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Inspection and Maintenance of

Course 206

PREVIEWPARTICIPANT GUIDE COURSE 206: INSPECTION AND MAINTENANCE OF INTERLOCKINGS MODULE 1: OVERVIEW & SAFETY

Inspection and Maintenance of Interlockings Participant Guide

Signals Maintenance Training Consortium

COURSE 206 ONLY

PREVIEW

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TABLE OF CONTENTS PAGE

How to Use the Participant Guide ...... V

MODULE 1 OVERVIEW AND SAFETY ...... 1

1-1 OVERVIEW ...... 2 1-2 SAFETY ...... 3 1-3 TOOLS AND MATERIALS ...... 7 1-4 TESTING ...... 10 1-5 DOCUMENTATION ...... 15 1-6 SUMMARY ...... 16 MODULE 2 TESTING & MAINTENANCE OF INTERLOCKINGSONLY ...... 17 2-1 OVERVIEW ...... 18 2-2 GENERAL INSPECTION PROCEDURES...... 20 2-3 STEPS FOR PERFORMING VARIOUS LOCKING TESTS ...... 25 2-4 INSPECTION AND TESTING OF INTERLOCKINGS ...... 36 2-5 MAINTENANCE ...... 44 2-6 SUMMARY ...... 45

PREVIEW

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LIST OF FIGURES Page Figure 1.1 Signal Maintainers working at an ...... 3 Figure 1.2 Portable detection device being installed on ROW ...... 6 Figure 1. 3 Personal alert device (PAD) worn by an employee ...... 6 Figure 1. 4 Work at interlockings located at grade crossings requires public safety precautions ...... 6 Figure 1. 5 Interlocking Tools ...... 8 Figure 1.6 Switch Tools ...... 9 Figure 1.7 Locking Test Form ...... 15 Figure 2.1 Form Used for Locking Tests –courtesy METRA ...... 19 Figure 2.2 Yard Interlocking Signal ...... 20 Figure 2.3 Interlocking Box ...... 21 Figure 2.4 Impedance Bond Layout ...... 21 Figure 2.5 Train Stop...... 22 Figure 2.6 Local Control Panel Diagram ...... 34 Figure 2.7 Local Control Panel ...... ONLY 35 Figure 2.8 Signal maintainer shunting a ...... 38 Figure 2.9 Mounted Interlocking...... 39 Figure 2.10 Vital Microprocessor Interlocking ...... 40 Figure 2.11 Power Off Timing Relay ...... 41 Figure 2.12 Movable Bridge ...... 42 Figure 2.13 Track Wires ...... 44 Figure 2.14 Switch machine ...... 45

LIST OF TABLES Table 1.1 Locking Tests Precautions Chart ...... 11 Table 1.2 Locking Tests, Process, Purpose and Frequency ...... 13 Table 2.1 InterlockingPREVIEW Inspection Summary Chart ...... 23

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Module 1 OVERVIEW AND SAFETY Outline 1-1 Overview 1-2 Safety 1-3 Tools 1-4 Testing 1-5 Documentation 1-6 Summary Purpose and Objectives: The purpose of this module is to provide a review of the safety procedures to be performed during the inspection, testing and maintenance of interlockings. Following the completion of this module, the participant should ONLYbe able to complete the exercises with an accuracy of 70% or greater:

• Describe safety procedures and requirements as per location and regulating authority • List tools and testing equipment used in the inspection, testing and maintenance of interlockings • Identify agency specific schedules for interlockings inspection and maintenance • List tests, frequency and purpose of each test per your authority • Describe inspection, maintenance and testing documentation for reporting as per agency regulations Key Terms • Clearing Area • Occupied Track • Designated Flagger Device (Dfd) • On-Track Safety • Flagman • Personal Alert Devices (Pads) • Foul Time • Roadway Worker • InterlockingPREVIEW Junction Boxes • Roadway Worker Protection • Interlocking Signal • Watchman/Lookout

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the activity. For example, a signal maintainer should use a vehicle strobe light if available. Be sure to follow your agency’s specific requirements for securing your worksite.

Warning: Safety Precautions!

• The signal maintainer should always follow regulatory body, OEM, and your transportation authority’s specific requirements for safety when inspecting and testing interlockings.

• Always take appropriate actions to secure the work area before performing any inspections/maintenance and testing. • Remember your safety, your co-worker’s safety and the safety of the public depends on you.

1-3 TOOLS AND MATERIALS

A signal maintainer is required to have a set of authority-approved tools to clean, test and maintain interlockings. In addition to standard tools carried by maintenanceONLY personnel, the signal maintainer also carries specific tools as they apply to the type of track circuits and interlockings on which they are working. Where applicable, all tools and devices used in testing and maintaining the interlockings must be approved by the rail authority and recommended by the OEM. Cleaning materials such as cloth, lubricants, solvents, brushes, and brooms may also be used.

