Government of India - Ministry of RailwaysResearch Designs & Standards Organisation

LUCKNOW – 226011

SIGNAL TESTINGLABORATORY

SIGNAL TESTING LABORATORY

1. AN OVERVIEW

RDSO, an ISO:9001 certified organisation, is the sole R&D organisation of Indian Railways and performs the following important functions:-

Adoption, absorption and development of new technologies for use on IndianRailways.

Development of new and improved designs.

Development of standards of materials and products specially needed byIndian Railways.

Technical investigation, statutory clearances, testing and providingconsultancy services.

Inspection of rolling stock, locomotive, signalling and telecommunicationequipments, track components etc. for ensuring quality.

Quality audit of Railway workshops & production units.

RDSO has a number of laboratories, which are well equipped with research andtesting facilities for development, testing, and design evaluation of various railwayrelated equipments and materials.

Signal Testing Laboratory are fully equipped for development, testing andinvestigations of most of the signalling equipments.

2. SIGNAL TESTING LABORATORY

Signal Testing Laboratory undertake testing of all types of signalling equipmentsinvolving safety such as Signalling Relays, Block Instruments, Power SupplyEquipments, Point Machines, Signalling Cables, Electromechanical SignallingEquipments/Components, Modern Signaling equipments, etc.

There is an exclusive section for environmental testing equipped with range ofclimatic test facilities as per IS: 9000. These include programmable environmental (heat& humidity), dry heat, cold, mould growth, salt mist spray, dust, rain chambers etc.

Environmental Section

The laboratory is equipped with full testing facilities for Power Supply Equipment(Battery Charger, DC-DC Converter, Transformer etc.), Signal lamps & Lenses, Relays(Metal to Carbon & Metal to Metal contact type). The laboratory is also equipped fortesting of electronic and microprocessor based equipments like Electronic Interlocking,Data Loggers, Axle Counters,Block Interface for optic fibre cable, LED Signals, AudioFrequency Track Circuits, Electronic Timers, Electronic Flashers,etc.

Modern Signaling Hall Axle Counter Testing Setup

Signal laboratory is also equipped for testing of all types of electromechanicalsignalling equipment like Point Machines, Signal Machines, Electric Point Detector,Electric Key Transmitters, SM’s Slide Frames, Primary Cells, all types of signallingcables and track fittings related to signalling gears. There is a small signalling yardadjacent to laboratory having four turnouts including thick-web high-speed turnout. Thelaboratory is provided with requisite facilities of conducting type tests includingperformance, endurance tests on all above types of signaling equipment.

Block Instrument Testing Setup Cable Testing Equipments

In addition to above, regular type tests and investigations are conducted on all theabove types of signal equipment

3. SIGNALLING EQUIPMENT DEVELOPMENT CENTRE

A Signalling Equipment Development Centre has been set up in the SignallingTesting Laboratory. Here working systems including EI, Digital Axle Counter, DataLogger, AFTCs, Block Instruments, LED signal lamps etc. are available. In addition,equipments developed by RDSO, such as signaling relay, polycarbonate lenses, triplepole double filament lamps, power supply equipment etc. have also been displayed. Thiscentre is being used for various testing at developmental stages and for furtherimprovements in the designs of various signalling systems. Training for newly inductedinspectors is also imparted in this center.

Electronic Interlocking Signalling EquipmentDevelopment Centre

4. FACILITIES

4.1 Environmental Testing

The following test chambers are available to carry out testing as per requirement of IS: 9000: -

Programmable Environmental TestChamber Dry heat chamber Cold chamber Rain chamber Salt mist spray chamber Dust chamber Mould growth chamber Recovery chamber

Programmable EnvironmentalTest Chamber

4.2 Test and Measuring instruments

Important test and measuring instrument used for testing of various signalling items available in the lab are as under:-

Spectrometer Chromameter Power Harmonics analyzer Digital Storage Oscilloscope Automatic Relay Testing Jig Electrical & electronic load High voltage tester Insulation resistance meter Cable testing equipments High Precision Digital Multimeters Power supplies Tensile Strength testing machines

4.3 LED Signals

Testing facilities are available for measurement of colour coordinates and luminanceby using spectrometer setup of all aspects of LEDsignals.

