World Class Engineered Cable Blog

How to specify the right communication cables for train cars for mechanical, physical, and electrical requirements

New generation train cars use communication cables and data protocol such as CAT 5E, CAT 6, CAT 7, MVB (Multifunction Vehicle Bus), WTB (Wire Train Bus), RS-485, LON (Local Operating Network), RS-422 and Canbus demanding 30-40 years in harsh environment.  As long as the electrical characteristics are achieved (like impedance and cross-talk), the cable can be made in different AWG sizes and materials for the conductor, insulation, shields and jacket.

When designing a communication cable for train cars environment, the following shall be considered

- Stranded conductor needs tol survive vibration and torque. The use of solid conductor should be avoided.
- Cross linked thermoset insulation and jacket should be preferred over thermoplastic materials. The cross-linked material is better in abrasion, cut through and notch propagation.
- The shield should be made of Tin Copper braid with an optional addition of an Aluminum/Mylar tape. The braid shield make the cable ruggedize with great resistance to crush and rough installation practices.

Other critical attribute is the capability of the cable to withstand temperature cycling and extreme hot or cold temperatures as the train exit out of the tunnel or parked and operated outdoors.

In addition to the mechanical, physical and electrical requirements of the communication cable, it needs to comply with local specifications for Flame, Smoke and Toxicity. (FST).   (Please refer to my other Blog regarding FST by visiting the RSCC Blog site)

To learn about communication cables for train cars FST requirements, please search the blog on the www.r-scc.com web site.

 

Properly designed high performance oil and gas cables for ocean rig drilling and land rig drilling can meet the challenge of maintaining equipment efficiency, reducing operational cost, and minimizing unscheduled maintenance.  Unforeseen and consistent rig downtime can directly affect top line day rates and contract renewal.  Key drilling components such as top drives, drawworks, pipe handlers, BOP controls, mud equipment and drilling control systems are the lifeline to a safe and efficient rig operation.

How can electrical cable minimize rig downtime?  One cable type is not fitting for each application.  Close collaboration with customers can determine cable turnover rates as it relates to mode of failure.  Products designed for certain applications can increase performance and minimize equipment downtime.

The good news is that EXANE cables are among those that can help!  State of the art cross-linking technology coupled with high grade compounds generate cables with improved life expectancy and field reliability.

 

When building the newest facility for one of the most innovative companies in the world, which cable did they pick for their Life – Safety systems?

In the public domain, such as a high-rise building or subway tunnel where people are present, clear standards exist to specify a fire safety cable to ensure notification, egress, and emergency system continued operation.

 

Communication cables for train cars can be different in construction, size and materials but they need to comply with NFPA 130 and other local codes as apply for a specific project. Train cars communication cables include CAT 5E, CAT 6, MVB (Multifunction Vehicle Bus), WTB (Wire Train Bus), RS-485, LON (Local Operating Network), RS-422 and Canbus.

FST is an abbreviation of Flame, Smoke and Toxicity and is used in local train cars specifications.
The Flame requirement includes two tests, NFPA 130-2017 and 49 CFR part 238, Appendix B.

Chapter 8 of NFPA 130-2017, NFPA 130-2014 and NFPA 130-2010 specifies that all cables including communication cables for train cars shall pass the UL 1685 with FT4/IEEE 1202 flame method. UL 1685 is a large scale flame test and the cables are bundled as specified. During the 20 minutes vertical flame test, the total smoke and peak smoke are measured and needs to be below a specific value to pass the test.

The 49 CFR part 238, Appendix B. is a small scale flame test that is done on a single cable per NEMA WC 3/ICEA S-19-81, paragraph 6.19.6. The test includes 5 applications of 15 seconds flame with 15 seconds rest. The flame propagation and monitored to a specific height and ignition of cotton under the sample.

The Smoke requirement is a small scale test of ASTM E662 that is done on the finished cable. The test is conducted in flaming and non-flaming modes with specific values after 90 second, 4 minutes and 20 minutes.

