01. Energy Railways (Long Version)

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Energy Division is a worldwide leader all along the power line with innovative solutions from generation to the end user

RailwaysRailways productsproducts

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Railways products – Energy Division

About us

Insulators

Raysulate

SurgeArresters

Connectors& Fittings

CableAccessories

ElectricalEquipment31

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About us1 Tyco International

World’s largest Manufacturer and Service Company

2003267.500 employees

$ 36.9 billion

30%Electronics

12%EngineeredProducts & Services

23%Healthcare

30%Fire & Security

5%Plastic & Adhesives

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About us1 Tyco International

A diversified Manufacturing and

Service Company

2003267.500 employees

$ 36.9 billion

Electronics 30%

Engineered Products & Services 12%

Healthcare 23%

Fire & Security 30%

Plastic & Adhesives 5%

A global leader in passive electronic components and major producer of active components.

The number one worldwide company offering Fire and Security solutions.

A leader in niche markets for plastics and adhesives products.

The world’s number one producer of sprinklers, valves and actuation.

One of the largest medical device and disposables companies in the world.

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About us1 Tyco Electronics

200380 000 employees

$10.4 billion

Business Segments Electronics

Manufacturer of Electronic Components

Submarine Telecommunication Systems

Telecommunication Systems

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About us1 Tyco Electronics

Worldwide Sales

2003 Sales27% Europe

55% Americas18% Asia/Pacific

18%Telecommunication

26%Automotive

Computer & Consumer Electronics

30%Industrial & Commercial

14%Distribution

5% Household appliances

3% Instrumentation5% Aerospace & Defense

4% Ind. Mach.& Equipment

9% Power Utilities

7% Other

12%

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About us1 Energy Division

A fully integratedBusiness Unit

20033 000 employees

$ 600 million

Canada France USA Germany

Headquarter in Munich, GermanyDedicated R&D, manufacturing, sales and marketingMore than 6000 customers worldwide

Connecting the World of Electrical Power

Thailand UK

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About us1 Energy Division

1999 - 2003Acquisition Milestones

2000

2001

2002

1999

2003Crompton Instruments

Jordan

UtiluxBowthorpe EMP

B&HCellpack AC

Dorman SmithSucofit

HellsternLa Prairie

ALRDulmison

AMPRaychem

SIMEL

Acquisitions

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Iarnrod EireannChiltern Railways

Carillion Rail

TransworldMass Transit

GTRMJarvis

Philippines National RailEuro Tunnel

Danish State Rail

SNCFAustrian Rail

Network RailJapanese Rail

Deutsche Bahn AG

Rail TrackBalfour Beatty

Taiwan Rail

KRC Kowloon - ChinaAlstom

Railway Customer BaseRailway Customer Base

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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Electrical and MechanicalEnvironmental StressDeflectionLong LifeReliabilityCost – Life Cycle CostCustom DesignEase of installationPollution FlashoverReduced MaintenanceShort Delivery TimesImpact Resistance – Vandal proofProduct Qualification

Rail Insulators Rail Insulators –– Customer RequirementsCustomer Requirements

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First manufactured housings in 1965

First rail installation 1975:- UK - Japan- Sweden - Denmark- Taiwan - Austria- Belgium

The benefits for the installer and end user are:- Long life- Ease of installation, giving lower costs- Impact and vandal resistance- Superior electrical performance in polluted

environments- Less cleaning required in tunnel applications

Polymeric InsulatorsPolymeric Insulators

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Primary product offering is 15 & 25 kV catenary and portal insulators

Construction method:- Aluminium or galvanised end fittings- End fittings are crimped onto a pull/extruded

fibre reinforced plastic (FRP) core- EVA housing material

Core competencies are crimping, moulding, material selection and design for mechanical load conditions.

- Custom designs available

Key specifications are: IEC 62217 (Draft), IEC 61952, IEC 61109 and EN 50151.

Polymeric InsulatorsPolymeric Insulators

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First manufactured in 1914

Service with rail authorities since 1983:- Australia - Malaysia- Hong Kong - Taiwan- UK

The benefits for the installer and user are:- Long life- Proven and mature technology- High rigidity- Design flexibility- Competitive prices

Porcelain InsulatorsPorcelain Insulators

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Full product offering for DC and AC rail insulators.

Construction method:- Wet process porcelain- Galvanised end fittings- Portland cement

Core competencies are in producing solid core porcelain insulators for tensile, cantilever or combined loading applications.- Custom designs available

Key specifications are: IEC 60383.