Spectrometer4.4 Relay Performance and Endurance Testing

Facilities for testing of all types ofsignaling relays including line relays, trackrelay, lamp proving relays and pointcontactor relays area available. Testbenches for measurement of all operatingparameters like pickup, drop-away,voltage/time, contact resistance, contactpressure, contact bounce time etc. areprovided for expeditious completion oftype tests. Endurance test set-ups fortesting of relay for 10 lakh operations arealso available for all types of plug-in typerelays.

Endurance Test Setup for Relays

4.5 Computerised Relay Testing

The testing of all electricalparameter and timing characteristics isbeing carried out with the help ofComputerised Automatic TestEquipment. By this faster testingsystem, human errors are eliminated &test results are very accurate.

Automatic Computerised Relay Test Bench4.6 Power Supply Equipment Testing

Facilities for High voltage test, induced highvoltage test, performance test, endurance test areavailable for all types of power supply equipment likeBattery Charger, DC-DC Converter, Transformer etc.used in Railway Signalling

Power Supply Section

4.7 Cable Testing

The following test facilities for underground Signalling cables (including axle counter cables) and indoor PVC cables/wires are available: -

i) Elongation and tensile strength testing, ii) Thermal stability test. iii) Ageing test. iv) Melt flow index test. v) AC/DC High voltage water immersion test.

vi) Measurement of insulation resistance (dry & wet), conductor resistance, specificgravity etc.

4.8 Electro-Mechanical Equipment Testing

The type test facilities including set up for endurance/performance test for the following electromechanical safety signalling equipment are available:-

i) Point machine ii) Signal machine iii) Electrical point detector iv) SM’s slide frame endurance v) Lever locks vi) Circuit controllers vii) Block instruments viii) Electric signal reversers ix) Electric key transmitter

Tokenless Block Instrument

4.9 Miscellaneous items

Other signalling items like PBT terminals, electric filament switching unit, choke etc. are also tested regularly in the laboratory.

4.10 PERFORMANCE

2013-14 2014-15

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100

150

200

250

300

350

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450416

149Initial Type/ Dev elopmental Test Maintenance Type Test Inv estigation Tests Climatic Test Total

Type of Tests 2013-14 2014-15Initial/ Developmental Test 52 56Maintenance Type Test 149 49

Investigation Tests 124 44

Climatic Test 91 22

Total 416 149

CONSOLIDATED LIST OF TYPE TEST (w.e.f. 01/04/2015)

Sl.No.

Description of Item for testingType testcharges(in Rs.)

1 ALL TYPES OF Block Instrument 2128812 SIGNALLING RELAYS (All Groups) 1988703 SIGNALLING RELAYS (Group "0") 114834 SIGNALLING RELAYS (Group"I") 184465 SIGNALLING RELAYS (Group"II") 474926 SIGNALLING RELAYS (Group"III") 1055437 SIGNALLING RELAYS (Group IV & V) 227228 SIGNALLING RELAYS (Group VI) 79739 SIGNALLING CABLES (EXCEPT SINGLE CORE) 110137

10 SINGLE CORE INDOOR SIGNALLING CABLES 3229611 ELECTRIC POINT/SIGNAL MACHINE 19348212 ELECTRO MECHANICAL SIGNALLING ITEMS

( MOTOTR FOR ELECTRIC POINT MACHINE, MOTOR FOR ELECTRIC LIFTING BARRIER, ELECTRIC POINT DETECTOR, PNEUMATIC RAIL TREADLE, LEVER LOCK, CIRCUIT CONTROLLER, ELECTRIC SIGNAL REVERSOR, ELCTRIC KEY TRANSMITTER, ARM & LIGHT REPEATOR, S.M.’S CONTROL FRAME, SIGNAL MOTOR, ETC.) 104269

