Beruflich Dokumente
Kultur Dokumente
Nexans Deutschland Industries GmbH & Co KG, (2) Contec Transportation System GmbH, (3) S-Bahn Hamburg GmbH, (4) DB Netz AG Moenchengladbach, Germany +49-2166-27-2723 harald.buethe@nexans.com
Harald Buethe (1), Dr. Christian Cornelissen (1), Bernd Friedhoff(2), Jan Schroeder(3), Walther Tutschke(4)
Abstract
This article describes the development process of the new and innovative Nexans DuoTrack cable with corresponding components which together provide a complete all-in-one cabling system solution for regional railway lines. The design concept is presented together with the extended qualification program, which was necessary because of the very specific and harsh environment of direct rail installations. The accompanying field studies and trials are also reported. They were necessary to examine the behavior of the DuoTrack system in its very complex field of application. The first pilot installation at the Odenwaldbahn in Hesse, central Germany, is described, explaining the all-important preliminary economic evaluation of the system, the stimulus for its later development. An overview is given concerning further prospects in Germany and the chances for using the product on regional lines in other countries, as well.
The cabling should be an all-in-one solution containing copper and optical fiber (OF) Copper and OF must be individually manageable Copper must be compatible with DBs signaling cables Optional Low-voltage (LV) power feed through copper Parallel operation of all copper services via copper cable
Since DuoTrack cable turned out to be quite revolutionary in several ways; a decision was already made at an early stage to complement it with all necessary components to form a complete cabling system. This was intended to support its introduction and make DuoTrack an economic and genuine all-in-one solution for DBs regional lines right from the beginning.
Keywords: DuoTrack, railways, copper, optical fiber, railmounted, signaling, electronic interlock.
1. Introduction
DB, the German national railway company, was looking for an economical alternative for their aerial cables installed on poles alongside some of their regional lines, as they require frequent and cost-intensive maintenance. DBs regional lines are usually single-track lines without electrification, outdated infrastructure with sometimes even no opportunity for using concrete troughs or burying cables alongside the track. This is an impediment to improving railway infrastructure so as to make it more modern, reliable and economical. Since the particularity of regional lines, in addition to their economic constraints, suspended the use of conventional trunk cabling methods quite frequently, the only alternative was direct rail installation. Previously, this was only approved for short cable lengths of up to a few hundred meters and was not accepted as an approved standard method for cable laying, based on research and reports from the eighties. After intensive discussions with DBs technical staff, the following conceptual definitions for an economic cabling system of their regional lines were agreed upon:
Copper cable
Figure 1. Cross section of DuoTrack cable with 16 quads The solution was a variation of the duplex cable concept, adopting the well-known figure-8 design, with the copper cable housed in the conventional cable section and the OF cable placed in the
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messenger wires compartment. The web joining both has a twofold function. It provides a link between the two distinct cables on the one hand, which allows the cable to be laid in a single step. On the other hand, it assures individual manageability of the copper and OF cable when being cut longitudinally.
Figure 2. The 16 quad DuoTrack cable Designed to be mounted on the rail vertically (i.e. with the OF cable uppermost), the figure-8 design shows striking similarities with the profile of the rail, itself, displaying an anisotropic geometrical moment of inertia. It is higher in the vertical axis which helps it to withstand intense mechanical vibrations and shocks from passing trains, which is an important feature for the longterm operation of the cable under these conditions. For the OF cable design we relied on Nexans experience with central stainless-steel tube cable designs used in submarine applications, as a PE-sheathed steel tube is the most basic and compact OF cable design for a rugged and rodent-protected outside plant application. Since modern train safety control is increasingly merging telecommunication protocols like ISDN for axle counter transmission, the less compact quad design was favored over the singlecore design for the copper elements; DBs other standard design for signaling cables. Dlk1.013.109y, the standard for star-quad signaling cables, served as a reference for cable characteristics, and thus assured immediate full compatibility with all connected equipment.
Table 1. Cable data table Custom cable lengths are available in particular for the 3 and 8 quad cable size. Hence a 3.5 km 8 quad cable had been realized the for a tunnel application in the Odenwaldbahn project.
