & Green colours respectively shall also be displayed prominently at conspicuous location on the VDU terminal to indicate that the colour monitor is healthy and all the three colours (Red, Blue & Green) are present in right proportion. IRISET

Page 54

COMPONENTS

5.3.2 The control terminal shall work with 230V ± 10%, 50Hz AC power supply, for which an UPS of adequate capacity shall be supplied along with the system. 5.3.3

A colour monitor (minimum VGA or better) shall be used for the VDU of the control terminal. It shall be possible to display the complete yard layout including the section on the monitor. It shall also have facility for displaying a portion of the yard or section in an enlarged mode ,if required.

5.3.4

The current position/ status of various field equipments and track circuits shall be displayed on the VDU using different colours / symbols, as desired by the purchaser.

5.3.5

The system shall have suitable interface to receive and process the information for displaying the status of field equipment on the control terminal. This interface shall be of standard type like RS 232 or any other approved type.

5.3.6

Availability of communication channel shall be indicated by a constantly flashing indication. Whenever the serial channel goes faulty, a suitable error message shall be displayed on the terminal.

6.

HARDWARE AND FAIL-SAFETY:

6.1

Requirements of SEM as laid down in relevant clause of latest version of RDSO / SPN / 144 shall be complied.

6.2

COMPONENTS: Components used shall comply with relevant clause of latest version of RDSC/SPN/144 and should be commercially available.

6.3

PROTECTION AGAINST ELECTROMAGNETIC AND ELECTROSTATIC INTERFERENCE: The requirements laid down in relevant clause of latest version of RDSO/SPN/144 shall be complied. The equipment chassis shall be connected to suitable earth.

6.4

PRINTED CIRCUIT BOARD:

6.4.1

The requirements laid down in relevant clause of latest version of RDSO/SPN/144 shall be complied.

6.4.2

Each card shall be marked with running serial number for identification of individual cards.

6.5

FAIL-SAFETY:

6.5.1

The requirements laid down in relevant clause of latest version of RDSO/SPN/144 shall be complied.

652

Either or both of hardware and software redundancy shall be provided to ensure that any single fault does not lead to unsafe failure.

653

MTBWSF should be minimum 10 9 hours.

6.6

The system shall have provision for accommodating additional 25% of 1/0 cards.

Page 55



7.0

SYSTEM ARCHITECHTURE:

7.1

One of the following architectures shall be employed in the system. (a)

Single Hardware architecture with diverse software. In addition, hot / Warm standby processor(s) /system shall be provided with facility of automatic changeover. In case of Warm standby system, the standby system should start functioning with a time delay of approximately 120 secs. of failure of main system. Preferably, the train operation shall not be affected or otherwise, there shall be no unsafe occurrence due to switching over from main system to standby system. in case of hot standby system, train operation shall not be affected. It should also be ensured that the fault, which affected the main processor/ system, does not affect the hot standby processor! system.

(b)

Two out of two hardware architecture with identical hardware and identical or diverse software. In addition, warm standby/ hot standby processor(s) / system using similar 2 out of 2 hardware and software architecture shall be provided with facility of automatic changeover. In case of Warm standby system, the standby system should start functioning with a time delay of approximately 120 secs. of failure of the main system. Preferably, the train operation shall not be affected or otherwise, there shall be no unsafe occurrence due to switching over from main system to standby system. In case of hot standby system, train operation shall not be affected, It should also be ensured that the fault, which affected the main processor/ system, does not affect the hot standby processor/ system.

(c)

Two out of three hardware architecture with identical hardware and identical or diverse software.

7.2

MAINTENANCE AND DIAGNOSTIC AIDS:

7.2.1

MT consisting of a standard PC with printer from a reputed manufacturer shall be provided for following Operations: i) ii) iii) iv) v)

Display of the current status of points, signals, controls etc. of the yard. Storage of minimum one month data or 10,00,000 events. Display of recorded events and Data transfer to floppy, CD, flash memory or any other storage media. Transfer of recorded events to external data logger.

7 .2.2 Result of the failure of any card/module in the system should be clearly indicated. The supplier should also indicate process of replacing such defective cards / modules. 7.2.3

Control operation of yard functions shall not be possible from the maintenance terminal.

7.2.4

In case of any module/ card becoming faulty, this fact should be displayed on MT with diagnostic facility to identify faulty module/ card.

IRISET

Page 56

SOFTWARE REQUIREMENTS

8.0

SOFTWARE REQUIREMENTS:

8.1

The software of system should have two layers: (a) Executive Software or System Software This Executive Software shall define what the system can do and how the various parts of the system operate together. It shall include all start up and operational safety tests (including checking the Executive Software itself) that are the parts of the processor for continual assurance of safety operation. (b) Application Software It shall be containing the logic that defines how the inputs and outputs for a particular station are related. This shall be station specific. The manufacturer shall program the Executive Software and Application Software into Read Only Memories (ROM). Both the ROMs shall be separated & isolated from each other. It shall not be possible to modify Executive Software. However, Application engineers should have the facility to modify application software as and when required.

8.2

Software used in El should have been developed in conformity with a software engineering standard issued by recognized standards body such as CENELEC with special relevance to safety critical applications. Particular software engineering standards used shall be specified and one complete set of such star1dards shall be made available to RDSO.

8.3

The selected El Software should have been independently verified and validated. As specified in the software Engineering Standards, full documentation on Quality Assurance Program specially the Verification and Validation (V&V) procedures carried out in-house or by any independent agency, should be made available to RDSO to check their conformity to the standards. If the procedure and documentation for V & V is considered inadequate, RDSO reserves the right to get the verification and validation of software and hardware done by an independent agency at the cost of the supplier.

8.4

The system shall conform to software requirements and self-check procedures as laid down in relevant clause of latest version of RDSO/SPN/144.

8.5

SELF CHECK PROCEDURES:

8.5.1

Self-check of the associated functional hardware as required by the hardware design should be performed periodically as laid down in relevant clause of latest version of RDSO/SPN/144. Sufficient self-check should be built into the system to detect possible hardware faults.

8.5.2

Integrity of the final vital output of the system for control of the field equipment should be continuously checked by reading both front & back s of relays to guard against inadvertent operation of the equipment.

9.

POWER SUPPLY REQUIREMENTS:

9.1

The El shall work on 110V/ 60V/ 24V/12V DC power supply.

9.2

Two different voltages shall be used, one to drive El equipment and the other for receiving the inputs from the field gears.

Page 57



9.3

The short circuit protection shall be provided.

9.4

The required protection shall be provided to protect from any malfunctioning due to false! spurious feed.

9.5

Suitable surge protection and proper earthling arrangement shall be provided in the power supply system to protect against transient voltages, lightning & spikes etc.

9.6

If CCIP and CIU are in separate building, then lightning and surge protection has to be provided for each core of copper cable connecting CCIP and CIU or else OFC cable .shall be used to connect CCIP & CIU.

9.7

A detailed Power supply arrangement diagram/ circuit shall be provided.

9.8

Power supply arrangement for individual processor should be such that, in case of fault in power supply of one processor, all processors should not cease to function simultaneously. It should be possible to switch off and take out faulty processor for repairing/replacement without affecting working of the balance system.

10.

INFORMATION TO BE FURNISHED BY THE MANUFACTURER I SUPPLIER: The manufacturer shall supply the following information. a)

Design approach for the system.

b)

Functions achieved in hardware & software.

C)

Mode of interaction between hardware &software.

d)

Salient feature through which fail safety has been achieved e.g. use of a watchdog timer, automatic shut down etc.

e)

Proof of safety in the form of process adopted for safety analysis and result thereof. Full documentation of Software Engineering followed during development.

f) g)

Full documentation of verification and validation procedure, Quality Assurance Program along with report and certificate from in-house Quality Assurance (QA) Group or an Independent Safety Auditor (ISA).

h)

If the Railways consider software validation necessary, the manufacturer! supplier will supply all the documents etc. to the Validator nominated by the Railways. Complete application software with facility for EPROM programming for entering yard data. In case of Cross-Acceptance, the firm should submit the performance as given below:

i) j) • • • • • • • • •

IRISET

Name of System/Equipment Make Model / Version No. Railway & Section Maximum Sectional Speed Average number of Trains per day Application of System/Equipment Problems faced and solutions evolved Failure data may be submitted as per format given below

Page 58

: : : : : : : : :

INFORMATION BY THE MANUFACTURER

Location

No. of System/ Equpt.

Date of Commissio -ning

Total hours in use

No. of safe side failures

No. of unsafe side failures

MTBF

MTBWSF

MTTR

Total

Proven ness criteria of Equipment Usage of same Type/Make & Model/Version shall be as under: S.No.

Category of Equipment / System

Minimum no. of Equipment Equipment

Hours

1.

Solid State interlocking

(i)

In use 2,16,000

25

At least 20% of the equipment/system, with a minimum of 10, should be in continuous operation for a minimum period of 720 days.

(ii) If the offered equipment has undergone minor hardware/software up-gradation to improve functionality/safety of the equipment in recent past, then the equipment utilisation of the earlier version (prior to minor modifications) can be considered for the proveness. However, in such cases, a minimum of 10 (Ten) equipments should be in continuous operation for a minimum period of 180 days. 10.1

10.2

The manufacturer shall supply the following documentation] manuals: I)

Installation & Maintenance Manual with pre-commissioning check list.

ii)

Diagnostic aids including troubleshooting charts: A trouble-shooting chart shall also be provided to indicate the step-by-step actions to be taken in case of failure of the equipment. It shall be possible to rectify the fault by replacement of defective PCB card by the maintainer at site.

iii)

Details of Hardware e.g. schematic diagrams of the system circuits/components, details for each type of assembled P06.

iv)

Details of software algorithm flow chart along with test/validation procedure used and the results thereof.

v)

Version No. of Signalling equipment shall be as per RDSOISPN / 144. In case of Cross-acceptance, Version No. as per manufacturer’s practice may be accepted.

vi)

Software checksum of EPROM(s) shall be provided as per RDSO/SPN/ 144.

The manufacturer shall provide the following certifications from approved validation agency: I) ii)

Correctness and safety of the software. Reliability and fail-safety of the interlocking system.

Page 59



iii) iv) v) vi)

Details of modifications carried out in the system and its subsequent validation. Expected MTBF. Expected MTBWSF. Expected MTTR.

11.

TESTS AND REQUIREMENTS:

1 1.1

Conditions of Tests Unless otherwise specified all tests shall be carried out at ambient atmospheric conditions.

11.2

For inspection of material, relevant clauses of IRS: S 23 and RDSOISPN/144 shall apply.

11.2.1 TEST EQUIPMENT: The firm should have all essential Testing Equipments as per latest STR. 11.3

TYPE TESTS:

11.3.1 Standard RDSO layout shall be used for conducting type tests. The following tests shall constitute type tests: a) b) c) d) e) f) g) h)

Visual inspection as per Clause 12.1 Insulation Resistance tests as per Clause 12.2 Card-level functional tests on all the cards and fail-safety tests on one card of each type. System level functional and fail-safety tests. Computerised testing for minimum two hundred thousand permutations and combinations as per Clause 12.3. Environmental/ climatic tests as per Clause No. 9.0 of RDSO/SPN/144, Revision 1 (Indoor Equipment). System Diagnostics test as per Clause 12.4. System Software tests as per Clause 12.5.

11.3.2 Any other tests shall be carried out as considered necessary by RDSO. 11.3.3 Only one El shall be tested for this purpose. The equipment shall successfully all the type tests for proving conformity with this specification. If the equipment fails in any of the type tests, the purchaser or his nominee at his discretion, may call for another equipment card (s) of the same type and subject it to all tests or to the test(s) in which failure occurred. No failure shall be permitted in the repeat test(s). 11.4

ACCEPTANCE TEST:

11.4.1 The following shall comprise acceptance tests: a) b) C) d) e) f)

Visual inspection (Clause 12.1) Insulation Resistance tests (Clause 12.2) Card level functional test on all the cards. System level functional tests. System Diagnostics test (Clause 12.4) Verification of application software vis-a-vis selection table (This shall be done by Railway).

11.4.2 Any other tests shall be carried out as considered necessary by the purchaser. IRISET

Page 60

ROUTINE TEST

11.5

ROUTINE TEST:

11.5.1 The following shall comprise the routine tests and shall be conducted by manufacturer on every El and the test results will be submitted to the inspection authority before inspection. The application software in proper format shall also be submitted to the inspection authority in advance. a) b) c) d) e) f)

Visual inspection (Clause 12.1) Insulation Resistance tests (Clause 12.2) Card level functional test on all the cards. System level functional test. Computerized testing for 1,00,000 permutations and combinations (Clause 12.3) System diagnostics test as per Clause 12.4.

11.5.2 Any other tests shall be carried out as considered necessary by the purchaser. 12

TEST PROCEDURE: The test procedure shall be based on the system design. The methodologies to be adopted for various tests shall be decided taking into the system design! configuration and shall be approved by the purchaser.

12.1

VISUAL INSPECTION: The equipment shall be visually inspected to ensure compliance with the requirement of Clauses 3 to 7 of this specification. The visual inspection will broadly include — i) System level checking: Constructional details Dimensional check General workmanship Configuration ii) Card level checking ROB laminate thickness General track layout Quality of soldering and component mounting Conformal coating Legend printing Green masking iii) Module level checking Mechanical polarisation General shielding arrangement of individual cards Indications and displays Mounting and clamping of connectors. Proper housing of cards

Page 61



12.2

INSULATION RESISTANCE TEST: This test shall be conducted between the equipment power supply line terminals and the earth. If there is a possibility of the meggering voltage reaching the cards, these will be taken out before starting the lR test. This test shall also be carried out after the climatic tests. The measurement shall be made at a potential of not less than 500 V DC. The lR value shall not be less than 10 Mega ohms. After the climatic tests, this value shall not be less than 10 mega ohms.

12.3

COMPUTERIZED TESTING: The manufacturer shall provide a computer-based test set up with the required software for automatic testing. The following tests shall be conducted with the help of this set up.

12.3.1 FUNCTIONAL TESTING: The system shall be tested functionally for all the signals with all routes, point operation, emergency point operation, route cancellation, emergency route cancellation, operation of G/F control points, level crossings and crank handle as per the selection table of the yard provided by the purchaser. 12.3.2 OPERATIONAL FAIL SAFETY TEST: These tests are conducted as per procedure given below: i)

After setting of points in main route & desired overlap, signal is cleared. Back locking of the route and overlap should be verified. It should also be checked that other yard functions are free. The track circuit of the route should be dropped one by one and it should be verified that it is not possible to clear the signal. All the routes are checked one by one.

ii)

12.4

Conditions required for route setting should be disturbed in various permutations and combinations and it should be verified that it is not possible to set the route with the disturbed conditions. Similarly, conditions required only for signal clearance (such as track circuits) should also be disturbed and it should be verified that the route is set but the signal is not cleared.

SYSTEM DIAGNOSTICS TEST: These tests shall be conducted by automatic test procedure through a PC. The diagnostic tests on the system shall be performed to test the integrity of the system software by ing the checksum. It shall be possible to the application program vis-a-vis the selection table by the , preferably through regeneration of the locking table from yard data. The PC at the end of the test shall print out summary of the tests conducted.

IRISET

Page 62

SYSTEM SOFTWARE TEST

12.5

SYSTEM SOFTWARE TEST: Checksum of system software and format of the application software shall be verified. In case of any change in the system software! format of application software, the same shall be validated.

12.6

Type test, Acceptance test and Routine test as given in para 11.3, 11.4 and 11.5 shall not be required in case of Cross- acceptance, The firm has to submit following documents to ensure that the system meets all requirements as mentioned in para 11: i) ii) iii) iv)

Certificates of Type tests done as required by RDSO specifications. List of Routine tests done and sample copy of results to be submitted. Acceptance tests to be done at the time of inspection of equipment to be supplied. Performance reports from Railways.

For the verification of same, a team of RDSO officials may visit the manufacturing facility of manufacturer in its respective Country(s). . Sample tests shall be carried out, if found necessary. However, at least one set of equipment shall have to be installed in Indian Railways, to prove its performance in Indian conditions. Details of cross acceptance procedure may be referred to in concerned document of RDSO. 13.

QUALITY ASSURANCE:

13.1

All materials & workmanship shall be of good quality.

13.2

Since the quality of the equipment bears a direct relationship to the manufacturing process and the environment under which it is manufactured, the manufacturer shall ensure QAP of adequate standard.

13.3

Validation and system of monitoring of QA procedure shall form a part of type approval. The necessary Plant, Machinery and Test instruments as given below shall be available with the manufacturer.

13.3.1 PLANT AND MACHINERY: The firm should have all essential Plant & Machinery as per latest STR. In case of CA, the above Plant and Machinery shall not be necessary to be available with Indian Partner if no TOT is taking place. In case of TOT, The same shall be required with Indian Partner of foreign firm. In case of CA, when TOT is not taking place, the Plant & Machinery may be verified by the team of RDSO officials visiting the Firm premises. 13.3.2 All test instruments as given in CI. 11.2.1 shall be available with the manufacturer. 3.4

Along with the prototype sample for type test, the manufacturer shall submit the Quality Assurance Manual.

Page 63



14.

PACKING: As per relevant clause of latest version of RDSOISPN/144.

15.

INFORMATION TO BE FURNISHED BY THE PURCHASER:

a)

Approved interlocking plan, selection table and diagram of the station(CI. 3.1).

b)

Whether CCIP (domino type) 0rVDU control terminal or both required (Cl. 5.1.4).

c)

System output required to drive field gears — relay interface or object controllers.

d)

110 V AC or DC usage for signal lamp lighting.

e)

Size of VDU monitor screen, if ordered.

***

IRISET

Page 64

ITEMS OF MLK II SYSTEM – CENTRALISED VERSION

Annexure – II Items of Microlok-II EI system (Centralised version) for a typical 4- Road Station Items of Schedule-A & Schedule-B for " Design, manufacture, supply, installation, testing and commissioning of " Solid state (Electronic) Interlocking system conforming to RDSO/SPN/192/2005 with latest amendments at stations (typical 4 road stations) of Indian Railways ". SL No.