Porcelain InsulatorsPorcelain Insulators

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First manufactured in 1985First rail installation 1985:

- Taiwan- UK- Denmark

The benefits for the installer and user are:- Long life- Proven and mature technology- High rigidity- Design flexibility- High pollution performance

Primary product offering is 15 & 25 kV catenary, substation and portal insulators

Hybrid InsulatorsHybrid Insulators

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Construction method:- Wet process porcelain, solid core- Recover EVA housing in place- Galvanised end fittings with Portland

cement

Core competencies used in producing porcelain and polymeric insulators are combined in this product.

- Custom designs available

Key specifications are: IEC 62217 (Draft), IEC 61952, IEC 61109, IEC 60383 and EN 50151.

Hybrid InsulatorsHybrid Insulators

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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For over 30 years Tyco’s Energy Division has supplied Polymeric Insulation Solutions to the World’s Electrical markets

These products plus many specially designed components are now widely used on Railways worldwide

Rail Networks continually strive for greater reliability, but many of the problems associated with the Overhead Catenary systems are preventable with the application of strategically located insulation

Raysulate Raysulate –– Asset ProtectionAsset Protection

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Wherever bare electrical systems can come into contact with foreign bodies there is potential for accidental bridging

Phase to phase, or phase to ground bridging causes flashover that can result in costly delay or serious equipment damage

Raysulate products, originally often heat-shrink, but more commonly now cold-applied, combine to be used to cost effectively eliminate such outages

LondonLondon


TokyoTokyo

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Tyco’s specialised polymeric materials have been widely used worldwide for over 30 years

That family of materials has been developed to provide protection in the most severe environments

Typically those materials offer :

- Improved Electrical performance

- Tracking and Erosion resistance

- Excellent UV performance

- High Thermal stability


Tracking & Tracking & ErosionErosion

Long Term Long Term AgeingAgeing

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Problems:

Bridging caused by birds (mostly), animals, vegetation, airborne debris, vandalism

Often “Tell-tale” burn marks from flashover

Experience tells us clearances < 40 cm are potential danger points


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Raysulate Raysulate –– Asset ProtectionAsset ProtectionApplications:

MVLC (Medium Voltage Line Cover)

- Fast, Cold Applied Wrap-Around insulation

- Prevents bridging of Catenary, Droppers

and any bare live conductor

- 3 Sizes cover up 38mm diameter

IBIC (I Beam Insulating Cover)

- Tool-Free, Clips onto “I” Beams

- Fits flange widths 125 mm to 200 mm

- Available in 1m lengths

MVLCMVLC

IBICIBIC

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Applications:

TCWC (Twin Contact Wire Cover)

- prevents flashover between contact

wires and structure above

- Fixed to contact wires by standard clamp

- Supplied in 1.5 m lengths

UBAC (Under Bridge Arm end Cover)

- Protects the raised connector that

attaches to contact wire

- Simple, Tool free, clip-on installation

- Works in conjunction with TCWC


TCWCTCWC

UBACUBAC

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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Polymeric (Silicone):

- PSR: 66 – 220 kV Systems

- 2P, 3P, 4P & 5P: 11 – 500 kV Systems

- 2 & 3 HSR: 66 – 132 kV Systems

Porcelain:

- MCA, MDA: 11 - 400kV Systems

- MAA: 11 – 220kV Systems

- MBA: 11 – 156kV Systems

Surge Counters: SC12 & SC13

HV Surge Arresters HV Surge Arresters

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Polymeric AC Traction Surge Arresters 15 – 25 kV

Polymeric DC Traction Surge Arresters 1 – 4 kV

SPG – Spark Gap Device 900 V

Traction System ProtectionTraction System Protection

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TLP Range of Surge Protectors are employed on Telecommunication Equipment Transmission Lines

RTM Single Phase Surge Protectors are employed on the incoming power supplies

LV Protection LV Protection

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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Catenary connectors Catenary connectors Two mains functions:

- Electrical, to distribute the supply along the catenary

- Mechanical, to support the catenary wires

Connectors are in copper, aluminium, bimetallic or cupro Aluminium

Connectors are designed according to dimensions and characteristics of messenger / carrier, feeder and contact wires

Standard dimensions of wires in Europe:- Cu 107/150 & 95 mm² for contact wire- Bz 65.4 & 116.2 mm² for messenger

EN 50119 for Railway applications

NF C 34-800 for contact wire

25 kV line in France25 kV line in France

1.5 kV line in France1.5 kV line in France

1.5 kV line in France1.5 kV line in France

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Connexion dropperConnexion dropperDistributes the current along the contact wire for 25 kV high speed line

Avoids the standard distribution connection

Articulated at upper and lower part

Dismountable on both side for messenger and contact wire

SNCF approved:Mechanical resistance under traction for 2 Millions cyclesElectrical ageing test

New European standard EN 61284 Conductive dropperConductive dropper

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Connexion dropperConnexion dropper

Bz bindingcable

Contact wire

Loads centerdistance LL mini = 277L maxi = 2077

Carrier or messenger cable

Special automatic manufacturing process for intensive production:

100% traction tested100% lengths checked

Possibility to cut to defined lengths in workshop according to installation order on site between two poles

Already installed:France for Mediterranean TGV (x 70 000)Belgium for LGV2 line (x 18 000)UK for CTRL Section 1 (x 3 000)Greece for Olympic Games 2004 (x 5000)

Note: dropper clamps for messenger and contact wire can beProposed individually

Dropper characteristicsDropper characteristics

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SIMAGRIF tool for dropperSIMAGRIF tool for dropper

To remove and install on new lines the dropper clamps on messenger and contact wires

Light and compact (2 kg)

Easy to handle by applying a low effort (<30 daN)

Reliable and safety connection

Higher quality level on installation by opposition of hammer use

Already sold in Belgium and UK

Special tool for dropperSpecial tool for dropper

HalfHalf--clamps multiclamps multi--versionversion

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Catenary Tools Catenary Tools

AUTOPUMP battery operated pump ⇒ Ni/Cd 24V-3A/h ; 700 bar ; 0.3 L/min ; 14.5 kg⇒ Equipped with fast coupler, 3m flexible hose & pushbutton

remote control ⇒ For intensive use on field or in workshop

V22 U crimping head⇒ 22T pressure ⇒ Up to 630 mm² for Cu, 400 mm² for Al with 22UE dies

AUTOPRESS C120 battery tool⇒ One hand control⇒ Easy and quick crimping from 6 to 300 mm² with 12SE dies⇒ Equipped with 14.4 V rechargeable battery using new

technologies NiMH 2.6 Ah⇒ 100 to 150 crimp operations before recharging⇒ Mainly used for signalling components

Crimping headCrimping head

Hydraulic pumpHydraulic pump

Battery operated toolBattery operated tool

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Signalling componentsSignalling components

Installed along the rail for signalling application:Return of the currentEarthing & grounding

Terminals and splices in copper, aluminium or bimetallic:

XCT rangeCTN for flexible copper wires (class 5)

Special lugs designed according to cable characteristics and palm dimensions

Electrical boxesElectrical boxes

Standard partsStandard parts

Special connectionsSpecial connections

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Proven technology for more than 40 years

Service with Overhead Power Networks Worldwide

Customers benefit from “Lowest life cycle cost”

The key features are:– Maximises contact between

connector and conductor surfaces

– Overcomes the problems with oxidation of metallic surfaces

– Maintains a constant force for the life of the connector

AMPACT Tap ConnectorAMPACT Tap Connector

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Simple and fool proof method for connector installationHeliformed® Dead Ends supply & manufacture over 30 years experienceService with rail authorities :

Hong Kong UK

The key features are:– Positive grip on the conductor – Even distribution of pressure over a wide

area – no concentrated forces– Fast, simple and uniform application– Compatible with the conductor to which

the fitting is being appliedSupplied to suit Copper Based and Aluminium

HeliformedHeliformed®® Dead EndsDead Ends

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Heliformed® Products supply & manufacture over 30 years experienceService with rail authorities :

Hong KongUK

The key features are:– Full restoration of conductor’s

electrical & mechanical properties– Superior conductor protection– Fast, simple and uniform application– Compatible with the conductor to

which the fitting is being appliedSupplied to suit Copper Based and Aluminium Based Conductors

HeliformedHeliformed®® Line Guards & Line SplicesLine Guards & Line Splices

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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Raychem has pioneered some of the most important technical advances in cable accessory technology over the last three decades.

Raychem Cable Joints and Terminations are suitable for all common single and three core polymeric cables up to 170kV.

Cross bonding, shield break and externalgrounding arrangements are easilyaccommodated. Link boxes can easily beattached adopting the network designrequirement. Short installation time reducesoutages while extensive field experience andtesting have proven the reliability of thetechnology used.

Cable AccessoriesCable Accessories

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Raychem and Guro products offer excellent insulating and sealing performance, with heat-shrinkable and resin materials.

Heat-shrink, resin and gel technologies.

Quick and easy installation.

Fuse Boxes.

Re-instatement and energisation can follow immediately after installation.

Raychem heat-shrinkable tubes, caps, breakouts, and wraparound systems seal and insulate cables from moisturedirt and corrosion.

Low Voltage Terminations and JointsLow Voltage Terminations and Joints

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Our Medium-voltage terminations have been used by utilities and industrial organisations worldwide for more than three decades.

Heat-shrink and elastomeric technologies.

Proven anti-tracking, erosion and UV-resistant insulating material for indoor and outdoor applications.

Experience gained in widely ranging conditions has now led to new modernised design.

Single and 3-Core termination systems available.

MV H/S Terminations for MV H/S Terminations for Polymeric CablesPolymeric Cables

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Cable preparation and installation techniques for Raychem MV joints are identical to those for heat-shrinkable terminations. The same basic design is also shared by Raychem joints for paper insulated cables.

In this respect the heat-shrinkable system sets new standards of efficiency and simplicity.

Few prefabricated components for easy reliable installation.

Versatility: jointing of round and sector-shaped, single and 3-core cables, a range of sizes, cables of cross-sections or over-sheath thickness in one joint.

Heat-shrink and elastomeric technology.

MV H/S Joints for Polymeric CablesMV H/S Joints for Polymeric Cablesup to 42kVup to 42kV

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Heat-shrinkable and cold applied systems for switchgear and standardised bushings for 250A and 400/630A have been installed by utilities and industrial organisations worldwide for more than 15 years.

Separable screened adaptor systems for 250A and 400/630A.Solutions for all cable constructions.

Sealing Systems, Repair Sleeves, Tubing & Tools.

These proven sealing systems are designed for plastic, concrete or steel duct cable entries into buildings and manholes.

MV Cable Connection Systems MV Cable Connection Systems up to 42kVup to 42kV

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For fifteen years, accessories have also been available for 69 kV, 72 kV and 84 kV transmission voltages.

For higher voltage classes we offer 145 kV to 170 kV prefabricated joints and terminations for indoor and outdoor switchgear and transformers.

Heat shrinkable and elastomeric technologies.

Testing to international standards under the supervision of independent test studies.

GIS and transformer terminations.

HV Terminations and JointsHV Terminations and Joints

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About us

Insulators

Raysulate

SurgeArresters


CableAccessories


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System Protection RelaySystem Protection RelaySignaling Supply Feeder protection- employed on the incoming power supplies

First manufactured in 1999

Service with rail authorities 2002:- UK - Ireland

The key features are:- Fully programmable- Electrical system metering - Digital communications- Protection of feeder cables- Allows reduction of cable sizes under fault conditions, with large cost savings

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Existing feeder protection with fusing- Cable resistance limits prospective fault current- Fuses require high fault currents to clear quickly- Fusing is only effective with large cable sizes- Or with short cable runs

Fuse Performance- Ineffective with incorrect cable sizes- Local faults will clear the fuse- Distant faults can cause cable fires

Safety IssuesThe only way to comply with IEE regulations is to use significantly over-sized cables

Alternatives- Use System Protection Relay to solve this problem

System Protection RelaySystem Protection Relay

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High sensitivity protection- Not effected by inrush current- Clears local faults within 5 seconds- Clears distant faults within 5 seconds

Advanced functions- Power supply monitoring- Up to 34 Electrical measurements displayed- Remote metering via RS485 communications- Time/Date event log for diagnostics

Significant cost reduction- Allows cable size to be optimised

SPR has been installed to protect signaling feeder cables, can operate faster than fuses, and is more selective to overload conditions

System Protection RelaySystem Protection Relay

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ConclusionConclusion

Tyco has an extensive range of products for the Rail Industry and is a one stop shop for our customers requirements

Design, Test and Manufacturing capabilities enables Tyco to customise products for individual customers

All of our manufacturing facilities are certified to ISO 9000:2000

It is our mission to partner with our customers to improve the reliability and economies of their rail networks and equipment.

Documents

01. Energy Railways (Long Version)