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Government of India - Ministry of Railways
Research Designs & Standards Organisation
LUCKNOW – 226011
SIGNAL TESTING
LABORATORY
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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 Indian
Railways.
Development of new and improved designs.
Development of standards of materials and products specially needed by
Indian Railways.
Technical investigation, statutory clearances, testing and providing
consultancy services.
Inspection of rolling stock, locomotive, signalling and telecommunication
equipments, 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 and
testing facilities for development, testing, and design evaluation of various railway
related equipments and materials.
Signal Testing Laboratory are fully equipped for development, testing and
investigations of most of the signalling equipments.
2. SIGNAL TESTING LABORATORY
Signal Testing Laboratory undertake testing of all types of signalling equipments
involving safety such as Signalling Relays, Block Instruments, Power Supply
Equipments, Point Machines, Signalling Cables, Electromechanical Signalling
Equipments/Components, Modern Signaling equipments, etc.
There is an exclusive section for environmental testing equipped with range of
climatic 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
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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 for
testing of electronic and microprocessor based equipments like Electronic Interlocking,
Data Loggers, Axle Counters,Block Interface for optic fibre cable, LED Signals, Audio
Frequency 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 electromechanical
signalling equipment like Point Machines, Signal Machines, Electric Point Detector,
Electric Key Transmitters, SM’s Slide Frames, Primary Cells, all types of signalling
cables and track fittings related to signalling gears. There is a small signalling yard
adjacent to laboratory having four turnouts including thick-web high-speed turnout. The
laboratory is provided with requisite facilities of conducting type tests including
performance, 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 the
above types of signal equipment
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3. SIGNALLING EQUIPMENT DEVELOPMENT CENTRE
A Signalling Equipment Development Centre has been set up in the Signalling
Testing Laboratory. Here working systems including EI, Digital Axle Counter, Data
Logger, AFTCs, Block Instruments, LED signal lamps etc. are available. In addition,
equipments developed by RDSO, such as signaling relay, polycarbonate lenses, triple
pole double filament lamps, power supply equipment etc. have also been displayed. This
centre is being used for various testing at developmental stages and for further
improvements in the designs of various signalling systems. Training for newly inducted
inspectors is also imparted in this center.
Electronic Interlocking Signalling Equipment
Development 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
Test Chamber
Dry heat chamber
Cold chamber
Rain chamber
Salt mist spray chamber
Dust chamber
Mould growth chamber
Recovery chamber
Programmable Environmental
Test Chamber
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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 luminance
by using spectrometer setup of all aspects of LED
signals.
Spectrometer
4.4 Relay Performance and Endurance Testing
Facilities for testing of all types of
signaling relays including line relays, track
relay, lamp proving relays and point
contactor relays area available. Test
benches for measurement of all operating
parameters like pickup, drop-away,
voltage/time, contact resistance, contact
pressure, contact bounce time etc. are
provided for expeditious completion of
type tests. Endurance test set-ups for
testing of relay for 10 lakh operations are
also available for all types of plug-in type
relays.
Endurance Test Setup for Relays
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4.5 Computerised Relay Testing
The testing of all electrical
parameter and timing characteristics is
being carried out with the help of
Computerised Automatic Test
Equipment. By this faster testing
system, human errors are eliminated &
test results are very accurate.
Automatic Computerised Relay Test Bench
4.6 Power Supply Equipment Testing
Facilities for High voltage test, induced high
voltage test, performance test, endurance test are
available for all types of power supply equipment like
Battery 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,
specific gravity etc.
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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.