Description of works

1

Installation, Testing and Commissioning of SSI equipments supplied as per items No. 1A of Schedule-B

2

Maintenance & supervision of SSI equipments for one year as per details given in para- 4.12 of Special Condition of contract at the stations below . For all the stns

3

Unit

Qnty

Job

1

SSI per stn

1

Training at site / Field / HQ office of CSTE ( Construction)

3A

Technicians/Sr. Engr. for installation, commissioning and testing including supply hard / soft copies of course modules.

Man month

14

3B

CSTE / DY.CSTE / DSTE / SSTE / ASTE in installation, commissioning, testing, trouble shooting and repairs including supply of hard copies of course modules.

Man month

14

4

Earthing of SSI equipments Relay racks, power equipments etc. to be done along with the supply of all requisite materials as per sound engineering practice. This includes supply of earth electrode, bricks, sand, cement, charcoal, salt, slalmanie weed and GI wire, copper lugs with bolts and nuts.

Job

1

SSI

1

(i) Three years AMC charges NOTE

Total of Sch-"A" = Rs: 18,10,000

Page 65


ANNEXURE- II

SL No.


Unit

Qnty

Design , manufacture and supply of Solid state interlocking system complete as per Special condition of contract and technical specifications enclosed , mainly consisting of microprocessor equipments , interface equipments , control cum indication , PC based operator's console with 19" VDU racks , relays , interlocking cables , maintenance terminals including Data logger , Power supply equipments, racks, fixture mounting arrangements and accessories necessary to make the system functional for stations listed above. List of various modules , equipments , sub assemblies and other stores, if any , with rate , quantity and the total cost as quoted by the tenderer is detailed below 1

For 1 stn as per details below

system

1

1.1 INTERLOCKING EQUIPMENT: i)

MLK II Cardfiles

Nos

4

ii)

MLK II U PCBs

Nos

4

iii)

MLK II PS PCB

Nos

4

iv)

MLK II Vital I/P PCB

Nos

15

v)

MLK II Vital O/P PCB

Nos

15

vi)

MLK II Non-Vital I/O PCB

Nos

15

vii)

VCOR Relay

Nos

4

viii) VCOR Relay base

Nos

4

ix)

Address Select PCB- 48 Pin

Nos

30

x)


Nos

15

xi)

U EEPROM PCB

Nos

4

xii)

1"- Wide Blank Front Assy.

Nos

15

xiii) PCB Keying plug

Nos

150

xiv) Lighting Arrestors- consists of

Sets

a) 230V/12V/24V Lightning arrestors

Nos

3

b) Isolators

Nos

2

c) Convertors

Nos

4

48- Pin Connector Housing Assy

Nos

28

xvi) 48- Pin Connector Guide Element

Nos

28

xvii) 96- Pin Connector Housing Assy

Nos

20

xviii) 96- Pin Connector Guide Element

Nos

20

xix) 48- Pin Female Connector

Nos

30

xx)

Nos

240

xv)

48- Pin Female Crimp

IRISET

Page 66


SL No.


Unit

Qnty

xxi) 96- Pin Female Connector

Nos

20

xxii) 96- Pin Female Crimp

Nos

250

xxiii) UPS for Computers

Nos

2

1.2 S/FASCIA/TILES

Nos

i) ii) iii)

Control-cum-Indication Computer(Maint Console) with 15" VDU Computer(Operators Console) with 21" VDU

Nos Nos Nos

1 1 1

iv)

Printer

Nos

1

1.3 RACKS i)

Microlok Rack with accessories

Nos

2

ii)

Relay Rack with accessories

Nos

2

iii)

Termination Rack

Nos

1

1.4

Design of Solid State Interlocking System to suit Interlocking plans

Stn.

1

1.5 RELAYS VITAL C/W BASES i)

QNN1 relays

Nos

44

ii)

QNNA1 Relays

Nos

44

iii)

QL1

Nos

12

iv)

Timer relays

Nos

4

v)

ECR/ON/OFF/Route/Shunt

Nos

51

vi)

EKT

Nos

4

1.6 Power Supply i)

Integrted power supply

Nos

1

ii)

DC/DC Converter for MLKII Cardfile

Nos

2

iii)

DC/DC Converter for MLKII Vital I/O Supply

Nos

2

iv)

DC/DC Converter for MLKII Non-Vital I/O Supply

Nos

2

TOTAL = 68,20,435 (Approx)

2

Supply of essential spares as stipulated in the provision laid down in special conditions of contract for SSI system ; Itemwise details of spare to be supplied with unit, is listed below .

Page 67


ANNEXURE- II

SL No. 2A

Description of works For all the 1 stns

Unit

Qnty

lot

1

Full & consolidated quantities of 13 LOTs consisting of :i)

MLK II U PCBs

Nos

1

ii)

MLK II PS PCB

Nos

1

iii)

MLK II Vital I/P PCB

Nos

2

iv)

MLK II Vital O/P PCB

Nos

2

v)

MLK II Non-Vital O/P PCB

Nos

2

vi)


Nos

2

vii)


Nos

2

viii) U EEPROM PCB

Nos

1

ix)


Nos

2

x)

48- Pin Connector Guide Element

Nos

2

xi)


Nos

2

xii)

96- Pin Connector Guide Element

Nos

2

xiii) 48- Pin Female Connector

Nos

2

xiv) 48- Pin Female Crimp

Sets

50

xv)

Nos

2

Nos

50

96- Pin Female Connector

xvi) 96- Pin Female Crimp Sub Total = Rs: 805883 3 (a) Supply of Documents as detailed below.

(I)

Technician/Sr. Engr at installation and maintenance level for installation, testing, commissioning and maintenance of the system.

6 sets for each E.I

1

(II)

Engineer;s level Technical and system module for diagnostic and trouble shooting for repair centre.

6 sets for each EI

1

6 sets for each EI

1

(III) Completion documents as per special condition of contracts. 3 (b) Supply of documents as per technical specifications 4

Supply of Instruments.

IRISET

Page 68

sets

1


SL No.


Unit

Qnty

Tools kits and measuring instruments for testing maintenance and repair at site.Each set consists of (I) Crimping tool 48/96 pin , (ii) Insertion tool 48 pin , (iii) Removal tool 48 pin , (iv) Locator Tool 48/96 pin , (v) insertion tool 96 pin , (vi) Removal tool 96 pin , (vii) Digital multimeter 4 and 1/2 digit , (viii) General purpose Tool kit ( Srew drivers , spanners etc.)and (ix) Wooden cabinet

sets.

1

Sub Total = 70600 TOTAL SCH-B. = Rs: 76,96,918 Add, Total of Sch-"A" = Rs: 18,10,000 Grand Total of Sch-"A" & Sch-"B" without optional item = Rs: 95,06,918 Grand Total in words: Rupees Ninety Five Lakhs Forty Six Thousand Nine Hundred and Eighteen Only. NOTE: (1) All items of Schedule-B will be inspected by the authorised representative of CSTE, except for the materials which are normally inspected by RDSO. (2) The cost of recommended spares as indicated in item no.7 above shall not be considered for tender evaluation. NOTE:- All items with RDSO specifications/drawings are to be procured from RDSO 's approved supplier conforming to RDSO specification and if not available then from reputed manufacturers of ISO standard.

(Disclaimer : Cost shown in this notes is for general information only and may vary . Readers have to from relevant sources for accurate information.) ***

Page 69


ANNEXURE- III

Annexure – III Items of “ All Indoor Works for provision of Microlok-II EI system (Distributed version with OFC) at Stations of Indian Railways” SCHEDULE OF WORK SCHEDULE ‘A’ : EXECUTION OF INDOOR WORKS SNo DESCRIPTION OF WORK UNIT 1 Installation, wiring, testing and commissioning of Electronic Interlocking System supplied as per item No:01 of Schedule 'B' including transportation from Consignee's depot to site of work. It also includes provision of EMI Job Protection and Ring earth arrangement as per technical specification enclosed. 2

3

4

IRISET

Maintenance supervision of Electronics Interlocking equipment for one year from the date of expiry of free maintenance period as per conditions of contract, as per the details given in special condition of contract agreement, as per the latest guidelines of CSTE, and provision mentioned in Signal Engineering Manual. All the records are to be maintained as per latest circulars prevailing in the Division. During maintenance at least two expert personnel from the firm should be available at the station round the clock.

Per Stn/ Per year

Design, preparation & supply of ferro copies of each document in seven copies along with original tracing of Gateway quality in AUTO CAD FORMAT. The tenderer has to provide proposed documents in original tracing to Railway for approval. After approval of the same final drawings are to be supplied in four copies. The work shall be executed only as per approved final drawing. After completion of the work, the completion drawings in 10 copies in addition to the original are to be supplied. List of Documents: [1] Front plate diagram [2] Route section diagram [3] Control Nos details [4] Route control chart [5] Non-vital and vital bit chart [6] Signalling circuit along with all logic details with proper analysis [7] Power supply details [8] Equipment layout particulars in relay room [9] Relay disposition diagram in Relay room, [10] Technical literature in three copies each for all the equipment for the EI including power equipment, axle counter etc. [11] Equipment History s: Relay , Equipment as per typical drawing prevailing in division [12] Cable allocation plan - as prescribed by the Railway authorized representative. Training: Man [a] Training of Jr. Engineer/Maintainers in installation commissioning and Months testing including supply of hard copies of course modules to each trainee. [b] Training of Sr. Engineers, at manufacturers premises, in installation, Man commissioning, testing, trouble shooting and repairs including supply of Months hard copies of course modules to each trainee. TOTAL OF SCHEDULE ‘A’ 8,90,650/-

Page 70

QTY

1

1

1

1

1

ITEMS OF MLK II SYSTEM -DISTRIBUTED VERSION

SNo 1

2

3

4

5

DESCRIPTION OF WORK

UNIT

Design, manufacturer & transportation of Electronic Interlocking System complete as per Special conditions of Contract & RDSO specification No. RDSO/SPN/192/2005 with latest amendment and as per enclosed technical specification mainly consisting of Microprocessor Equipment, Interface Equipment, VDU with standby, Vital Relays, Interconnecting Cables, Maintenance Terminals including Data logger, Power supply System equipment, Racks, Fixtures, SM console, Mounting arrangements and Accessories necessary to make EI system functional. Inspection of EI equipment by RDSO. The E.I. equipment must be CENELEC Safety Integrity Level SIL-4 compliant. Essential spares as stipulated in the special condition of contract [part-II] Clause-20 for the EI system I.e. 10% of all the vital modules. Inspection by LS RDSO. PC based workstation for Data in-put & configuration, simulation & functional testing, diagnostic & Trouble shooting and commissioning of EI system as per specifications enclosed. Inspection by Representative of Dy. CSTE [CON]. System NOTE: Workstation should be capable of reconfiguring the system in case of any' Alterations' in the yard or Interlocking in future. Documents: - [I] Technician/Junior Engineer [Installation and Maintenance level]- Manual for installation, Testing, Commissioning and Maintenance of the system. [ii] Engineers level: Technical & System Module for Diagnostic & Trouble Shooting for repair Center. [iii] Higher Management: Functioning and system over view. Inspection by representative of Dy. CSTE[C]. Instruments/kits: Tool kits and measuring Instruments for Technicians/Junior Engineers for testing, maintenance, Trouble shooting, and repair of Hardware and Software including one digital millimeter Fluke187. Details as per specifications enclosed. Inspection by representative of Dy. CSTE[C] TOTAL OF SCHEDULE ‘B’ = 45,59,500/TOTAL OF SCHEDULE ‘A’ & ‘B’ = 54,50,150/-

1

1

1

Set of six per E.I.

1

Set

1

(Disclaimer : Cost shown in this notes is for general information only and may vary . Readers have to from relevant sources for accurate information.)

Page 71

QTY


ANNEXURE- IV

Annexure – IV TECHNICAL SPECIFICATION AND SCOPE OF WORKS (FOR ITEM NO. 1 OF SCHEDULE-‘A’ & ‘B’ OF INDOOR EI WORKS) 1

Electronic Interlocking Equipment:

1.1

Design, manufacture and supply of EI equipment with software, installation, testing and commissioning of Electronic Interlocking system including supply of spare cards consisting of 5 per cent of working cards subject to a minimum of one card for each type. The equipment shall conform to RDSO specification RDSO/SPN/192/2005 with latest amendment.

1.2

The electronic equipment is to be used in distributed mode. The electronic interlocking equipment at central location is to be connected to the object controllers with relay drive cards at end locations by OFC on a ring basis. (Railways will do the laying and termination of OFC). The scheme of Electronic interlocking installation is enclosed. (A provisional signaling plan of the stations can be had from the office of the Dy. CSTE/Const. in person).

1.3

Stations Interlocking shall be implemented by the Central processors connected with Operators console. Warm/hot standby shall be provided to these processors. These processors apart from implementing the Interlocking, shall also drive the I/O cards for the following functions: (a) (b) (c) (d)

Double line Block Instruments. LVCD Resetting. Berthing Track circuits and Loop line Axle counters. IB, Sidings, L.C. Gates, etc.

There is no need to provide standby to I/O Cards. 1.4

The role of the processors provided at the ends of yard shall be limited to driving the I/O cards. No Interlocking shall be implemented by these processors. There is no need to provide standby to these processors. There is no need to provide standby to I/O cards.

2

Details of supply of materials and Scope of the work (a) Supply of PC based work station with VDU of 21" size TFT- LCD type Samsung LCD model no. Sync Master 214T or similar. (b) Supply of Spare VDU, Key board with mouse suitable to above. [details as per technical specification. (c) Supply of PC based work station with VDU- type Samsung LCD model no. Sync Master 214T or similar for Maintainer to monitor the system. (d) Supply of Godrej Table model no. T-102 two no. (e) Supply of Revolving chair Godrej make - one no (f) Supply of Godrej make computer Table - two no (g) Execution of Labour portion of Interface relay wiring. This includes erection of relay racks, fixing of relays and other associated work in relay room. (The wiring material , Relay racks, Relays and fuses for interface relays wiring will be supplied by Railways. The tenderer shall supply the terminals, fuses, bus bars, etc. required for wiring of interface relays). Note : Interface relays to be supplied by Railways. (h) Provision of ring earth arrangement and electromagnetic interference shielding inside the relay room. The contractor shall supply all the material required.

IRISET

Page 72

TECHNICAL SPECIFICATION AND SCOPE OF WORKS

(i) Supply and installation of lightening and surge protection arrangements as per the manufacturer's specifications (j) The Electronic Interlocking equipment at central and end-locations shall contain suitable modems/ communication cards with necessary interface ports to take required number of fibres to work on ring topology. (k) The tools and measuring instruments required for maintenance of Electronic Interlocking equipment shall be supplied along with the equipment. (l) The system shall be wired and equipped with 5 % extra input and out put cards. These cards are in addition to the cards to be supplied as spares indicated above (i.e additional spare cards consisting of 5 per cent of working cards subject to a minimum of one card for each type shall also be supplied). Note : The cost involved in implementing the technical specifications as committed by the tenderer shall be borne by the contractor. (m) Stable 110 D.C. supply will be made available by Railways at Central location and end goomties where I/O cards are located. The D.C. power required for functioning of the equipment shall be derived from 110V DC supply through a suitable DC-DC converter supplied by the tenderer. (n) If the equipment works on AC supply suitable inverter shall be provided by the tenderer. (o) However, suitable B&C class surge protection equipment as per RDSO recommendation on IPS shall also be provided by the tenderer at central and end locations. Wherever materials supplied with RDSO inspection, contractor shall submit inspection certificates to the Railway stores.

3.

Details of installation works: The contractor shall execute the following works at station and end Goomties:(a) Installation of complete EI equipment including all subsystems at station Relay Room and at end Goomties.. (b) Installation of all racks pertaining to EI system at station Relay Room and at end Goomties which includes input and output Relay housing racks except Outdoor Cable Termination Racks. (c) Installation of VDUs, SM Console etc. and all other accessories. (d) Connecting E.I. Equipment with OFC through pig tails etc. (e) Supply of wires and wiring materials and inter-wiring of EI equipment, Relay Racks, VDUs and up to outdoor Cable Termination rack. (f) Complete laddering for interconnecting wiring up to outdoor Cable Termination rack. (g) Two VDUs shall be installed for operation by the operator. One shall be working and other shall be in standby mode. Arrangement shall be made to switch over to the standby VDU as and when required by the operator and command can be given through any one of the VDUs.

Page 73


ANNEXURE- IV

(h) Entire yard diagram along with all details including counters and alarms shall be depicted on the VDUs as per approved Front Plate Diagram. (i)

VDU shall be Sony/Samsung/Philips/LG make.

(j)

Supply and installation of suitable Surge Protection Devices to the E.I. Equipment.

(k) Testing of complete installation and generation of pre-commissioning check lists. (l)

Testing of interlocking and generation of test reports.

(m) All sorts of cutting, Drilling, riveting, masonary works etc. wherever required. (n) Painting and lettering works as per Railway standard and guidelines. (o) Transportation of all materials from Railway stores to station and back shall be done by the contractor for which no additional payment shall be made by the Railways. (p) The contractor shall arrange inspection of all items by the Railway authorities before installation irrespective of the Inspection clause. (q) The contractor shall be responsible for handling and safeguarding of all equipments till commissioning the station. (r) Contractor shall undertake 12 months free maintenance after commissioning of the system. (s) Phoenix / Wago terminal with suitable fixing arrangements shall only be used for termination of indoor wires. The Terminals shall be supplied by the contractor and inspected by the Railway representative at site before use. 20% spare terminals are to be kept as spare. (t) Approved type of Fuse base with cartridge are to be used for wiring of E.I. Equipment and 20% spares Fuse base with cartridges subject to minimum 4 Nos. shall be provided by the contractor. The type of rating fuses to be supplied shall be as per manufacturer’s instructions and Railways guidelines (u) For provision of external Data logger the potential free of all input and output Relays shall be extended to Tag Blocks. The tenderer shall execute the work which include supply of Tag Blocks, fixing, wiring and termination of cables for the above works. Extended Data logger shall be provided by Railways.

