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Overhead lines

An overhead line or overhead wire is an electrical cable that is used to transmit electrical energy to electric locomotives, electric multiple units, trolleybuses or trams. The generic term used by the International Union of Railways for the technology is overhead line.[1] It is known variously as overhead catenary, overhead contact line (OCL), overhead contact system (OCS), overhead equipment (OHE), overhead line equipment (OLE or OHLE), overhead lines (OHL), overhead wiring (OHW), traction wire, and trolley wire.

An overhead line consists of one or more wires (or rails, particularly in tunnels) situated over rail tracks, raised to a high electrical potential by connection to feeder stations at regularly spaced intervals along the track. The feeder stations are usually fed from a high-voltage electrical grid.

Overview

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Electric trains that collect their current from overhead lines use a device such as a pantograph, bow collector or trolley pole. It presses against the underside of the lowest overhead wire, the contact wire. Current collectors are electrically conductive and allow current to flow through to the train or tram and back to the feeder station through the steel wheels on one or both running rails. Non-electric locomotives (such as diesels) may pass along these tracks without affecting the overhead line, although there may be difficulties with overhead clearance. Alternative electrical power transmission schemes for trains include third rail, ground-level power supply, batteries and electromagnetic induction.

Vehicles like buses that have rubber tyres cannot provide a return path for the current through their wheels, and must instead use a pair of overhead wires to provide both the current and its return path.

Construction

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Lineworkers on a maintenance of way vehicle repairing overhead lines (Poland)
Overhead over a switch in Toronto: Two runners for pantographs flank the trolley pole frog.

To achieve good high-speed current collection, it is necessary to keep the contact wire geometry within defined limits. This is usually achieved by supporting the contact wire from a second wire known as the messenger wire or catenary. This wire approximates the natural path of a wire strung between two points, a catenary curve, thus the use of "catenary" to describe this wire or sometimes the whole system. This wire is attached to the contact wire at regular intervals by vertical wires known as "droppers" or "drop wires". It is supported regularly at structures, by a pulley, link or clamp. The whole system is then subjected to mechanical tension.

As the pantograph moves along under the contact wire, the carbon insert on top of the pantograph becomes worn with time. On straight track, the contact wire is zigzagged slightly to the left and right of the centre from each support to the next so that the insert wears evenly, thus preventing any notches. On curves, the "straight" wire between the supports causes the contact point to cross over the surface of the pantograph as the train travels around the curve. The movement of the contact wire across the head of the pantograph is called the "sweep".

The zigzagging of the overhead line is not required for trolley poles. For tramways, a contact wire without a messenger wire is used.

Depot areas tend to have only a single wire and are known as "simple equipment" or "trolley wire". When overhead line systems were first conceived, good current collection was possible only at low speeds, using a single wire. To enable higher speeds, two additional types of equipment were developed:

  • Stitched equipment uses an additional wire at each support structure, terminated on either side of the messenger/catenary wire.
  • Compound equipment uses a second support wire, known as the "auxiliary", between the messenger/catenary wire and the contact wire. Droppers support the auxiliary from the messenger wire, while additional droppers support the contact wire from the auxiliary. The auxiliary wire can be of a more conductive but less wear-resistant metal, increasing transmission efficiency.

Earlier dropper wires provided physical support of the contact wire without joining the catenary and contact wires electrically. Modern systems use current-carrying droppers, eliminating the need for separate wires.

The present transmission system originated about 100 years ago. A simpler system was proposed in the 1970s by the Pirelli Construction Company, consisting of a single wire embedded at each support for 2.5 metres (8 ft 2 in) of its length in a clipped, extruded aluminum beam with the wire contact face exposed. A somewhat higher tension than used before clipping the beam yielded a deflected profile for the wire that could be easily handled at 400 km/h (250 mph) by a pneumatic servo pantograph with only 3 g acceleration.[citation needed]

Parallel overhead lines

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A switch in parallel overhead lines
Trolleybus wire switch

An electrical circuit requires at least two conductors. Trams and railways use the overhead line as the positive terminal of the circuit and the steel rails as the negative terminal of the circuit. For a trolleybus or a trolleytruck, no rails are available for the return current, as the vehicles use rubber tyres on the road surface. Trolleybuses use a second parallel overhead line for the return, and two trolley poles, one contacting each overhead wire. (Pantographs are generally incompatible with parallel overhead lines.) The circuit is completed by using both wires. Parallel overhead wires are also used on the rare railways with three-phase AC railway electrification.