PERFORMANCE OF SIGNAL LAB (2013-14)
Type of Tests 2013-2014
Initial/ Developmental Test 52
Maintenance. Type Test 149
Investigation Tests 124
Internal Climatic Test 91
Total 416
0
50
100
150
200
250
300
350
400
450
2013-14
416Initial Type/ Developmental Test
Maintenance Type Test
Investigation Tests
Climatic Test
Total
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TYPE TEST CHARGES (w.e.f. 01/04/13)
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No
Description of Item for testing Type test charges
(in Rs)
1 ALL TYPES OF Block Instrument 170276
2 SIGNALLING RELAYS (All Groups) 127988
3 SIGNALLING RELAYS (Group "0") 9078
4 SIGNALLING RELAYS (Group"I") 15041
5 SIGNALLING RELAYS (Group"II") 41611
6 SIGNALLING RELAYS (Group"III") 83605
7 SIGNALLING RELAYS (Group IV & V) 20114
8 SIGNALLING RELAYS (Group VI) 6373
9 SIGNALLING CABLES (EXCEPT SINGLE CORE) 86828
10 SINGLE CORE INDOOR SIGNALLING CABLES 25842
11 ELECTRIC POINT/SIGNAL MACHINE 153427
12 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.)
85663
13 POWER SUPPLY ITEMS
( BATTERY CHARGERS, INVERTORS, FERRO RESONANT
VOLTAGE REGULATOR, STATIC TRANSFORMER,
TRANSFORMER RECTIFIER SET, PRIMARY CELL ETC.)
103961
14 POWER SUPPLY ITEMS
(TESTING OF TRANSFORMER & 'B' TYPE CHOKE, TFBC &
OTHER SMALL ELECTRICAL SIGNALLING ITEMS)
54930
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. )
58062
16 Signal lenses & Roundels 5705
17 EARTH LEAKAGE DETECTOR 110212
18 SOLAR PANELS AND CHARGE CONTROLLER 108714
19 SIGNAL LAMPS 48415
20 FILTER UNIT 95170
21 AC METAL CAN CAPACITOR 68920
22 BUMP TEST (1000 Bump in each direction) 8585
23 DRY HEAT TEST ( ONE CYCLE of 16 hrs. ) 14542
24 DAMP HEAT TEST / HUMIDITY( ONE CYCLE of 24 hrs. ) 15990
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25 DAMP HEAT TEST / HUMIDITY ( SEVEN CYCLE ) 26428
26 DUST TEST ( ONE CYCLE of two hrs. ) 8815
27 COLD TEST ( ONE CYCLE of two hrs. ) 8930
28 COLD TEST ( ONE CYCLE of 16 hrs. ) 14722
29 SALT - MIST TEST (2 hrs. + 22 hrs. damp; 3 cycles)
( test for corrosive atmosphere) 11533
30 SALT - MIST TEST ( 2 hrs. plus severity of 7days damp: 3 cycles
i.e.21 days)( test for corrosive atmosphere) 23442
31 SALT - MIST TEST ( 2 hrs. plus severity of 7days damp: 4 cycles
i.e.28 days)( test for corrosive atmosphere) 26506
32 SALT - MIST TEST ( 48 hrs. continuous)( test for corrosive
atmosphere) 15125
33 SALT - MIST TEST ( 96 hrs. continuous)( test for corrosive
atmosphere) 16001
34 MOULD - GROWTH TEST ( 28 days)
( Test for fungus effect) 30074
35 RAIN TEST ( ONE CYCLE of two hrs. ) 8690
36 CHANGE OF TEMPERATURE TEST ( Three cycles )
( One cycle of 8 hrs. ) 16030
37 SMPS BASED IPS 161800
38 DATALOGGER 233394
39 UFSBI 213537
40 BPAC Using UFSBI 246048
41 BPAC WITH UFSBI & Multi-Combiner 308074
42 Indigeneous UNIVERSAL AXLE COUNTER SYSTEM 182989
43 Indegeneous SSBPAC( Solid State block proving with Axle counter) 1015576
44 SSDAC/MSDAC (Single/Multi Section Digital Axle Counter 1030883
45 LED CLS SIGNALLING LAMP 88454
46 LED SEMAPHORE LAMPS 47855
47 AFTC EQUIPMENT, INCLUDING TRANSMITTER, RECEIVER,
TUINING UNIT, POWER SUPPLY BONDS ETC. 164120
48 IMPEDANCE BOND OR LINE MATCHING UNIT 58250
49 ELECTRONIC INTERLOCKING INDIGENIOUS 1503229
50 Battery operated LED based Torch Lighting/Flashing Hand Signal
Lamp 22900
51 FOGPASS 111385
52 ENDURANCE TEST FOR TELECOM ITEMS 168 hrs 22214