Vibration test in three axis with 28g (vertical), 14g (transversal) and 5g (longitudinal); 72h @ -25 C Vibration test in 90 bent condition; 13g, 72h @ -25 C Vertical shock test with 42g; 72h @ -25 C
Figure 3. Shock test of 8 and 16 quad DuoTrack cable The tests were performed at the VDE test institute in Offenbach with the Shaker Mounting Plate housed in a climate chamber. The OF cable was coiled and loop-spliced at both ends to enable con-
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tinuous attenuation measurement @ 1550nm during the entire test, to verify a variation below 0.1 dB. All tests were passed with excellence, which we consider due to the rigidity of the DuoTrack design, which obviously helps to absorb shocks in the vertical axis better than a round cable. Extending the test duration, we discovered that there is also sufficient headroom in the mechanical performance of DuoTrack cable.
Non-electrified railway lines Train speeds up to 160 km/h Continuous operating voltage of 420 VAC / 600 VDC A temperature range of +5C to +50C for cable laying and -25C to +60C during operation.
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important feature considering the prevalence of cable thievery, which is becoming a global problem, driven by continuous high copper market prices.
handicaps (like axle counter or insulation rail joints) are encountered and extra lengths of cable along the track.
4. Field Studies
Figure 6. The Contec DuoTrack clamp After preliminary discussions and design studies in March 2004, the project definition was made in December 2004. Parallel to that, a preliminary of roadmap was outlined for the elaborate approval process that DB and EBA required for a completely new cabling system.
Figure 7. The Contec DuoTrack cable laying vehicle The solution was a to equip a special, 25m long railway wagon with four cable pay-offs, followed by a tension controlling section and a cable laying arm of approx. 8m length, attached at the back of the wagon with a forming section at its end to change the orientation of the DuoTrack cable from horizontal to vertical position, without damaging it. The laying truck is moved by a Unimog, a two-way vehicle, at a laying speed up to 3 km/h. considering setup-time, interruptions for the preparations at closure positions, bypassing of handicaps at the track, subsequent mounting of the clamps the average laying speed is 2,000 m per shift. Compared to conventional cable laying of up to 100-300 m per shift only for the installation of the concrete troughs, this represents tremendous time savings, not to mention reduced civil engineering costs for planning, execution and surveying items which are not always taken into account in overall financial estimates.
Figure 9. Compacting and cleaning construction trains As the compatibility with line maintenance was an essential criterion for the acceptance of this track cabling system, it was decided to initiate a preliminary field trial with a round cable of a diameter equivalent to the biggest DuoTrack cable size.
Figure 10. Pneumatic hammers of the compacting train A 34 mm telecom cable was selected and installed over approximately 300 meters along a railway station which was expecting roadbed maintenance the next day. In addition, we took this opportunity to test different methods of cable branching. This field trial, conducted in April 2005, was passed with positive results. It also determined that the preferred branching method would be on top of the tie, or sleeper, which is shown in figure 10 below.
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Diagram 2 shows the exceptional stability of this parameter over two years.
Zeitliche nderung der kapazitiven Im-Vierer Kopplung (k1)
3500
29.07.05 03.11.05
3000
2000
1500
1000
500
Figure 11. Layout of the test track 4.2.1 Long term durability test The non-electrified main line between Hamburg and Lubeck was chosen, since it is carrying passengers and goods to and from Scandinavia, with axle loads of up to 24 tones, with a maximum speed of 140 km/h for passenger trains and 100 km/h for freight trains, summing up to an average of 1.2 million axles per year. Taking into account the total number of axles on an average regional line adds up to a long-term prognosis of at least 10 years, despite the difference in axle loads and a significantly lower number of freight trains on regional lines. The electrical and optical parameters of DuoTrack cable were measured periodically to disclose possible degradations of the cable or the components under the environmental and mechanical conditions of rail-mounted installation.
Verlauf der nderung des Schleifenwiderstandes
0,365
Diagram 2. Variation of capacitance unbalance within quad The DuoTrack cable represents the very first application of an OF track cable for DB! Thus the optical parameters had to be thoroughly observed. All fibers were looped to enable two-sided OTDR measurement of the complete line from one end. Diagram 3 shows the variation of the OTDR attenuation @ 1310nm, where the increase is caused by the operation wavelengths of the different OTDRs used during the observation time. The white top line shows the variation after wavelength normalization, and proves that the attenuation and therefore the fibers, themselves are in stable condition during the entire observation period.