13 POWER SUPPLY ITEMS ( BATTERY CHARGERS, INVERTORS, FERRO RESONANT VOLTAGE REGULATOR, STATIC TRANSFORMER, TRANSFORMER RECTIFIER SET, PRIMARY CELL ETC.) 129285

14 POWER SUPPLY ITEMS (TESTING OF TRANSFORMER & 'B' TYPE CHOKE, TFBC & OTHER SMALL ELECTRICAL SIGNALLING ITEMS) 67752

15 NYLONE/PBT MATERIAL (PBT/BACKLITE TERMINAL BLOCKS, PBT 8 WAY TERMINALS, IB JOINTS, COPOLYMER BUSH, SAN JAR AD CELLS, TRACK LEAD JUNCTION BOX, BOOT LEG, IRJ/TOP& BOTTOM ROLLER ETC. ) 70716

16 Signal lenses & Roundels 730517 EARTH LEAKAGE DETECTOR 13602718 SOLAR PANELS AND CHARGE CONTROLLER 13439919 SIGNAL LAMPS 6143720 FILTER UNIT 12006921 AC METAL CAN CAPACITOR 7949222 BUMP TEST (1000 Bump in each direction) 10987

23 DRY HEAT TEST ( ONE CYCLE of 16 hrs. ) 1854824 DAMP HEAT TEST / HUMIDITY( ONE CYCLE of 24 hrs. ) 2007425 DAMP HEAT TEST / HUMIDITY ( SEVEN CYCLE ) 3101626 DUST TEST ( ONE CYCLE of two hrs. ) 1121727 COLD TEST ( ONE CYCLE of two hrs. ) 1133728 COLD TEST ( ONE CYCLE of 16 hrs. ) 1873829 SALT - MIST TEST ( 2 hrs. + 22 hrs. damp; 3 cycles)

( test for corrosive atmosphere) 1411630 SALT - MIST TEST ( 2 hrs. plus severity of 7days damp: 3

cycles i.e.21 days)( test for corrosive atmosphere) 2776331 SALT - MIST TEST ( 2 hrs. plus severity of 7days damp: 4

cycles i.e.28 days)( test for corrosive atmosphere) 3093432 SALT - MIST TEST ( 48 hrs. continuous)

( test for corrosive atmosphere) 1915633 SALT - MIST TEST ( 96 hrs. continuous)

( test for corrosive atmosphere) 2006234 MOULD - GROWTH TEST ( 28 days)

( Test for fungus effect) 3471535 RAIN TEST ( ONE CYCLE of two hrs. ) 1109836 CHANGE OF TEMPERATURE TEST ( Three cycles )

( One cycle of 8 hrs. ) 2012937 SMPS BASED IPS 20612038 DATALOGGER 28359639 UFSBI 25814640 BPAC Using UFSBI 31488441 BPAC WITH UFSBI & Multi-Combiner 39112542 Indigeneous UNIVERSAL AXLE COUNTER SYSTEM 23082043 Indegeneous SSBPAC( Solid State block proving with Axle

counter) 127650844 SSDAC/MSDAC (Single/Multi Section Digital Axle Counter 130510745 LED CLS SIGNALLING LAMP 10582546 LED SEMAPHORE LAMPS 5664447 AFTC EQUIPMENT, INCLUDING TRANSMITTER, RECEIVER,

TUINING UNIT, POWER SUPPLY BONDS ETC. 20631348 IMPEDANCE BOND OR LINE MATCHING UNIT 7083749 ELECTRONIC INTERLOCKING INDIGENIOUS 190633950 Battery operated LED based Torch Lighting/Flashing Hand

Signal Lamp 2790551 FOGPASS 14136252 ENDURANCE TEST FOR TELECOM ITEMS 168 hrs 2786753 FUSE AUTO CHANGEOVER SYSTEM 8355454 DOMINO TYPE CONTROL PANEL 61628