Types of wires

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In the Soviet Union the following types of wires/cables were used.[2] For the contact wire, cold drawn solid copper was used to ensure good conductivity. The wire is not round but has grooves at the sides to allow the hangers to attach to it. Sizes were (in cross-sectional area) 85, 100, or 150 mm2. To make the wire stronger, 0.04% tin might be added. The wire must resist the heat generated by arcing and thus such wires should never be spliced by thermal means.

The messenger (or catenary) wire needs to be both strong and have good conductivity. They used multi-strand wires (or cables) with 19 strands in each cable (or wire). Copper, aluminum, and/or steel were used for the strands. All 19 strands could be made of the same metal or a mix of metals based on the required properties. For example, steel wires were used for strength, while aluminium or copper wires were used for conductivity.[3] Another type looked like it had all copper wires but inside each wire was a steel core for strength. The steel strands were galvanized but for better corrosion protection they could be coated with an anti-corrosion substance.

In Slovenia, where 3 kV system is in use, standard sizes for contact wire are 100 and 150 mm2. The catenary wire is made of copper or copper alloys of 70, 120 or 150 mm2. The smaller cross sections are made of 19 strands, whereas the bigger has 37 strands. Two standard configurations for main lines consist of two contact wires of 100 mm2 and one or two catenary wires of 120 mm2, totaling 320 or 440 mm2. Only one contact wire is often used for side tracks.[4]

In the UK and EU countries, the contact wire is typically made from copper alloyed with other metals. Sizes include cross-sectional areas of 80, 100, 107, 120, and 150 mm2. Common materials include normal and high strength copper, copper-silver, copper-cadmium, copper-magnesium, and copper-tin, with each being identifiable by distinct identification grooves along the upper lobe of the contact wire. These grooves vary in number and location on the arc of the upper section.[5] Copper is chosen for its excellent conductivity, with other metals added to increase tensile strength. The choice of material is chosen based on the needs of the particular system, balancing the need for conductivity and tensile strength.

Tensioning

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Line tensioning in Germany

Catenary wires are kept in mechanical tension because the pantograph causes mechanical oscillations in the wire. The waves must travel faster than the train to avoid producing standing waves, which could break the wire. Tensioning the line makes waves travel faster, and also reduces sag from gravity.

For medium and high speeds, the wires are generally tensioned by weights or occasionally by hydraulic tensioners. Either method is known as "auto-tensioning" (AT) or "constant tension" and ensures that the tension is virtually independent of temperature. Tensions are typically between 9 and 20 kN (2,000 and 4,500 lbf) per wire. Where weights are used, they slide up and down on a rod or tube attached to the mast, to prevent them from swaying. Recently, spring tensioners have started to be used. These devices contain a torsional spring with a cam arrangement to ensure a constant applied tension (instead of varying proportionally with extension). Some devices also include mechanisms for adjusting the stiffness of the spring for ease of maintenance.

For low speeds and in tunnels where temperatures are constant, fixed termination (FT) equipment may be used, with the wires terminated directly on structures at each end of the overhead line. The tension is generally about 10 kN (2,200 lbf). This type of equipment sags in hot conditions and is taut in cold conditions.

With AT, the continuous length of the overhead line is limited due to the change in the height of the weights as the overhead line expands and contracts with temperature changes. This movement is proportional to the distance between anchors. Tension length has a maximum. For most 25 kV OHL equipment in the UK, the maximum tension length is 1,970 m (6,460 ft).[6]

An additional issue with AT equipment is that, if balance weights are attached to both ends, the whole tension length is free to move along the track. To avoid this a midpoint anchor (MPA), close to the centre of the tension length, restricts movement of the messenger/catenary wire by anchoring it; the contact wire and its suspension hangers can move only within the constraints of the MPA. MPAs are sometimes fixed to low bridges, or otherwise anchored to vertical catenary poles or portal catenary supports. A tension length can be seen as a fixed centre point, with the two half-tension lengths expanding and contracting with temperature.