IRISET

Page 74


ADDITIONAL INFORMATION/REQUIREMENTS WITH REFERENCE TO TECHNICAL SPECIFICATIONS [SHALL BE READ ALONG WITH RDSO SPEC. No: RDSO/SPN/192/2005 WITH LATEST AMENDMENTS]

Para of RDSO Clarification Tech. Spec. 3.4 The system shall be capable of operating on control-cum-indication but equipped with operation on VDU only. In addition to working VDU one standby VDU shall also be provided and connected with the system. 3.10. The tenderer shall supply -friendly graphic based design tool to generate station specific application software to carryout future yard modifications. 3.12 The connection between the electronic interlocking equipment at central location and object controllers at both ends of the yard shall be on OFC. 3.13.1 The proof of compliance of SIL-4 of CENELEC standards or equivalent international standards for hardware and software shall be submitted by the tenderer. 3.13.2 The third party validation certificate of software of EI system and warm/hot standby change over software for the offered configuration shall be submitted. 5.1.2 The cycle time and response time of the system shall be clearly indicated. 5.1.4 VDU control terminals only is required. 5.1.5 Event logging for 10,00,000 events and facility for automatic serial transfer to central monitor through data logger shall be available in the system. 5.1.7.7[i] The object controller shall have only relay driver cards duly validated and meeting all safety requirement to drive points, signals and other field gears. 5.1.7.3 The medium of communication between CIU and OCs shall be OFC (confirming to ITU-T-G652 standards i.e. mono mode cable ) provided on ring basis. Four fibers will be made available for system working - two working fibers and two spare fibers. In case of failure of working fibers, the system shall change over to spare pair of fibers without causing interruption to EI system. 5.3.1(i) The size of VDU monitor shall be 21” and the VDU is of TFT-LCD type with mounting arrangement. 7.1 The warm/hot standby arrangement is required for processor only. The input/output cards need not have standby facility. However, the system shall be upgradeable to hot standby for input and output cards by inserting I/O cards in the empty slots provided in the system. Necessary software shall be supplied free of cost to provide hot standby for I/O cards at a later date by the contractor. 8.2 The software engineering standards followed for developing software shall be made available to RDSO. 8.3 The verification and validation procedures carried out in house or by independent agency shall be made available to RDSO. 8.5.2 The system shall switch the output to safe state when the vital output relay of the system for control of field equipment is energized due to false feed created either intentionally or unintentionally. 9.1 The EI shall work on 110V/60V/24V/12V DC or 230V AC supply. 15(a) Approved interlocking Plan shall be supplied by Railway. 15[b] VDU with standby arrangement. 15[c] Relay Interface. 15[d] 110V DC 15[e] 21 Inches.

Page 75


ANNEXURE- IV

GENERAL: The term Track Circuit may be read as Track circuit/Axle counter wherever it appears in the Technical Specifications. The functional requirements of Data logger included along with supply of E.I. in Schedule will be generally in conformity with the RDSO ‘s Specification No. IRS/S/99/2001 with latest amendments. SPECIFICATIONS FOR PC BASED WORK STATION [ITEM NO: 3 OF SCHEDULE ‘B’

Processor

Operating system Standard memory Maximum memory System memory Cache Hard drive Optical drive Graphics. Modem Net work

Pre-installed licensed software. Battery Display Pointing device. I/O interfaces

Compatibility/compliance

PC card slots Status display

Key board Weight Warranty Make Inspection.

IRISET

Intel[R] Pentium [R] M Processor 750 [ ] s Enhanced Intel [R} speed step Technology [1.86 GHz, 2 MB L2 cache, 533MHzFSB] Microsoft [R}] Windows [R} XP Professional 512MB [1 X 512MB] DDR SDRAM [333 MHz] Upgradeable to 2GB max [with discard] 512 MB [ x 1 512MB] DDR SDRAM [333MHz], upgradeable to 2GB. 2MB Level-2 Cache. 80GB[4200 rpm] Dual Layer DVD+_RW/+_R Intel [R] Graphics Media Accelerator 900 [up to 128 MB Shared Memory]. High speed 56 K Modem Integrated 10/100 LAN Ethernet, Intel[R} Pro/Wireless 2200 802. 11g integrated wireless LAN, integrated Blue tooth. Symantec Norton Anti Virus, Symantec Norton Internet Security 2005. 43Whr 6-cell Lithium-lon battery. 19” colour TFT WXGA [1280 X 768 resolution] high definition Bright View 15:9 Wide screen. Touch pad pointing device with 4-way scroll and on/off switch button. [1] 6-in-1 Digital Media Reader slot, [1] IEEE 1394 port, [1] S-video port, [1] VGA port, [1] Port Replicator connector, [1] Headphone, [1] External Microphone, [1] AC power connector, [1] RJ-11, [1] RJ-45 [3] USB 2.0 port. Plug-and-ply, Ethernet network compatibility, Advanced Configuration and Power Interface [AI], Hibernation/Sleep modes. Type-I/II PC Card Slot with for 16-bit PCMCIA and 32-bit Card bus. System Power, NUM Lock, CAPS Lock, SCROLL Lock, Battery Charging, HDD/Optical activity, Touch pad on/off, Media Slot, Mute, Wireless. Full-sized keyboard with touch pad 2.41 Kg approx 1 Year Limited Warranty [1 Year Parts/1 Year Labour] HP Pavilion, Lenovo, Dell, Compaq Presario V 2317 AP or equivalent. Consignee.

Page 76


SPECIFICATION FOR OPERATORS INTERFACE EQUIPMENT AND VDU [TO BE SUPPLIED ALONG WITH E.I. EQUIPMENT AGAINST SCHEDULE-B- ITEM No: 1 Sl No. 1 2

3

Description The E.I. system shall work with two sets of control terminal VDUs in lieu of control cum-Indication . Control terminal VDUs shall be configured in hot standby mode such a way that if one system fails another should take over without losing any control and data. The control terminal VDUs shall consist of: Industrial grade PC of repute make capable of working continuously Intel Pentium IV @. 3.06 GHz, U with 1MB Cache and 533FSB 512MB DDR RAM. 80 GB Seagate SATA HDD. Parallel ATA to serial ATA converter [two serial ports] Logitech keyboard. [should dust & water proof] Logitech optical scroll mouse MTBF figures: Not less than 101, 713 Hours Operating Temperature zero degree Centigrade to 60 degree Centigrade [32 degree F to 140 degree F] Humidity 5% to 95% RH, non-condensing. Heavy duty steel, 19” Rack mount 4U chassis Cooling Fan, Air filter. Vibration: 1.5G Max and 0.1” p-p at 5 to 500 Hz. Shock: 10G peak acceleration [10m/Sec] EMI: FCC Class A and E Minimum of 21” TFT colour monitor of Sony/ LG/ SUMSUNG/ Philips. The Industrial grade PC[IPC] must ensure that all IPC components are carefully selected and checked for electromagnetic compatibility[EMC], temperature resistant and resistant to vibration. The heavy duty enclosure/chassis must protect the PC from the envirmental disturbance like dust, EMI, temperature and vibration, etc.

Tool kits and measuring instruments for technicians/Jr. Engineer for Testing, maintenance and repair at site. SN 1 2 3 4 5 6 7 8 9 10

DESCRIPTION. Each set will consists of: Crimping Tool Ratchet 48/96-pin Crimping Tool 48-pin Crimping Tool 96 -pin Insertion Tool 48 -pin Removal Tool 48-pin Insertion Tool 96-pin Removal Tool 96 pin General purpose Tool [set of screw Drivers & Spanners] Digital Multi-meter-Fluke 187 Cabinet [Medium Size].

Page 77

QUANTITY.


ANNEXURE- IV

TECHNICAL SPECN. FOR ELECTRO-MAGNETIC INTERFERENCE [EMI] SHIELDING. 1.

Electromagnetic Interference [EMI] shielding shall be done with the bare standard copper conductor of size 10 sq.mm.

2.

The bare copper conductor shall run the four walls inside the E.I. equipment room in 4 rows.

3.

The spacing between the row shall be kept at 75 CM.

4.

Those wires of each row shall finally connected to Earth Bus bar of the E.I. equipment room.

5.

The Earth Bus Bar shall be installed at a height of 0.5 Mtrs from the floor level wherever installed.

6.

The Earth Bus Bar shall be insulated from the building structure with low voltage insulator spacers of height 60mm. The whole assembly shall be fixed on a Hylam sheet 0+6mm thickness mounted on wall.

7.

The conductors for EMI shielding shall be fixed on the walls by providing suitable mounting arrangements and insulated spacers of height of 60 mm.

8.

All the bare conductors shall be connected to Earth Bus Bar at a common point.

9.

The work includes supply of all materials by the contractor at his own cost.

10. The work shall be executed as per the approved drawings of Railway. TECHNICAL SPECIFICATION FOR RING EARTH ARRANGEMENT

IRISET

1.

Ring Earth arrangement shall be installed surrounding the S&T service building or at a suitable place as advised by the Railway authorities as per the site conditions at each station.

2.

Ring earth shall consist of minimum 8 [Eight] Nos. of earth pits connected in a Ring formation.

3.

Each earth shall be executed as per specification No. and Drawing No.

4.

For inter connection of earth electrode and connection between earth pit to earth Bus bar shall be executed by providing cium Bronze wire of 35 Sq. mm bare conductor as per RDSO Specification No: RDSO/SPN/178/2003.

5.

The combined earth value shall be less than 1 ohms [one ohms].

6.

The contractor shall supply all materials required for the work at his own cost.

7.

The contractor to submit the test certificate of materials supplied by the contractor.

8.

All materials shall be inspected by representative of Dy. CSTE[C] before execution of the work.

9.

The value of the earth shall be measured by the contractor tly with Railway authorities and earth value shall be recorded in prescribed and also painted on each earth pit by the contractor.

Page 78


10. The earth leads shall be extended to Equipment room, Power Supply Room and E.I. equipment room by providing suitable earth Bus bar as per standard drawing and connect the same with the concerned equipment which are necessary to be earthed and as advised by the Railway authorities. TECHNICAL SPECIFICATION [FOR DRAWING] TECHNICAL SPECIFICATION FOR DESIGN OF RAILWAY SIGNALLING DRAWINGS INCLUDING CIRCUITS / WIRING DRAGRMS ETC.

1

All the plans should be compliable with requirement of non- RE/RE area and as per site requirement.

2

The deg of Circuit Diagrams shall be done as per extant Railway practice, SEM, General and Subsidiary rules, the guide lines provided by RDSO and as per the latest rules prescribed by the Railway. Wiring diagram for provision of DATA LOGGER shall be prepared on separate sheets.

3

Alteration column should be shown on every sheet and sufficient space should be left for further alteration on each sheet.

4

All drawings shall be prepared with suitable CAD system. All original drawings shall be supplied in tracing paper of 90/100 GSM of GATEWAY qualities. All drawings shall be prepared on A2 size unless otherwise stated specifically. Each drawing sheet shall have Border Line, Margin, Name Plate / Approval Column, Alteration Column and drawing space as per latest approved practice of East Coast Railway.

5

At least 20% of available drawing space shall be kept blank at the bottom of each original sheet, above Name Plate / Approval Column, to accommodate future expansion.

6

In addition to the above specifications the contractor shall follow any other standards as followed by the S&T Dept. of East Coast Railway during preparation of drawings.

7

All original drawings and prints shall have relay no. / terminal no. / fuse no. already incorporated.

8

During preparation of the drawings the following shall be kept in view: (a) Optimization in using of relays. (b) Economisation in using relay s. (c) Optimization in using of cables.

9

All Original drawings shall be printed through Ink Jet Plotter. (a) No hand correction shall be allowed on the original tracing. If any connection is required on a sheet the original tracing of that particular sheet shall be replaced with a new one and the same shall be submitted for fresh approval of Railway. (b) Railway reserves the right to add/delete/modify the requirement of Drawings at any point of time. (c) Checking of check prints shall be done only one time by Railway. (d) Copy/Prints of drawings whenever submitted shall be accepted by Railway in the form of ‘Ferro Prints’ only.

Page 79


ANNEXURE- IV

(e) After the initial checking is over subsequent drawings shall be submitted in original tracing only. (f) In case of repeated mistakes the drawings shall be rejected and fresh drawing shall be submitted by the contractor for which no extra payment shall be made by Railway. (g) In case of any modification in Engineering plan or Interlocking Plan the subsequent modifications in all drawings shall be carried out by the contractor at his own cost. (h) All transaction shall be made through Dy.CSTE [C] . (i)

The contractor shall be responsible for collection of all field data from the site of work for preparation of ‘As made’ drawings.

(j)

Original Tracings of approved ‘As Planned’ drawings shall be submitted by the contractor to the Railways if so advised.

10

Inspection & Approval: By Design and Drawing office of CSTE.

11

For all Technical discussions with Railways regarding the work, the authorized qualified Design Engineer(s) , who is well versed in Railway Signalling system shall attend concerned Railway Offices and represent the tenderer. ***

IRISET

Page 80

FAILURE SUMMERY OF EI SYSTEM

Annexure – V Failure summary of Electronic Interlocking system at Stations of Indian Railways

Year Wise Failures-US & S make Sl.

No. of Failures 20052006200706 07 08

2003-04

200405

3

2

1

4

7

2

19

0

0

0

0

0

3

3

4

2

0

3

5

0

14

0

0

0

0

0

0

0

02.09.1995

1

6

2

0

2

4

15

Ulavapadu

17.12.1995

2

2

2

7

6

3

22

5

Singarayakonda

31.05.1999

3

1

1

0

2

3

10

6

Tanguturu

30.03.1997

0

0

0

0

0

0

0

7

Surareddypalem

31.05.1997

5

0

5

5

1

1

17

8

Ongole

04.03.2000

3

0

0

3

1

3

10

9

Karavadi

19.03.1998

0

0

1

0

0

1

2

10

Uppugunduru (Safelok)

02.04.1998

0

0

0

2

0

1

3

11

Vetapalem

29.01.1997

0

0

5

2

1

2

10

21

13

17

26

25

23

125

No.

Station Srivenkateswara Palem (MLK-I)

DOI 12.01.1995

Srivenkateswara Palem (MLK-II)

06.07.2008

Kavali (MLK-I)

10.07.1994

Kavali ( MLK-II)

16.05.2008

3

Tettu

4

1

2

Total

Page 81


200809

Total

ANNEXURE - V

S.C.RLY- A Z D - P R A H A Sl. No

Station

Date of installation

Total failures

Reset/ Restored

Power Supply

Cable failure + connector

Card failure

staff working

Relay

1

Pedapalli

19.03.2006

3

1

2

-

-

-

-

2

Kolanur

12.01.2007

4

4

-

-

-

-

-

-

3

Potkapalli

04.02.2006

7

2

2

1

1

-

1

-

4

Uppal

19.08.2005

8

5

1

1

-

-

-

-

5

Chutalpalli

18.08.2006

0

-

-

-

-

-

-

-

6

Yelgur

06.07.2006

4

3

-

-

-

1

-

-

7

Nekonda

25.05.2006

4

2

2

-

-

-

-

-

8

Kesamudram

15.06.2006

6

-

1

-

2

-

3

-

9

Mahabubabad

29.09.2006

10

7

-

-

2

-

-

1

10

Gundrathimadugu

29.10.2006

7

5

1

-

-

1

-

-

11

Madhura

28.11.2006

6

2

-

-

2

-

1

1

59

31

9

1

7

2

5

2

TOTAL

IRISET

Route cancellation

Page 82

-

FAILURE SUMMERY OF EI SYSTEM

C.RLY-GENERAL ELECTRIC Sl. No

station

Date of installation

Total failures

Reset/ Restored

Right Auto

Power Supply

Card Failure

Staff Working

Fuse Blown off

Route cancellation

1

Shirawade

28.09.2007

2

-

1

-

-

-

-

-

2

Karad

28.11.2008

1

-

-

-

1

1

-

-

3

Shwnoli

20.12.2007

9

-

4

2

2

-

1

-

4

Takari

22.10.2008

21

-

16

-

-

-

-

5

5

Kirloskarwadi

22.02.2009

4

-

1

1

-

-

2

-

6

Bhilawadi

04.02.2009

1

-

1

-

-

-

-

-

7

Bhavani Nagar

10.12.2008

1

-

-

1

-

-

-

-

8

Nandre

16.01.2009

0

-

-

-

-

-

-

-

9

Jaisingpur

20.12.2008

2

-

-

1

-

-

-

Relay 1

10

Hatkangle

31.12.2008

1

-

-

-

-

-

-

11

Rukadi

08.03.2009

4

-

2

-

1

-

-

1 1 ()

12

Gurumarket

31.03.2009

5

-

2

-

1

-

-

-

27

5

5

1

3

8

TOTAL

51

Page 83


ANNEXURE - V

S.C.RLY- Union Switch & Signal System Sl. No. 1

CAUSE DATE OF TOTAL INSTALLATION FAILURES

Station Srivenkateswara Palem - MLK-I Srivenkateswara Palem - MLK-II

RESET/ POWER CARD CABLE & STAFF RESTORED SUPPLY FAILURES CONNECTORS WORKING

12.01.1995

19

2

4

11

2

0

0

06.07.2008

3

0

0

2

0

1

0

Kavali - MLK-I

10.07.1994

14

2

4

5

0

3

0

Kavali - MLK-II

17.05.2008

0

0

0

0

0

0

0

3

Tettu

02.09.1995

15

2

5

6

1

0

0

4

Ulavapadu

17.12.1995

22

7

3

8

0

5

0

5

Singarayakonda

31.05.1999

10

8

0

1

0

1

0

6

Tanguturu

30.03.1997

0

0

0

0

0

0

0

7 8 9

Surareddypalem Ongole Karavadi Uppugunduru – Safelok

31.05.1997 04.03.2000 19.03.1998

17 10 2

12 6 0

1 2 2

4 2 0

0 0 0

0 0 0

0 0 0

02.04.1998

3

0

1

2

0

0

0

Vetapalem

29.01.1997

10

7

0

1

0

2

0

125

46

22

42

3

12

0

2

10 11

Total

***

IRISET

REJECTED & RESTORED

Page 84

FACTORY AND SITE ACCEPTANCE TEST OF MLK II

Annexure – VI Factory Acceptance Test and Site Acceptance Test of Microlok II Factory Acceptance Test: 1. Purpose This document defines the procedure for factory testing of Microlok II station interlocking, where tests are executed in a factory environment. Results of the tests are observed and documented in a Test Report.

