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Questions re. Tensorex

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McRhu

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Three questions...

1) Do wiring lengths ever have Tensorex at one end of the run and pulleys at the other? I ask because I have seen a new single pulley system in use on the WCML in the Polmadie - Cambuslang area of the WCML where there is also Tensorex and wonder if each end of the runs have different tensioning devices. Not sure if this is indeed a mix and match approach or simply replacement of the old 3-wheel pulleys with new pulley set up. Hard to tell from a moving train.

2) Tensorex seems to have an earth wire leading from the insulated wiring section just ahead of the unit to the mast. I have never noticed this with the pulley system. Why is it needed?

3) Is Tensorex suitable for existing MK1 and MK111/UK1 installations and if so are there plans to gradually replace weights & pulleys?

Many thanks in advance for any illumination on the above.
 
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WiredUp

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1 - There is nothing in the standards or design manuals which explicitly states that you can't mix and match BWA's with Pfisterer Tensorex C+ units - either for permanent arrangements or for temporary wiring configurations during staged works etc. The NR preference is for C+ units, then Siemens anti-fall BWA's. Plain BWA's are unlikely to be approved without good reason. NR policy is to tension the contact and catenary wires separately however the combined 22kN C+'s have been used with Mk3 equipment quite happily and simplify the tail wire arrangements.

2 - It's called an earthing 'rope' and earths the out of running tail wires - located between the terminal insulators and the C+ units in overlaps - to the main steelwork.

3 - In theory yes - providing the combinations of tensions and compensating lengths (which is the allowable along track movement which can be accommodated, which is based on wire run lengths) are available from Pfisterer's quite broad range. C+ units are simply a replacement for a balance weight anchor so for any auto-tensioned OLE arrangement you could rig up a C+ unit to work - subject to the preceding caveat. The basic design ranges which contain C+ units are Series 1, Series 2 and UKMS, though C+'s have been used with Mk3B, Mk3D and Mk1 (retrofit) to my knowledge. I'm not aware of an overarching NR policy to replace all BWA's but if there is a good case for it and it is viable to replace the BWA then I'm sure it will be done. A case in point are a couple of BWA's on the MML which are now C+'s (around the Kentish Town area).

C+ Units are available in the UK which would work for the following nominal tensions:

8.195kN - Mk1 Super-tensioned catenary wire (UKMS-R1L), Mk1 Original tensioned contact or catenary wires (UKMS-R1S)
11kN - Mk3b, D, Series 2 (11/11kN type) and UKMS100 contact or catenary wires
11.3kN - Mk1 (UKMS-R1S) Super-tensioned contact wire
12kN - UKMS125 and Series 2 (14/12kN type) catenary wires
13kN - Series 1 and future UKMS140* catenary wires
14kN - Series 2 (14/12kN type) contact wire
15kN - UKMS125 contact wire
16.5kN - Series 1 and future UKMS140* contact wires
22kN - combined for contact and catenary wires for Mk3B, MK3D.

I've not seen C+'s used with UK1 though the 14kN one could be used for the 225km/h UK1 contact wire (had that ever happened).

*If it ever gets issued into UKMS...
 
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McRhu

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1 - There is nothing in the standards or design manuals which explicitly states that you can't mix and match BWA's with Pfisterer Tensorex C+ units - either for permanent arrangements or for temporary wiring configurations during staged works etc. The NR preference is for C+ units, then Siemens anti-fall BWA's. Plain BWA's are unlikely to be approved without good reason. NR policy is to tension the contact and catenary wires separately however the combined 22kN C+'s have been used with Mk3 equipment quite happily and simplify the tail wire arrangements.

2 - It's called an earthing 'rope' and earths the out of running tail wires - located between the terminal insulators and the C+ units in overlaps - to the main steelwork.

3 - In theory yes - providing the combinations of tensions and compensating lengths (which is the allowable along track movement which can be accommodated, which is based on wire run lengths) are available from Pfisterer's quite broad range. C+ units are simply a replacement for a balance weight anchor so for any auto-tensioned OLE arrangement you could rig up a C+ unit to work - subject to the preceding caveat. The basic design ranges which contain C+ units are Series 1, Series 2 and UKMS, though C+'s have been used with Mk3B, Mk3D and Mk1 (retrofit) to my knowledge. I'm not aware of an overarching NR policy to replace all BWA's but if there is a good case for it and it is viable to replace the BWA then I'm sure it will be done. A case in point are a couple of BWA's on the MML which are now C+'s (around the Kentish Town area).

C+ Units are available in the UK which would work for the following nominal tensions:

8.195kN - Mk1 Super-tensioned catenary wire (UKMS-R1L), Mk1 Original tensioned contact or catenary wires (UKMS-R1S)
11kN - Mk3b, D, Series 2 (11/11kN type) and UKMS100 contact or catenary wires
11.3kN - Mk1 (UKMS-R1S) Super-tensioned contact wire
12kN - UKMS125 and Series 2 (14/12kN type) catenary wires
13kN - Series 1 and future UKMS140* catenary wires
14kN - Series 2 (14/12kN type) contact wire
15kN - UKMS125 contact wire
16.5kN - Series 1 and future UKMS140* contact wires
22kN - combined for contact and catenary wires for Mk3B, MK3D.

I've not seen C+'s used with UK1 though the 14kN one could be used for the 225km/h UK1 contact wire (had that ever happened).

*If it ever gets issued into UKMS...
Thank you very much indeed for that impressively comprehensive reply. Much appreciated.
 

59CosG95

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1 - There is nothing in the standards or design manuals which explicitly states that you can't mix and match BWA's with Pfisterer Tensorex C+ units - either for permanent arrangements or for temporary wiring configurations during staged works etc. The NR preference is for C+ units, then Siemens anti-fall BWA's. Plain BWA's are unlikely to be approved without good reason. NR policy is to tension the contact and catenary wires separately however the combined 22kN C+'s have been used with Mk3 equipment quite happily and simplify the tail wire arrangements.

2 - It's called an earthing 'rope' and earths the out of running tail wires - located between the terminal insulators and the C+ units in overlaps - to the main steelwork.

3 - In theory yes - providing the combinations of tensions and compensating lengths (which is the allowable along track movement which can be accommodated, which is based on wire run lengths) are available from Pfisterer's quite broad range. C+ units are simply a replacement for a balance weight anchor so for any auto-tensioned OLE arrangement you could rig up a C+ unit to work - subject to the preceding caveat. The basic design ranges which contain C+ units are Series 1, Series 2 and UKMS, though C+'s have been used with Mk3B, Mk3D and Mk1 (retrofit) to my knowledge. I'm not aware of an overarching NR policy to replace all BWA's but if there is a good case for it and it is viable to replace the BWA then I'm sure it will be done. A case in point are a couple of BWA's on the MML which are now C+'s (around the Kentish Town area).

C+ Units are available in the UK which would work for the following nominal tensions:

8.195kN - Mk1 Super-tensioned catenary wire (UKMS-R1L), Mk1 Original tensioned contact or catenary wires (UKMS-R1S)
11kN - Mk3b, D, Series 2 (11/11kN type) and UKMS100 contact or catenary wires
11.3kN - Mk1 (UKMS-R1S) Super-tensioned contact wire
12kN - UKMS125 and Series 2 (14/12kN type) catenary wires
13kN - Series 1 and future UKMS140* catenary wires
14kN - Series 2 (14/12kN type) contact wire
15kN - UKMS125 contact wire
16.5kN - Series 1 and future UKMS140* contact wires
22kN - combined for contact and catenary wires for Mk3B, MK3D.

I've not seen C+'s used with UK1 though the 14kN one could be used for the 225km/h UK1 contact wire (had that ever happened).

*If it ever gets issued into UKMS...
IIRC there were a few Tensorexes used after the PARR (Polmadie & Rutherglen Renewals) programme. There's also one on a classic Mk1 next to Longsight Depot, although I can't remember if it's anchoring a UK1 or Mk1 wire run.

More interestingly, two of the 22kN C+ units were used for the Fletton Jn Dn Slow Linespeed improvements - these have both since been replaced with Siemens anti-fall balance weights.
(slightly further north, as part of the Werrington Grade Separation works, new "classic" BWA assemblies were installed for the DF, UF, US and 1271pts/1272pts/1273pts crossover - although these were renewals of the existing assemblies at existing locations, with the existing weight stack re-used. The weights in the new order were credited back accordingly.)

I expect there will be a program of sorts to replace legacy BWAs with either Tensorexes or Siemens anti-falls, but which one gets used is likely to be the choice of the route in question. I think the MML is likely to favour Tensorexes more than the ECML - Colton Jn is a case in point, as the existing Mk3b assemblies have been re-anchored on the new structures installed by TRU, but on Siemens anti-falls.
 

McRhu

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IIRC there were a few Tensorexes used after the PARR (Polmadie & Rutherglen Renewals) programme. There's also one on a classic Mk1 next to Longsight Depot, although I can't remember if it's anchoring a UK1 or Mk1 wire run.

More interestingly, two of the 22kN C+ units were used for the Fletton Jn Dn Slow Linespeed improvements - these have both since been replaced with Siemens anti-fall balance weights.
(slightly further north, as part of the Werrington Grade Separation works, new "classic" BWA assemblies were installed for the DF, UF, US and 1271pts/1272pts/1273pts crossover - although these were renewals of the existing assemblies at existing locations, with the existing weight stack re-used. The weights in the new order were credited back accordingly.)

I expect there will be a program of sorts to replace legacy BWAs with either Tensorexes or Siemens anti-falls, but which one gets used is likely to be the choice of the route in question. I think the MML is likely to favour Tensorexes more than the ECML - Colton Jn is a case in point, as the existing Mk3b assemblies have been re-anchored on the new structures installed by TRU, but on Siemens anti-falls.
Interesting, thank you very much. As an aside, how does the SieCat anti-fall tensioner achieve the same effect with its one wheel as the traditional three wheel pulley? I always understood the three wheels functioned like gears on a bike to increase the leverage from the weights on the wire.

And as another aside while I'm amongst people in the know.... Has SieCat been used anywhere apart from Larkhall and as a replacement for MKII on the Glasgow-Gourock line? I know it's part of the Master Series Index but it seems the UK has opted for Series 1 and 2 assemblies since those schemes.
 

WiredUp

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Interesting, thank you very much. As an aside, how does the SieCat anti-fall tensioner achieve the same effect with its one wheel as the traditional three wheel pulley? I always understood the three wheels functioned like gears on a bike to increase the leverage from the weights on the wire.

And as another aside while I'm amongst people in the know.... Has SieCat been used anywhere apart from Larkhall and as a replacement for MKII on the Glasgow-Gourock line? I know it's part of the Master Series Index but it seems the UK has opted for Series 1 and 2 assemblies since those schemes.
Forget the number of pulleys - this as you state has the effect of increasing (by 3:1) the load on the OLE similar to a traditional BWA. The anti fall weight tension wheels are toothed and attached to the masts on a pivoted 'swing lever'. A tail wire / pulley is attached to a central spindle, and if the OLE parts, the weight of the balance weights cause the tension wheel to drop locking it out against the latching plate, this prevents the OLE losing all tension in it entirely. The 3:1 ratio is obtained by the difference in diameter between the central spindle and the rim of the tension wheel. The anti-fall weight BWA's predate SiCAT (and thus UKMS) and were first used with UK1 on the WCRM.

SiCAT has been used for Stevenage Platform 5 and was introduced to diversify the supply chain. As with CLever it aims to reduce the mass of the cantilever assemblies and simplify the number of components. GWEP, NWEP, GOBE, etc all predate SiCAT and use Series 1 or 2 (Barking Riverside uses Series 2 as well) so there is the likelihood that SiCAT will be used more in future, though as to whether this occurs will be up to the preference of each route. I personally don't like SiCAT that much - the straight steady arms look stupid!

Tensorex C+'s are the preferred NR installation choice so will probably dominate for new electrification schemes. Anti-fall weights will be probably used where it would be too awkward to change any masts or the tailwire/termination arrangements. Or if the E&P RAM simply prefers them...?
 

59CosG95

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SiCAT has been used for Stevenage Platform 5 and was introduced to diversify the supply chain. As with CLever it aims to reduce the mass of the cantilever assemblies and simplify the number of components. GWEP, NWEP, GOBE, etc all predate SiCAT and use Series 1 or 2 (Barking Riverside uses Series 2 as well) so there is the likelihood that SiCAT will be used more in future, though as to whether this occurs will be up to the preference of each route. I personally don't like SiCAT that much - the straight steady arms look stupid!

Tensorex C+'s are the preferred NR installation choice so will probably dominate for new electrification schemes. Anti-fall weights will be probably used where it would be too awkward to change any masts or the tailwire/termination arrangements. Or if the E&P RAM simply prefers them...?
SICAT is being used in anger on TRU (definitely all routes East of Leeds, possibly also Leeds to Standedge. The E&P RAM for the North West Route wanted Series 2 equipment west of Diggle, so that's confirmed as being Series 2)
 

WiredUp

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SICAT is being used in anger on TRU (definitely all routes East of Leeds, possibly also Leeds to Standedge. The E&P RAM for the North West Route wanted Series 2 equipment west of Diggle, so that's confirmed as being Series 2)
Interesting.... 'Each to their own' I suppose for SiCAT!

In terms of materials holding splitting up TRU into Series 2, and SiCAT, with OLEMI sandwiched in the middle at Leeds, isn't the wisest choice in the world. In our part of the world sensible heads have managed what has been introduced to avoid this combination of new OLE ranges....

Series 2 for part of TRU, west of Diggle makes some sense to tie in with the equipment used on NWEP.
 

McRhu

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I quite like the Siemens as (apart having a bit of the old Mecanno about its demeanour) it most closely resembles MK111. (Series 2 cantilevers are upside down and Series 1 is hideously heavy and seems to have an undue number of parts between the mast and contact wire. )I can see the disadvantages in having different systems scattered about here there and everywhere though.

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@WiredUp

I wonder if I might plumb the depths of your OLE knowledge one more time... You mentioned 'straight steady arms'... Is there any advantage with curved register arms? Mk 1 used very acute arms, or arms curved to match the pan profile; all to accommodate wire rise as the pan passed underneath. Mk 2 likewise (although straighter than the others) and MK 3 used (on cantilevers) a more gently curved profile. UK1, Series 1 and 2 follow suit (although Series 1 has the look of a Helix setsquare). Siemens alone goes for a straight arm. I would imagine this lifts the wire ever so slightly as well as registering it laterally. Who is right?
 
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59CosG95

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I quite like the Siemens as (apart having a bit of the old Mecanno about its demeanour) it most closely resembles MK111. (Series 2 cantilevers are upside down and Series 1 is hideously heavy and seems to have an undue number of parts between the mast and contact wire. )I can see the disadvantages in having different systems scattered about here there and everywhere though.

== Doublepost prevention - post automatically merged: ==

@WiredUp

I wonder if I might plumb the depths of your OLE knowledge one more time... You mentioned 'straight steady arms'... Is there any advantage with curved register arms? Mk 1 used very acute arms, or arms curved to match the pan profile; all to accommodate wire rise as the pan passed underneath. Mk 2 likewise (although straighter than the others) and MK 3 used (on cantilevers) a more gently curved profile. UK1, Series 1 and 2 follow suit (although Series 1 has the look of a Helix setsquare). Siemens alone goes for a straight arm. I would imagine this lifts the wire ever so slightly as well as registering it laterally. Who is right?
MkIII (and presumably UK1 too), Series 2 and Series 1 also have "straight arms", although these are usually for the out-of-running wires at overlaps. The SICAT "straight" arms are used with the "in-running" equipment, at overlaps and everywhere else.

The more gently curved MkIII arms were also used on headspans (which normally used the arms with a deeper curve) on some overlaps and also at low encumbrance locations, where uplift needed to be kept low. The "shallow curve" arms used on cantilevers (on lines with speeds lower than 100mph) had a lower uplift than ones with 101-125mph speeds (which required the "deep curve" arms).
If I remember correctly as well, the Series 2 equipment has a "heel setting" (vertical distance from contact wire to reg arm bracket) of 200mm, while MkIII, UK1 (presumably) and SICAT all have a 150mm heel setting. All these dimensions vary between equipment types to achieve that same uplift setting (250mm to 300mm IIRC).
 

McRhu

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MkIII (and presumably UK1 too), Series 2 and Series 1 also have "straight arms", although these are usually for the out-of-running wires at overlaps. The SICAT "straight" arms are used with the "in-running" equipment, at overlaps and everywhere else.

The more gently curved MkIII arms were also used on headspans (which normally used the arms with a deeper curve) on some overlaps and also at low encumbrance locations, where uplift needed to be kept low. The "shallow curve" arms used on cantilevers (on lines with speeds lower than 100mph) had a lower uplift than ones with 101-125mph speeds (which required the "deep curve" arms).
If I remember correctly as well, the Series 2 equipment has a "heel setting" (vertical distance from contact wire to reg arm bracket) of 200mm, while MkIII, UK1 (presumably) and SICAT all have a 150mm heel setting. All these dimensions vary between equipment types to achieve that same uplift setting (250mm to 300mm IIRC).
Thank you. Off to digest that information. I remember seeing videos of APT at speed and hearing the 'gently-curved' MK111 arms hitting off the rise dampers in a way which (I assume) wasn't intended.
 

WiredUp

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Thank you. Off to digest that information. I remember seeing videos of APT at speed and hearing the 'gently-curved' MK111 arms hitting off the rise dampers in a way which (I assume) wasn't intended.
A lot of work went on at the time (1970's) to evaluate whether the WCML OLE could be operated at >100mph with the APT, the findings were that the high uplift forces from the pantographs would have caused issues at 250km/h. Further work was also carried out in the mid 1990s for the WCRM as the Mk1 and Mk3A equipment was not felt capable of being used beyond 110mph (both in terms of reliability and dynamic behaviour/power draw). Whilst BR thought that a mix of modifications from Mk3B (mainly cantilevers with deeper drop brackets) and Mk5 (150mm2 contact wire) might solve some of the problems, we eventually ended up with UK1....

I'm not sure what you mean by 'rise dampers'? I assume you mean the shallow curve steady arms were hitting their uplift stop limits on the drop brackets?

Straight steady arms tend to be used where radial loads mean curved arms can't be used, or for reachover arms. It's a also a bit of a misnomer that shallow curve steady arms can't be used above 100mph - they are fitted after all to overlaps, crossovers and fitted bridge approaches - all of which operate at up to 125mph. Mk3A north of Crewe on the WCML also happily used shallow curve arms at 110mph on cantilevers for many years before UK1 came along. Series 2 does indeed have a heel setting of 200mm but this can be reduced to 100mm such as where the radial load is too high. The nominal 150mm heel settings 59CosG95 gave for Mk3B, UK1 and SiCAT are correct - good memory....
 

McRhu

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A lot of work went on at the time (1970's) to evaluate whether the WCML OLE could be operated at >100mph with the APT, the findings were that the high uplift forces from the pantographs would have caused issues at 250km/h. Further work was also carried out in the mid 1990s for the WCRM as the Mk1 and Mk3A equipment was not felt capable of being used beyond 110mph (both in terms of reliability and dynamic behaviour/power draw). Whilst BR thought that a mix of modifications from Mk3B (mainly cantilevers with deeper drop brackets) and Mk5 (150mm2 contact wire) might solve some of the problems, we eventually ended up with UK1....

I'm not sure what you mean by 'rise dampers'? I assume you mean the shallow curve steady arms were hitting their uplift stop limits on the drop brackets?

Straight steady arms tend to be used where radial loads mean curved arms can't be used, or for reachover arms. It's a also a bit of a misnomer that shallow curve steady arms can't be used above 100mph - they are fitted after all to overlaps, crossovers and fitted bridge approaches - all of which operate at up to 125mph. Mk3A north of Crewe on the WCML also happily used shallow curve arms at 110mph on cantilevers for many years before UK1 came along. Series 2 does indeed have a heel setting of 200mm but this can be reduced to 100mm such as where the radial load is too high. The nominal 150mm heel settings 59CosG95 gave for Mk3B, UK1 and SiCAT are correct - good memory....
Very interesting information, thank you again. What is the effect of a high radial load (is this the force pulling on the steady arm?) on a curved arm? Does it make its (toe?) end rise? As regards 'rise damper' - yes I meant the uplift stopper. Not sure where I heard 'rise damper'.
 

WiredUp

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Very interesting information, thank you again. What is the effect of a high radial load (is this the force pulling on the steady arm?) on a curved arm? Does it make its (toe?) end rise? As regards 'rise damper' - yes I meant the uplift stopper. Not sure where I heard 'rise damper'.
From a mechanical point of view high radial loads cause the curved steady arms to straighten out - or the reverse is true (buckle) if the arm is in compression. Anecdotally I have been told that they also can cause early failures of crimped end fittings.

As a secondary (but no less important consideration) high radial loads are also a construction risk which designers have to identify on design drawings so that the construction staff or maintainers are aware that if they release the contact wire/catenary from the cantilever/steady arm, it will pull back due to the tensioning on it - potentially injuring any operatives.

The opposite of high radial loads are low radial loads; this manifests itself in the form of higher impedance at the interface between the steady arm and the registration arm ring fitting (where it attaches to the cantilever) which can cause arcing damage. In cases where the load is less than say 50N - 80N, and/or wind causes a reversal in loads, a continuity jumper is fitted for F+F derived equipment - GEFF, Series 1 and UKMS. The jumpers can also be fitted if the location is used for earthing purposes such as a DEP...
 

McRhu

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There's a lot more to OLE than meets the eye. Thank you (and 59cosG) for your insights. It's helped fill in some gaps in my (very limited) knowledge and opened up a lot of new questions.
 

WiredUp

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No problem, see if you can find Gary Keenors book. It's pretty good and covers all the basics and design philosophy. Fire away if you have any more questions.
 

McRhu

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You are both very kind. It's great to have these questions answered. Yes - I have Gary Keenor's book as a PDF. It is indeed very good, very well presented and very readable. I suspect there is just as much interest in OLE as in any other aspect of The Railway. And with the advent of Series 1 on the GWML - and a certain amount of controversy regarding the aesthetics - it has come very much to the fore. For me the zenith of the overhead was MK IIIa, but I look at it with a layman's eye and its elegance, rather than as an engineer. I have heard it said on one hand that MKIII was riddled with design faults. and on the other hand that its apparent shortcomings are down to lack of the correct level of maintenance.

I think it's unlikely that either of you will have had experience of MKII due to its location (Glasgow-Gourock), but I remember it being unpopular with the OLE teams at Glasgow. Was there ever a prospect of MKII being more widely adopted throughout the UK?
 

WiredUp

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You are both very kind. It's great to have these questions answered. Yes - I have Gary Keenor's book as a PDF. It is indeed very good, very well presented and very readable. I suspect there is just as much interest in OLE as in any other aspect of The Railway. And with the advent of Series 1 on the GWML - and a certain amount of controversy regarding the aesthetics - it has come very much to the fore. For me the zenith of the overhead was MK IIIa, but I look at it with a layman's eye and its elegance, rather than as an engineer. I have heard it said on one hand that MKIII was riddled with design faults. and on the other hand that its apparent shortcomings are down to lack of the correct level of maintenance.

I think it's unlikely that either of you will have had experience of MKII due to its location (Glasgow-Gourock), but I remember it being unpopular with the OLE teams at Glasgow. Was there ever a prospect of MKII being more widely adopted throughout the UK?
Mk3A isn't wildly different from Mk3B - the last complete range in the UK - prior(ish) to UKMS. Mk3B gets a bad rap but a lot (not all) of the issues were down to Railtrack's 'maintenance holiday'.... beyond matters of aesthetics trying to say which basic design range is best is tricky. Series 1 is very robust but the design is driven primarily by multiple pantograph operation. Mk3B is cheap but contains certain flaws, as you mention, which aren't acceptable today. If you were to try to take the 'best' parts of Mk3B and incorporate current industry best practice and all of the campaign changes which were subsequently introduced by NR you'd end up with pretty good equipment which would be very near to what Series 2 (which is essentially Mk3D on steroids) is....this might include - from a contact systems POV - the following:

- All mechanically independently registered - no headspans, or spanwire TTC's/portals
- No AWAC - so BZII catenary/flexible droppers that are now found in UK1, Mk3D onwards
- Sensible span and wire run lengths with more accurate calculations of blow off
- Polymeric insulators
- Tensorex C+ or Siemens anti-fall BWA's, and the elimination of tail wires crossing over other wire runs
- Tangential wiring, no crossed contact bars
- Improved earthing and bonding capable of tolerating higher fault currents.
- Miscellaneous campaign changes (i.e. reliability driven)
- Elimination where possible of pulley wheels.

In answer to your second point Mk2 was an intermediate step before BR figured out that it (along with Mk1) was too expensive to use - resulting in the Mk3 family, so it was unlikely to have been used further than where it was (Glasgow - Gourock). However there are at least three historic 'what-ifs' where some evolution of Mk3B suitable for 140mph - 155mph would certainly have been used by BR if further routes had been electrified, or existing OLE upgraded:

(a) The full GWML from Airport Jnc to Bristol or Cardiff - using an ATF system.
(b) WCML for IC250 again using ATF and some ******* mix of Mk1, Mk3A, Mk3B and Mk5.
(c) Upgrades of the Mk3B on the ECML for 140mph and/or IC250 again with a mix of Mk3B and say Mk5.

All would have likely have required needed heavier 120mm or 150mm contact wire (Mk3B is 107mm2), level running OLE and probably stitched or compound OLE running at higher tensions.
 
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McRhu

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Fantastic, thanks! Once again, a lot to digest there and very gratefully received. So there was some validity in compound catenary for higher speeds then? I remember (being from the Glasgow area) that the original MK1 from GLC to Motherwell was wired from the outset compound catenary in places, but never saw anything other than Class 303s (max 75mph); at least not until late 1973/74. The auxilliary catenary wire has since all been removed. Does compound catenary require more weights/force to keep it in tension and is it more suceptable to high winds? And if I can ask another question relating to the nuts'n'bolts evolution of the equipment... The flat steady arms of MK1 never made it to MKII/MKIII etc. Was there a problem with these distorting?
 

WiredUp

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17 May 2021
Messages
97
Location
Bedford
Fantastic, thanks! Once again, a lot to digest there and very gratefully received. So there was some validity in compound catenary for higher speeds then? I remember (being from the Glasgow area) that the original MK1 from GLC to Motherwell was wired from the outset compound catenary in places, but never saw anything other than Class 303s (max 75mph); at least not until late 1973/74. The auxiliary catenary wire has since all been removed. Does compound catenary require more weights/force to keep it in tension and is it more susceptible to high winds? And if I can ask another question relating to the nuts'n'bolts evolution of the equipment... The flat steady arms of MK1 never made it to MKII/MKIII etc. Was there a problem with these distorting?
Compound catenary is there for two reasons (a) to provide an auxiliary current path but primarily to (b) control the uplift of the contact wire and hence current collection quality by minimising variations in OLE 'compliance' (sometimes called 'elasticity') e.g. mm/N of uplift, so that uplift is maintained as constant as it possibly can be in-span between points of registration, i.e. cantilevers etc. The alternative, which is cheaper, is to use a stitch wire at each registration point but this requires perhaps more adjustment and maintenance, cheaper still is pre-sag.

Mk1 is fine if you accept the limitations of its age, its cost (lots of Copper and Phosphor Bronze as well as fixings) and some of the reliability issues it has such as over boom pulley wheels. You could feasibly squeeze a reasonable amount of speed out of it in its super-tensioned guise - say 125mph for a single pantograph. The stumbling block might be the loading and unloading of the droppers which can be a fatigue issue with the 4mm stainless steel droppers - perhaps no more so than Mk3B to be fair. BR modified it in the 1980's going from 100mph to 110mph running on the WCML primarily by removing the auxiliary catenary wire, ditching the loop droppers and converting it to simple AT equipment, as well as super-tensioning it up to 11.3kN/8.195kN. In compound configuration it requires at at least two sets of tensioning devices (these are traditional balance weights): One for the contact wire and auxiliary catenary wire - using a compensating plate to obtain the correct tensions, and one for the primary catenary wire. As a flavour of the nominal tensions required:

Mk1 Compound AT (Late 1950s/Early 1960s) - Contact Wire: CdCu 107mm2 at 8.9kN, Auxiliary Catenary: CdCu 7/2.1mm at 3kN, Catenary: 19/2.1mm CdCu at 8.6kN
Mk1 Super-tensioned pre-sagged Simple AT (Mid 1980s) - CdCu 107mm2 at 11.3kN, Catenary: 19/2.1mm CdCu at 8.195kN
Mk4 Compound AT (Mid 1970s) - Contact Wire: CdCu107mm2 at 21.0kN, Auxiliary Catenary: AWAC 7/3.95mm at 11.0kN, Main Catenary: 19/3.39 AWAC at 24.0kN.

I've mentioned Mk4 (or BRB HSTT range as it is named in OLEMI) as this was BR's planned OLE range for future high speed lines (200km/h+) using a mix of Mk1 and Mk3A equipment, it was tested in a scaled configuration on the Old Dalby Test Track but never used in anger. Gary Keenor says that it was planned as a WCML upgrade for the APT-P which make some sense. BR had a habit of planning or optioneering 200km/h, 250km/h, 300km/h and even 400km/h versions of the APT (those numbers are correct BTW) so a supporting OLE system capable of these speeds makes some sense in terms of forward planning. Mk4 had potential for at least 155mph and the literature available suggests BR thought it could have been stretched up to 186mph. Certainly the tensions are in the ballpark for a high speed line comparable to the simple AT V300 OLE which SNCF uses, where the contact wire is at 20kN and the catenary is 14kN.

This shows Mk1 in its compound catenary configuration (note the loop droppers) and this after conversion to simple configuration. As to whether it (compound OLE in general) is more susceptible to high winds - generally the higher the tension in a wire the less it is liable to blow-off and unwanted dynamic behaviours. There is also a design factor called the critical wave speed which this paper explains. BR did quite a bit of work on simple (contact wire + catenary) OLE and it was reckoned that this would be just about acceptable up to 140mph for single pantograph operation, above that speed the greater uplift and need for a stitch wire meant that simple equipment would have been inadequate in terms of current collection quality.

The curved steady arms are there to provide clearance to the pantograph, as to why the straight Mk1 arms were not incorporated into Mk2 or Mk3 I don't have an answer for that I'm afraid. Mk3 has straight arms but these are cheaper crimped galvanised steel items so I would guess the cost of copper came into play. There are still a number of straight steady arms in legacy OLE ranges which can still be allocated, I'm not aware of whether there was an issue in terms of radial loads.
 

McRhu

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Lanark
Wonderful again, thank you. Am going to peruse all the above several times over. It's great to get an insight into not just the technicalities, but the thinking behind them. Very grateful.
 

Zerohero

New Member
Joined
10 Jan 2023
Messages
2
Location
Nottingham
1 - There is nothing in the standards or design manuals which explicitly states that you can't mix and match BWA's with Pfisterer Tensorex C+ units - either for permanent arrangements or for temporary wiring configurations during staged works etc. The NR preference is for C+ units, then Siemens anti-fall BWA's. Plain BWA's are unlikely to be approved without good reason. NR policy is to tension the contact and catenary wires separately however the combined 22kN C+'s have been used with Mk3 equipment quite happily and simplify the tail wire arrangements.

2 - It's called an earthing 'rope' and earths the out of running tail wires - located between the terminal insulators and the C+ units in overlaps - to the main steelwork.

3 - In theory yes - providing the combinations of tensions and compensating lengths (which is the allowable along track movement which can be accommodated, which is based on wire run lengths) are available from Pfisterer's quite broad range. C+ units are simply a replacement for a balance weight anchor so for any auto-tensioned OLE arrangement you could rig up a C+ unit to work - subject to the preceding caveat. The basic design ranges which contain C+ units are Series 1, Series 2 and UKMS, though C+'s have been used with Mk3B, Mk3D and Mk1 (retrofit) to my knowledge. I'm not aware of an overarching NR policy to replace all BWA's but if there is a good case for it and it is viable to replace the BWA then I'm sure it will be done. A case in point are a couple of BWA's on the MML which are now C+'s (around the Kentish Town area).

C+ Units are available in the UK which would work for the following nominal tensions:

8.195kN - Mk1 Super-tensioned catenary wire (UKMS-R1L), Mk1 Original tensioned contact or catenary wires (UKMS-R1S)
11kN - Mk3b, D, Series 2 (11/11kN type) and UKMS100 contact or catenary wires
11.3kN - Mk1 (UKMS-R1S) Super-tensioned contact wire
12kN - UKMS125 and Series 2 (14/12kN type) catenary wires
13kN - Series 1 and future UKMS140* catenary wires
14kN - Series 2 (14/12kN type) contact wire
15kN - UKMS125 contact wire
16.5kN - Series 1 and future UKMS140* contact wires
22kN - combined for contact and catenary wires for Mk3B, MK3D.

I've not seen C+'s used with UK1 though the 14kN one could be used for the 225km/h UK1 contact wire (had that ever happened).

*If it ever gets issued into UKMS...

Tensorex C+ is no longer a Pfisterer product. The Pfisterer railway business was bought out last year by Mosdorfer and now goes by the name Mosdorfer Rail. As i understand, Tensorex C+ is now a Mosdorfer Rail product and the patent name has changed over. I think they have the same team of people and they still manufacture the units in Sheffield
 

59CosG95

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18 Aug 2013
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Beeston (Notts)
Tensorex C+ is no longer a Pfisterer product. The Pfisterer railway business was bought out last year by Mosdorfer and now goes by the name Mosdorfer Rail. As i understand, Tensorex C+ is now a Mosdorfer Rail product and the patent name has changed over. I think they have the same team of people and they still manufacture the units in Sheffield
That is indeed true; there were plenty of brochures to that effect at Mosdorfer's stand at Rail Live 2022.
 

mr_moo

Member
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7 Sep 2009
Messages
647
Location
Cambridgeshire
Fascinasting info - thank you.
Is there a big difference in the plant needed to install a tensorex vs a BWA? i.e. cranes or standard MEWPS or scaffolds etc? Are tensorexes easier and thus faster to install?
 

59CosG95

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Fascinasting info - thank you.
Is there a big difference in the plant needed to install a tensorex vs a BWA? i.e. cranes or standard MEWPS or scaffolds etc? Are tensorexes easier and thus faster to install?
Slightly faster in terms of the lift (and definitely less cumbersome), but they can be trickier to set up at the right temperature - that's my experience with them.

(I've only worked with them being anchored on masts in the cess, similar to Mk3 BWAs etc.; it may well be feasible for both Tensorexes on an anchor pipe (on a Series 1 Boom) to be lifted together with a crane.)
 
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mr_moo

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7 Sep 2009
Messages
647
Location
Cambridgeshire
Interesting - I've only ever seen them up on masts, but I am a Westen man so it was all new stuff for the electrification out here of course. I didn;t know you could mount them at ground level. Does that make a big change to the installation requirements? And is there any risk from having a highly tensioned coil at ground level? I assume not if it's approved but it feels a bit odd.

This thread is so useful and informative - thank you so much everyone.
 

59CosG95

Established Member
Joined
18 Aug 2013
Messages
6,855
Location
Beeston (Notts)
Interesting - I've only ever seen them up on masts, but I am a Westen man so it was all new stuff for the electrification out here of course. I didn;t know you could mount them at ground level. Does that make a big change to the installation requirements? And is there any risk from having a highly tensioned coil at ground level? I assume not if it's approved but it feels a bit odd.

This thread is so useful and informative - thank you so much everyone.
AFAIK the tensioning is still done once the units are in place, be it on a boom or on a mast. As per my previous post, the 2 units would just be attached to the stovepipe for a given wire run, then the stovepipe itself (with both units attached) would be lifted into position. (This is of course just a hypothesis, and it may be easier to lift and mount individually)
 
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