Most systems include a brake to stop the wires from unravelling completely if a wire breaks or tension is lost. German systems usually use a single large tensioning pulley (basically a ratchet mechanism) with a toothed rim, mounted on an arm hinged to the mast. Normally the downward pull of the weights and the reactive upward pull of the tensioned wires lift the pulley so its teeth are well clear of a stop on the mast. The pulley can turn freely while the weights move up or down as the wires contract or expand. If tension is lost the pulley falls back toward the mast, and one of its teeth jams against the stop. This stops further rotation, limits the damage, and keeps the undamaged part of the wire intact until it can be repaired. Other systems use various braking mechanisms, usually with multiple smaller pulleys in a block and tackle arrangement.

Breaks

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Lines are divided into sections to limit the scope of an outage and to allow maintenance.

Section break

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A section insulator at a section break in Amtrak's 12 kV catenary

To allow maintenance to the overhead line without having to turn off the entire system, the line is broken into electrically separated portions known as "sections". Sections often correspond with tension lengths. The transition from section to section is known as a "section break" and is set up so that the vehicle's pantograph is in continuous contact with one wire or the other.

For bow collectors and pantographs, this is done by having two contact wires run side by side over the length between 2 or 4 wire supports. A new one drops down and the old one rises up, allowing the pantograph to smoothly transfer from one to the other. The two wires do not touch (although the bow collector or pantograph is briefly in contact with both wires). In normal service, the two sections are electrically connected; depending on the system this might be an isolator, fixed contact or a Booster Transformer. The isolator allows the current to the section to be interrupted for maintenance.

On overhead wires designed for trolley poles, this is done by having a neutral section between the wires, requiring an insulator. The driver of the tram or trolleybus must temporarily reduce the power draw before the trolley pole passes through, to prevent arc damage to the insulator.

Pantograph-equipped locomotives must not run through a section break when one side is de-energized. The locomotive would become trapped, but as it passes the section break the pantograph briefly shorts the two catenary lines. If the opposite line is de-energized, this voltage transient may trip supply breakers. If the line is under maintenance, an injury may occur as the catenary is suddenly energized. Even if the catenary is properly grounded to protect the personnel, the arc generated across the pantograph can damage the pantograph, the catenary insulator or both.

Neutral section (phase break)

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Neutral Section Indication Board used on railways in the UK. Six of these would be required at crossings
A pantograph of EMU passes neutral section of 25 kV 50 Hz AC overhead line without lowering but with switching off a circuit breaker

Sometimes on a larger electrified railway, tramway or trolleybus system, it is necessary to power different areas of track from different power grids, without guaranteeing synchronisation of the phases. Long lines may be connected to the country's national grid at various points and different phases. (Sometimes the sections are powered with different voltages or frequencies.) The grids may be synchronised on a normal basis, but events may interrupt synchronisation. This is not a problem for DC systems. AC systems have a particular safety implication in that the railway electrification system would act as a "Backdoor" connection between different parts, resulting in, amongst other things, a section of the grid de-energised for maintenance being re-energised from the railway substation creating danger.

For these reasons, Neutral sections are placed in the electrification between the sections fed from different points in a national grid, or different phases, or grids that are not synchronized. It is highly undesirable to connect unsynchronized grids. A simple section break is insufficient to guard against this as the pantograph briefly connects both sections.[7]

In countries such as France, South Africa, Australia and the United Kingdom, a pair of permanent magnets beside the rails at either side of the neutral section operate a bogie-mounted transducer on the train which causes a large electrical circuit-breaker to open and close when the locomotive or the pantograph vehicle of a multiple unit passes over them.[8] In the United Kingdom equipment similar to Automatic Warning System (AWS) is used, but with pairs of magnets placed outside the running rails (as opposed to the AWS magnets placed midway between the rails). Lineside signs on the approach to the neutral section warn the driver to shut off traction power and coast through the dead section.

A neutral section or phase break consists of two insulated breaks back-to-back with a short section of line that belongs to neither grid. Some systems increase the level of safety by the midpoint of the neutral section being earthed. The presence of the earthed section in the middle is to ensure that should the transducer controlled apparatus fail, and the driver also fail to shut off power, the energy in the arc struck by the pantograph as it passes to the neutral section is conducted to earth, operating substation circuit breakers, rather than the arc either bridging the insulators into a section made dead for maintenance, a section fed from a different phase, or setting up a Backdoor connection between different parts of the country's national grid.

