Spec - MCS - 0080
Spec - MCS - 0080
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
PERFORMANCE SPECIFICATION
FOR
MODULAR CANTILEVER SYSTEM (MCS)
FOR
25 KV AC TRACTION
ISSUED BY
INDEX
1.0 SCOPE 3
10.0 RELIABILITY 9
11.0 MAINTAINABILITY 9
12.0 WARRANTY 9
1.0 SCOPE:
1.1 In 25kV Over Head Traction System, bracket assembly supports both the main
conductors and is more or less pivoted to the structures, capable of swiveling
along the track as well as adjustable in transverse direction. This assembly holds
the 65 sq. mm (diameter: 10.5 mm) Cadmium Copper Catenary (1000/1200 kgf
tension) and 107/150 sq. mm. hard drawn Copper Contact wire(1000/1200 kgf
tension) in simple polygonal design (drawings attached as Annexure -I). A
schematic diagram of bracket assembly is placed at Annexure-II.
1.2 This specification covers the requirement of “Modular Cantilever System”
(henceforth referred as MCS)” to suit the foot print dimensions on OHE
masts/portals and insulators that exists on Indian Railway’s 25kV ac traction
network. Details of existing cantilever assembly components viz-a-viz Modular
Cantilever System components are given in Annexure-III.
1.3 MCS shall consist of cantilever, suitable mast attachment fittings, 25kV bracket &
stay insulators, catenary wire suspension system, steady arm and other
components & assemblies essentially required to support the over head
conductors for smooth current collection, without hard spots.
1.4 This specification covers the requirement of field trials of MCS on the nominated
section of Indian Railways at a maximum speed for that section for six months
period. The device shall be put for field trials, to observe its performance. Data
shall be recorded in the format enclosed at Annexure-IV to help in taking decision
regarding adoption of type of Modular Cantilever System suitable for Indian
Railways.
1.5 Modular Cantilever System shall be Light Weight and capable for use with trains
speed 200 kmph (minimum). Manufacturer shall submit the performance
certificate for 200 kmph speed.
1.6 As the requirements are defined for development of the Modular Cantilever
System, better specification/parameters may be accepted for trial/testing by
Indian Railways. Deviation in the specified parameters may also be considered by
Indian Railways on merit and mutual agreement basis. However, manufacturers
must note that once the product is developed and stabilised, Indian Railways
reserve the right to freeze/ standardize any particular design or may provide its
own design which shall be binding on all the manufacturers.
2.1 The latest version of the above mentioned Specifications shall be available with the
firm.
2.2 Any special requirements given in the relevant drawings submitted by manufacturer
& approved by RDSO will override the specification.
Drawings : (i) MCS(Plan & Elevation) including Stay & Bracket (Porcelain or Composite)
Insulators, Mast & Portal attachment, Bent steady Arm and associated
fittings & fastners.
Detailed dimensional drawing of each part and component.
Design: (i) Design safety calculations details.
(ii)Manufacturer shall submit the Internal test report of tests carried out on
MCS along with the offer.
Note (i): Each drawing shall carry the tabulation for item reference, item’s name, drawing
number, material grade, material specification, test specification, quantity &
weight.
Note (ii): Salient technical particulars of the assembly/components shall also be
mentioned in the respective drawings.
Technical Literature & Other Details:
(i) Manufacturer shall submit the Product Catalogue, Handling, Storage &
Installation Instructions for MCS and Maintenance & Service Manual.
(ii) Manufacturer shall submit the Tabulation Sheet for weight of MCS.
SN Part name Part no Quarterly Weight of each part Total weight
4.2 After all the drawings and design documents are approved, the manufacturer shall
submit two Reproducible Tracing Films (RTF) in standard size of 210mm x 297 mm
or multiples of this for signature of approving authority. Only after all the design
and drawings have been approved and clearance given by purchaser/ RDSO to this
effect, the manufacturer shall take up manufacture of the prototype for RDSO's
inspection. It is to be clearly understood that any changes required to be done in
the prototype as required by RDSO shall be done expeditiously.
4.3 All fittings and fasteners shall be suitable for connection to the existing OHE mast
and portals. Details of interfacing between OHE mast and cantilever assembly will
be as per following details:
4.4 Modular Cantilever System shall be suitable for maximum span length of 72 meter.
4.5 All components of MCS shall be freely inter-changeable between various types of
assemblies.
4.6 MCS shall be able to take vibrations due to wind and passage of trains and at times
to impact loading in case of breakage of OHE conductors/Insulators during their life
span.
4.7 The MCS shall be suitable for maximum tension length 1500 m of overhead
equipment. An anti-creep is provided at middle of the tension length.
4.8 MCS shall be corrosion resistant to withstand the polluting & corrosive atmosphere
such as in the coastal areas, in the vicinity of chemical plants and diesel loco sheds
etc. Material specification should fulfill these requirements.
a) Both stay & bracket insulators shall be attached to the mast with the same type of
fitting.
b) It shall be possible to have different types of bracket assembly to suit the OHE
design (for implantation in the range 2.36 m to 3.6 m) by changing minimal
number of parts.
c) Types of tube fittings will be minimum.
d) Types of fasteners will be minimum.
e) Assembly, fixing, replacement will be easier and faster.
f) Maintenance check points will be least.
g) Maintenance periodicity will be higher.
h) Modular Cantilever Assembly shall be designed to have minimum number of
components.
been found unsatisfactory, all the samples in the lot may be inspected for
dimensional characteristics and the defective ones be removed, if agreed by the
purchaser. The lot shall then be tested for the remaining tests. Any item failing to
meet the requirement of tests, shall be considered as defective.