2. Overview The Factory Acceptance Test ensures that Microlok II based station interlocking system fulfills the station control table requirements and working in safely manner if any false inputs/information received. FAT is carried out through simulation set up (using toggle switches or MISS software) at factory which all field inputs are simulated. FAT shall also be carried out for each station interlocking applicable to the project.

3. Scope On doing FAT for each station interlocking at factory before delivering to site it minimizes the site error and reduces the correction at site.

4. Responsibility Principles Tester - The person appointed by ASTS to perform principles tests. The Principles Tester shall be independent of design and installation but can perform any preceding tests. Tester in Charge - The person appointed by ASTS to ensure that all testing, inspections and recordings of all testing activities are managed in an orderly manner, to an agreed program. He has responsibility to keep all the test records and also ensures that all the applicable forms being completed / closed out before dispatching to site.

5. Abbreviations ASTS FAT FRVD I/O PC SIP VCOR VDU .ml2 .mll .mlp

-

Ansaldo STS India Pvt. Ltd Factory Acceptance Test Free Run Variable Display Input / Output Personal Computer Signalling Interlocking Plan Vital cut off Relay Video Display Unit Microlok II Source file Microlok II Listing file Microlok II compiled file

6. Inputs To proceed the FAT, the following inputs are supplied to Tester In charge with “Testing copy” stamp, a) Microlok II .ml2, .mll & .mlp file (Hardcopy & Read-only Softcopy) b) Station SIP c) Station Route control chart d) Station Control cum indication diagram e) Cross tables

Page 85


ANNEXURE -VI

7. FAT Setup The following equipments are required to set up the FAT; Tester In charge is responsible to set up for FAT according to station specific. a) Microlok II b) Cardfile (may require Special cardfile if all station U’s are placed in one) c) Communication equipment if required (E-patch , Cable) d) PC’s (Simulator, Maintenance PC & Operator PC) e) Power supply Equipments (Converters, Cable Extension Cards) f) Simulation if required Simple Block Diagram (FAT Setup)

Simulator PC

OR

Operator VDU Microlok II

Simulator

Maintenance PC

8. Testing with simulator setup Availability of the I/O PCB’s to the station specific, the simulation testing shall be carried out through Simulation . The simulation consists of toggle switches to simulate the track and point detection conditions and rotary switches to simulate the lamp proving detection. Any additional requirements such as block, IBH, Crank handle, Level crossing & Axle counters pertaining to indications are simulated according to the requirement of station layout by switches. The indication portion of control cum indication is to be tested through VDU .

9. Testing with MISS software (Simulator Pc) Simulation testing shall be carried out through MISS setup if I/O cards are not available or if station layout is large / yard which requires more physical wiring. All I/O bits are simulated through PC via serial communication between PC & MLK II. The simulation system (SMPC) is used to operate control bits in order to set/cancel routes, set points and give releases. MISS will also provide make and break controls to the Field Equipment Simulation System e.g. Clear / occupy track circuits, make / break point detection, make / break lamp proving etc.

10. Types of Testing The following testing shall be carried out while doing FAT,

IRISET

•

Power On

•

VCOR

•

Communication testing

•

Correspondence Test

•

System integrity Test

•

Principle’s Test

•

Interlocking testing Page 86


11. Procedure Before proceeding to the .mlp file, the .mll shall be verified by the tester to ensure the exceeds of bit usages, Timer section, Compiler version etc.

Power ON Test: Power ON Test includes extending power to Microlok II card files – 12Volts and 24 Volts DC from rectifiers and 230Volts AC mains to the VDU computer. Check the voltages given to the Microlok cardfiles are within ranges.

VCOR test: After power is extended, the application data to the Microlok-II units and Check whether VCORs of Microlok II units are energized. After energizing VCORs it indicates that the Microlok units are healthy and the programs loaded are error free.

Communication test: Both Microlok and VCOR is picked up, this will automatically enable the communication between Microlok Units. When the VDU software is run, this will automatically enable communication between VDU and Microlok, and indications at the VDU will be dynamically updated based on the status received from Microlok. Check the communication status in LEDs and alpha-numeric display at Microlok show the communication status and check the indication status in VDU.

Correspondence Test: The Tester shall correspond all controls and indications between the VDU and the Microlok II. A list of all controls and indications that are to be tested is available in the serial section definition of the Microlok II communication link. Refer relevant Microlok II Application data for this serial section definition. System Integrity Test System Integrity test is to prepare the simulator to the station specific needs before starting Interlocking tests. To initialize the station interlocking, field inputs (Tracks status - Unoccupied, Points status - Normal and Signal status – Red or ON) from simulation /PC are kept in favorable position Check whether indications in VDU are in correspondence with the field simulations Toggle all track circuits from Simulation /PC one after another and check VDU display changes correspondingly. Operate Points from VDU and change the field status from simulator /PC and check the VDU display changes accordingly Toggle Signal lamp (Red) switches and check VDU indication flashes

Principles Testing: To ensure that the Application Logic is functioning in accordance with the client’s signalling principles a principles test is carried out. This test ensures that all locking requirements are met, signals clear to the correct aspect, all the controls required to clear the aspect are set to the required positions and the design is in accordance with the client’s signalling principles. An Assistant Tester shall record the individual tests on the control tables and test sheets.

Control Table Validation: As the Principles Tester carrying out testing to the source documents [SIP’s – Signalling Plans and Route Table(s)], a second tester shall be checking the tested functions (as witnessed from the testing) against the control tables.

Page 87


ANNEXURE -VI

FRVD (Free Running Variable Display) is a facility available in Microlok Maintenance tool which shall be utilised to monitor the status of bits defined in Application Data. SET means value=1 and CLEAR means value=0 in Boolean equations. While doing specific control table test, by means of FRVD it has to ensure all the relevant bits applicable to test shall be “Set or Clear” and other irrelevant bits to check as well whether is updated for the test.

Vital Timers: In order to minimise testing time, if required, the application logic timer variable setting will be reduced for nominated variables (as nominated by the Principles Tester). A List of timers altered for test purposes is recorded on test certificate Timers Altered for Testing Log. NOTE: It is essential that the original times are reinstated and validated at the completion of testing.

Route Setting, Locking Test: Aim: To check: • The route gets set and locked if the favourable conditions are met. • The Signal goes to OFF aspect after route is set and locked Procedure: • Set the FRVD for LR, UCR, ASR and HR bits of the required route. • TEST 1: Check the ASR bit is SET. Initiate route set from VDU. The LR, UCR bit shall SET. This shall be followed by ASR bit in CLEAR and HR bit in SET. • Test for the following conditions while route is set and locked: o TEST 2: Route shall remain set and locked even if approach lock tracks are occupied. o TEST 3: Route shall remain set and locked but signal is put back to danger if back lock track or overlap track is failed. The signal shall restore when tracks failure resolves except Replacement track. o TEST 4: Route shall remain set and locked but signal is put back to danger in case point detection is lost. The signal shall restore when point detection is restored. o TEST 5: The signal is put back to danger in case Level crossing, crank handle or siding lock detection is lost. When locking of crank handle or keysiding is restored, the route must be released with the elapse of timer. o TEST 6: Route shall remain set & locked and signal shall remain OFF, if points & tracks are operated for other routes. o TEST 7: Under Route set and locked condition, the conflicting routes shall not be available or cannot be set. Also Test for the routes (which are not conflicting but are available), the routes shall get set & locked independently and simultaneous train movement on these routes does not affect the route under test. This test is performed as per Cross table.

Route Cancellation Test: Aim: To check: • The manual route cancellation shall be immediate if the approach tracks are unoccupied; • The manual route cancellation with appropriate timer if the approach tracks are occupied; • The manual route cancellation with appropriate timer if dead approach is applicable; • The route cancellation with train movement (including sectional route release if applicable). Procedure: IRISET

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• • • •

Set the FRVD for EUYR, EUUYR, LR, UCR, ASR and HR bits of the required route. Simulate route set and locked condition for the given route. Ensure manual route release is applicable only when signal is put back to danger using ‘Signal Stop’ command from VDU. With the following preconditions, simulate the route cancellation. o TEST 1: Precondition of approach lock tracks unoccupied, apply ‘Signal Stop’ followed by ‘Route Release’ command from VDU, the route shall release immediately. o TEST 2: Precondition of approach lock tracks occupied, apply ‘Signal Stop’ followed by ‘Route Release’ command from VDU, the route shall release after elapse of appropriate time. o TEST 3: Precondition of dead approach routes, apply ‘Signal Stop’ followed by ‘Route Release’ command from VDU, the route shall release after elapse of appropriate timer. o TEST 4: Simulate the train movement over the route set and locked, the route shall get released after the completion of train movement and full occupation of berthing track. [NOTE: Simulate short train (one track occupied) and long train (all back lock tracks occupied) simulation to test the route release sequence]. In case, sectional route release is applicable, the track sections in the route shall be released with the train movement based on TLSR/ TRSR settings as per control table definitions.

Signal Aspect Sequence: Aim: To check: • The change in signal aspect with the status of ahead signal aspect. • The movement of train (occupied status of replacement track circuits) replaces the signal aspect in sequence OFF (G or Y) R. • The lamp failure conditions leading to more restrictive aspects. • Procedure: • Set and lock the routes for the signals as per SIP and Control Table definitions, simulate and check the following: o

o o o o

o

All the track circuits shall be cleared (Unoccupied). The Level crossings shall be closed. The signal under test shall reflect OFF aspect as per control table definition. TEST 1: Simulate occupancy of the control track circuits including overlap track circuit, the signal under test shall display RED (R) aspect. TEST 2: Simulate the ahead signal as RED (R) aspect, the signal under test shall display aspect as per SIP definition. TEST 3: Simulate the ahead signal as Yellow (Y) or Double yellow (YY) or Green (G) aspect, the signal under test shall display aspect as per SIP. TEST 4: Simulate the ahead signal as blank aspect, the signal under test shall display RED aspect as per SIP. Calling ON signal shall display ON aspect. TEST 5: Calling-ON signal is OFF aspect only when main signal is failed.

Point Control Test: Aim: To check:

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ANNEXURE -VI

• • •

The points are called, moved and locked in desired position as per control table definition, when route is called or call for individual point operation; The point movement in Normal, Free for Route Call and Reverse, the power feed shall be cut off immediately when point detection is received or after elapse of appropriate timer if the point detection is not received; The emergency point movement in case the point track circuit has failed depicting occupancy of point tracks;

Procedure: • Check for the point movement under following condition: o TEST 1: Precondition is point shall be in “Free” for route call position but not in favourable condition as per control table. Simulate a route call using VDU, the points shall move and get set and locked in the desired position as per control definition. Ensure that signal shall display OFF aspect only when points in the route and in the overlap are locked and detected in the desired position. The signal shall be put back to danger in case point detection is lost. o

TEST 2: Precondition is point shall be in “Free” position, detected in reverse direction and route is not set. Simulate point movement to “Normal” position using VDU Menu commands, the feed to the points shall be extended using NWR and WCR output bits. Ensure feed is cut off either immediately if the point position is detected in Normal or after elapse of appropriate time if point position is not detected in Normal direction.

o

TEST 3: Precondition is point shall be detected in “Normal” or “Reverse” position and route is not set. Simulate point movement to “Free” position using VDU Menu commands, ensure no feed is extended to track device but the indications are changed on VDU screen.

o

TEST 4: Precondition is point shall be in “Free” position, detected in Normal direction and route is not set. Simulate point movement to “Reverse” position using VDU Menu commands, the feed to the points shall be extended using RWR and WCR output bits. Ensure feed is cut off either immediately if the point position is detected in Reverse or after elapse of appropriate time if point position is not detected in Reverse direction.

o

TEST 5: Precondition is route is not set and the point zone track circuit has failed. Ensure movement of point is not possible using Normal Point Menu Commands from VDU. Simulate movement to “Free”/ “Normal”/ “Reverse” position using Emergency point movement commands from VDU, ensure feed is cut off either immediately if the point position is detected in Reverse/ Normal or after elapse of appropriate time if point position is not detected in Normal/Reverse direction depending on the position called for. Also ensure that Emergency movement is not possible under Route Set and Locked condition.

Level Crossing, Crank Handle & Siding Control Test: Aim: To check: • The release and locking of crank handle. • The release and locking of Siding key locked levers. • The release and locking of Siding key locked levers.

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Procedure: • Set the FRVD of related bits. •

TEST 1: Simulate the release of key for crank handles using VDU. Ensure the route becomes unavailable if the route is not set and locked. In case route was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall go back to danger.

•

TEST 2: Simulate the release of key for Siding Control Lever using VDU. Ensure the route becomes unavailable if the route is not set and locked. In case route was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall be put back to danger.

•

TEST 3: Simulate the release of key for Level Crossing using VDU. Ensure the route becomes unavailable if the route is not set and locked. In case route was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall be put back to danger.

Following tests also will be carried out in addition to the above individual tests: o o o o o o o o o o o o o o o o o o o o o o

Signal & route - clear Signal & route – Indication Point Indication CH & LC indication Track Occupied Indication Break test and Mid stroke test – Point (Control and Indication) Break test – Track Break test – Ahead signal, CH, LC etc. Conflict signals and routes Reverse move Jump moves Normal release Emergency release Approach release Overlap release Auto release (Train move) Sectional route release Back lock test Signal track test SM’s control Cross test with all other elements Special tests

Results: All the above test results shall be logged and signed off in a marked up copy of the: • Control Table • Activities Event log • Acceptance Test Incident Report (ATIR) if required.

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Re-testing Application Logic: If it is necessary to undertake application logic changes as a result of incidents arising from Principles Testing or for other reasons then the details shall be documented on an ATIR. Following update of application logic to address a deficiency, the designer shall produce a “difference list” that highlights the changes made to the previous version of the application logic. Minor Logic changes need not be updated individually but can be completed as one data change.

12. Documentation: All the test results obtained for the particular installation under test shall be part of the ing documentation package for the Microlok II Application Logic Principles Testing. The ing documentation package shall be available for review during Microlok II Application Logic Principles Testing as various tests are completed.

Site Acceptance Test: 1. Purpose This document defines the procedure for Site testing of Microlok II Station interlocking, where tests are executed at site environment. Results of the tests are observed and documented in a Test Report.

2. Overview The Site Acceptance Test ensures that all the equipments installed at site i.e Microlok II, Communication equipments, Power supply equipments, Relays and Control cum indication are functional correctly as per approved system configuration & station interlocking requirements and working in safely manner and failsafe if any equipment fails / false inputs/information received. SAT mainly involves the System integrity and functional testing of all equipments and interlocking testing also shall be carried out with full setup except the trackside equipments. SAT shall also be carried out for each station applicable to the project.

3. Scope On doing SAT for each station interlocking at site ensures the overall system safety and error free system is being delivered to the client.

4. Responsibility Principles Tester - The person appointed by ASTS to perform principles tests. The Principles Tester shall be independent of design and installation but can perform any preceding tests. Tester in Charge - The person appointed by ASTS to ensure that all testing, inspections and recordings of all testing activities are managed in an orderly manner, to an agreed program. He has responsibility to keep all the test records and also ensures that all the applicable forms being completed / closed out before handing over to client.

5. Abbreviations

IRISET

ASTS

-

Ansaldo STS India Pvt. Ltd

CCIP

-

Control Cum Indication

I/O

-

Input / Output Page 92


PC

-

Personal Computer

SAT

-

Site Acceptance Test

SIP

-

Signalling Interlocking Plan

VCOR

-

Vital cut off Relay

VDU

-

Video Display Unit

.ml2

-

Microlok II Source file

.mll

-

Microlok II Listing file

.mlp

-

Microlok II compiled file

6. Inputs To proceed the SAT, the following inputs are supplied to Tester In charge with “Testing copy” stamp, a) Microlok II .ml2, .mll & .mlp file (Hardcopy & Read-only Softcopy) b) Station SIP c) Station Route control chart d) Station Control cum indication diagram e) Cross tables f) Wiring circuits

7. SAT Setup All the equipments involved for station working is being installed before proceeding SAT, so there is no need of separate set up is required except to simulate the field inputs; Tester In charge is responsible to set up for field inputs simulation including lamp aspects according to station specific. All the field inputs are simulated through toggle switches and inputs are sending to Microlok II via relays and the field outputs are sending to lamps through relays. SAT setup block diagram is nothing but Station configuration including with Simulation for field inputs and the Tester in charge is responsible to check all connectivity as per Microlok II system configuration.

8. Types of Testing The following testing shall be carried out while doing FAT, •

Visual test

•

Wire count test

•

Bell test

•

Insulation resistance test

•

Earthing test

•

Power On

•

VCOR

•

Communication testing

•

Correspondence Test

•

System Integrity Test

•

Interlocking testing

•

Change over test

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ANNEXURE -VI

9. Procedure Before proceeding the below tests, Tester needs to check all the activities as mentioned in Pre-commissioning checklist. Visual Test The visual test is to ensure the quality of workmanship carried by the construction team and to confirm everything followed as per the requirement of customer and as indicated in the design drawing. Any changes required to be informed to Site Manager & Project Manager to take necessary corrective action prior to starting of testing. On doing the visual check the construction checklist is updated to ensure all installation done properly. Wire Count Test This is to ensure the number of wires used in each relay and terminals is as per testing copy issued by Design. Any mismatch found in this is to be logged and informed to Site Manager & Project Manager and corrective action to be taken prior to starting of bell test. Bell Test This is to ensure the continuity in each wire used and the wiring is made as per the testing copy issued by Design. Any mismatch found in this is to be logged and informed to Site Manager & Project Manager and corrective action to be taken prior to starting of simulation test. Insulation Resistance Test This is to ensure the safety to the persons involved in testing to confirm that there is no between any of the power circuit with body of the any metallic equipment such as racks, etc. Any low insulation resistance found in this is to be logged and informed to Site Manager & Project Manager to take necessary corrective action prior to starting of System integrity & Simulation Test. EARTHING TEST The first step in providing effective personnel and equipment protection is preparing a low resistance grounding electrode or grounding electrode system at each equipment housing room. Once the low resistance earth ground is established for a signal housing the apparatus in the house should be connected to the earth ground as described in Grounding and surge protection and EM Compatibility requirements for Microlok II based Interlocking systems Measurement of earth resistance is conducted in presence of customer. If earth resistance is found above 5 Ohms, this is to be logged and informed to Site Manager & Project Manager to take necessary corrective action prior to starting of Power On Test. Power ON Before extending power to the equipments, it needs to ensure all the output voltages from IPS is set at correct voltage as mentioned in the power supply equipments/design and also ensures that Battery is connected & charged fully. After that Power On test shall be conducted, it includes extending power to all input terminals installed at site and ensures the correct voltages are measured at input & at end terminals as per wiring design before connecting to the equipments. VCOR test After power is extended, the application data to the Microlok-II units and Check whether VCORs of Microlok II units are energized. After energizing VCORs it indicates that the Microlok units are healthy and the programs loaded are error free. Communication test Both Microlok and VCOR is picked up, this will automatically enable the communication between Microlok Units. When the VDU software is run, this will IRISET

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automatically enable communication between VDU and Microlok, and indications at the VDU will be dynamically updated based on the status received from Microlok. Check the communication status in LEDs and alpha-numeric display at Microlok show the communication status and check the indication status in VDU. Correspondence Test The Tester shall correspond all controls & indications between control cum indication and Microlok II and also correspond test shall be performed for Vital I/O between Microlok II and simulation connected via relays. A list of all controls & indications and Vital I/O that are to be tested is available in the I/O bit list. Refer relevant Microlok II Application data or wiring circuits for this Bit list. System Integrity Test System Integrity test is to prepare the simulator to the station specific needs before starting Interlocking tests. •

To initialize the station interlocking, field inputs (Tracks status - Unoccupied, Points status - Normal and Signal status – Red or ON) from simulation are kept in favorable position

•

Check whether indications in CCIP are in correspondence with the field simulations

•

Toggle all track circuits from Simulation one after another and check CCIP display changes correspondingly.

