COMPANY PROFILE. Innovation in power transmission 2 CARIBONI ALSTOM

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1 RIGID CATENARY

2 COMPANY PROFILE Innovation in power transmission Cariboni, an Alstom company since 2008, is a leading European player in the design and manufacturing of materials for power transmission. Established in 1908, with about 85 employees operating in the surroundings of Lake Como one of the main industrialised areas of Northern Italy the company specialises in: - Design and manufacturing of components for railways, tramways and trolley bus contact lines - Bus-bar ducts for power plants - HV/MV connectors and fittings - Power supply systems for overhead cranes and hoists Our excellent workforce is committed in the seamless effort to manage the most demanding projects aiming at achieving top notch customer satisfaction. Nowadays, we can offer our customers all kinds of products and services, ranging from the design, engineering, testing and manufacturing of complete cantilevers to the manufacturing of all sorts of droppers, fittings and clamps based on customer-specific requirements. Our mission is to meet our customers expectations, both when they need an integrated service or when they need products manufactured on time and according to the highest quality level. Cariboni is proud of being included in the list of the most important European manufacturers of railway systems and of being a reliable partner of all the major worldwide leading manufacturers of overhead contact line systems. Cariboni specialises in the design and manufacturing of contact lines for railways, metro lines, tramways, undergrounds and trolley-buses. We are ready to fully meet all your needs. 2 CARIBONI ALSTOM

3 CONTENTS INTRODUCTION 4 CONDUCTOR PROFILE 5 JOINT PLATES 5 EXPANSION JOINTS 6 AIR GAP EXPANSION JOINTS 6 MECHANIC EXPANSION JOINT 6 SECTION INSULATOR 7 TRANSITION BAR 7 THE PROTECTIVE SHEATH 8 SUPPORT HANGERS 8 CLAMPS AND ANCHORAGES 9 ANCHORAGES 9 FIXED POINT CLAMPS 9 SUSPENSION SYSTEM 10 POWER FEEDER CLAMP 10 GROUNDING CLAMP 11 SPECIAL EQUIPMENTS FOR THE INSTALLATION

4 RIGID CATENARY I. INTRODUCTION The rigid catenary comes from the needed to reduce height during the construction of electrification systems, mostly in metropolitan tunnels but also in parking and railway line. In contrast with the traditional one, it no needs auxiliary droppers to ensure straight contact wire that so works without any mechanical tensile. The maximum span between two suspensions is 12 m and varies in relation to the speed of the electric tractive units. The contact line in a rigid catenary is comprised of an aluminum conductor profile with insert a copper contact wire, the staggering of contact line is done by adjusting the position of the suspension clamps. The fixed point clamps, installed in the middle of the rigid catenary, allow to split in two directions the variations of length due to the thermal expansion caused by temperature changes. To allow for expansion without deformation, the sections of rigid catenary have a maximum length of 400 m. At the entrance of tunnels, the contact wire and the messenger wire of the traditional line are anchoring to the front wall of the tunnel. In the area of transition between the traditional line and the rigid catenary, special bars are used to ensure a smooth passage of the pantograph between two areas with different elasticity. 4 CARIBONI ALSTOM

5 II. CONDUCTOR PROFILE Bars are made of a special aluminum-magnesium-silicon alloy. Each side has eight holes to allow the installation of junction plates. Eight vents (made at a distance of 4 m from one another) ensure that any condensed water buildup in the bar itself is discharged. The elasticity of the aluminum alloy facilitates assembly, without distorting the contact line. CHARACTERISTICS OF CONDUCTOR PROFILE NUMBER CHARACTERISTIC UNIT OF MEASUREMENT VALUE 1 Cross Section Area mm Equivalent Copper Cross Section mm Theoretical Weight kg/m 6, C Resistance µω*cm 3,25 5 Linear Expansion Coefficient 1/K 24* Tensile Strength Rm N/mm % Proof Strength (Rp 0.2) N/mm Min. manual bent radii of conductor profile on horizontal m Min. mechanical bent radii of current bar profile on horizontal m Length of Current bar profile m 12 III. JOINT PLATES The joint plates are made in order to allow for the connection between the aluminum conductor profile in rigid catenary. The geometric shape of the plates fits the bar s cavity. The whole joint is made of two plates that connect the contiguous ends of the aluminum conductor profile using stainless steel bolts. The mechanical and electric continuity between the aluminum conductor profile that form the catenary is achieved by tightening sixteen screws. 5

6 IV. EXPANSION JOINTS IV.1 Air Gap Expansion Joints Air gap expansion joints allow for the longitudinal expansion of the conductor profile caused by thermal expansion. They consist of a conductor profile bent at one end that allows for a smooth contact of the pantograph. The maximum absorbed length variation is about 250 mm. IV.2 Mechanic Expansion Joint Considering the linear expansion coefficient of aluminum, the maximum length of a continuous line of catenary is m, depending on the ambient temperature range. The lower part of the expansion joint ensures a regular passage of the pantograph while the upper part is equipped with copper braided flexible connections to guarantee continuity of electricity supply along the catenary. 6 CARIBONI ALSTOM

7 V. SECTION INSULATOR It is comprised of a central body made of fiberglass. At each end a clamp is provided to fix the system to the bars while two blades allow for the passage of pantograph. The insulating system is made of a silicon-coated fiberglass part that is capable of withstanding the mechanical stress due to traction of the system load. VI. TRANSITION BAR The bar allows for a stepwise transition from the traditional catenary to the rigid one, allowing for a smooth passage of the pantograph between two areas with different elasticity, thus preventing detachment of the pantograph. These components consist of a 4m-8m long segment onto which notches are made to reduce the section in order to increase the elasticity and flexibility of the profile. On one side are eight holes for fixing joint plates. A special plastic protection can be used to prevent the formation of water and dust buildups on the transition bar. L variable 6x480 =

8 VII. THE PROTECTIVE SHEATH L variable 89 Where leakage or other risks are present, a protective sheath is placed onto the conductor profile. Such protection prevents the formation of dust and liquids buildups on top of the transition bar. It is made of PVC and its shape facilitates installation on the aluminum conductor profile. L variable VIII. SUPPORT HANGERS Support hangers are made of bronze. A plastic insert allows the bar to slide in the event of expansion while reducing friction 8 CARIBONI ALSTOM

9 IX. CLAMPS AND ANCHORAGES IX.1 Anchorages Anchor plates are made of stainless steel. They anchor the rigid catenary at the beginning of the tunnel. IX.2 Fixed Point Clamps To split in the two directions the variation of length of the aluminum conductor profile caused by thermal expansion, a fixed point is made halfway between the two expansion joints or overlaps. It is made by putting together two anchoring devices composed of a stainless steel plate placed on the upper part of the aluminum conductor profile and wired to the tunnel. 9

10 X. SUSPENSION SYSTEM Composed by an insulated traverse, it can be connected to the roof of the tunnel by means of threaded rods and bronze clamps. THREADED ROD INSUALTED TRAVERSE SUPPORT HANGER ALUMINIUM RIGID CATENARY PROFILE XI. POWER FEEDER CLAMP In order to electrical feed the rigid catenary power feed clamps must be used. The number of this clamps depends of the electrical features of the line. It is installed on the upper part of the conductor profile, and there are holes to connect the cable lugs. When necessary bimetallic (Cu-Al) plates can be provide. 10 CARIBONI ALSTOM

11 XII. GROUNDING CLAMP Grounding is necessary to create an attachment point for the grounding foil on the aluminium conductor profile that forms the rigid catenary. It is installed on the upper part of the conductor profile that forms the contact line. XIII. SPECIAL EQUIPMENTS FOR THE INSTALLATION In order to install the components of the catenary, special equipments are used such as: railcar for the contact wire insertion, special cutting tools; drilling tools, and a special antioxidant paste made of grease with powdered zinc specifically used during installation. 11

12 Alstom S.p.A. Viale Regina Margherita, Roma Tel Fax Alstom Ferroviaria S.p.A. Bari Via dei gladioli, Modugno Z.I. (Ba) Tel Fax Bologna Via di Corticella, Bologna Tel Fax ALSTOM ALSTOM, il logo ALSTOM e qualsiasi versione alternativa dello stesso sono marchi registrati e di servizio di ALSTOM. Gli altri nomi menzionati, siano essi o no registrati, sono di proprietà delle rispettive aziende. I dati tecnici e di altro genere contenuti nel presente documento sono forniti esclusivamente a scopo informativo. ALSTOM si riserva il diritto di modificare o cambiare questi dati in qualsiasi momento senza ulteriore preavviso. Graphic Design: Studio Luviè. Immagini: Alstom, G.Fassino, M. Brega. Colleferro Via sabotino Colleferro (roma) Tel Fax Guidonia Via Lago dei Tartari, guidonia (roma) Tel Fax Lecco Via Roma, Pescate (LC) Tel Fax Savigliano Via Ottavio Moreno, Savigliano (CN) Tel Fax Sesto San Giovanni Via Fosse ardeatine, sesto s. g. (MI) Tel Fax Verona Via dell Elettronica, 19 Z.a.I. 2 Basson Verona Tel Fax