Rckstreudmpfung bei 1310 nm
0,375
A>E E>A
0,370
Nettest CMA400
Mittelwert Bewertet
Acterna MTS 8000 Agilent E6000 Agilent E6000
22,70
1>3 (a)
22,60
0,360
1>3 (b)
22,50 Schleifewiderstand fr 20 C [Ohm/km] 22,40 22,30 22,20 22,10 22,00 21,90 21,80 21,70 28.05.2005
0,355
0,350
0,345
0,340 28.05.2005
05.09.2005
14.12.2005
24.03.2006
02.07.2006 Datum
10.10.2006
18.01.2007
28.04.2007
06.08.2007
Diagram 1. Variation of the loop resistance Diagram 1, showing the variation of the loop resistance over approx. two years, reveals no significant resistance increase, with only random variation, although most of the copper splices had been broken and redone two times in the course of the system compatibility test. This demonstrates no degradation of the solid conductors, due the excellent mechanical properties of the DuoTrack cable design. The copper pairs were all looped to enable one-sided access. Thus the NEXT measurement no longer seemed to make any sense. To compensate for that, the capacitance unbalance within a quad was measured, which is a reliable indicator of the integrity of the quad and thereby correlates well with the transmission characteristics.
4.2.2 System compatibility test The copper part of DuoTrack cable was designed to carry all the services that are usually handled by various conventional cables. This was to be verified in a field trial on the test track. This trial was managed by DBs TZF, the central technical staff for telematics, control and interference technique; and took place in 2005 from 1316 December. Siemens and Alcatel/Thales, the two big system suppliers of DB, assisted with their recent signaling components: axle counters, wheel sensors, circuit switching, levelcrossing equipment, remote control, surveillance and power transformers helped to simulate the activation of switch drives with voltages of up to 2 kV. TZF defined the wiring of the cable and the test sequence. Due to the upcoming Christmas holidays and bad weather conditions, Siemens and Alcatel decided to connect all their equipment at once and run the sequentially scheduled test series in parallel.
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This even exceeded the intention to simulate the worst condition of parallel operation of all tested devices from one supplier, which never happens in reality and thereby upgrades the test result. TZF continuously recorded the signals during the test, and except for one lamp switching on and off which was AC powered through a standard outlet no interference was detected. Even the influence from the unsymmetrical power feeding of the lamp disappeared after grounding of the screens on the feeding side, which was erroneously missing. Although nobody really expected the DuoTrack cable to fail, the complete test team was surprised about its sophisticated performance. Finally, this important compatibility test was again passed with excellence, an essential precondition to proceed from a test to a pilot installation. 4.2.3 EMI investigations DuoTrack is approved for non-electrified railway lines and thus features no intrinsic screening protection against electromagnetic fields from catenaries. But even diesel trains feature a single phase busbar with the back current running through the rail, to feed electric lamps, and in particular, the heaters in the passenger cars, which is likely to induce interference in the rail-mounted cable. The power supply, running at a frequency of 22.5 Hz, is either triangular, rectangular or trapezoidal, and reaches 1 kV and a current up to 400A. DB managed to organize a train for the system-compatibility test, with five passenger cars and a trapeze-shaped power feed running at 200 A with all lights and heater of the passenger cars switched on. The influence of the back current was continuously monitored with the previous test setup. All systems were connected and the train was subjected to three interference conditions: 1. 2. 3. stationary over the cable passing slowly over the cable at approx. 30 km/h passing over the cable at full speed at 100 km/h
6. Economic evaluation
Placing an economic evaluation here at the end of this paper risks obscuring its importance at the very outset of project definition. Cost saving was the main driving force for this development, and it became evident when direct rail installation was decided for cable laying, since this had significant cost advantages over conventional cable laying in concrete troughs. Rail mounting eliminates time-consuming and costly civil engineering, which usually represents up to 80% of the total costs of a cable installation. As can be seen from the extensive development process, the requirements for the cable were very demanding. Thus DuoTrack is not just a cost-effective cabling solution, it also meets (and indeed surpasses) the most stringent requirements for track installation and assures reliable and failsafe operation in an extremely tough operating environment. In conclusion, the pilot project Odenwaldbahn confirmed the initially expected cost saving of app. 40% ! This impressive figure still does not take into account further cost savings associated with significantly reduced working time, which will be evaluated later.
No interference with the operation signals was detected, which proved, that the special DuoTrack core design fully met the requirement of running all services through a single copper cable.
