SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

DELHI METRO RAIL CORPORATION LIMITE5D

DMRC ELECTRICAL STANDARDS &

DESIGN WING (DESDW)

SPECIFICATION NO.
DMES- T/___/ DMRC-E-TR-CANTILEVER-1

SPECIFICATIONS FOR MODULAR CANTILEVER FOR

OHE

DELHI METRO RAIL CORPORATION LTD.

7 th Floor, B-Wing, Metro Bhawan,
Fire Brigade Lane, Barakhamba Road,
New Delhi -110 001

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

Previous Record of specification

Stage Date
Draft -1

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

INDEX

ITEM NO. HEADING PAGE

1.0 DETAILED DESCRIPTION OF THE EQUIPMENT AND ITS 4

APPLICATION IN DMRC
2.0 GOVERNING SPECIFICATIONS 5-6

3.0 ENVIRONMENTAL REQUIREMENTS 7

4.0 GENERAL & TECHNICAL REQUIREMENT 7-9

5.0 9
INTERFACE/MODULARITY OF THE SYSTEM:

6.0 9-11
MATERIAL SPECIFICTAION

7.0 INSPECTION & TESTING 11-13

TEST METHODS
8.0 13
9.0 CRITERIA FOR ACCEPTANCE OF FINISHED PRODUCT
14
PACKING AND MARKING
10.0 14
11.0 INSTALLATION, COMMISSIONING & TRIAL 15

12.0 RELIABILITY 15

13.0 MAINTAINABILITY 15

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

1.0 DETAILED DESCRIPTION OF THE EQUIPMENT AND ITS

APPLICATION IN DMRC –MODULAR CANTILEVER

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 multi-
stranded Catenary with (1000/1200 kgf tension) and 107/150 sq.
mm Contact wire with (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
DMRC’s 25kV ac traction network.

1.3 MCS shall consist of cantilever, suitable mast attachment fittings,

25kV bracket & stay insulators, catenary wire support system,
steady arm and other components & assemblies essentially
required to support the overhead conductors for smooth current
collection, without hard spots.

1.4 The Modular cantilever should be of superior design and

have a proven service record in high speed rail system
owing to its corrosive resistivity and light weight shall be
used on a normal mast (either conventional or tubular).
Preference would be given to the design already proven &
successfully used in earlier phase of DMRC system. The
cantilever shall be suitable for meteorological conditions as
specified in contract. Modular Cantilever System shall be
capable for use with trains speed 200 kmph (minimum). Vendor
shall submit the performance certificate for 200 kmph speed.

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

2.0 GOVERNING SPECIFICATIONS:

In preparation of this specification, reference has been made to the
following specification:

1. IS : 1285-2002 Specification for wrought aluminum and aluminum

alloys, extruded round tube and hollow sections (of
general engineering purposes).
2. IS : 2673-2002 Specification for Dimensions for wrought aluminum
and aluminum alloys, extruded tube (round).
3. IS:4711-1974 Methods for sampling of pipes, tubes and fittings.
4. IS :504-1963 Methods of Chemical Analysis and its alloy
5. IS:1608-1995 Mechanical Testing of Metals-Tensile Testing
6. IS:5052-1993 Aluminum& its Alloy - Temper Designation
7. IS: 6051-1970 Code for Designation of Aluminum& its Alloy
8. ASTM B221M Standard Specification for Aluminum-Alloy Extruded
Bar, Rod, wire, Profiles and Tube (Metric)
9. ASTM Standard Specification for Aluminum-Alloy Extruded
B317/B317M - 07 Bar, Rod, Tube, Pipe, Structural Profiles, and Profiles for
Electrical Purposes (Bus Conductor)
ASTM B557 Tension testing of wrought and cast aluminum &
10.
magnesium alloy products
11. ASTM E-155-00 Reference for Radiographs for inspection of Aluminum
(2005)/DIN EN VDE & Magnesium castings.
0216
12. TI/SPC/OHE/INS Specification for solid core porcelain insulators for
/0070 25kV, AC 50Hz Overhead traction lines.
13. TI/SPC/OHE/INS Specification for composite insulator for 25kV, AC 50Hz
COM/1070 Overhead traction lines.
14. TI/SPC/OHE/FA Specification for Steel Fasteners & Stainless Steel
STNERS/0120 Fasteners for 25 kV A.C. Traction Overhead Equipment
15. TI/SPC/OHE/ Technical specification for 25 kV AC OHE Fittings
FITTINGS/0130
EN 12165/ ASTM Specification for Copper and Copper Alloy Forging
16. B124 Rod, Bar & Shapes
17. EN 1706/ASTM B 85 Specification for Aluminum Alloy Die Castings

2.1 The latest version of above specification mentioned shall be available

with the firm

2.2 Any Special requirements given in the relevant drawings submitted by

manufacturer and approved by DMRC will override the specifications

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

3.0 ENVIRONMENTAL REQUIREMENTS:

The MCS shall be used in varying atmospheric and climatic conditions

as tabulated below.