•

Operate Points from CCIP and change the field status from simulator and check the CCIP display changes accordingly

•

Toggle Signal status (Red) switches and check CCIP indication flashes

Control Table Validation As the Principles Tester carrying out testing to the source documents [SIP’s – Signalling Plans and Route Table(s)], a second tester shall be checking the tested functions (as witnessed from the testing) against the control tables.

Route Setting, Locking Test: Aim: To check: •

The route gets set and locked if the favourable conditions are met.

•

The Signal goes to OFF aspect after route is set and locked

Procedure: •

Test for the following conditions while route is set and locked: o o

o

o

o

TEST 1: Route shall remain set and locked even if approach lock tracks are occupied. TEST 2: Route shall remain set and locked but signal is put back to danger if back lock track or overlap track is failed. The signal shall restore when tracks failure resolves except Replacement track. TEST 3: Route shall remain set and locked but signal is put back to danger in case point detection is lost. The signal shall restore when point detection is restored. TEST 4: The signal is put back to danger in case Level crossing, crank handle or siding lock detection is lost. When locking of crank handle or keysiding is restored, the route must be released with the elapse of timer. TEST 5: Route shall remain set & locked and signal shall remain OFF, if points & tracks are operated for other routes.

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ANNEXURE -VI

o

TEST 6: Under Route set and locked condition, the conflicting routes shall not be available or cannot be set. Also Test for the routes (which are not conflicting but are available), the routes shall get set & locked independently and simultaneous train movement on these routes does not affect the route under test. This test is performed as per Cross table.

Route Cancellation Test : Aim: To check: •

The manual route cancellation shall be immediate if the approach tracks are unoccupied;

•

The manual route cancellation with appropriate timer if the approach tracks are occupied;

•

The manual route cancellation with appropriate timer if dead approach is applicable;

•

The route cancellation with train movement (including sectional route release if applicable).

Procedure: •

Simulate route set and locked condition for the given route.

•

Ensure manual route release is applicable only when signal is put back to danger using ‘Signal Stop’ command from CCIP.

•

With the following preconditions, simulate the route cancellation. o

o

o

o

TEST 1: Precondition of approach lock tracks unoccupied, apply ‘Signal Stop’ followed by ‘Route Release’ command from CCIP, the route shall release immediately. TEST 2: Precondition of approach lock tracks occupied, apply ‘Signal Stop’ followed by ‘Route Release’ command from CCIP, the route shall release after elapse of appropriate time. TEST 3: Precondition of dead approach routes, apply ‘Signal Stop’ followed by ‘Route Release’ command from CCIP, the route shall release after elapse of appropriate timer. TEST 4: Simulate the train movement over the route set and locked, the route shall get released after the completion of train movement and full occupation of berthing track. [NOTE: Simulate short train (one track occupied) and long train (all back lock tracks occupied) simulation to test the route release sequence]. In case, sectional route release is applicable, the track sections in the route shall be released with the train movement based on TLSR/ TRSR settings as per control table definitions.

Signal Aspect Sequence: Aim: To check: •

The change in signal aspect with the status of ahead signal aspect.

•

The movement of train (occupied status of replacement track circuits) replaces the signal aspect in sequence OFF (G or Y) R.

•

The lamp failure conditions leading to more restrictive aspects.

Procedure: •

IRISET

Set and lock the routes for the signals as per SIP and Control Table definitions, simulate and check the following: Page 96


o

o o o o

o

All the track circuits shall be cleared (Unoccupied). The Level crossings shall be closed. The signal under test shall reflect OFF aspect as per control table definition. TEST 1: Simulate occupancy of the control track circuits including overlap track circuit, the signal under test shall display RED (R) aspect. TEST 2: Simulate the ahead signal as RED (R) aspect, the signal under test shall display aspect as per SIP definition. TEST 3: Simulate the ahead signal as Yellow (Y) or Double yellow (YY) or Green (G) aspect, the signal under test shall display aspect as per SIP. TEST 4: Simulate the ahead signal as blank aspect, the signal under test shall display RED aspect as per SIP. Calling ON signal shall display ON aspect. TEST 5: Calling-ON signal is OFF aspect only when main signal is failed.

Signal Aspect Cascading Test: Aim to check: •

To change the signal aspects if any aspect on same mast fails due to lamp failure.

Procedure: •

Set and lock the routes for the signals as per SIP and Control Table definitions, simulate and check the following: o

o

o

o o

All the track circuits shall be cleared (Unoccupied). The Level crossings shall be closed. The signal under test shall reflect OFF aspect as per control table definition. TEST 1: Simulate failure of Green aspect (if applicable) of signal under test, the signal under test shall display next restrictive aspect ie Double Yellow (YY) aspect in this case. TEST 2: Simulate failure of Double Yellow (YY) aspect (if applicable) of signal under test, the signal under test shall display next restrictive aspect ie Yellow (Y) aspect in this case. TEST 3: Simulate failure of Yellow (Y) aspect of signal under test, the signal under test shall display Red (R) aspect. TEST 5: Simulate failure of Yellow (Y) aspect of signal having route indicator (YU) under test, the signal under test shall display Red (R) aspect without route indication.

Point Control Test: Aim: To check: •

The points are called, moved and locked in desired position as per control table definition, when route is called or call for individual point operation;

•

The point movement in Normal, Free for Route Call and Reverse, the power feed shall be cut off immediately when point detection is received or after elapse of appropriate timer if the point detection is not received;

•

The emergency point movement in case the point track circuit has failed depicting occupancy of point tracks;

Procedure: •

Check for the point movement under following condition:

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ANNEXURE -VI

o

TEST 1: Precondition is point shall be in “Free” for route call position but not in favorable condition as per control table. Simulate a route call using VDU, the points shall move and get set and locked in the desired position as per control definition. Ensure that signal shall display OFF aspect only when points in the route and in the overlap are locked and detected in the desired position. The signal shall be put back to danger in case point detection is lost.

o

TEST 2: Precondition is point shall be in “Free” position, detected in reverse direction and route is not set. Simulate point movement to “Normal” position using VDU Menu commands, the feed to the points shall be extended using NWR and WCR output bits. Ensure feed is cut off either immediately if the point position is detected in Normal or after elapse of appropriate time if point position is not detected in Normal direction.

o

TEST 3: Precondition is point shall be detected in “Normal” or “Reverse” position and route is not set. Simulate point movement to “Free” position using VDU Menu commands, ensure no feed is extended to track device but the indications are changed on VDU screen.

o

TEST 4: Precondition is point shall be in “Free” position, detected in Normal direction and route is not set. Simulate point movement to “Reverse” position using VDU Menu commands, the feed to the points shall be extended using RWR and WCR output bits. Ensure feed is cut off either immediately if the point position is detected in Reverse or after elapse of appropriate time if point position is not detected in Reverse direction.

o

TEST 5: Precondition is route is not set and the point zone track circuit has failed. Ensure movement of point is not possible using Normal Point Menu Commands from VDU. Simulate movement to “Free”/ “Normal”/ “Reverse” position using Emergency point movement commands from VDU, ensure feed is cut off either immediately if the point position is detected in Reverse/ Normal or after elapse of appropriate time if point position is not detected in Normal/Reverse direction depending on the position called for. Also ensure that Emergency movement is not possible under Route Set and Locked condition.

Level Crossing, Crank Handle & Siding Control Test: Aim: To check: •

The release and locking of crank handle.

•

The release and locking of Siding key locked levers.

•

The release and locking of Siding key locked levers.

Procedure:

IRISET

•

TEST 1: Simulate the release of key for crank handles using CCIP. Ensure the route becomes unavailable if the route is not set and locked. In case route was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall go back to danger.

•

TEST 2: Simulate the release of key for Siding Control Lever using CCIP. Ensure the route becomes unavailable if the route is not set and locked. In case route Page 98


was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall be put back to danger. •

TEST 3: Simulate the release of key for Level Crossing using CCIP. Ensure the route becomes unavailable if the route is not set and locked. In case route was set and locked, the route shall be released before releasing the key. If the key is forcibly extracted, the signal shall be put back to danger.

Following tests also will be carried out in addition to the above individual tests: •

Signal & route - clear

•

Signal & route – Indication

•

Point Indication

•

CH & LC indication

•

Track Occupied Indication

•

Break test and Mid stroke test – Point (Control and Indication)

•

Break test – Track

•

Break test – Ahead signal, CH, LC etc.

•

Conflict signals and routes

•

Reverse move

•

Jump moves

•

Normal release

•

Emergency release

•

Approach release

•

Overlap release

•

Auto release (Train move)

•

Sectional route release

•

Back lock test

•

Signal track test

•

SM’s control

•

Cross test with all other elements

•

Special tests

Results: All the above test results shall be logged and signed off in a marked up copy of the: •

Control Table

•

Activities Event log

•

Acceptance Test Incident Report (ATIR) if required.

Change Over Test: The Tester has to ensure the system change over between Microlok II is happening if any one of the system fails or in the Diagnostic Mode. This change over shall be conducted and ensured there is no unsafe situation arise for the following scenarios, •

Route being set & Signal cleared

•

Route being set & Approach locked

•

Train taken the Route

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ANNEXURE -VI

•

Point is under operation

•

Other few special conditions

Re-testing Application Logic: If it is necessary to undertake application logic changes as a result of incidents arising from Principles Testing or for other reasons then the details shall be documented on an ATIR. Following update of application logic to address a deficiency, the designer shall produce a “difference list” that highlights the changes made to the previous version of the application logic. Minor Logic changes need not be updated individually but can be completed as one data change.

10. Documentation. All the test results obtained for the particular installation under test shall be part of the ing documentation package for the Microlok II Application Logic Principles Testing. The ing documentation package shall be available for review during Microlok II Application Logic Principles Testing as various tests are completed.

IRISET

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SIMIS S EI SYSTEM

Annexure – VII SIMIS S EI SYSTEM 1

Introduction:

SIMIS S is the newest generation of SIEMENS electronic interlocking systems represents the newest cost effective invention of the spread proven system. The SIMIS S interlocking architecture is integrated in the SIMIS product family. The safety architecture is based on a coded Mono Processor philosophy embedded in the SIMIS interlocking system environment. SIMIS S system is designed in accordance to European standards approved and in use by several prominent railways. The SIMIS S basic system meets the Generic CENELEC SIL4 safety standards.

2 This systems are Characterised by the following features: (a) Interlocking functions are carried out using the interlocking table principle or geografical principle. (b) The SIMIS systems are based on the standardised hardware platforms. The SIMISS is following the most common standard of coded monoprocessing as 1-out-of-1 principle or TWO 1-out-of-1 processors in standby configuration. (c) SIMIS Systems can be customised in a fast and efficient way to meet a wide range of different operating regulation requirements since the complete signalling logic can be executed on an integrated and independently working state-of-the-art computer technology. (d) Operation through VDU (Console) or Operation through Control .

3

Features of SIMIS S System:

3.1 Safety: A controlling and monitoring computer system for railway signalling is defined as fail-safe if no unacceptable failure can occur. In general the system has to be fulfil two qualifications: (a) Accurate and normal function. Fail-safe behaviour if failures occur within the system or the operating modules (b) Reaction time of less than 1.5 seconds for showing a restrictive aspect after a hazardous event occurs.

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ANNEXURE -VII

3.2 Layered System Architecture: The SIMIS S System is developed in a layered structure. Independent generic approved layers are standardised to minimize specific approval efforts and guarantee reliable and proven functional modules.

3.3 Availability: Maximum availability can be achieved by a 2 (1-out-of-1) processors in standby configuration.

3.4

Modular technology for Inputs and Outputs: (a) Track site components: For connection of track site equipment to the SIMIS S interlocking, several safe Input and Output PCBs are available to interact with approved signalling relay groups. (b) Operators : The operator’s consisting of conventional indicators and pushbuttons can be connected via standard digital Input / Output modules. Typically a two-button operation is implemented.

3.5

Communication:

PROFIBUS (Process Field Bus) Protocol: (i) PROFIBUS protocol is used as a standard communication interface between different computer systems. (ii) PROFIBUS is the multi-functional field bus system and complies with the International Standard EN 50170. (iii) Two redundant communication links can be installed for availability. (iv) The safe PROFIBUS protocol includes fault detection, because of safety reasons no correction procedure is implemented. If a telegram is detected as false this telegram is send again. (v) Profibus with copper cable works up to 200m distance. If the distance of communication between two processors is more than 200m then Profibus repeater is required at every 200m. (vi) Profibus with OFC works up to 15KM. Other Serial- and WAN/LAN Communication links: (i) The SIMIS S provided with a communication processor, PCBs and the corresponding software driver modules. (ii) This system provides the ability to communicate via RS 232/422, T/IP, Ethernet and other standard protocols via communication Processor or via existing onboard interfaces or PCs can be operated.

IRISET

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COMMUNICATION

4

Standard Configuration (Centralised) of EI Station is Shown below:

Centralised configuration of SIMIS S Electronic Interlocking System Fig No : 1

5

System Components: The SIMIS S is made up of various modular components. The modules are mounted on a mounting rail. SIMIS S series is a failsafe, Modular Controller. The Modular Controller consists of the following components: (a) Power Supply Modules. (b) Central processing units Us. (c) Communications Processor, . (d) Digital Input and Output Modules. (e) Additional components such as relays, circuit breakers.

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ANNEXURE -VII

5.1

Power Supply Modules (SITOP): (a) SITOP power supply is well proven power supply in the design of the SIMIS S. The output is protected against short-circuit and open-circuit conditions and adjustable. The power supply is connected to a 230 V, 50 Hz single-phase AC. The output voltage is +24V. (b) The power supply is snap-mounted onto the S7 rail and has LEDs for the indication of voltage failures. (c) A separate power supply module need not be provided if a reliable, external 24 V DC power feed is made available. (d) This module is not preferred, generally Supply is taken from the IPS module.

5.2

Central processing units Us: The 300 and 400 series of processors belong to the same family their architecture

remains the same except for the enhanced memory capacity. The U Units are the basis for control of SIMIS S interlocking system. The U contains firmware, which independently performs all additional functions of the interlocking. The Us have status and error displays. LEDs indicate events such as hardware, programming, time, I/O, battery or bus errors/faults and operating statuses such as RUN, STOP. The Us have a plug-in socket for a memory module in which a Flash EPROM is inserted. This EPROM ensures a permanent storage of the program even in the case of a power supply failure. Both Us have back-up batteries that provide a backup of the program in the RAM. A programming device can be connected to the U board.

Fig No : 2 IRISET

CENTRAL PROCESSING UNIT- 317F Page 104

Us

Diagnostics via LED Fault scenarios, which are graded according to their means of access, provide not only for maintenance purposes, but also for diagnostics. For diagnostics and fault location, there are different LEDs on the circuit boards. These LEDs indicate operating states and any faults that occur and therefore facilitate fault location. LED SF

BATF

Description Comes in the event of: •

Hardware faults.

•

Programming errors

•

Parameter assignment errors

•

Calculation errors

•

Timing errors

•

Faulty memory card

•

Battery fault or no backup at power on

•

I/O fault/error (external I/O only)

•

Communication error.

•

The backup battery is missing, faulty or not charged.

Comes when:

Note: It also comes on when an accumulator is connected. The reason for this is that the program is not backed up by the accumulator. STOP

Comes on when: •

The U is not processing a program

•

The U requests a memory reset.

Flashes when:

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ANNEXURE -VII

Displays for the U: SF

(Red)

Hardware or software faults

BATF

(Red)

Battery fault

DC5V

(Green)

5 V DC supply for U and S7-300 bus is ok.

FRCE

(Yellow)

RUN

(Green)

PU in RUN; LED flashes at start-up with 1 Hz; in HLT mode with 5 Hz

STOP

(Yellow)

PU in STOP or HALT or start-up; LED flashes at memory reset request

Force request is active

Mode Selector Positions The positions of the mode selector are explained in the order in which they appear n the

U. Position

Description

Detailed Description

RUN-P

RUNPROGRAM mode

The U scans the program. The key cannot be taken out in this position.

RUN mode

RUN mode

The U scans the program The program cannot be changed without confirmation. The key can be removed in this position to prevent anyone changing the operating mode

STOP mode

STOP mode

The U does not scan programs. The key can be removed in this position to prevent anyone changing the operating mode.