• Please note that UL 1685 has a smoke measurement test that needs to be satisfied.

The Toxicity test is specified as BSS 7239 per Boeing standard. The test is done in a smoke chamber and the various gases are measured by tubes. The gases includes Carbon Monoxide (CO), Hydrogen Fluoride (HF), Nitrogen Dioxide (NO2), Hydrogen Chloride (HCL), Hydrogen Cyanide (HCN), Sulfur Dioxide (SO2).

Local specification list the maximum ppm value per gas.

To learn about communication cables for train cars Physical, Mechanical and electrical requirements, please use link below to request a FREE CONSULTATION.

The short answer is “yes” they should.  Critical electrical circuits or Fire Safety Systems are referred to as Life Safety Systems intended to operate under extreme heat and flame to SAVE Lives.   As a manufacturer of fire safety cables, RSCC produces VITALink brand cables sold for the commercial installation market that pass UL 2196 in the U.S. and ULC-S139 in Canada.

You need to meet both NFPA 130 AND AAR-S-501 Transit Authority standards
to comply and ensure safety.

Specifiers of wire and cable in Transit Car electrical systems know that Vehicle Procurement Contracts let for the past five years require that wire and cable used in Rolling Stock must meet the NFPA 130 standard. But, in addition to the NFPA 130 standard, wire and cable also must meet additional physical and electrical requirements set by the Transit Authority.

The NFPA 130 standard requires wire and cable to meet the Underwriters Labs (UL) 1685 flame test (UL 1685 flame method is per IEEE 1202/FT4) and is primarily focused on 2 aspects of safety: Flame Spread and Smoke Generation. The primary purpose of the standard is to set limits to the spread of flame and also to set limits on the amount of smoke generated by the wire and cable once it comes into contact with the a fire. By setting these limits, the ability of the occupants of the vehicle to escape a fire event increases significantly.

However, it is important to note that NFPA 130 is not a stand-alone document for wire and cable performance in a Transit Vehicle application. It is an add-on to the Transit Authority base specification. The cable must be compliant to NFPA 130 and must also meet the other physical and electrical requirements of the Transit Authority Specification.  AAR-S-501 or RP-585 provide all the base requirements for wire and cable used by most Transit Authorities.   Cables should meet these requirements in addition to those specified in NFPA 130.  

Most current transit car procurement standards require compliance to NFPA 130 2014, however, the most current version available is NFPA 130 2017 (see web link below)

For your convenience, we are providing a summary of the AAR-S-501 or RP-585 key points by downloading a reference document

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What cables meet US requirements for offshore rig installations in a hazardous area environment?  Although it makes economic sense to standardize on one cable type, specifying engineers need to be cautious when trying to standardize as some applications which meet IEC standards do not in fact meet the requirements of the US API RP-14F standard or even meet the minimal cable construction requirements of IEEE Std.1580 as Marine Shipboard Cable.

Do you want to risk specifying less expensive electrical cables on your offshore oil rig that could cause a multi-million dollar electrical system failure?

The oil and gas industry has documented that by not specifying the highest performing cable at relatively modest additional cost has led to systems and operator downtime sometimes as expensive as $500,000 to $600,000 per day per incident.

Cables specified for electrical and fire safety systems need to operate in extreme environments for cold, high heat, wet, chemical exposure (minerals and esters), sunlight, and longer and hotter operating times.

Thermoset materials are better than thermoplastic types when exposed to extreme temperature and drilling muds with harsh chemicals and oils.   However, not all thermoset materials perform the same. Some materials have trade-offs such as low resistance to thermal cycling or failure in arctic temperatures down to -70C.

When specifying cables for offshore marine oil rig electrical systems don’t risk fire safety and electrical failures. Exane ® MR, manufactured by RSCC Wire & Cable, East Granby, Connecticut, has a historical industry position of meeting and exceeding standards required by IEC 61892-4 and NEK 606.