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GrayBarPoint Heating Presentation

Graeme J Ford

Eng.Tech. MIET. IoD

Managing Director

GrayBar Limited

UK

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Welcome Who are we ? Our Customers Railway Cable Accessories Railway Points Heating Systems DC Contact Rail Heating System Design Manufacture Commission

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Product Locations UK – Network Rail UK – Light Rail & Tram Systems Northern Ireland Iarnrod Eireann Belgium France Sweden Finland Norway USA

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Introduction

Basic principles of Point Heating Installations

Why Heat Points ?

How is Point Protection achieved ?

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Efficient Point Heating

Many railway switch points suffer during the winter months, from snow and ice restricting the moving rails and point mechanisms

The solution is efficient and reliable electric point heating

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Types Of Point Heating

High performance Self Regulating Heaters

Traditional Constant Wattage Heaters

Constant Wattage Pad & Cartridge Heaters

Gas Heating Oil Heating

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Constant Wattage Heaters

Disadvantages; Traditional – Old Technology Short Fixed Lengths Limited life span Constant current draw Ridged inflexible heater Poor low temperature performance 12 month product warranty

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Self-Regulating Heaters

Advantages; High Performance polymer Extremely reliable - no filament Flexible elements Long circuit lengths Long life ( 40+ years) Efficient power draw Universally accepted 10 year product and system Warranty

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•Assesses ambient/rail temperature along entire heater length

•Equivalent to millions of hot and cold rail sensors

•Unlike ‘constant wattage’ heaters cannot suffer ‘burnout’

•Only draws current required to heat rail at that specific point

•Flexible heater

•Easy transportation and storage

•Long circuit lengths available

Self – Regulating Heater Element

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Chamber Test Self-regulating Point Heating

-30-25-20-15-10

-505

10152025

1hr 2hr 3hr 4hr 5hr 6hr 7hr 8hr

Air Temp

Current

Rail Temp

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xx

Poor Heater Positioning

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Correct Heater Strip Positioning

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Rev Date By Description Ckd Aprd

GrayBar Tel: 01933 676700

Fax: 01933 676800

Project

Catalogue Drawing Title

Heater Layout – 113lb 4-Way Drawn By Date Checked By Date Approved By Date

ALT Mar 02 Scale Sheet size

NTS A4 Drawing No.

DRO 144 This drawing is the property of GrayBar and may not be reproduced without permission.

Switch RailStock Rail

Section A - A

A

A

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Insulated Self–Regulating Heaters

Spring clip fixing Fibreglass heat

shield; Improves heat

transfer to rail; Compliant with

Network Rail Specification

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Fitted Heater Elements

Example of self-regulating insulated heaters and GRP heatshield fitted to bullhead rail points in a DC electrified area (Network Rail)

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Typical UIC 60 type point heating installation

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Heating fitted to HPSS type point

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Point Heating Design

Utilise all the benefits of Self-regulating insulated heaters,

Install combined control/transformer cubicles with simple weather sensors,

Minimise Cabling on-track e.g. use longer heater elements (up to 22 metres) and remove the need for rail probes,

Use off-track junction boxes, Reduce material and installation costs, Keep maintenance needs to a minimum.

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Controlling The Heaters

Transformers to provide the correct voltage to the heaters

Control cubicle Associated cabling Suitable power supply

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Simple Controls for Self-regulating Point Heating

Air temperature sensor Snow detector Set point e.g. +3°

Note

No need for Rail temperature probes

No need for complex switching of heaters

No PLC required

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Basic circuit arrangement

PRECIPITATIONSENSOR

TEMPERATURECONTROLLER

HOT/COLD RAILSENSORS

REMOTE CONDITION

MONITORING

MANUALOVERRIDE

CONTROLSYSTEM

CONTACTORFOUR

CONTACTORONE

CONTACTORTWO

CONTACTORTHREE

TRANSFORMERS1 TO 3

TRANSFORMERS4 TO 6

TRANSFORMERS7 TO 9

TRANSFORMERS10 TO 12

POINT HEATING,POINTS 1 TO 3

POINT HEATING,POINTS 4 TO 6

POINT HEATING,POINTS 7 TO 9

POINT HEATING,POINTS 10 TO 12

CONTROLROOM

WIRELESSGSM LINK

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Typical R.C.M. Cable Layout - Complex Design

Roadway

Pavement

Pavement

OHL Structure

Transformer

Control Cubicle

Supply Cubicle

Network Rail

Boundary Fence

Signal Location Case

Signal Post

Barrier/Handrail

Hot and Cold Rail sensors

Steel Bridge

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Roadway

Pavement

Pavement

OHL Structure

Control Cubicle

Supply Cubicle

Network Rail

Boundary Fence

Signal Location Case

Signal Post

110v 8-Core Heater Feed/Monitoring Cable

Recommended Point Heating Layout

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Premier Cubicle GrayBar trackside

control cubicle

All controls in the cubicle

Can control all forms of electric strip point heating

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Cubicle Transformers Integral

transformers mounted inside control cubicle

Easy maintenance in a safe location

All cable connections are base entry

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Channel Tunnel Rail Link This is a Universal Back

to Back Cubicle (St.Pancras throat).

Front houses the system controls

The back houses the transformers

All in the one location for a safer and more reliable maintenance regime

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St Pancras Station Approach

Graybar designed, manufactured and commissioned the point heating for whole of the high speed Channel Tunnel Rail Link (HS1) between London and the Channel Tunnel

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GrayBar Kits – Clip it and goTools needed:

-Hammer

-Screwdriver

Tools supplied in our heater kit:

-grease brush

-wire brush

-full installation instructions

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Self-regulating heater around chair block

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Off Track Junction Box

For connecting the heater leads to the heater feeder cable

Safe method of working off the track

Easy access to all cable connections

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Heater kit packaging

Complete Heater Kits In Easy To Transport, Store & Carry Boxes

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Transportation to site

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Special Installations

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Swingnose Heating

Swingnose with 380 Watt Per Metre double element insulated self-regulating heaters with heat shield (Network Rail)

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DC Contact Rail Heating

Illustration of general arrangement of 750 volt DC conductor rail heating. Self-Regulating heater circuits up to 200 metres in length

Section of rail

Side view

DRO 03

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Light Rail & Tram Point Heating

The light rail and tram systems in the UK have exclusively selected Graybar self-regulating heaters since 1990 e.g…

Croydon (South London) Tram

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Tram Points Heating

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Tram Control Cubicle

Stainless steel modular tram control cubicle similar to our Network Rail cubicles but modified for public street locations

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Installing Cables on a Tram System

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Connection box

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London Underground, Metronet have recommended and installed the Graybar self-regulating insulated heating system over many years

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London Underground installation

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Network Rail Company Line Standard and Code of Practice

RT/E/S/40045 & RT/E/C/45002

Graybar self-regulating point heating system has product approval:

NR Certificate PA05/688

Performance Specification and Code of Practice

•Allows innovative solutions

•Mandatory Documents

•Important Note: Graybar self-regulating heaters with a heat shield have been proven to comply with the low temperature performance requirements of the standard

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CTRL Section 2 GrayBar Point Heating

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HPSS Applications

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In Action – snow melted

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Sweden

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End of our presentation

Now the start of the Points Heating Season

Plan now for optimum end results

GrayBar for all Your Points Heating © GrayBar

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Cable Accessories