MRES mode

Memory reset

Momentary- position of the mode selector for U memory reset (or a cold start as well in the case of the 318-2). Resetting the memory using the mode selector requires a special sequence of operations

Diagnostics by Programmer: Programming can be carried out by an appropriately trained personnel with basic knowledge of STEP 7 programming. (STEP 7 is the Programming language for developing programs for SEMIS S system)

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Us

Central Processing Unit 416F:

Fig No : 3 Fig No : 4 CENTRAL PROCESSING UNIT- 416F Mode Selector switch Positions: The positions of the mode selector are explained in the order in which they appear in the U. Position RUN

Explanation If there is no start-up problem or error and the U was able to go into RUN, the U either executes the program or remains idle. You can program from the U to the programming. (U PC)

STOP

You can program from PC to the U (PC U) The U does not execute the program. The digital signal modules are locked. You can program from the U to the programming. (U PG) You can program from PG the U (PG

MRES (U Memory Reset ; Master Reset)

U)

Momentary – position of the toggle switch for the U Memory RESET.

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ANNEXURE -VII

5.3

Communications Processors ( 341, 343, 342- 5):

Fig No : 5

341, 343-1 and 342-5

The communication processors provide an economical and complete solution for serial communications via point-to-point links. They allow the SIMIS S to be attached to Profibus / Ethernet. The following mechanical features characterize the communications processors: (a) Rugged plastics housing. (b) LEDs for status information. (c) Communications interface. Three different types of communication processors are used: - 341 used for serial / for Modbus Communication with the data logger. - 343-1 is used for T/IP Ethernet communication. Currently this is not used in the system. This will be used only when Ethernet protocol connectivity comes into the picture. This may be provided in future to provide the functionality of CTC. - 342-5 for PROFIBUS communication.

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DIGITAL INPUT/OUTPUT MODULE

5.4

Digital Input and Output Modules (I/O): The following section describes the various I/O modules used in the SIMIS S system. The system allows modular configuration of all standard boards available. (a) Digital Input Module (Vital). (b) Digital output Module (Vital). (c) Digital Input Module 326 (Vital). (d) Digital output Module 322 (Non-Vital). (e) Digital Input / Output Module 323 (f) Digital Input Module – Standard (Non-Vital) (g) Digital Output Module – Standard (Non-Vital) (h) Optical Link Module (OLM). (i)

Repeater Module.

(j)

Interface Module IM 151

(k) Electronic Terminal (ET) Station Module. (a) Digital Input Module (Vital) :

Fig No : 6 Digital Input Module (Vital) The digital input board (Vital) converts the external binary signals from the process into the internal signal levels of the SIMIS S. The green LEDs indicate the signal states. Signal cables can be connected with front connectors and can be labelled in a lettering field next to the LEDs.

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ANNEXURE -VII

As per SIL4 safety requirement every input reading has to be done by sensing two s, generally one front and one back of the same relay input that has to be sensed. Hence 8 digital input s can sense 4 numbers of inputs in a failsafe manner. The general practice is to sense the front through Vs1and back through Vs2. The address switch is a ten-position dipswitch that has to be set in the required position, so that the processor is able to identify the correct Input card. The processor logic contained in the Input card multiplexes the input information and sends it to the main processor through "Back Plane Bus". The module also has "SF" (System Fault) to indicate group fault. A high input is indicated through a green LED Display on the module. Galvanic separation is provided through optical isolation of signals between "Processor logic" and "Back Plane Bus Interface". The technical specs are as below: (i) Suitable for 8 digital inputs equivalent to 4 nos. of SIL4 inputs. (ii) Rated input voltage 24 V DC. (iii) Two sensors for each of the four inputs 1 Vsf & 2 Vsf (Vsf : Voltage supply fault). (iv)Group fault display SF (System Fault). (v) Status display for each input. Input delay 3 Milli seconds. (vi)Internal optic isolation in data link. (vii) Hot swapping of module. (viii) Low power consumption of 4 W. (ix)Length of unshielded cable connection 200 m. (x) Normal voltage 24 VDC. Range 20.4 V to 28.8 V. (xi) Sensing range: “1” = 15V to 30 V & “0” = –30V to + 5V. (xii) HW Coding. (xiii) SW (dipswitch) coding. (b) Digital output Module (Vital) : Four relays can be driven by one module. The outputs are grouped as 2 outputs on the left side and two on the right side. The address switch is a ten-position dipswitch that has to be set in the required position, so that the processor is able to identify the correct Output card. Galvanic separation is provided through optical isolation of signals between "Processor logic" and "Back Plane Bus Interface". The module also has "SF" (System Fault) to indicate group fault. A high output is indicated through a green LED Display on the module.

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The digital output Module converts the internal signal levels of the programmable logic controller into the external binary signal levels needed for the process.

Fig No : 7

Fig No : 8

Digital Output Module (vital)

Digital Input Module 326 (Vital ),

Digital output modules are characterized by the following features: (i) Suitable for driving 4 failsafe out puts. (ii) Rated drive voltage 24 VDC. Range 20.4 V to 28.8 V (iii) Load resistance range 12 Ohms to 1K Ohms. (iv) Power dissipation 3.5 W typical. (v) Suitable for driving relays or indications. (vi) Status display for each driven output. (vii) Optic isolation with Profibus. (viii) Hot swapping feature. (ix) Output indication. (x) HW coding.

(xi) SW (dipswitch) coding.

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ANNEXURE -VII

(c) Digital Input Module 326 (Vital) : Digital Input Module 326 (Vital ), SM326:DI 24 X DC24V has the following features: (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii) (xiii)

24 inputs, isolated groups of 12. 24V DC rated input voltage. Suitable for switches. 4 short circuit-proof sensor (isolated in groups of 2) supplies for 6 channels. Group error display (SF) Safety mode display (SAFE) Status indicator for each channel. (Green LED) Reconfiguration in Run (CIR) – possible in standard mode. Assignable diagnostics. Diagnostic alarm with assignable parameters. Usable in standard and safety modes. Configure 1-out of –1 and 1-out of –2 for each channel Simplified PROFI safe address assignment.

(d) Digital output Module 322(Non-Vital) :

Fig No : 9

Fig No : 10

Digital output Module 322(Non-Vital)

Digital Input / Output Module 323

Digital Output module 322(Non-Vital) i.e SM 322: DO 8 x 24 VDC /2A has the following salient features: (i) 8 Outputs, isolated in groups of 4. (ii) 2A output current. (iii) 24 VDC rated load voltage. (iv) Suitable for Solenoids , DC ors and indicator lights.

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(e) Digital Input / Output Module 323 : The following mechanical features characterize digital input/output modules: (i) Compact configuration. (ii) Green LEDs to indicate signal states at the inputs and outputs. (iii) Front connector protected by the front cover. (iv)Labeling area on the front cover. (v) Easy installation. There are no slot rules. The output addresses are defined by the slots. When they are used in the ET 200M in combination with active bus modules, hot-swapping is possible. (vi) friendly wiring. Digital input/output modules convert: -

The levels of the external digital signals from the process into the internal signal level of the PLC.

-

The internal signal level of the PLC into the external signal levels required for the process.

-

8 nos. of Digital Inputs and 8 nos. of Digital Outputs at 24 VDC / 0.5A.

(f) Digital Input Module – Standard (Non-Vital) :

Fig No : 11

Fig No : 12

Digital Input Module Standard (Non-Vital)

Digital Output Module Standard (Non-Vital)

The digital input board (Non-Vital) converts the external binary signals from the process into the internal signal levels of the SIMATIC S controller. The green LEDs indicate the signal

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ANNEXURE -VII

states. Signal cables can be connected with front connectors and can be labelled in a lettering field next to the LEDs. (i) Shows green indication of “high” input channel Module failure manifests when operation of button on is not effective. (iii) Check if the Interlocking is accepting the command by observing the “button operation indication” on the The technical specs are as below: - Suitable for sensing 4 standard inputs (push buttons). - Optic isolation of inputs. - Rated drive voltage 24 VDC. - Unshielded cable length at input - 1000 m - Power dissipation 0.7 W typical. - Input signal “1” = 15V to 30V and “0” = –30V to 5V - Input current for ‘1’ signal 7mA @ 24VDC - Status display of high input.

(g)

Digital Output Module – Standard (Non-Vital) :

The digital output Module converts the internal signal levels of the programmable logic controller into the external binary signal levels needed for the process. The following features characterize digital output modules: (i)

Suitable for driving four standard out puts (LEDs)

(ii)

Optic isolation of outputs

(iii) Status display of high output (iv) Power dissipation 0.8 W typical (v)

Unshielded cable length at output - 600 m

(vi) Rated drive voltage 24 VDC

IRISET

(vii)

Shows green indication of “high” output channel

(viii)

Module failure manifests when LED indication fails to appear.

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OPTICAL LINK MODULE

Optical Link Module (OLM) :

Fig No : 13 PROFIBUS OLM

Fig No : 14: Repeater Module

(i) PROFIBUS OLMs are designed to be used in optical PROFIBUS field bus networks. (ii) They enable electrical PROFIBUS interfaces (RS 485 level) to be converted into optical PROFIBUS interfaces and vice-versa. (iii) A complete PROFIBUS field bus network with modules in line, star or ring topology and an arbitrary combination of these, are built up. (iv)The redundant ring is also ed, thereby increasing the fail-safety of the field bus network. (v) Each module has two or three mutually independent ports, which in turn consist of a transmitting and a receiving component. (vi)The device is powered by 24V DC voltage. A redundant feed increases operational safety. (vii) The electric port is a 9-pole Sub-D socket (female). An RS 485 bus segment in line with the PROFIBUS standard EN 50170 is connected to this port. (viii) Four multicolored light-emitting diodes indicate the current operating status and possible operating malfunctions. (ix)With the PROFIBUS OLM (Optical Link Modules) Version 3, optical PROFIBUS networks can be assembled in line, star and redundant ring topology.

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ANNEXURE -VII

(x) The transmission rate of an OFC line depends on the distance and may be up to 12 Mbps. (xi) Function: Automatic recognition of all PROFIBUS transmission rates: 9.6 Kbps to 12 Mbps. High availability through media redundancy. The distance between two OLMs in the redundant ring is limited only by the optical sensing range of the modules. (xii) There are 3 types Optic Link Modules that are used for the following applications. -

OLM P12 (type 6GK1502-3CAXX) is used when the fiber optic cable is of plastic type for distances up to 80 meters and 400 meters with Plastic Coated Fibre.

-

OLM P12 (type 6GK1502-3CBXX) is used for connectivity for distances of 3 km with Quartz Glass Optic Fibre.

-

OLM G12-1300 (type 6GK1502-3CCXX) is used for connectivity for distances of 15 km with Quartz Glass Optic Fibre.

(h) Repeater Module : Function: -

Automatic data transmission rate search

-

Data transmission rate of 45.45 Kbit/s possible

-

24 V DC voltage display

-

Display bus activity segment 1 and 2

-

Isolation of segment 1 and 2 possible by switch

-

Isolation of the right segment part when terminating resistor is inserted

-

Decoupling of segment 1 and segment 2 in the event of static interference.

Mode of operation

IRISET

-

Increasing the number of stations (max. 127) and the coverage

-

Regenerating the signals in amplitude and time

-

Electrical isolation of the connected bus systems Data transmission rate in KBPS

Max. segment length in m

9.6

1000

19.2

1000

45.45

1000

93.75

1000

187.5

1000

500

400

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INTERFACE MODULE

Data transmission rate in KBPS

Max. segment length in m

1500

200

3000

100

6000

100

12000

100

Designed for Industry: -

To increase the number of stations and the expansion

-

Galvanic isolation of segments

-

Start-up assistance o

Switch for disconnecting segments

o

Display of bus activity

o

Isolation of segment with wrongly inserted terminating resistor

(i) Interface Module IM 151 : ( For Electronic Terminal Station) (i) Provides Interface between the profibus and Input / Output modules in an ET200 station. (ii)

Provides internal “electronic” supply to the back plane bus for IO modules.

(iii)

Inbuilt Electrical Isolation.

(iv)

Type of interface: RS 485.

(v)

Rated supply voltage: 24 VDC.

(vi)

Polarity reversal protection provided.

(vii) Power dissipation : 3.3W typically.

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ANNEXURE -VII

Fig No : 15

Interface Module IM 151

Indications: - SF-group error - Blank when there is no error & Steady R when is a group error. Causes: o Short circuit, over load, wire break, internal error. o Missing external auxiliary supply in respective ET Station. - BF-group error - Blank when there is no error. Steady R when is a group error. Causes: o Profibus connection is open. o ON indication is blank likely causes are o Wire break. Check relative circuit. o External aux. power supply missing. Check the power supply. o Internal error. Replace the module o Short circuit in sensor. Corrective action – eliminate short circuit.

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INTERFACE MODULE

(k) ET (Electronic Terminal) Station Module :

Fig No : 16 Electronic Terminal Station Module is used for Distributed Interlocking System. The ET stations consists of: - Profibus connectors o Connection of the profibus cable to the Interface Modules and the U. -

Data Logger o Used to log all the events during the operation of the system and can be used to trace the faults in case of a failure after viewing of the detailed reports generated by the logger.

-

Interface Module o Acts as an interface between the U and the I/O modules.

-

Power Module o Provides the current to the drive relays through the output modules and sensing voltage to the input modules to check the status of the relays.

-

Digital Input and Output Modules o Used to sense the inputs given through the operating in case of Standard Input module and status of the relays in case of Vital Input Module o To drive the relays feeding the outside gears like signals, points etc. for Vital Output cards and to light the indications on the indication for a Non vital Output Module

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ANNEXURE -VII

6

Ring configuration of distributed EI station is shown below:

Fig No : 17

7

Periodic Maintenance: The Electronic Interlocking system by its nature is maintenance free. However it is suggested that the following be checked periodically. (a) Dust protection of the system. To maintain the relay and Electronic Interlocking system free from dust. In case of dust accumulation the modules should be cleaned with a vacuum device and not a blower. (b) Checking of supply voltages for all elements e.g.: IPS, points, signals for any variation. (c) Check whether the all the lamps and relays are operational. (d) Check that the earth connection on the Electronic Interlocking i.e Electronic Earth and Power Earth is firm and proper. Check its continuity using a multi meter. (e) Check the Earthing Values of Electronic earth and Power Earth at the earth pit. (Should be less than 2 ohms) (f) In case the system has any sparingly used field objects, the same shall be operated to check its integrity.

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MAINTENANCE INSTRUCTIONS

8

Maintenance Instructions:

8.1

Do’s: (a) All wiring connection should be neat and tightened. (b) All modules should be properly inserted and screwed. (c) Electronic earth and Power earth should be firm and proper. (d) All earthing points of electrically should be connected to module (Electronic Earth) (e) Mains voltage should be less than 28 volts. (f) In case of dust accumulation the module should be cleaned with a vacuum device not a blower. (g) In case of module replacement load voltage must be switched off. (h) When exchanging F-module, it has to be ensured that the address Switch (DIP switch) setting of modules match.

8.2

Don’ts: (a) Do not changes to the code are being made on the terminal Module. (b) Do not switch off the U (Central Processing Unit ) power supply. (c) Do not switch of the control supply. (d) Do not reset the memory off U (Central Processing Unit). (e) Do not remove the module when power supply is in on condition.

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ANNEXURE -VIII

Annexure – VIII ESA11- IR Electronic Interlocking System Manufactured by AZD Praha BZA-BPQ section in S.C.Rly 1

Introduction:

The Electronic Interlocking System model ESA11-IR is a well designed, documented proven and tested product, fully meeting the CENELEC standards for highest Safety integrity level SIL-4 and is currently operational in the High speed Euro corridor (ESA11), with enger carrying trains, on the Czech Railway having train speeds of 160 KMPH. The ESA11 product has been designed developed and patented (patent no: 282967) by M/S AZD praha of Czech Republic. In association with M/s Hytronics Enterprises, the ESA11 electronic interlocking system has been developed to suit Indian Railway signalling rules i.e. ESA11-IR. This system has been validated by an independent third party as conforming to CENELEC specs and meeting SIL4 norm requirements. 2

Salient Features of ESA11-IR are: •

Designed as 2 out of 2 architecture, with 100% hot standby at vital processor level.

•

Designed with two independent software’s. In other words elimination of ‘common mode’ failures.

•

Health of the computers are monitored by intrinsically fail safe hardware comparator modules- which initiate power ‘cut off’ to vital computers, in case of nonagreement with 2 out of 2 result. In such a case all vital outputs (signals) will be driven to ‘safe state’.

•

Any failure of working ‘pair’ U’s will result in smooth change over to hot standby ‘pair’ of U’s without disturbing train traffic i.e. the routes which were already ‘set’ and functioning are preserved.

•

Uses 2 out of 2 architecture, for field I/O modules, called Executive Computers.

•

Uses two independent software’s in the field modules. In other words elimination of ‘common mode’ failures.

•

Power ‘cut off’ feature for field modules, in case of non-agreement with 2 out of 2 result. In such case all vital outputs (signals) will be driven to ‘safe state’.

•

ESA11-IR can be controlled by a VDU or conventional DOMINO type operation cum indication . Control from an VDU is more advantageous to the , than control from the domino , as the VDU can display more relevant, dynamic and additional information.

•

Application software can be easily developed by the use graphic based menu driven software tool.

•

The hardware is ‘modular’ in design and can be easily expanded as and when ‘needs arise’ to change the yard layouts.

•

Yard remodeling is very easy as field modules can be added or removed as per needs and similarly software can be reprogrammed by the use of graphic interface and menu driven software interlocking.

•

Simulation of complete interlocking of a yard is possible before installing the software in the field.

•

Use of BRS relays for field interface between Electronic Interlocking equipment & out door signaling Gears.

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ESA11- IR ELECTRONIC INTERLOCKING SYSTEM

3

•

Operator personal identification with special chip cards or smart (PIK)cards

•

Provision of maintainer () terminal.

•

Extensive EVENT “data logging” facility including capability of “event happened” simulation facility.

•

Facilities for ing data into floppies or to any other storage medium.

•

Facilities for remote data logging.

•

Provision for more than ONE PLACE Control. In fact control can be made from more than twelve places. This feature gives capability of mini CTC Control of ading stations.

•

Provision for ATP/ATC interface.

•

Provision for CTC interface.

•

Provision for “auto” generation of Running Map i.e. train charting.

•

Facility for “numbering” the trains & monitoring the movement of trains by their numbers on the VDU .

•

One ESA11-IR has provision to control one single yard having upto 1600 vital outputs, & 3200 vital inputs.

•

ESA11-IR uses standard Indian voltages.