1 Ambient air temperature -50C to (+)550C

2 Maximum temperature of metallic 700C
object in sun
3 Maximum relative humidity 100%
4 Earthquake Zone Zone-4
5 Pollution (Very Heavy) as per IS 60815
latest edition.
6 No. of Rainy days/annum 120
7 Annual Rain fall Dry Acid Region and also
monsoon affected regions
with annual rain fall range
from 1750 to 6250 mm
8 No. of thunder storm/annum 85
9 No. of thunder Dust/annum 35
10 Basic wind pressure As per IS 875 latest edition.
11 Corrosion Heavy corrosion prone
areas, saline environment
12 Vibration level 3g

4.0 GENERAL AND TECHNICAL REQUIREMENTS:

4.1 The Modular cantilever system offered shall be based on proven
design. The vendor shall submit design, drawings and design safety
calculation for scrutiny & approval of DMRC. The vendor shall also
submit the detailed literature which also includes Photographs
and precautions for handling, storage & installation of MCS, product
catalogue, maintenance and service manual.
Drawings: (I)
MCS (Plan & Elevation) including Stay & Bracket (Composite)
Insulators,
Mast & Portal attachments,
Steady Arm and associated fittings &fasteners.
Detailed dimensional drawing of each part and component.

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

Design:-
I. Design safety calculations details.
II. Vendor shall submit the internal test report of tests carried
out on MCS.
Note:
I. Each drawing shall carry the tabulation for item reference,
item's name, drawing number, material grade, material
specification, test specification, quantity & weight.

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,
and Storage & Installation Instructions for MCS and
Maintenance & Service Manual.
II. Manufacturer shall submit the Tabulation Sheet for weight of
MCS.

S.No. Part Part Quantity Weight of Total

name no each part weight

4.2 All fittings and fasteners shall be suitable for connection to the existing
OHE mast and portals with proper provision of nuts and check
nuts.

4.3 Modular Cantilever System shall be suitable for maximum span length
of 72 meter.

4.4 All components of MCS shall be freely inter-changeable between

various types of assemblies.

4.5 MCS shall be able to take vibrations due to wind and passage of trains
on viaduct and at grade and at times to impact loading in case of
breakage of OHE conductors/Insulators during their life span.

4.6 The MCS shall be suitable for maximum tension length 1500 m of

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

overhead equipment. An anti-creep is provided at middle of the tension

length.

4.7 MCS shall be corrosion resistant to withstand the polluting &corrosive

atmosphere such as in the vicinity of chemical plants and railway
lines etc. Material specification should fulfill these requirements.

4.8 Manufacturer’s monogram and Identification Number shall be engraved

on all parts of MCS as per the relevant drawings.

4.9 INTERFACE/MODULARITY OF THE SYSTEM:

The MCS must fulfill the following essential requirements:

a) Both stay & bracket insulators shall be attached to the mast with the
same type of fitting for reducing the inventories.
b) Types of tube fittings will be minimum for better reliability.
c) Type of fasteners shall be suitable to handle vibration impact and
meteorological condition as specified in clause no 3.
d) Types of fasteners shall be provided with suitable nuts along with
second line of defense like check nuts or split pins or even both.
e) Assembly, fixing, replacement will be easier and faster.
f) Maintenance check points will be least.
g) Maintenance periodicity will be higher.

4.11 MATERIAL SPECIFICATION:

a) Material of MCS items shall be as specified in Annexure-III
b) Stay Tube, Bracket Tube, Register Arm Tube and Bent Steady Arm
shall fulfill design requirements. The tube shall be of the size such
that the ratio of combined bending & axial stresses shall be < 1.
Following details shall be submitted by the manufacture along with
the loading diagram, calculation for permissible stresses and values
of actual stresses as well as reference of standard, grade proposed
to be used for manufacturing of components of MCS.

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

StayTu Bracket Register Steady

S.No.
Parameters be Tube Arm Arm

1 Nominal Diameter(mm)

2 Outside Diameter(mm)
3 Inside Diameter (mm)
4 Thickness(mm)
5 Mass (kq/m)
6 Area of cross section (cm2)
Volume
7 External (cm3/m)
Internal (cm3/m)
8 Moment of Inertia (cm4)
9 Modulus of Section (cm3)
10 Radius of Gyration (cm)
11 Yield Stress (Mpa)
12 Tensile Stress (Mpa)
13 Elongation
14 Permissible Axial stress in tension (Mpa)

15 Actual Axial stress in tension(Mpa)

16 Factor of Safety
17 Permissible Axial stress in
compression(Mpa)
18 Actual Axial stress in compression(Mpa)
19 Permissible Bending stresses(Mpa)
20 Actual Bending stresses(Mpa)
21 Permissible Shear stress(Mpa)
22 Actual Shear stress(Mpa)

23 Ratio of combined bending and axial

stresses

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

c) Insulators: The system shall allow use of composite insulators;

however, mounting system shall be same for both types. Insulators
shall meet the requirement of DMRC specification no. DMES-
0030/DMRC-E-TR-Insulator-1 & minimum creepage distance shall
not be less than 1600 mm. The metal parts of these insulators shall
be as per the design of the manufacturer of MCS.

5. TESTS:
5.1 The following type tests shall be conducted:
S.No. TEST TYPE ACCEPTENCE ROUTINE Clause
TEST TEST TEST no/Standard/
Drawings

1.0 Visual examination (fittings Y Y Y Cl. 6.1

& tubes)
2.0 Verification of dimensions Y Y Y As per approved
(fittings & tubes) Drawings
3.0 Chemical composition test Y Y Y Cl. 4.11
(fittings & tubes)
4.0 Radiographic Testing of Y Y Y Cl. 6.2
fittings & Tubes
6.0 Physical properties & failing Y Y Y Cl. 6.3
load test for fitting
7.0 Insulator's testing Y Y Y Cl. 4.11

8.0 Test on Fasteners Y Y Y TI/SPC/OHE/Fatn

ers/0120

5.2 Sampling for type test

a) Three set of each fitting & tubes used in MCS shall be produced by
the vendor, on which tests shall be carried out for ascertaining their
conformity to the requirements of this specification.
b) The lot which has been found satisfactory in visual examination
shall be tested for dimensional characteristics. Any items failing to
meet one or more dimensional requirements shall be considered as
defective. In case of those lots which have 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,

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

shall be considered as defective.

5.3 ACCEPTANCE TESTS&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 vendor 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. 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)and DMRC’s approved
drawings. 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

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

determined in accordance with methods specified in ASTM B-557

and shall not be less than the values specified for the Grades
given in DMRC 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. 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.

8. PACKING AND MARKING:

Part identification No., vendors 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.
Vendor's name Content details (Part Name, Part
a) b)
No. & Quantity)
Net and gross weight Production batch number
c) d)
consignee Any other particulars specified by
e) f)
the purchaser.
Inspector's stamp and seal on Date of inspection
g) h)
components & box

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

9. INSTALLATION, COMMISSIONING & TRIAL:

The OEM shall supervise the installation and commissioning of the
cantilever. Vendor shall submit an undertaking from the OEM that
the cantilevers have been installed under their supervision and as
per their satisfaction.
10. RELIABILITY:
a) MCS assembly as a unit is expected to provide reliable service for at
least 40 years irrespective of polluting & corrosive atmosphere
vicinity of chemical plants and Railway lines 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 vendor shall submit the schedule of guaranteed performance for
MCS.
11. MAINTAINABILITY:
11.1 Vendor will submit to DMRC the requirements of maintenance.
11.2 The vendor shall furnish list of recommended spares, tool & plants
for proper upkeep and trouble free service of MCSs.
11.3 An undertaking that spares shall be made available during the
service life (40 years) of MCSs shall be furnished along with the
offer.

12. WARRANTEE: The manufacturer shall provide warrantee for

satisfactory performance of MCS for a period of 24 months from the
date of commissioning.

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

ANNEXURE-I

Cross Dimensions (mm) Dimensions (Degree)

Section
of
Contact
Wire
(mm 2 )
A B C D E F L M N
107 12.24±0.10 - - 6.92±0.15 6.50 4.43 27(+1-0) 51(+1-0) 78(+2-0)
150 12.24±0.10 - 6.92±0.15 6.50 4.00 27(+1-0) 51(+1-0) 78(+2-0)

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

Annexure-II

A. Distance between the Mast Stay Arm Fitting (Top Attachment) and the
center 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 center 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 1200 mm.
R. Distance between Contact Plane and Mast Bracket Fitting. It is normally
300 mm.

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SPECIFICATION FOR MODULAR CANTILEVER SYSTEM (MCS) FOR 25 kV TRACTION SYSTEM

ANNEXURE-III
Details of existing Cantilever assembly:

S.No. Name of Fitting Material Standards

Al tube 55x6 (in m) Aluminium Alloy
1 IS:1285 or its
Al tube 70x6 (in m) Equivalent
2 Specification
End Cap PVC Non rigid
3 black
Clevis end fitting 70 (B622/3)
4
Clevis end fitting 55
5
Eye clamp 55 (B622/4)
6 Aluminium alloy DIN EN 1706 (2010-
06) Aluminium and
Eye clamp 70 aluminium alloys -
7
Castings - Chemical
Steady Arm composition and
8 mechanical properties
Catenary wire support clamp
9
Hook clamp 55 &70
10
Contact wire clamp with bolt sets CuNi2Si (Copper
11 (nut and check nut/ split pins)
Nickel Silicon)
EN 12165 or its
equivalent
Fasteners with proper nut and
12 check nut arrangement. Stainless steel
DIN 934 for Nuts and
check nuts
DIN 125 for washers
BS EN ISO 3506 for
stainless steel fastners
Inclined Dropper Stranded
13 Stainless steel
wire

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