Raysulate Insulation Enhancement: Introduction to Products

Raysulate Insulation Enhancement:Introduction to Products for Railways

Don Barrett and Ian Bond

Product Management

Tyco Electronics \ Raychem Brand

February 2013

http://energy.tycoelectronics.com/

February 26, 2013page 2 /

Raysulate Insulation EnhancementIntroduction to Rail Products

• More than 40 years experience in Medium Voltage Rail Infrastructure Applications.– Insulation Enhancement– Surge Protection– Catenary Insulators– Catenary Connectors and Droppers



• To Reduce the number of outages and flashovers– Flashovers occur when heavily pollution, salt or industrial contamination,

collects on bushings and insulators– Flashover situations are where birds, animals, vegetation, air-bourne or

even human intervention bridges the air clearance around live metalwork

• To Increase the level of Equipment Asset Protection– As a general rule, we consider anything less than400mm of air clearance to be a potential risk to theequipment.

• To Enhance the overall Reliability of the Network– To reduce the number of Circuit Breaker trip– Keep the passenger moving



• Historically we have used heat shrink products from the specialist Raychem Brand of polymers– For more than 40 years TE Connectivity has supplied unique polymeric

products for various electrical power applications

• There is now a growing range of technologically advanced materials for a wider range of applications– Heat shrink tube, heat shrink tape, cold applied line covers and tape

• Manufacturing Expertise– Extrusion, Crosslinking, Injection Moulding and Vacuum Forming

• Material Technology– Humidity, Salt Fog, Temperature, UV Radiation, Mechanical Impact,

Electrical surface activity



• Enhanced properties for materials and productsReliable, durablecurrent interruption

Resin technology

Excellent resistanceto surface electrical activity

Shape memory

Reduced contactresistance

Excellent resistanceto thermal aging andUV light

Fiber reinforced resins

Excellent bimetallicinterface

Insulation thickness memory

Total harmonicdistortion analysis

Void-free interfacial bonding

Moisture blockingImpermeabilityto cable oils

Electrical stress control

PowerGel

Wireless mesh network andPower linecommunication


Potential Problems:Conductors and Structures

• Grounded Structures too close to supply wires– Look for evidence of Flash marks

• Birds and other animals contact to phase– Sometimes full contact is not required. The bird can cause a flash by

passing close to each phase.


Potential Solutions:Conductors and Structures

• Barrier Board– RRBB: Rigid Red Barrier Board

• An extruded HV Material Sheet, crosslinked for increased performance• It can be drilled or cut to make required shapes• Secure it to structures with UV plastic fixings• 1,500mm x 1,000mm x 3mm• 15kvK\mm• Network Rail, UK, approved material



• Barrier Boards– IBIC: “I” Beam Insulating Cover

• An extruded section that clips directly over the grounded structure preventing direct contact by conductors or birds from bridging phase to ground

• Completely tool free, IBIC clips into position easily in a short time and is then self supporting. It needs no more fixing in place.• Supplied in 1Metre lengths it fits to “I” Beamwith flanges 125mm to 200mm.• Does not become detached during bad weather• Network Rail, UK, approved material



– UBAC: Under Bridge Arm Cover• Under Bridge Arm and insulator are too close to the roof, see flashover

marks….

• Clipped to end fitting of under bridge arms that are even closer to the surrounding ground plane that the contact wire

• Two sizes available for large old style UK Rail and newer Ribosio design• Network Rail, UK, approved


Raysulate Insulation Enhancement:Medium Voltage Line Cover

–MVLC is a cold applied wrap around cover that provides retrofit insulation for overhead rail conductors for situations such as:• Birds closing air clearance between conductor and structure• Reduced air clearance from the contact wire in the static position

moves to the dynamic position when the train passes• Earth return wires passed through the metal stanchion

–MVLC offers many advantages• Can be installed from any position on the span• Can be driven onto the conductor from a power tool or a hand tool• Proven lightweight, high performance material: 21kv\mm


Medium Voltage Line Cover:Specifications

–Three Voltage classes• 15kV: without mastic filled channel• 25kV: with mastic filled channel• 40kV: with modified material and thickness for

higher voltage and improved Flame Retardancy performance– Approved by Russian Ministry of Rail– Only size -18 available– Non standard quantities

• Three range taking sizes

MVLC Size Max Cond. Diam(mm)

Conductor Size(mm2)

Weight(kg/m)

-14 12.7 up to 99 0.27-18 18 up to 185 0.40-38 38 up to 300 0.52


Medium Voltage Line Cover:Installation Tooling

–Hand Tool• For shorter spans < 10M• MVLC-HAND-TOOL-02

–Powered Installation Tool• For use on longer spans using:

–Hand crank–Electric Drill–Compressed air

• MVLC-TOOL-2006-03


Medium Voltage Line Cover:Installations

–Tunnel: Scandinavia• Reduced air clearance after electrification• Insulated connector and dropper



–Platform Footbridge: Germany

–Euro Tunnel:–UK\France



–Bridge: France• Reduced air clearance to service pipework on the bridge• MVLC or HVBT



–Platform structures insulated from birds• Create a local solution with MVLC and HVBT



–Maintenance facility safety• MVLC with pre-formed connector \ dropper cover


Medium Voltage Line Cover:

–Reference List• UK, Network Rail• France, SNCF• Germany, Deutsche Bahn• Japan: JR• Korea: KR• Denmark: Banedanmark• China: Flame Retardant version• Russia: Flame Retardant version

Energy Division / page 19

Trackside Repeater and Substations



–Trackside Repeater and substations can suffer from the same Wildlife and Pollution issues as utility substations• Nesting birds or small mammals looking for warmth or cover can

cause flashovers or trips due to contact between phases.– BCIC: Bushing Connector Insulation Covers

• Cold applied retrofit covers for 25kV connector insulation



– Pollution from coastal salty winds, petrochemical factories, coal mines, power stations or cement works can cause insulators and bushings to flashover and become damaged.• Creepage Extenders add creepage length, dry arc distance and increase

dry areas under skirts to improve the rating of the equipment• Adding 20% of Creepage length doubles the contamination withstand• Heatshrink, or Wrap Around for applications where equipment can not

disconnected



–Underground Busbar Systems• Heat shrink Tube and cold applied BCIC Covers insulate busbars

from accidental touch across phases



The main components, all of which are completely compatible with each other and other insulation systems for 25kV Rail Applications

• MVLC Cold applied Overhead conductor cover

• HVBT Heat shrink Tape

• UBAC Under Bridge Arm Covers

• IBIC / RRBB Frame protection and Barrier Boards

• BCIC Cold applied pre-formed parts

For trackside applications

• BPTM / BBIT Heat shrink tubing

• BCIC Cold applied pre-formed parts

• HVCE Heat shrink/Cold applied flashover protection for insulators



Summary• Railways are one of the few industries of the world to see continuous

investment on a global scale

• That investment demands better service, shorter journey times and above all, more reliability

• The growing Raychem brand from Tyco Electronics family of Rail products can prevent any type of bridging outage with either standard or bespoke products designed to improve long-term reliability

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Raysulate Insulation Enhancement: Introduction to Products