•

ESA11-IR works safely under 25 KV AC traction or any other traction conditions such as 3000 VDC or 600 VDC traction’s etc.

•

ESA11-IR fully complies with all environmental clauses specified vide IRS /RDSO specifications. Design approach:

ESA11-IR easily interfaces with the existing outdoor Signalling gears on the Indian Railways, the interfacing being achieved through standard BRS ‘Q’ style relays. An ESA11-IR systems consists of the following sub-systems: a) Commanding Level (traditional operation ) b) Control level (Previous technology Relays-now U’s) c) Executive level (previous technology Relays-now Input/output Modules) d) Relay Interface Level (Interface between Electronics Interlocking & outdoor Signalling gears) e) Remote Control Level (CTC) f)

Level of wayside elements (Outdoor Signalling Gears)

g) Power Supply Level h) Inner Diagnostics (Event Logger) i)

GTN (Running Map generation for ‘train Controller’ applications)

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ANNEXURE -VIII

DOMINO PROCESSOR

Z-LAN (Ethernet) ZPC -2

ZPC-1

T-LAN (Ethernet)

Z-LAN (Ethernet) ACTIVE - TPC 1

ACTIVE - TPC 2

STANDBY – TPC 3

STANDBY TPC 4

PRV-1

PRV -

PRV -2 n

Interface Relays Way Side Signalling Equipments Fig: TYPICAL BLOCK DIAGRAM OF ESA11-IR

PRV….. Executive Computers (Object Controllers with Relay interface) TPC….. Vital computer pairs ZPC…...SM terminal (VDU ) COMMANDING LEVEL: (Operator cum Indication ) Conventionally Indian Railways uses a Domino type Operation cum Indication , which is located in the SM (station master) room, for controlling the train movements in the station yard. ESA11-IR equipment has got provision to interface with VDU based Control cum Indication or/ and conventional Domino type operating cum indication .

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But keeping in view of the modern technology, the advantages of controlling the train movements in the stations yard through VDU based operating cum indication far outweigh that of controlling the train movements in the station yard through Domino type operating cum indication . Some of the advantages available are (when VDU based operating cum indication is used for the ESA11-IR system): Alterations:

No need for physical alteration and re-wiring to the Operating cum Indication when Yard layouts are modified or changed due to operational requirements. All alterations are done in software. It is easy to carry out alterations in a working . All needed alterations are done off line and the modified yard layout SW is loaded in less than 5 minutes.

Occupation of Space:

VDU occupies less space.

Electro-mechanical Counters/buttons/keys etc:

No need for provision of any buttons, keys or electro-mechanical ‘counters’ for logging certain station master operations, as such information is logged automatically in the built-in data logger. (In a Domino , a simple button stuck situation brings the complete operations to a standstill).

Yard display colours:

In a traditional Domino , before any route is selected the track indications are blank on the . And when the route is selected the track indications show ‘white’ (yellow in case of LED’s). And when the train is in the section or track is occupied the track indications turn to ‘red’ colour. And when the route release takes place, after the train movement is completed the track indications become blank once more. In VDU based operation, the station master has the advantage of seeing the unoccupied & unselected tracks in ‘Grey’ colour & as soon as the Route is selected, the track indications turn to ‘green’ colour & when the train has entered the section the track indications go to ‘red’ colour & when the route release takes place after completion of the train movement, the track indication return back to ‘Grey’ colour. Much more & intelligent information can be made available to the operator on theVDU . For Example: Train Routes on VDU are shown in green Colour & the SHUNT Routes are shown in ‘white’ colour. Calling ON routes are shown in Yellow colour.

SM Key:

In conventional Domino only one SM’s key is provided but in VDU each operator or SM can have his own ‘smart card’ & separate ‘data log’ will be maintained about each operators actions.

Advantages of a VDU (when compared to Domino )

The VDU is more reliable as there is no necessity to change the fused bulbs etc. Less power consumption More aesthetic & elegant

Additional facilities on VDU (for ESA11-IR systems):

Provision of Additional information on the VDU is possible for better convenience to the operator/station master, which is not possible on the DOMINO type .

Train Numbering:

Train numbers can be assigned to the incoming or outgoing trains & the operator can follow the movement of the trains by train numbers which move along with the movement of the train indication on the .

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ANNEXURE -VIII

Warning labels:

Warning label/s can be established on any track circuit. Whenever the on duty SM tries to set a route, the warning label/s will appear, which the on duty SM has to acknowledge, for enabling the route setting operation to continue.

Traffic Closure labels:

Similarly ‘traffic closure’ label/s can be set on any track circuit (for example ‘rail crack’). Whenever the on duty SM tries to set a route, the ‘traffic closure’ label/s will appear, which the on duty SM has to acknowledge, and then the system will display a ‘risk page’ which the on duty SM must acknowledge by a digital signature, for enabling the route setting operation to continue.

Clamping of points:

A ‘software lock’ can be established on any point machine, which prohibits the operation of that point. Whenever TSL (Temporary Single Line) mode of working is adopted, the SM can establish a ‘software lock’ on the points required to dispatch a train, which greatly reduces the time required to dispatch a train under TSL working mode.

Auto signal working:

At the click of a mouse each signal can be converted into an ‘auto signal’ i.e. the whole yard can be converted into an ‘auto territory’.

Pre-setting of routes:

There is provision to pre-set train routes and as soon as the previous train route is completed the computer fetches the preset route and establishes the route and so on till all the preset routes are exhausted.

Absence of AT supply indication:

Whenever AT traction AT supply fails, the tracks which do not have the traction AT supply, are indicated (enveloped) in dark blue colour, drawing the attention of SM immediately.

Macro Setting:

For large yards where complex route setting is possible (from A to D via B & C routes), the SM (each) can set his own macro, to quickly establish the route by two clicks, instead of the normal 4 clicks.

Domino type Operation cum Indication :

Information about Domino type operation cum indication is not being presented here as railways are very familiar with this type of equipment- except that it conforms to IRS/S/36 specification.

VDU Based Operation cum Indication :

The ESA11-IR electronic Interlocking equipment is controlled through two or more VDU’s. One VDU is used for displaying the yard layout, and the second VDU is used for displaying Text based information. Bigger Yards may require more than One VDU for displaying the complete Yard.

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Note: Above is a example of a typical Control with 2 VDU’s for geographic display cum control purposes.

Normally one Colour VDU is used for Graphic Display & one Monochrome VDU is used for Text Based information Display.

A typical yard display in graphic form for Display & control through GUI based graphic symbols

Typical PRV- Executive Computers

The VDU based control is controlled by a computer terminal called ‘ZPC’. The VDU allows the traditional control of the movement of trains in the station yard and realises the interlocking functions. Normally for a way side station ONE VDU is sufficient to display the complete yard (upto a station with 6 to 8 lines). In case the yard is bigger & also if geographical control of a yard is proposed, then only second VDU is added A maximum of 3 colour VDUs along with 1 monochrome VDU is possible for one station yard or alternatively you can use 4 colour VDU’s without any monochrome VDU. Provision is also made to scroll the yard from left to right.

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ANNEXURE -VIII

The VDU can be configured as: (a) to have full 100% functional capability of the complete station yard (b) with geographic limitations of functions i.e you can control part of the yard (c) with very many limited functions (d) with combined limitation i.e both geographic and functions

Standby VDU: Provision exists (optional) to have a standby colour VDU (monitor) in case the main VDU fails due to any reason Operation from a VDU :

In Domino type operating cum indication push buttons are used for setting a route or any other authorised movement. In VDU the operator has two choices. (a) Mouse (b) Key Board

In ESA11-IR the Operator can either use a MOUSE or a Key Board to carry out the Train movement operations of a station.

All VDU based operations except ‘emergency’ operations are possible only after the ‘operator’ inserts his ‘smart card’ (equivalent to SM’s KEY) into the ZPC. All operations of an ‘operator’ are automatically ‘logged’. However, The following ‘emergency’ operations on the VDU can be carried out at all times without the insertion of the ‘chip card’ or ‘smart card’.

Shifting of Signals to ‘stop’ aspect.

The process of route setting is exactly similar to domino based operation i.e click the ‘entry’ signal button & the ‘exit’ track button on the VDU . As soon as ‘command’ is ed on the VDU , the responds by: ◊ Change of colour of the particular function ◊ In predefined functions, ‘audible’ indication is also given ◊ If ‘safety’ information is relevant, it will be displayed on the text portion of VDU on the “page of risks”. ◊ In all cases the command is automatically “logged”

CONTROL LEVEL: (Interlocking Level)

In the Relay Logic, the safety of the Interlocking is achieved by the use of Relay Circuits. Here in Electronic Interlocking, the safety is achieved through software and reliability is achieved by using 2 out of 2 architecture with 100% hot standby. This Level consists of a Special Rack, which houses the vital Computers, the maintainer terminal, the communication terminals etc. The typical equipment of such a special rack is shown below:

IRISET

Page 128


Front View

Rear View

Fig.: The typical control Level TPC Cabinet Rack.

The ESA11-IR Control level or Electronic Interlocking level consists of technologic cabinet/rack in which are housed the following equipment: 1. Vital computer-TPC1 2. Vital computer-TPC2 3. Vital computer-TPC3 4. Vital computer-TPC4 5. Maintainer Computer- PCU 6. Maintainer Monitor 7. Communication HUBS 8. Associated Fuses, Power supply indicators etc.

All these are housed in a special 19” cabinet rack (TPC Cabinet).

The vital Computers TPC1, TPC2 are normally working computers functioning as 2 out of 2 Architecture i.e each computer or each channel works in total independence from the other & has a special comparator module which monitors the health of its own vital computer and during cross comparisons between TPC1 & TPC2 computers, if any discrepancies are found, the comparator module will generate a Fail Safe Reaction by ‘cutting off’ the power supply to its own vital computer. This reaction in turn will switch off the power supply to the second vital computer.

Page 129


ANNEXURE -VIII

When TPC1 & TPC2 are in state of ‘active mode’, TPC3 & TPC4 take up the role of Hot Standby computers & vice versa.

Each Computer i.e TPC1 & TPC2 is having its own separate ‘General Software’ which is totally different from each other. Each ‘General Software’ is designed, & developed by different software teams. This assures that there will be no ‘Common Mode’ failures, which is an essential feature of CENELEC standard.

EXECUTIVE COMPUTERS: (INPUT/OUTPUT MODULES):

Executive level (PRV) serves as the interface between the Control (interlock) level on one side and the outdoor signalling gears on the other side.

After completion of an interlocking process step at the Control (interlock) level, i.e. after the dual processing of the data in each TPC & then after comparison between the TPC1 & TPC2 outputs, the resultant decision is then ed on to the respective executive computers PPa & PPb i.e. TPC1 to PRVa & TPC2 to PRVb, through serial links RS 485 or PENET. (PRVa is called Channel ‘a’ & PRVb is called Channel ‘b’ and both put together are called Executive Level PRV).

In ESA11-IR, the Executive Computers too use, dual U’s like at Control (interlock) Level, having its own intelligent diagnostic features, i.e. two independent channels are provided to receive the ‘data’ from their respective vital computers & then it on to the field equipment after a successful cross comparison activity.

The Capacity of each Executive Computer is: 1. Vital Outputs : 40 2. Vital Inputs : 80 3. Non- Vital outputs : 32 Please note that ESA11-IR treats all inputs as VITAL inputs.

The ESA11-IR has provision to connect 40 such Executive computers to one Interlocking Level i.e. at each installation the capacity of inputs outputs are: 1. Vital Outputs : 1600 2. Vital Inputs: : 3200 3. Non Vital Outputs : 1280

The Executive Level consists of the following modules: ◊ DU 1 & DU 2 Modules……..U Modules ◊ DOUT Module…………………….Vital Output Module ◊ PDOUT Module………………….Associated module for Vital Output ◊ BVR Module………………………Vital Output Interface Module ◊ DINP Module………………………Vital Input Module ◊ PDINP Module…………………….Associated Module for Vital Input ◊ BN Module…………………………Power Supply Module ◊ SO Module…………………………Resetting Module

***

IRISET

Page 130

VHLC-E I OF M/S G E

Annexure – IX VHLC - Electronic Interlocking of M/S. GE INTRODUCTION • • • • •

In PUNE-KOLHAPUR section of PUNE division of CR, 13 stations were commissioned during 2007-2009. It consist of two sets of VHLC (A/B) in normal and standby configurations, which provides redundancy for both processors and I/O modules. One domino type operating cum indication for operation. Vital neutral line relays for interfacing VHLC I/O to field gears. One PC with LCD VDU for maintenance.

VHLC (Vital Harmon Logic Controllers) • • • •

1 2

It contains main VHLC (A1/B1), which performs interlocking control functions and additional VHLC (A2/B2) provides for additional inputs & outputs. One VHLC chassis provides card slots for up to 12 plug in modules. Standard modules: VLP, A & SSM at slots 1, 2 & 3 and power supply on the rear of chassis. Application modules: VGPIO, VGPI & NVIO at slots 4 to 12.

3

4

5

6

7

8

9

10

11 12

VHLC & TERMINATION RACK

Page 131


ANNEXURE -IX

VHLC (Block diagram)

VLP module (Vital Logic Processor) & A module • • • • • •

Dual microprocessor design with dual co-processor, based on 2 out of 2 check redundant system. It has U & Bus master for VHLC. Controls all other modules in chassis through mother board. It performs all the vital logic equations and generates message packets for exchange with other units. On board reset switch resets all VLP circuits. LEDs & Check points for health of the card.

VLP module

A module

A module (Auxiliary Communication Processor) • • • • • • •

IRISET

Contains non-vital EPROM U9, U10 and processes non-vital logic equations. Also contains non-vital Executive EPROMs IC 30-33. Handles serial data communication up to five external devices. Maintains log of events with in system for diagnostic purposes. Contains 16 characters, four buttons, CDU for status checking. Front side, 9-pin RS232 connector for diagnostic purpose. On board reset switch resets all A circuits.

Page 132

VHLC-E I OF M/S G E

SSM module (Site Specific Module)

SSM module • • • •

VGPIO modules

VGPI modules

Contains EPROMs (IC 14, 15, 17) of vital logic equations. Contains setup data for a particular site. It is half in size compared to any other card. Equation and configuration information is generated by ACE.

VGPIO & VGPI modules • VGPIO accepts 8 vital inputs for sensing voltages & provides 8 vital outputs for driving relays. • VGPI accepts 16 vital inputs for sensing voltages. • Green LED shows module health. • Red LEDs show input & output state. • It buffers signals from VLP & provides address decoding & module enable circuits. • Inputs are polarity sensitive & accepts voltages up to 32VDC. Hysterisis is included in input interface so that input voltage must rise above 8VDC for energized input & fall below 6VDC for de-energized input. • Signature generator provides for rejecting the AC voltages that may be included into the wires connecting to de-energized vital input. It presents unique pattern identification for each input. • Each output has two circuits one for chopper AND gate and one for the power gate. Both gate must be energized for powered output. • All VGPIO/VGPI module cables are uniquely keyed to prevent incorrect module installation. Rear of the CHASSIS • • • • • • • •

It contains +5 VDC power supply and up to 5 serial I/O module from A to E. Chassis ID is located behind the U which is 16 characters in length. Application logic program must match this ID. ‘A’ & ‘C’ ports are RS 485 which are used for communication between VHLC & PC. ‘B’ & ‘D’ ports are RS 232 which are used for communication between two VHLC units. ‘E’ port is for CLA. ‘1’ is power supply module, it provides up to 40W of regulated +5 VDC output (adjustable form 4.5 to 5.5 VDC) from 10-16 VDC input and ‘2’ is I/O cables. An output logic signal drops & initiates a VLP reset & holds it in reset when the output voltage drops 250 mV below the set point.

Page 133


ANNEXURE -IX

CLA (Current Loop Adaptor) • • • •

Interface between VHLC & CL. Communicates serially with CL. It does not supply current to transmit or receive, it only switches the current supplied by the CL. Transmits & receive data for 128 outputs & 128 inputs.

CLA CL (Custom Local Control )

CL

• Handles max 128 Outputs for indication & max 128 inputs for button controls. • It has only four wire connection to CLA module. ACE (Application Compiler Editor) • It is a window based computer program that allows an application engineer to input wayside site configuration and application logic. • This software has four key features: 1. Editing 2. Data entry 3. Compiling 4. Reports Adding a Module to VHLC • •

IRISET

Select the MODULE tab. Right-click an unsigned slot in the tree & select the type of module you want to add from the menu that appears. Page 134

VHLC-E I OF M/S G E

• •

First 3 slots are reserved for VLP, A & SSM and rest 4-12 for VGPIO, VGPI, NVGPI. After adding the module, if 4-12 then its input/ output status settings are displayed to the right of the slot tree.

Adding an equation • Select the EQUATION tab. • From the equation menu, select NEW for entering the equation name e.g. 2GNR, 20 DR, 115 NWKR etc. • If that name is not defined on a module output, a message box will be displayed for attention. If the equation of same name already exists, ACE will also notify for the same. • Once the valid equation name is entered, ACE will create a new equation & display it in editing window. Adding a • To add a new to a wire, an existing or source must be selected. • From the edit menu, select ADD then TO RIGHT FRONT or press Ctrl+R. • From the edit menu, select ADD then TO RIGHT BACK or press Ctrl+K or Ctrl+Shift+R. • After adding the , select the with mouse and type new status name. Adding a wire • • • •

Click the location where the start of wire to be connected. Select ADD WIRE or press Ctrl+W. Select ADD BACK WIRE or Ctrl+B. To complete the add wire operation, t the wire as required .

Compilation • After saving the diagram, select COMPILE from file menu. • The application needs to the consistency check before the application can be compiled. • The consistency checks will run to ensure:a. Module O/Ps has equations. b. Undefined status are not used as equation I/O. c. Equations O/Ps are being used. d. Timers are not defined with zero duration. e. Any required status has been entered. EPROM Programming • After compiling, the application EPROM files are created and updated. • Now click VIEW LOG to view the log file, it contains the validation CRC to be used in the validation. • To select the device, click EPROM under device menu. • Click BLANK to check the EPROM is empty, if not empty press ERASE. • Load the file from file menu. • Finally check the CHECK SUM of the program written on the EPROM and it with the original file check sum.