Generally, during the inspection and maintenance of interlockings the following tools are required. Note that the use of these tools and others may vary among rail transit agencies. • Shunt strap • Terminal wrench • Stop watch • Obstruction gauge • Multi-meter (calibrated according to OEM and agency specific guidelines) • Laptop • Switch tools • Portable radio • Relay tester • FeelerPREVIEW gauges

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The switch tools (Figure 1.6) depicted here are used in the general inspection, testing and maintenance of interlocking switch machines.

TYPICAL OBSTRUCTION LARGE SWITCH TOOL SCREWDRIVER WRENCHES

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CUP AND CRANK FEELER TOOL GAUGE

Figure 1.6 Switch Tools PREVIEW

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interlockings wherein the direction of traffic is established through the manipulation of traffic levers on mechanical interlocking machines. To ensure that the direction of traffic cannot be changed or opposing signals cleared while the section of track involved is occupied or a signal is displayed for movement to proceed into that track section.ONLY Approach • Establish route* To ensure that the approach locking Locking • Verify display signal circuits are effective and (CFR 236.377) functioning properly. • Shunt/drop the approach and verify that the proper relays are de-energized • Cancel the signal • Assure no other conflicting route(s) can be established until the specified time has elapsed

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1-5 DOCUMENTATION

Documentation is a critical part of the process of testing, inspection and maintenance of interlockings. No test is complete until appropriate forms and documentation have been properly completed representing the actual tests performed. Retention and distribution of the form(s) should be in accordance with your rail agency’s guidelines.

Each agency must maintain records for compliance with federal, state, local and/or agency standards. The following is an example of a Locking Tests Form (Figure 1.7) used by one rail transit agency.

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Figure 1.7 LockingPREVIEW Test Form

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Module 2 TESTING & MAINTENANCE OF INTERLOCKINGS Outline 2-1 Overview

2-2 General Inspection Procedures

2-3 Steps for Performing Various Locking Tests

2-4 Inspection and Tests for Interlockings

2-5 Maintenance

2-6 Summary Purpose and Objectives: The purpose of this module is to provide a general description ofONLY locking and interlocking tests to be performed during the inspection and maintenance of interlockings.

Following the completion of this module, the participant should be able to complete the exercises with an accuracy of 70% or greater: • Perform route locking test. • Perform approach locking test. • Perform time locking test. • Perform indication locking test. • Identify FRA standards for locking tests. • Identify all interlocking apparatus. • Identify general maintenance procedures.

Key TermsPREVIEW • Automatic Interlocking • Relay Interlocking

• Interlocking Control Panel • Timing Relay

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2-2 GENERAL INSPECTION PROCEDURES

The American Public Transportation Association (APTA) publishes rail transit safety standards which, in its own words, represent “an industry consensus on safety practices for rail transit systems to help achieve a high level of safety for passengers, employees, and the general public.”

APTA recommends the following minimum requirements for interlocking inspection.

1. Notify the operations control center (OCC) – also known as rail control center, rail operations center, rail service control center, or train command center – or other authorities of the inspection activities to be performed. 2. Inspect interlocking signals, masts, ladders, and route selection boxes (Figure 2.2) for rust, corrosion, damage, cracks, and for defective latches, lenses, hoods, hinges, latches, padlocks, and for missing or loose components and hardware. Replace burned out bulbs as required. 3. Inspect interlocking insulated joints, gauge plates, and switch machine rods for broken or deteriorated insulation, metal shavings, or loose or missing hardware. ONLY

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Figure 2.2 Yard Interlocking Signal

4. Inspect interlocking junction boxes (Figure 2.3) and other enclosures for the presence and condition of stored circuit drawings, terminal list, wire tags and instructions.

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Indication Locking

Mechanical Relay and Electronic Interlocking and Lock on Signal Levers Lock on Switch Levers lnterlockings Control Points Indication locking of • Line the first route to be • Line the first route to be • At all relay or electronic interlockings and in CTC levers prevents a given tested but do not clear the tested but prevent the first territory, indication locking at each home signal lever from being signal. switch movement in the route and approach signal (where indication locking is operated full-stroke until from completing its full in service) and at each power-operated switch, • Place the signal lever in the all of the prerequisite stroke. or moveable point frog must be tested as indicating position, then operating units have follows: open the lock circuit on the • Verify that the lock lever properly completed their lever. cannot be unlatched. • Switch Indication Locking required movements. • Verify that the signal lever • Allow the operating • Each power operated switch, derail and moveable

cannot be restored to. its movement to complete its full point frog must be tested by first determining the full normal position while stroke. ONLYswitch repeater relay (WPR) correctly repeats the the lock circuit is open. position of the switch, derail or moveable point • Verify that the lock lever can frog. • Repeat this test for the now be unlatched. signal lever of each • De-energize the appropriate WP relay by opening • Repeat this test for each interlocking route. each contact in the switch machine circuit operating movement in each controller. Also, verify the same results using the interlocking route. dual selector lever.

• Perform this test in the normal and reverse positions. • In addition, if the switch is located in a crossover, arrange the crossover so that one switch is lined full normal and the opposite end of the crossover is lined full reverse. Verify that both WP relays are de-energized. • This test must be made with the dual selector lever in the motor position and the motor circuit contact opened manually or prevented from closing. Test PREVIEW with the switches in the crossover opposing each other in both the normal and reverse positions.

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Interlocking Machines with Mechanical Locking Test A complete check and tests shall be made of mechanical locking on all interlocking machines as follows: • Levers shall be tested to ensure that each lever when reversed and with latch down, locks all other levers in the positions as required by the locking sheet. • Complete test of the locking from a signal layout or interlocking plan shall be made as follows: o Test locking between switch, derail and movable point frog levers. o Test locking between facing point lock and switch, derail and movable point frog levers. o Set up route and endeavor to reverse each signal lever that should be locked by that route; then reverse signal lever governing movements over route and endeavor to operate each lever that should be locked by the signal lever; then restore signal lever to normal position and make similar tests with lever for the opposing signal. o Where route or traffic levers are used, locking tests shall be made. o Parallel or other routes shall be set up and signal levers operated for movements in both directions on each route to ensure that the locking of one route does not interfere with other routes. Warning: Safety Precautions!ONLY

Always follow the regulatory body, OEM and your company’s guidelines for interlocking maintenance safety and procedures.

PREVIEW

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Inspection and Tests of Different Types of Interlockings

Automatic Interlocking Check and test to ensure that when any track circuit between home signals on any route is shunted, home signals for all conflicting routes, and for the route shunted, cannot be cleared. By opening or shunting approach track circuit (Figure 2.8) no conflicting signal can be cleared. Note that tests shall be made for each signal and route.

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Figure 2.8 Signal maintainer shunting a track Make sure thatPREVIEW when each track circuit is shunted in sequence to correspond with the passage of a train on each route, the interlocking is released as the rear of the train leaves the interlocking. Ensure manual release circuit operates as required. (Clear signal for a route, then shunt approach of conflicting route and operate manual release. As always, tests shall be made for each signal and route.)

Check that aspects of operative distant signals conform to the aspects of the appropriate home signals. Be sure that adjustment, inking and operation of graphic time recorders, where used, are correct or electronic event recorders operate as intended. Ensure that a loss of shunt of five seconds or less shall not permit an established route to be changed.

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Relay Interlocking Tests, checks and inspection shall be made to ensure that system functions as intended and that no conditions exist where manipulation of the control machine by an operator can create incorrect routes or signal aspect.

Perform the following test when relay based interlockings are placed in service, modified, or disarranged. In the following steps, note that the abbreviation TER refers to Timing Element Relay and ASR refers to Approach Stick Relay.

1. Clear signal governing movement into the track section under test. 2. Check traffic indication(s) at entering end. If connected to an electronic coded ABS territory (i.e. EC4 etc.), verify that the opposing traffic indicator at the opposite end of the traffic block is de-energized (tumbled out). 3. Request the opposing signal (Figure ONLY 2.9). Verify that the opposing signal does not change traffic and does not clear. Cancel signal requested in Step 1. 4. Verify TER is running time and repeat Step 3. If equipped with approach locking, de-energize approach circuit prior to canceling signal.

5. Restore approach circuit after Figure 2.9 Mounted Interlocking completing Step 3. 6. Re-clear signal governing movement into track section under test. 7. De-energize first track circuit immediately in advance of the signal. 8. Momentarily de-energize the second track circuit in advance of the signal to release time locking on the ASR circuit. If second circuit is outside of the interlocking, an HR may be used if the TR is not in the location. If equipped with approach locking, this step may not be required.PREVIEW 9. Verify that the ASR for the signal under test is energized, and then repeat Step 3. 10. Simulate progressive train movement to the next track circuit of the route, and then restore previous circuit. If the previous circuit has Loss of Shunt protection, verify TPR is energized. Also, in electronic coded territory, allow 10 seconds for previous circuit to recover. 11. Repeat Step 3. Continue this sequence until all circuits in the traffic block have been tested. 12. Repeat Steps 1 through 8 with traffic established in the opposite direction.

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