1 Energy Division is a worldwide leader all along the power line with innovative solutions from generation to the end user Railways Railways products products
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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
Connectors& Fittings
CableAccessories
ElectricalEquipment31
24
5
6
7
Railways products – Energy Division
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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
Connectors& Fittings
CableAccessories
ElectricalEquipment31
24
5
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Railways products – Energy Division
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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
Raysulate Raysulate –– Asset ProtectionAsset Protection
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
Raysulate Raysulate –– Asset ProtectionAsset Protection
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
Raysulate Raysulate –– Asset ProtectionAsset Protection
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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
Raysulate Raysulate –– Asset ProtectionAsset Protection
TCWCTCWC
UBACUBAC
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About us
Insulators
Raysulate
SurgeArresters
Connectors& Fittings
CableAccessories
ElectricalEquipment31
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Railways products – Energy Division
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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
Connectors& Fittings
CableAccessories
ElectricalEquipment31
24
5
6
7
Railways products – Energy Division
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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
Connectors& Fittings
CableAccessories
ElectricalEquipment31
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Railways products – Energy Division
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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
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Railways products – Energy Division
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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.