5.6 ACCEPTANCE & ROUTINE TESTS: The manufacturer shall carry out the specified
tests, during production, on the samples taken at regular intervals, to ensure
conformity to relevant specifications as also to maintain proper control over the
process of manufacture. The manufacturer shall maintain the frequency of the
various tests and shall produce a certificate at the time of inspection, showing the
frequencies of various inspections/tests which have been exercised during
production.
6.0 TEST METHODS:
6.1 Visual examination:- All fittings & tubes of modular cantilever systems shall be
visually examined as per RDSO’s Specification No. TI/SPC/OHE/Fittings/0130
(10/2013).Components made by casting process shall have clean finish and free
from cracks, surface flaws, harmful inclusions, blow holes etc. No repair shall be
done to the castings to hide defects. MCS shall also be checked for identification
nos. and firms monogram, as mentioned in the relevant drawings.
6.2 Radiographic Test : All cast components shall subjected to radiography as per
ASTM E-155-00(2005)/DIN EN VDE 0216 and shall satisfy the RDSO Specification
No. TI/SPC/OHE/Fittings/0130(10/13). .
6.3 Interchangeability test: If the components (fittings/tubes) of one Modular
cantilever are able to fit in place of components of other cantilever, randomly
selected, without any further modifications for interchangeability and ease in
erection & maintenance and MCS so made meet the requirements of clause 6.2, the
requirement of this test shall be deemed to have been complied with.
6.4 Physical properties and failing load test: The tensile strength, yield stress and
percentage elongation shall be determined in accordance with methods specified in
ASTM B-557 and shall not be less than the values specified for the Grades given in
RDSO approved drawing. Bending test shall be conducted in accordance with ASTM
B 317. Calculation for permissible stresses along with the copy of relevant standard
shall be submitted.
7.0 CRITERIA FOR ACCEPTANCE OF FINISHED PRODUCT:
a) Lot shall be made from the same production batch. Three modular assemblies from
each batch shall be selected at random from the offered lot (not more than 100
nos.) for tests. Samples from three selected units shall be subjected to the tests as
specified above.
b) If any sample fails to comply with any test(s) specified in this specification, test(s)
shall be repeated on three samples, taken from the same batch but limited to the
test(s) in which failure occurred. If in the retest(s) any sample fails, the batch
represented by the sample shall be deemed not to comply with specification and
the complete batch shall be rejected.
c) Only after clear written approval of the results of tests on the prototype is
communicated by the DG/TI/RDSO to the manufacturer, he shall take up bulk
manufacture of MCSs which shall be strictly with the same material and process as
adopted for the prototype.
8.0 PACKING AND MARKING: Part identification No., Manufacturers monogram and
month/year of manufacture shall be marked on each part of the MCS. The modular
cantilever system complying with this specification shall be properly packed, duly
assembled, in strong wooden boxes so as to avoid damage during transit. The box
shall carry on its outer face the following information.
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10.0 RELIABILITY:
a) MCS assembly as a unit is expected to provide reliable service for at least 40 years
irrespective of polluting & corrosive atmosphere such as in the coastal areas, in the
vicinity of chemical plants and diesel loco sheds etc.
b) The manufacture shall, therefore, ensure that the system supplied including all parts
and components etc. used are free from manufacturing defect. MCS shall be of
highest quality and in conformity with the specification.
c) The manufacturer shall submit the schedule of guaranteed performance for MCS.
11.0 MAINTAINABILITY:
12.0 WARRANTEE: The manufacturer shall provide warrantee for satisfactory performance of
MCS for a period of 30 months from date of supply & 24 months from the date of
commissioning, whichever is earlier.
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Annexure-I
Contact wire profile
Annexure-II
EXISTING CANTILEVER ASSEMBLY
a Distance between the Mast Stay Arm Fitting (Top Attachment) and the centre of Hook of
Catenary Suspension Bracket.
b Distance between the Vertical Axis of the Mast Bracket Swivel and the axis of the
Catenary Suspension Bracket.
c Distance from the bottom Cap of Bracket Insulator to the axis of the Register Arm Hook.
d Horizontal distance between the centre of the Register Arm Hook and the vertical axis of
Catenary Suspension.
e Encumbrance
Distance between the axis of Catenary and Contact wires. It is normally kept 1400 mm.
f Distance between Contact Plane and Mast Bracket Fitting. It is normally 300 mm.
L Suspension Distance
Horizontal distance from the extreme face of Mast Stay-Arm Fitting to the Suspension
point of Catenary wire. This is different from Setting Distance to the extent of stagger of
Catenary Clamp and thickness of Multiple Cantilever Cross Arm or Extension Chairs, if
provided.
r Distance between the Contact Plane and the Register Arm axis (including Raised Register
Arm) - which is assumed to be horizontal. It is normally 300 mm for the running Contact
Plane.
Inclination of Bracket tube to the horizontal
(as indicated) = 1 + 2 . It is generally 38o. Thus the Mast Bracket Fitting axis has an
inclination of 38o to horizontal.
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Annexure-III
19 Mast fitting for hook 3021 -do- Mast fitting Aluminium TI/SPC/OHE/Fitting
insulator. assembly Alloy s/0130(10/13) or
20 Mast bracket fitting assembly 3070-1 MCI its equivalent
(150) Steel Galv. specification.
Mast bracket fitting assembly 3070-2 MCI (EN/IEC/BS etc.)
21 (200) Steel Galv.
Note: If equivalent specification is proposed then the differences between the specified & proposed
specification shall be submitted during submission of design details itself .Its acceptance will be
subjected to RDSO’s approval.
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Annexure-IV
Note: The Railway while giving the performance report shall also comment on the following: