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‘1’

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION
FOR
METALLISED CARBON STRIPS SUITABLE FOR
PANTOGRAPH WITH AUTO DROPPING DEVICE
PROVISION
FOR
25 KV A.C. ELECTRIC LOCOMOTIVES AND EMU /
MEMU

Specification No: RDSO/2014/EL/SPEC/0114, Rev. ‘1’

Issue Date /Year XX.XX.2020

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226011

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Status of Revision

S.N. Date of Page no. Revision Reasons for Revision

Revision
1. - All 0 First Issue

2. xx.xx.2021 3, 4, 5, 6, 9, 1 Specification revised to

10, 11-21, incorporate test procedure,
25, 27 & 28 acceptance criteria and
parameters of metallised
carbon strips

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CONTENTS

S.N. CONTENTS PAGE No.

0.0 Foreword 4
1.0 Scope 4
2.0 References 5
3.0 Supplier’s Responsibility 5
4.0 Infringement to Patent 6
5.0 Terminology 6
6.0 Climatic, Environmental and Operating 7
Conditions
7.0 Scope of Supply 8
8.0 Properties 9
9.0 Drawing & OHE Parameters 9
10.0 Inspection and Tests 10-22
11.0 Corrosion Protection of Metal Sheath 23
12.0 Marking 23
Annexure- Technical details existing OHE of 24
IA Indian Railway
Annexure- Design of OHE for Double Stack 25-26
IB Container Trains
Annexure Performance Report Format 27
–II
Annexure RDSO’s Drg. NO. SKEL-4994 (Alt.‘0’) 28
–III

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0.0 FOREWORD:

This specification is intended to serve as a guide line to the

manufacturers of Metallised Carbon Strip for Pantographs with
auto dropping device provision being used on 25 kV, A.C., 50
Hz of A.C. Electric Locomotives and EMU/MEMU for the
existing OHE as well as high rise OHE of dedicated freight
corridor on IR. The specification covers the technical
requirement of metallised carbon strips suitable for Pantograph
with Auto Dropping Device (ADD) provision.

Auto Dropping Device (ADD) system for Pantograph shall lower

the pantograph as per clause 4.9 of IEC-60494-1-2013 and also
in case of too high wear of collector strips. The purpose of
incorporation of auto dropping device system is to minimise the
risk of consequential damages to OHE and pantographs in the
event of pantograph entanglement with OHE. There is an air
channel in the metallised carbon strip which is supplied with
compressed air. If case of damage of metallised carbon strip
during entanglement with OHE, compressed air vents out from
metallised carbon strip which causes lowering of pantograph.
In addition to the above, if the metallised carbon strips wears to
a particular level below condemning limit, Auto Dropping Device
shall lower the pantograph thus preventing any damage to the
OHE.

1.0 SCOPE:

On Indian Railways, 25 KV AC electric locomotives / motor

coaches of EMUs draw current from OHE through the
Metallised carbon Strips fitted on pantographs of electric
locomotives / EMUs /MEMUs to reduce the wear of contact
wire thereby increasing its life.
This specification applies to Metallised carbon Strips for use on
25 kV, A.C., 50 Hz, electric locomotives and EMU/MEMU
pantographs with Auto dropping device system for satisfactory

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operation up to speeds of 250 Kmph under catenary heights

varying from 4.54 meters to 7.57 meters from the rail level. This
Specification covers manufacturing and testing of metallised
carbon strips used on Pantograph with Auto Dropping Device
provision in A.C. electric locomotives and EMU/MEMU.

The Metallised carbon Strips grades used for pantograph with

ADD in manufacturing of the strips shall be as per approved list
of grades issued by RDSO periodically.

This design of Metallised carbon strip for Pantograph shall be

suitable for all class of Electric locomotives and AC
EMU/MEMU.

2.0 REFERENCES:

STANDARDS:
(i) IS: 13466– 1992, Reaffirmed 2019
“Brushes for Electrical Machines”
(ii) IS: 13584-1993, Reaffirmed 2019
“Brush Material for Electrical Machinery.”
(iii) Specification No: RDSO/2009/EL/SPEC/0097, Rev. ‘1’
Technical Specification of metallised Carbon Strips Suitable
for Pantograph without Auto Dropping Device of 25 kV A.C.
Electric Locomotives and EMU/ MEMU
(iv) EN 50405 -2006 Current collector systems- Pantographs,
testing methods for carbon contact strips
(v) IEC-62499: 2008 Railway applications – Current collection
systems – Pantographs, testing methods for carbon contact
strips
(vi) Latest version/revision of the standards and specifications etc
shall be followed, unless specifically mentioned otherwise.

3.0 SUPPLIER’S RESPONSIBILITY

3.1 The Metallised carbon strip of pantographs offered shall be

complete with all parts and accessories necessary for its
efficient operation. All such parts and accessories shall be
deemed to be within the scope of this specification whether
specifically mentioned or not.

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3.2 Technical guidance and assistance for proper operation,

investigation and generally all aspects of technical liaison
that may be required during the service trial period as per
extant ISO guideline shall also be organized by the
Contractor.

3.3 Supplier shall engrave/emboss/pad printing identification

marks indicating their monogram/brand names and the
month and year of manufacture at a conspicuous place on
all the components. Pad printing shall be applicable on
metallised carbon strip portion for identification of
condemning limit and grade.

3.4 Supplier is advised to familiarize themselves with

pantographs and roof equipments layout on the existing
locomotives.

3.5 Once a prototype is approved, no Supplier shall change his

source of supply or sub-Supplier for purchased
components and sub-assemblies without RDSO approval.

4.0 INFRINGEMENT TO PATENT

Indian Railway shall not be responsible for infringement of

patent rights arising due to similarity in design, manufacturing
process, components used in design, development and
manufacturing of Metallised Carbon Strips and any other factor
which may cause such dispute. The responsibility to settle any
issue lies with the Supplier.

5.0 TERMINOLOGY:

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Terms/abbreviations used frequently in the document are

explained below:

IR Indian Railways

Research Designs
RDSO&S Research Designs & Standards Organisation.

CLW Chittaranjan Locomotive Works

Tenderer Firm/companies participating in the tender.

Supplier The person, firm or company on whom the order

for supply of the work has been placed

Sub Any person, firm or company from whom the

Supplier Supplier may obtain any materials or fittings to
be used for the Pantograph.

Inspecting Nominated person to inspect the Metallised

Officer carbon strips.

OEM Original Equipment Manufacturer

BG Broad Gauge 1676 mm used in IR

IS Indian Standard

IRS Indian Railways Standard

IEC International Electro technical Commission

ISO International Standards Organization

OHE Overhead Equipment

AC Alternating Current

EMU / Electrical Multiple Unit / Mainline Electrical

MEMU Multiple Unit

ADD Auto Dropping Device

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6.0 CLIMATIC, ENVIRONMENTAL AND OPERATING CONDITIONS:

Atmospheric Under Sun: 75°C max.

temperature
In shade: 55°C max.
Minimum temperature: -10°C
(also snow fall in certain areas during
winter season)

Humidity 100% saturation during rainy season.

Altitude 1776Mts. above mean sea level.

Rain fall Very heavy in certain areas.

No. of Rainy days per May be as high as 120 days.

annum

No. of May be as high as 85 days

thunderstorms
days/ year.

Coastal area Metallised carbon Strips shall be designed

to work in coastal areas in humid and salt
laden atmosphere with maximum pH
value of 8.5, sulphate of 7 mg per liter,
max. Concentration of chlorine 6 mg per
liter and maximum conductivity of 130
µSiemens/Cm, wind pressure reaching
150 kg/cm2.

7.0 SCOPE OF SUPPLY:

The deliverables include complete Metallised carbon Strips

suitable for pantographs with Auto Dropping Device provision
along with all its components including the hardware & air
tube-

(i) Operating and maintenance manual containing essential

technical information like composition of material, hardware
details, details of ADD operation and tightening torque etc.
shall be supplied. The manual shall be in A4 size sheet
printed on one side in suitable folder in English.
Drawings/sketches shall be in A4 /A3 size sheets only. The

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Supplier shall list out the special tools, if any which shall be
required for installation and maintenance of the Metallised
Carbon Strips.

(ii) Acceptance Tests reports of Metallised Carbon strips

8.0 PROPERTIES

The properties of Metallised carbon strips are as under:-

Parameters Unit Requirements

Hardness BHN 5/100 95±10%

Or Or

HRB 5/100 105±10%

Bulk density gm/cm3 Min. 2.0

Copper content by weight 15% to 33%

* %age of other metal by weight Max. : 10%

Transverse Strength M N / m² Min. : 75

(Bending strength)

Compressive Strength M N / m² Min. 250

Resistivity µΩ– m Max. : 11.0

Note:*Lead being a hazardous material shall be avoided. If considered

absolutely necessary, its percentage to be kept minimum.

9.0 DRAWING & OHE PARAMETERS:

A) DRAWINGS:
RDSO’s Drg. NO. SKEL-4994 Alt. ‘0’ indicates the
constructional and fitment features in brief of metallised
carbon strips for pantograph with ADD and is enclosed as
Annexure II. Unspecified Tolerance shall be as per EN 22768.

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B) Physical Design of Metallised Carbon strip:

The length of the strip shall be approximately 1030±2 mm

having a flat zone of 800 +0/-20 mm in the middle and both the
ends should be tapered for the pantograph with ADD. This
Metallised Carbon Strip shall be of single piece design only.

C) The condemning limit mark line shall be Painted/ pad printed as

indicated in the Drawing no. SKEL 4994 (Alt. ‘0’ ) for Metallised
carbon strip with ADD.

D) The impact force required for Auto Dropping Device shall be

tested in accordance with EN-50405.

E) OHE PRAMETERS:

Technical details existing & Dedicated Freight Corridor OHE of

Indian Railway is enclosed as Annexure IA & Annexure IB.

10.0 INSPECTION AND TESTS

The tests to be carried out on finished Metallised Carbon Strips at

the manufacturers’ works are classified as Type, Routine &
Acceptance. After completion of successful prototype test the
metallised carbon strips with ADD system shall be subjected to
extended field trial for quantity and period as per extant ISO
guideline. The performance report format is included in Annexure
II. Prototype approval will be provided after such successful field
trial. Tests shall be conducted as per table given below:

The following Table gives the details of tests to be carried out on

finished Metallised Carbon Strips:

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S. PARAMETER TYPE ROUTIN ACCE TEST METHOD

E PTAN
NO.
CE

1. Hardness BHN(5/100) or
Rockwell B 5/100

2. Bulk Density - - As per

IS: 13584
Clause 6.2

3. Copper √ - Chemical Analysis

Content

4. Percentage of √ - Chemical Analysis

Other Metal

5. Transverse - - As per
Strength
IS: 13584 Clause 9
(Bending
Strength)

6. Resistivity - - As per
IS: 13584 Clause 8

7. Dimension √ √ As per SKEL Drg.

Check No. 4994 (Alt. 0)
with ADD

10.1 Hardness Test shall be carried out as per Clause 7 of IS-13584:

1993 Reaffirmed 2019 or subsequent Clause of latest revision.

General
There are two methods in general use for determining the hardness
of carbon materials, namely:
a) Rebound method (7.2 of IS-13584),
b) Indentation method (7.3 of IS-13584).
Test shall be carried out by using one of the above methods and
detailed procedure shall be mentioned in the report.

10.2 Bulk Density The bulk density shall be determined as per Clause
6.2.2 Measurements-and-weight method of IS-13584: 1993
Reaffirmed 2019 or subsequent Clause of latest revision and
detailed procedure shall be mentioned in the report.

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10.3 Chemical composition of Metallised Carbon Strips: shall be

determined by Chemical Analysis from approved labs or in-house
facility available with firm.

10.4 Transverse Strength (Bending Strength): Test shall be carried

out as per clause 9 of IS-13584: 1993 Reaffirmed 2019 or
subsequent Clause of latest revision by using test specimens of 10
mmx 10 mm x 64 mm and detailed procedure shall be mentioned
in the report.

10.5 Resistivity test shall be carried out as per Clause 8 RESISTIVITY

of IS-13584: 1993 Reaffirmed 2019 or subsequent Clause of latest
revision.
8.1 General
There are several different methods in general use for determining
the resistivity of brush materials.
The methods used most frequently for production quality control
are as follows:
a) Voltmeter-ammeter method (8.2 of IS-13584),
b) Kelvin bridge method (8.3 of IS-13584).
Test shall be carried out by one of the above methods and detailed
procedure shall be mentioned in the report.
10.6 In addition to the above tests the following test must also be
carried out.
List of tests as per IEC-62499:

IEC-62499 Test Description Routine Type test

Clauses test
5.2.1 Test for the temperature characteristic of -
the carbon contact strip under rated
current loading
5.2.2 Test for deflection and extension of the -
carbon contact strip under extremes of
temperature
5.2.3 Test for flexural characteristic of the -
carbon contact strip
5.2.4 Test of shear strength of the carbon -
contact strip X
5.2.5.2.1 Sealing integrity
5.2.5.2.2 Temperature test -
5.2.5.2.3 Flow continuity
5.2.5.2.4 Impact function of the autodrop -
detection sensor
5.2.6 Test of mechanical fatigue resistance of -
the carbon contact strip
5.2.7 Test of the electrical resistance of the
carbon contact strip

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10.6.1 5.2.1 Tests for the temperature characteristic of the carbon

contact strip under rated current loading

5.2.1.1 General
The test aims to determine the temperature characteristic to
stability of the carbon contact strip at the maximum designed
current loading.
5.2.1.2 Test method
The carbon contact strip shall be fixed at one end and freely
supported at the other end (see Figure 1).
The current supply connection shall be made by clamping suitable
interfaces to the vertical faces of the carbon, but not in contact
with the carrier material (see Figure 2). The current take off shall
be made at the normal design interface(s).

Key
1 parallel clamp (steel)
2 carbon contact strip fixed end
3 temperature sensor 2 mm above carbon carrier interface
4 power supply
Figure 1 – Arrangement of test device for testing temperature
characteristic

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Key
1 current supply connection (steel, copper)
Figure 2 – Example of current supply connection
The temperature shall be monitored adjacent to the current supply
connection at a point 2 mm above the carbon / carrier interface.
The maximum rated current loading shall be applied to the carbon
contact strip until the monitored temperature remains constant
and then for a further 30 minutes. The temperature shall be
continuously recorded during the test as a temperature – time
characteristic.
Test acceptance criteria: The carbon contact strip shall remain
fit for purpose. The contact strip shall remain in accordance with
drawing at room temperature.
10.6.2 5.2.2 Test for deflection and extension of the carbon
contact strip under extremes of temperature

5.2.2.1 General
The test aims to determine the vertical displacement and change in
length of the carbon contact strip under extremes of temperature.
5.2.2.2 Test method
5.2.2.2.1 High temperature test
This test may be carried out concurrently with the test described in
5.2.1. Under the steady state heated conditions of 5.2.1.2, the
change of length of the carrier (∆l) and vertical displacement of the
strip (∆h) from the room temperature condition shall be recorded
(see Figure 3).

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Key
1 carbon contact strip fixed
2 vertical displacement
3 change of length
Figure 3 – High temperature test
5.2.2.2.2 Low temperature test
The contact strip shall be cooled by a suitable method until the
temperature of the strip is -40 °C. The contraction and vertical
displacement from the room temperature condition shall be
recorded.
Test acceptance criteria: The carbon contact strip shall remain
fit for purpose. The contact strip shall remain in accordance with
drawing at room temperature.
10.6.3 5.2.3 Test for flexural characteristic of the carbon contact
strip

5.2.3.1 General
The test aims to determine the flexural characteristic of the carbon
contact strip at room temperature.
5.2.3.2 Test method
The flexural characteristic is determined by three point bending of
the complete contact strip when supported at each end of the strip
along the longitudinal centre line of the contact strip and loaded
vertically at the centre. The force shall be gradually applied until
permanent deformation is recorded on a force-deflection chart. The
effective stiffness shall be determined from the results of the test
and the applied force at which permanent deformation is recorded.
10.6.4 5.2.4 Test for shear strength of the contact strip

5.2.4.1 General
Definition of shear strength: Τs = Fs / A (N/mm2)
This test shall demonstrate that the adhesion between carbon and
supporting structure meets the minimum shear strength criteria at
room temperature, at specified temperatures (criteria specified by
the manufacturer) and thermal fatigue. The shear strength at

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failure of the specimen at room temperature shall exceed a

minimum acceptable value or result in failure of the parent carbon
material alone.
5.2.4.2 Test method
5.2.4.2.1 Test at room temperature
Samples of the contact strip material shall be prepared in
accordance with Figure 4:

Key
1 carrier
2 carbon
Figure 4 – Preparation of samples
A minimum of 3 samples shall be prepared from a production
contact strip and shall include each end of the contact strip and
the centre. Each sample shall be prepared to a preferable length of
30 mm. Each sample shall be installed in a suitable fixture (see
Figure 5) in order that the applied shear force Fs is guided directly
into the interface defined as area of adhesion A between carrier
and carbon (see Figure 6).The force of failure of the sample shall be
recorded. The shear strength shall be determined by calculation of
Ts.
Test acceptance criterion: The minimum calculated shear
strength shall be 5 N/mm².

Key
1 sledge

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2 metal pins
3 test specimen
Figure 5 – Example of suitable fixture for testing shear strength of
carbon contact strip

Key
1 carrier
2 carbon
3 force
Figure 6 – Example of testing configuration of shear strength test
5.2.4.2.2 Test at specified temperature
Test specimens shall be prepared in accordance with 5.2.4.2.1.
Specimens shall be cooled / heated to - 40 °C, 100 °C, 200 °C, 250
°C and the steady state temperature recorded in test 5.2.1 where
this is greater than 250 °C. The temperature shall be measured at
the retention interface of the carbon and supporting structure. It
shall be verified that the temperature of the monitoring point is
representative of temperature at the interface and maintained
during the test. The force of failure of each sample shall be
recorded. The characteristics of Ts with temperature shall be
provided.
5.2.4.2.3 Thermal fatigue test
The contact strip used in 5.2.1 shall be thermally cycled from room
temperature to the maximum temperature achieved in 5.2.1.2 for
100 cycles. The electrical resistance shall be measured before and
after the test (see 5.2.7). The shear strength of the contact strip
shall be measured at the conclusion of the test by taking samples
from the heated region.
Test acceptance criteria: It shall be demonstrated that the
electrical resistance and method of attachment of carbon to the
carrier have not deteriorated during the test.
10.6.5 5.2.5 Test of autodrop detection sensor integral with
contact strips

5.2.5.1 General

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The following tests shall demonstrate the sealing integrity of the

contact strips, the flow continuity of the detection sensor and the
operation of the detection sensor.
NOTE The tests are applicable only to contact strips that are
equipped with a channel at the base of the carbon as a sensing
device.
5.2.5.2 Test method
5.2.5.2.1 Sealing integrity
The carbon contact strip autodrop detection sensor shall be
inflated for a minimum of 10 seconds at maximum operating
pressure of the automatic dropping device (ADD). The maximum
operating pressure shall be specified by the manufacturer and be
agreed by the customer; a pressure of 10 bar is suggested.
The air leakage rate shall be measured and demonstrated at room
temperature. Maximum operating pressure shall be applied to the
contact strip and the leakage rate shall be measured using a flow
meter.
Alternative methods of measurement are acceptable where it can
be demonstrated that they equate to the above leakage rate at
maximum operating pressure.
Test acceptance criterion: The leakage rate shall not exceed
0.1l/min.
5.2.5.2.2 Temperature test
The carbon contact strip, tested under 5.2.2, where fitted with an
autodrop detection sensor, shall be inflated during the test
described in 5.2.2 to the maximum operating pressure of the
automatic dropping device as specified by the manufacturer and be
agreed by the customer (a pressure of 10 bar is suggested) and the
sealing integrity during this test shall be continuously monitored.
Test acceptance criterion: The leakage rate shall not exceed
0.1l/min.
5.2.5.2.3 Flow continuity
A flow meter shall be connected between the air supply and the
contact strip. The supply shall be inflated to a minimum operating
pressure of the autodrop system as specified by the manufacturer
and be agreed by the customer (a pressure of 5 bar is suggested)
and the blanking plug sealing the autodrop sensing system shall
be removed.
Test acceptance criterion: The flow rate shall be recorded and
shall exceed the minimum ADD requirement.
5.2.5.2.4 Impact function of the autodrop detection sensor
5.2.5.2.4.1 General

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The test shall demonstrate the operation of the autodrop detection

sensor by impacting the contact strip and causing a severe failure
of the carbon material.
5.2.5.2.4.2 Test method
The carbon contact strip shall be supported at the interface
between the pantograph and carbon carrier at a height to allow the
striking point of the pin to be in line with the maximum wear line
of the collector at mid span of the collector strip (example Figure
7). An air supply and monitoring equipment shall be connected
and the system shall be inflated to the minimum operating
pressure (Figure 8). The mass shall be retracted to a height h to
provide sufficient energy to cause a successful operation of the
autodrop detection sensor with one strike, or to an energy level as
defined in the customer specification. In addition also a linear
impact method producing the equivalent energy level defined by
the customer is permissible.
The energy shall be derived from the following formula:
Energy (Joules) = Mass m (kg) × gravity g × height h (m)
Test acceptance criteria: Successful autodrop operation shall be
demonstrated and the energy level recorded.

Key
1 typical length of pendulum 1 m
2 typical striking pin contact diameter 13 mm
3 clamp
4 carrier
5 carbon
Figure 7 – Typical impact test device

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Key
1 clamps at normal working position
2 carbon
3 air supply
4 on/off valve
5 flow meter
6 pneumatic tube with appropriate length & size
7 pressure gauge
Figure 8 – Air supply and monitoring equipment

10.6.6 5.2.6 Test of mechanical fatigue resistance of the carbon

contact strip

5.2.6.1 General
This test shall demonstrate that the structural integrity of the
assembly will not deteriorate in service.
5.2.6.2 Test method
The carbon contact strip shall be supported at the interface
between the pantograph and the carbon carrier. A sinusoidal
varying load including a random frequency sweep shall be applied
vertically downward on the carbon at the midpoint or the
maximum distance from the mechanical support of the contact
strip. The carbon contact strip shall be subjected to 1.2 x106 cycles
at a minimum frequency of 0.5 Hz, with a vertically applied load
equivalent to twice the static contact force applied by the
pantograph to a single contact strip. The maximum load generated
shall be greater than 150 N and the vertical displacement shall be
at least 4 mm. A minimum of 10 million cycles shall be completed
and shall include random frequency sweep.
Test acceptance criterion: No structural deterioration of the
contact strip shall be observed.

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10.6.7 5.2.7 Test of the electrical resistance of the contact strip

5.2.7.1 General
This test shall demonstrate the electrical conductivity (or
resistance) from the carbon surface to the supporting structure
and can be used to demonstrate consistent manufacture.
5.2.7.2 Test method
The resistance shall be measured by using a tool which
incorporates contact points for the transmission of current and
monitoring of voltage drop (see Figure 9). The tool shall be applied
with repeatable force to test locations at a maximum distance of 10
cm along the length of the contact strip.
At each application a constant DC current of minimum 1 A shall
be applied and the mV-drop at the location of current application
shall be recorded (see Figure 10).
Test acceptance criterion: Resistances shall be within the
manufacturer’s declared resistance limits for the carbon contact
strip.

Key
1 carrier
2 carbon
3 contact points for the transmission of current
4 mV meter
Figure 9 – Test of electrical transfer resistance from the carbon
contact surface to the supporting structure

Key
1 contact points for the transmission of current
2 mV meter
Figure 10 – Connection scheme for test of electrical resistance

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10.7 TYPE TESTS

To be carried out on prototype samples of carbon strips of the
given design. Complete type tests shall be organised and
conducted by the manufacturer in presence of the authorised
representative of RDSO. The test results of any grades once
approved by RDSO shall be valid for a period of Five years.
Supplier shall submit internal test report alongwith following
details prior to offering the metallised carbon strip for type
testing:

(i) The Bill of material indicating drawing no, material, sub

Supplier etc.

(ii) Complete technical details of air tubes insert inside the

current collector metalised carbon strip.

(iii) If TOT with the firm outside India is involved, then the
supply experience of collaborator shall be furnished.

10.8 ROUTINE TESTS

To be carried out by the manufacturer on each lot. The

manufacturer shall maintain record of test results to be produced
as and when required by the authorized inspecting agency.

10.9 ACCEPTANCE TEST

To be carried out by the manufacturer at the time of acceptance

of supplies. The sampling procedure and criteria for acceptance
shall be as per Annexure C of IS 13466-1992. Acceptance test
shall be conducted on 0.5% subject to a minimum of 2 samples
(drawn at random) against each order. Routine test results of the
lot will also be submitted by manufacturer.

In addition to above, the purchaser shall have right to carry out

stage inspection also at firm’s premises particularly with
reference to manufacturing process, quality control and
compliance with various clauses of the specification.

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10.10TESTS ON RAW MATERIALS/ BOUGHT OUT ITEMS

The manufacturers shall maintain Quality Assurance Plan of all

raw materials/bought out items used in the manufacture of
Metallised carbon strips to ensure the quality and compliance to
prescribed standards.

(a) Type tests:

To be carried out on prototype samples of raw

materials/bought out items.

(b) Acceptance tests:

To be carried out on each batch of supply. The manufacturer

shall maintain record of test results to be produced as and
when required by the authorized inspecting agency.

11.0 MARKING:

Condemning limit and grade shall be pad printed on each

metalised carbon strips and the following particulars shall be
legibly and engraved/ embossed/pad printed on each Metal
sheath/carrier of Metalised carbon Strips

• Grade of carbon strips.

• Identification of source of manufacturer, and
• Batch number, month and year of manufacture.
********

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ANNEXURE – IA

TECHNICAL DETAILS EXISTING OHE OF INDIAN RAILWAY)

Sl.No. PARAMETERS
1.0 OHE Simple Polygonal OHE (regulated)
2.0 Span 72M (Max.) on tangent track suitably reduced
on curves. Maximum variation between two
adjoining span is 18 Mtrs.
3.0 Tension 1000 kgf. for catenary and 1000 kgf. for contact
wire.
4.0 Contact wire 107 mm2 Hard drawn grooved copper (HDGC)
5.0 Catenary 95 mm2 Cadmium copper

6.0 Maximum 415 mm

blow off
7.0 Stagger of 200 mm on straight track& 300 mm on curves.
contact wire
8.0 Relative movement of pantograph with reference to contact
wire.

i) Dynamic Normally the contact wire is within the 520 mm

zone on either side of the track centre line i.e.,
1040mm which is the flat zone of the
pantograph. However, during wind conditions
the contact wire may go beyond this flat zone
extending up to 800 mm on either size of the
centre line i.e., to cover a range of 1600 mm.
(Taking into account other factors such as
oscillations, loose joints etc.
ii) Static For heavy wind conditions 860mm from the
centre line of pantograph is taken in to account.
9.0 Mid span sag Partly 50mm to 100mm varying from span 27
Mts. to 72 Mts.
10.0 Condemnation 74mm2 (reduction in vertical height from
size of contact 12.24mm to 8.25mm)
wire
11.0 Gradient of The maximum contact wire gradient is 3mm per
contact wire meter and permissible variation in gradient over
2 consecutive spans is 1.5 mm per meter.
(Variation of 1.5mm/m on consecutive span.)
12.0 Spacing of First dropper 2.25m from support, second one is
droppers 4.50m/6.75m and thereafter the droppers are at
9m spacing.
13.0 Permissible 60 mm (at registration arm)
uplift of
contact wire

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Annexure -IB
Design of OHE for Double Stack Container Trains
A. Max Moving Dimension on DFC
(a) For DFC
Width 3.66 Mts.
Height 6.810 Mts.
(b) For feeder Routes
Width 3.5 meter
Height 6.81 meter with double stack containers
Height 4.385 meter on other routes
Max. Width of Fixed structure 2.825 Mts.
B. OHE Parameters
Height of Contact wire at support up to 7.570 Mts. from
Rail Level
Height of Contact wire at mid span 7520mm from Rail level
Height of Double stack container 7.1 Mts. from RL
(6.81+0.250+0.020)
Wind Load 155kgf/m2
Speed 200 kmph
C. Minimum Vertical Clearance Under Over-line structure
Heavy overhead structure such as ROB 8050 mm
Light overhead structure such as FOB 8430 mm
Heavy overhead structure at turnouts 8430mm
D. Design of OHE
OHE Design for Contact wire height 7.570Mts.
double stack
Catenary wire height 8.970Mts.
container
movement Mast length 11.4 Mts.
Minimum 2.8 Mts.
implantation
Pre-sag 50 mm or 100 mm

Span Existing Spans

(54 metres for wind
load 155 kgf/Sq. m,
67.5 meters for wind
load 105 kgf/Sq. m)
Tension in contact 1000 kgf

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Tension in catenary 1000 kgf

Tension length 1.5 km
Foundations: FOS > 2.5
Common Masts, Conductors, Auto-tensioning
components devices, Insulators, Steel tubes, All fittings.
Merging with Mainline OHE: 5.5 M Max. 5.8 m
existing OHE
High Reach OHE Max. 7.570m
Difference 1.77 m.
C.W. gradient in @10mm/m
OHE for merging
with existing lines

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ANNEXURE-II

Shed Loco Provided in Date of material Date of Average wear Cases of Remarks, if
No. single or both received fitment rate per 10,000 failures, any
pantograph Kms. if any

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ANNEXURE – III

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