Raysulate Insulation Enhancement: Introduction to Products ...
Transcript of 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
February 26, 2013page 3 /
Raysulate Insulation EnhancementIntroduction to Rail Products
• 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
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Raysulate Insulation EnhancementIntroduction to Rail Products
• 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
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Raysulate Insulation EnhancementIntroduction to Rail Products
• 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
February 26, 2013page 6 /
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.
February 26, 2013page 7 /
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
February 26, 2013page 8 /
Potential Solutions:Conductors and Structures
• 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
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Potential Solutions:Conductors and Structures
– 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
February 26, 2013page 10 /
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
February 26, 2013page 11 /
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
February 26, 2013page 12 /
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
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Medium Voltage Line Cover:Installations
–Tunnel: Scandinavia• Reduced air clearance after electrification• Insulated connector and dropper
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Medium Voltage Line Cover:Installations
–Platform Footbridge: Germany
–Euro Tunnel:–UK\France
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Medium Voltage Line Cover:Installations
–Bridge: France• Reduced air clearance to service pipework on the bridge• MVLC or HVBT
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Medium Voltage Line Cover:Installations
–Platform structures insulated from birds• Create a local solution with MVLC and HVBT
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Medium Voltage Line Cover:Installations
–Maintenance facility safety• MVLC with pre-formed connector \ dropper cover
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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
February 26, 2013page 20 /
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
February 26, 2013page 21 /
Trackside Repeater and Substations
– 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
February 26, 2013page 22 /
Trackside Repeater and Substations
–Underground Busbar Systems• Heat shrink Tube and cold applied BCIC Covers insulate busbars
from accidental touch across phases
Energy Division / page 23
Trackside Repeater and Substations
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
Energy Division / page 24
Raysulate Insulation EnhancementIntroduction to Rail Products
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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