Page 135


ANNEXURE -X

ANNEXURE- X Pre-commissioning Check Lists:-

Sl.No

Check Points

1.

Earth pit & Pipe burial

2.

REB-Earth pit (1st Earth pit) connection

3.

Earth Resistance

4.

Earth Lead is the correct Size

5.

6. 7.

8.

IRISET

Equi potential Earth of room, Signal Equipment Room (Relay Room) and Power room Foundations and insulation bases for racks and s Grounding

In Signal Equipment Room Racks to REB connection

Requirement

Check whether Earth pit and pipe burial is done, as shown in UM-6800B manual section 12.3. Check whether 3/16” Cium cable is used between REB and the first earth pit and it is connected by exothermic welding at both the ends. Measure the earth resistance of the peripheral/ring earth alone before connecting the Room Earth Bar (REB) to the earth pit and ensure that it is less than 1 Ohm. Refer section 12 of UM-6800B manual. Connect the REB to the 1st earth pit and measure the earth resistance in the REB and ensure that it is less than 1 Ohm. Check the size of the earth lead as per the US&S drawing. Earthing Lead is correctly connected to the protective fitting. Check the redundant cable from REB to the peripheral/ring earth pit. Earthing Lead Terminations are Readily Accessible. Check whether both earthing leads terminations are readily accessible. Earthing Lead connections are Mechanically Sound and Protected. Check Whether the Microlok II earth pit, power room earth pit and room earth pits are connected together to form equip otential bonding, as given in UM6800B manual, section 12.1 (Fig-4 & 5). Check whether the foundation for , Microlok II and other racks are firm, straight and permissible height. Check whether card file body is connected to rack earth. Check whether one end of every serial cable shield is connected to rack earth. Check whether ground conductors routed with physical separation from wiring connected to equipment. Check whether all unused wires grounded at this termination points. Check whether all grounding wires are without any sharps and bendings. Check whether each rack body (Microlok II and relay racks) in the signal equipment room is individually connected to REB. The earth connection between REB and the rack earth point should be as straight as possible. No coiling of additional length of cables.

Page 136

Observed Result OK / Not OK / NA

PRE- COMMISSIONING CHECK LISTS

Sl.No

Check Points

9.

Racks/IPS/Ladder connected to REB

10.

Visual inspection on Microlok II rack

12.

Visual check of card file back plane (Standard card file and Split card file)

13.

Visual check of all boards

14.

Keying plug fixing

15.

Card file/boards dust cover

16.

48/96 Connector pin locking

Requirement


Check whether the IPS and the racks in the power room are connected to the power room REB. Check whether Batteries are mounted properly. Check whether proper lugs are used to connect the wires at battery end. Check whether power room REB is connected to signal equipment room REB. Check whether Cable Ladder is connected to signal equipment room REB. Check whether painted surface are scraped to the clean metal surface where grounding connections are to be made. Check whether proper ventilation (fan trays) is provided in the rack. Check whether free space is available in the rack for maintenance. Check whether proper nomenclature of the module (slot details of the cards) is fixed on the rack as per the interface circuits. Check for proper mounting of EEPROM PCB on U card and Address Select PCBs on all I/O cards. Check for 48/96pin connectors are fixed as per I/O circuits. Check for neat wiring harness. Check for correct jumper settings on the Address select PCBs as per the I/O Boards configuration of the Station. Check whether input and output cables from the cards are routed separately. Unpack all the boards from their covers and check whether the boards are inspected by RDSO. Check for RDSO inspection stamp on the board. Visually check all the boards for their neat finish and plug them in the card file except U card. Check whether all the cards are mating with the top 48/96 pin connector properly for each card insertion. Note down the serial number and part number of each board. Check whether keying plugs are inserted in the correct location for the cards that are being inserted in each slot. Check whether card file motherboard cover is intact at the back plane. Fix the 1 wide blank facia in the unused slots except U board slot. Check whether the 48 and 96 pin connector hoods are properly locked to the card files.

Page 137


ANNEXURE -X

Sl.No

Check Points

17.

EEPROM wiring

18.

S – U 250 Hz wire

19.

System power wiring

20.

MLK II system input power supply

21. 22. 23. 24.

Interconnect cables routing cable routing Diode terminals for Outputs Tranzorbs across output (Mlk II) relay coils

25.

I/O wire routing

26.

Visual check of NonVital board output line filter box (This is applicable only when the room and the Signal equipment room are situated in different buildings)

Requirement Check the EEPROM PCB wiring to the 48-pin connector in U board slot 18 and19. Check whether 250Hz wire from U board is connected to Power supply board. Check whether system power wiring is done as per the interface circuits in of wire thickness, Phoenix terminal type and rigid connection using proper lugs. Check whether Tranzorb (Part No 5KP16A or 6KZ16A) connected across the MLK II system input power supply, as shown in UM-6800B manual section 3.2. Check whether interconnect cables are routed properly. Check whether cable routing is done properly. Check whether diode terminals are provided for +ve vital output from Microlok II. Check whether tranzorbs of specified make are installed properly across all relay coils that are driven by Microlok II. Check the polarity of the tranzorbs for correctness. Check whether input cables are twisted pair from Microlok connector to the respective relay rack termination. Check whether output cables from diode terminals are twisted pair to relay coils. Check whether the input, output and power cables are routed in different troughs separated with a gap of minimum 6 inches. This should be maintained in Microlok II rack, cable trays, ladder arrangements and relay rack.

Check whether proper mounting of Non-Vital board output line filter box, as given in UM-6800B manual, section 7.15.

Check the sticker and the labelling on Microlok II Nonvital board output line filter box. Check the tested OK sticker on Microlok II Non-vital board output line filter box. Check the phoenix connector for proper fastening.

27.

28.

IRISET

VCOR wiring/Receptacles locking

Relay type

Check the VCOR coil wiring and wiring are done as per the interface circuits of the station. Check whether VCOR receptacles are inserted properly and the receptacles are locked in the base. Check whether the type of the relays inserted in the relay racks are as per the relay disposition chart given in the interface circuits.

Page 138



Sl.No

29.

Check Points Fuses Terminals/Fuse ratings/Fuse fixing

30.

Terminals/connector s Tightness

31.

230V surge suppressor for Operator PC/Maintenance PC

Requirement


Check whether fuse terminals are fixed with proper fuse ratings as per the interface circuits. Check the mechanical dimensions of the fuse also so that the fuse fits in the fuse holder properly and there is no loose connection. Check whether the wire ends are crimped with correct size lugs and there are no loose connections at the terminals. Check whether all the wirings in the terminals are properly lugged and securely tightened. Check whether OBO 230V surge suppressor is provided in PC power supply and check the wiring is as per interface circuits. Check whether earth terminal of the OBO arrestor is connected to the REB in respective rooms.

32.

33.

Visual check installation of surge protection equipment DC-DC Converter for MLK II system power (12V)

Check the whether surge protection placement is as much as close to the REB, as given in UM-6800B manual, section 8.3. Check whether 12V DC-DC converter (N+1) configuration is provided for Microlok II card file supply. Check whether DC-DC Converter is not connected to earth ground. Check the wiring as per interface circuit.

34.

DC-DC Converter for MLK II I/O Boards & power (24V)

Check whether 24V DC-DC converter (N+1) configuration is provided for Microlok II I/O Board & supply. Check whether DC-DC Converter is not connected to earth ground. Check the wiring as per interface circuit.

35.

DC-DC Converter for RTC & Event Log Backup (5V)

Check whether 5V DC-DC converter configuration is provided for Microlok II RTC & Event Log Backup. Check whether DC-DC Converter is not connected to earth ground. Check the wiring as per interface circuit.

Page 139


ANNEXURE -X

Sl.No

36.

Check Points Serial port wiring (Port 1, Port 2, Port 3, Port 4 & Port 5 of MLK II)

37.

Serial/Fiber equipment location

38.

Diagnostic port connection

39

Serial link cable routing

40.

Fiber cable

IRISET

Requirement Check the serial communication cable wiring is done as per the interface circuits.

Check whether Twisted pair wires are used for Port 1 & Port 2. Check whether Non-Twisted serial cable (Single wire) is used for Port 3, Port 4 & Port 5. Check whether the shield of each serial communication cable is connected to rack earth at one end only. Check in all serial ports whether unused pairs of wires/extra wires are connected together and connected to signal common at both ends for best noise immunity. Check whether the serial Opto isolators and RS232<>485 Converters, Serial to Ethernet converter, Rugged server units, OSD units or equivalent are properly placed and wired as per the interface circuits, between Microlok to Microlok, Microlok to OP.PC, Microlok to M.PC and Microlok to Data Logger. Check whether all the diagnostic ports are wired from Microlok II rack to the location where Maintenance PC is located and terminated in a box. Check whether serial link cables are routed separately from both power and I/O wirings. Check whether splicing is done using the skilled personnel as per the fiber optic termination standards requirement. Check whether proper type of Fiber Management System (FMS) is used for the fiber cables, fiber equipment and fiber patch leads. Check whether proper routing of fiber cable is done inside the FMS. Check whether proper routing of fiber patch leads are done inside the FMS. Check whether the Adapter (fiber connector), Pigtails and splicing trays are fixed properly inside the FMS. Check whether Industrial type fiber connectors are used in the fiber equipment. Check the dB loss for every fiber core using optical power meter. Check whether the dB loss is within the specified limit of the fiber equipment. Check whether redundant path arrangement is working properly (i.e., seamless transfer of one fiber path to the other fiber path). Check whether OFC between SER to SER/LSC/SM’s Room is laid in independent trenches having different entries to those rooms. Check whether OFC is laid using HDPE pipe. Check the splice loops stored in the splice tray. Check whether all fiber loops are neatly dressed with in the splice tray. Check whether OFC equipment power supply & LED status is proper..

Page 140



Sl.No

Check Points

41.

230V cable routing

42.

Isolator/Converter/M odem/Switch wiring

43.

RS-232 Isolator

44.

Converter Cum Isolator switch settings of Operator PC

45.

Isolator for Maintenance PC

46.

MLK II power supply wire routing

47.

Wire size for 12V, 24V & 110V Microlok II supply

48.

IPS connections including PCs

49.

No Loose Conductors or Fittings

50.

Fittings are adequately ed

51.

Labels/Markers/Ferr ule/Heat shrink

Requirement


Check whether the one end of the armored OFC cable earthed or not. Check whether the Optical Time Domain Reflector (OTDR) Report is done for each and every fiber core after the splicing (Fusion Splicing) the fiber. Check whether fiber optic communication test reports are filled and signed off Check whether 230V supply cable for Operator/Maintenance PC is routed properly and is kept away from I/O cables and serial communication cables. Check the isolator/485 converter/Modem/Switch wiring as per the interface circuits. Check whether RS-232 Isolator is provided between Microlok – Microlok serial link. This is applicable where the ATD >= 50, as shown in UM-6800B manual Appendix-A. Check the 485 converter switch settings as per that is given in this document. Check whether opto-isolator is wired for the serial port coming out of Maintenance PC, as given in UM-6800B manual, section 9.1. Check whether MLK-II power supply wiring is routed properly and is kept away from I/O wiring. Check the wire size of the 12V, 24V & 110V supply connections from the IPS room to the Microlok II rack as per the interface circuits. Check the wire size of the 12V, 24V & 110V supply connections between Microlok II racks as per the interface circuits. Check the power connections from the IPS to all equipments in the Signal Equipment Room (Relay Room) and the operator VDU PCs. Ensure that there are no loose conductors in any of the circuits. Ensure that there are no loose connections in any of the terminations. Ensure that all the fittings in the racks are adequately ed and will withstand the vibration due to train movement.. Ensure that all terminations have markers and ferrules for their right connection. Check whether gaskets are provided on the cable entry cut outs in the racks and cable trays Check whether the wire size of the power switching circuits (in case of warm standby) is as per the interface circuits.

Page 141


ANNEXURE -X

Sl.No

Check Points

Requirement

52.

230V power cable laying

Isolate 230V power cable close to MLK II related area.

53.

Block cable routings

Check Block cable routings are separated from other cables/wires.

54. 55.

56. 57.

Axle/VFT/Misc. functions cable routings Switching circuit & wiring

Insulators for Racks & Ladders Lithium Battery CR2032 Panasonic U backup

58.

KELVIN connection

59.

24V or110V DC External supply for Fan supply

60.

MLK-II Fan input supply

61.

U jumper settings

62.

Jumper settings for loading the application software

63.

RTC Coin Battery jumper setting

64.

Voltages at IPS/MLK II

IRISET

Check Axle/VFT/Misc. functions cable routings are separated from other cables/ wires. Check the switching circuit and wiring as per the interface circuits. Check the wire size of the switching circuits is as per the interface circuits. Check whether Racks are insulated from the floor. Check whether Ladders are insulated from the Racks/walls. Check whether Lithium battery CR2032 is installed on “BATT1” location in the U board is loaded with right polarity. Check whether SPD is provided as per the KELVIN connection is done as shown in UM-6800B manual, section 13. Check whether Fan is fed with separate 24V or 110V DC is connected External supply, as shown in UM-6800B manual section 14. Check whether Tranzorb (Part No 5KP30A) connected across the MLK-II Fan input supply, as shown in UM6800B manual section 14. Check the jumper setting on the U board. Check whether they are inserted as per the given of UM-6800B manual section 3.1. Remove the U card from the card file and put the jumpers JMP 20 and JMP 23 to position 2-3. This is applicable to all the U cards installed in the Station/Section/ Yard. Check whether RTC Coin Battery jumper JMP35 on the U board is set to ENABLE position 1-2, as given in UM-6800B manual section 3.1 Fig-2. After switching on the Power, check the voltages at the IPS terminals & at the respective Microlok II power terminals and ensure that all the Microlok II card file power terminals have minimum 13.5V DC. Load the application data in all the U boards one by one as per the procedure given in UM-6800C manual section 5.9. On completion of program in the U, Microlok II will not be started (VCOR will drop). Enter the application data in the system configuration Mode. Refer “Clear KILL” UM-6800E manual section 5.1 for detailed information. Enter the checksum of the application data in the EEPROM checksum . Ensure that the 24V I/O supplies at respective Microlok II terminals are 27V DC minimum after the VCOR has picked up.

Page 142



Sl.No

65.

Check Points

Check Voltages in respect to earth for every Bus

Requirement


Ensure that Zero voltage recorded when connected to different bus polarity. If all the Microloks are up, switch them off all. Remove the U card from each Microlok card file and set jumpers JMP20 - JMP23 to position 1-2 (after ing the service version of Application program) in the Station/Section/Yard.

66.

Application Program

67.

RTC Time Setting

Set the RTC time on each U card and manually clear S in each Microlok in the Station/Section/Yard.

68.

Yard layout and its indications on Control cum indication , VDU and MT

Check the yard layout on CCIP/VDU/MT whether it is according to the approved signalling plan.

69.

VDU Active flashing indication

Check the RGY colour bar on the right hand top corner of the VDU screen is flashing in sequence. The flashing of this indication depicts that the VDU is active.

70.

protection for Emergency operation

Check from VDU that all emergency operations are protected with .

71.

Check-sum

72.

CRC

Check the Check-sum of the Application Software of each MLK II Unit in that Station /Section/ Yard from the Microlok II Complier generated Microlok Listing (MLL) file. Check the Check-sum of the Executive Software version CC 2.0 is 14FE Check CRC of the Application Software of each MLK II Unit inthat Station /Section/ Yard from the Microlok II Complier generated MLL file. Check the CRC of the Executive Software Version CC 2.0 is 08B1.

Page 143


ANNEXURE -XI

Annexure – XI REVIEW QUESTIONS 1. What is Solid State of Interlocking ? 2. Write the advantages of Electronic Interlocking. 3.

Write Short Notes on :a) VCOR, b) Vital Card,

c) Non Vital Card,

d) PSU,

e) U

4. Compare between Vital & Non-vital PCB of MLK2 system 5. Write the different hardware features of Micro Lok-II 6. Write the equivalent logic (Boolean Equation ) for the following circuit :A

B

C X D

7. Write the equivalent conventional circuit form the following Boolean Equation :A* ∼B * (∼ C* D + E)

TO

X

8. Draw the overall system configuration of MLK-II which is at IRISET .

9. Tick/Mark the correct option only:1. Each Vital input PCB has a) 8 input b) 16 input

c) 32 input

d) None the above

2. Non-vital PCB has a) 8 input & 8 out put b) 16 input & 16 out put c) 32 input & 32 ou put d) None the above 3. Non-Vital Inputs are a) Push Button, Key c) VCOR indication

b) Track Ckt., Point Detection d) None the above

4. Vital & Non-Vital cards are suitable for a) 6 V DC b) 12 V DC c) 24 V DC

b) Both (b) & (c)

5. VCOR relay has a) 6F/B dependent c) 6F, 6B

b) 6F/6B independent d) All the above

6. VCOR Relay rated current a) 3 mAmp b) 3 Amp

c) 30 mAmp

IRISET

Page 144

d) 30 Amp

REVIEW QUESTIONS

7. Slow to pick” is defined as a) “SET = 1 SEC” c) “SETUP = 1 SEC”

b) “Clear = 1 SEC” d) “DELAY=1SEC”

8. Slow to Release” is defined as a) “SET = 1 SEC” b) “Clear = 1 SEC” c) “SETUP = 1 SEC” d) “DELAY=1SEC”

9. Microprocessor used in Microlok-II is a) Motorola 68332 b) Intel 8086 c) Intel 68332 d) Motorola 8086 10. In the Card File the Power Supply PCB is placed in a) Slot No. 18 & 19 b) Slot No. 16 & 17 c) Slot No. 15 & 16 d) In any slot Q. Fill up the Balnks :1. 4 Flash EPROM of 8 MB are used for storing __________________ 2. 4 fast static RAM of 64 KB each are used for storing ________________ 3. Software used in SSI are a) ___ _________________ b) ___ _________________

c) ___ ________________

Match The Following :1) Processor used in Microlok-II is

(a) Push Button, Key

2) Processor used in Safelok is

(b) Intel – 8086

3) Each Vital Card PCB has input & Out Put

(c) 32

4) Each Non-Vital Card PCB has input & output

(d) 16

5) Vital Input are

(e) 6F/B , 3 Amp

6) VCOR Relay

(f) Motorola-68332

Page 145


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