7. Outlook
The experience gathered on the Odenwaldbahn over the next two years will determine the conversion of the prototype into a fullfledged system with unlimited approval and the further prospect that DuoTrack could become DBs standard cabling system for their regional lines. Figure 12. Measuring busbar and back current Advanced EMI investigations are scheduled for late 2007 or early 2008. The main track HamburgLubeck is now being converted to an electrified line. Previous results and first theoretical calculations indicate that DuoTrack cable may sufficiently benefit from electromagnetic protection of the rail. This would immediately widen the field of application, which is very interesting for export markets, where regional lines are not necessarily non- electrified as in Germany. Meanwhile, DB has defined a limited rollout program for DuoTrack over the next two years to expand its empirical database for final evaluation. It will be used with electronic interlocks (ESTW), a light version of electronic interlocks (ESZB) and DBs GSM-R rollout program on their secondary lines. Several other railway companies have already signaled their interest in the DuoTrack system. Despite national differences, regional lines are facing very similar economic restrictions worldwide.
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8. Conclusions
Nexans together with its partner Contec and in close cooperation with DB succeeded in developing a completely new and innovative cabling system for direct rail installation. The system was thoroughly tested in extended field studies, tests and laboratory experiments over a two-year period, before Nexans was awarded the first pilot installation for the Odenwaldbahn. The pilot project confirmed expected cost savings of app. 40 %, making DuoTrack a quantum step forward for the fast and economical modernization of regional railway infrastructure.
Technology of RWTH. In February 2006 he started working as a Project Manager within the Nexans Group, being responsible for the DuoTrack pilot project, among other projects. Since June 2007 he has been head of the Engineering Department in the Nexans plant in Monchengladbach, Germany, and therefore responsible for the development of materials and applications of industry cables. He is a member of Cigr and VDE
9. Acknowledgments
This article is in memoriam of Paul Gregor, one of the pioneers of OF track cables, who initially started the development in March 2004, but passed away in February 2005 without being able to witness the long-awaited success of OF rail-side cable. Special thanks to the staff from Nexans Norway for their valuable support on steel tube technology, Nexans Interface for their valuable support in the field of accessories and Nexans Opticable for their valuable assistance in OF testing. We thank DB for their wide support in field tests and for their valuable technical assistance.
Bernd Friedhoff (1954) joined the technical staff of the army for twelve years including one year training at the German air force base in the US and graduated as master craftsmen of electro-technics. After he left the army, he studied electrotechnical engineering at the FH Cologne. From 1991 until 1998 he worked in the sales department of Erico and joined Contec in 1998 as a senior sales manager.
10. Authors
Harald Bthe (1953) studied communication engineering at the FH Niederrhein Krefeld, graduated as a Dipl.-Ing. in 1975 and continued his mathematics and physics studies at Dsseldorf University, graduating in 1982 after a state examination. In 1986 he joined the optical fiber production of the Monchengladbach cable plant as an engineer specializing in optical fiber measurement techniques. Since then, he has been involved in several different functions and product lines, i.e. OF-, CATV- and telecom cables of various types. Since 2001, he has been head of product development of telecom cables and while there became involved in the development of the DuoTrack cable design. Since Dec. 2004 he has been responsible for the DuoTrack system development. Christian Cornelissen (1972) studied physics at the RWTH Aachen University, Germany and received his diploma in 1998. In 2003, he received a doctoral degree in engineering at the same university. Since then he has been Chief Engineer at the Institute for High Voltage
Jan Schrder (1974) studied communication engineering at the FH Hamburg and graduated as Dipl.Ing. in 2001. He joined Fortec AG as a sales engineer of electronic components awhile before he entered DB in March 2002. He started in the central assets management of regional lines in Frankfurt with the main focus on telecommunication, GSM-R electronic interlocks and the development of their light version. Since April 2007 he has been head of technical equipment and coordination of construction operations of the S-Bahn in Hamburg.
Walther Tutschke (1942) studied electrotechnical engineering at the FH Hannover and graduated as Dipl.-Ing. in 1973. He entered DB and passed through several different functions like district manager for S&T, planner, trainer in S&T services and at the end was head of the department with the main focus development of future trends for S&T. In this function he initiated the development of DuoTrack, together with Paul Gregor. He retired in July 2007 and now works as a freelance consultant.
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