25 kV AC neutral zone in Romania

On the Pennsylvania Railroad, phase breaks were indicated by a position light signal face with all eight radial positions with lenses and no center light. When the phase break was active (the catenary sections out of phase), all lights were lit. The position light signal aspect was originally devised by the Pennsylvania Railroad and was continued by Amtrak and adopted by Metro North. Metal signs were hung from the catenary supports with the letters "PB" created by a pattern of drilled holes.

Dead section

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A special category of phase break was developed in America, primarily by the Pennsylvania Railroad. Since its traction power network was centrally supplied and only segmented by abnormal conditions, normal phase breaks were generally not active. Phase breaks that were always activated were known as "Dead Sections": they were often used to separate power systems (for example, the Hell Gate Bridge boundary between Amtrak and Metro North's electrifications) that would never be in-phase. Since a dead section is always dead, no special signal aspect was developed to warn drivers of its presence, and a metal sign with "DS" in drilled-hole letters was hung from the catenary supports.

Gaps

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A swing bridge near Meppel, the Netherlands. There is no overhead line on the bridge; the train coasts through with raised pantograph.

Occasionally gaps may be present in the overhead lines, when switching from one voltage to another or to provide clearance for ships at moveable bridges, as a simpler alternative for moveable overhead power rails. Electric trains coast across the gaps. To prevent arcing, power must be switched off before reaching the gap and usually the pantograph would be lowered.

Overhead conductor rails

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B&O's overhead third-rail system at Guilford Avenue in Baltimore, 1901, part of the Baltimore Belt Line. The central position of the overhead conductors was dictated by the many tunnels on the line: the -shaped rails were located at the highest point in the roof to give the most clearance.[9]

Given limited clearance such as in tunnels, the overhead wire may be replaced by a rigid overhead rail. An early example was in the tunnels of the Baltimore Belt Line, where a Π section bar (fabricated from three strips of iron and mounted on wood) was used, with the brass contact running inside the groove.[9] When the overhead line was raised in the Simplon Tunnel to accommodate taller rolling stock, a rail was used. A rigid overhead rail may also be used in places where tensioning the wires is impractical, for example on moveable bridges. In modern uses, it is very common for underground sections of trams, metros, and mainline railways to use a rigid overhead wire in their tunnels, while using normal overhead wires in their above ground sections.

Operation of the overhead conductor rails at Shaw's Cove Railroad Bridge in Connecticut

In a movable bridge that uses a rigid overhead rail, there is a need to transition from the catenary wire system into an overhead conductor rail at the bridge portal (the last traction current pylon before the movable bridge). For example, the power supply can be done through a catenary wire system near a swing bridge. The catenary wire typically comprises messenger wire (also called catenary wire) and a contact wire where it meets the pantograph. The messenger wire is terminated at the portal, while the contact wire runs into the overhead conductor rail profile at the transition end section before it is terminated at the portal. There is a gap between the overhead conductor rail at the transition end section and the overhead conductor rail that runs across the entire span of the swing bridge. The gap is required for the swing bridge to be opened and closed. To connect the conductor rails together when the bridge is closed, there is another conductor rail section called "rotary overlap" that is equipped with a motor. When the bridge is fully closed, the motor of the rotary overlap is operated to turn it from a tilted position into the horizontal position, connecting the conductor rails at the transition end section and the bridge together to supply power.[10]

Short overhead conductor rails are installed at tram stops as for the Combino Supra.[11]

Crossings

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Tram overhead wire (diagonal) crossing trolleybus wires (horizontal), photographed in Bahnhofplatz, Bern, Switzerland
Annotated version of the previous photo, highlighting components
  tram conductor
  trolley bus wires
  insulated trough

Trams draw their power from a single overhead wire at about 500 to 750 V DC. Trolleybuses draw from two overhead wires at a similar voltage, and at least one of the trolleybus wires must be insulated from tram wires. This is usually done by the trolleybus wires running continuously through the crossing, with the tram conductors a few centimetres lower. Close to the junction on each side, the tram wire turns into a solid bar running parallel to the trolleybus wires for about half a metre. Another bar similarly angled at its ends is hung between the trolleybus wires, electrically connected above to the tram wire. The tram's pantograph bridges the gap between the different conductors, providing it with a continuous pickup.

Where the tram wire crosses, the trolleybus wires are protected by an inverted trough of insulating material extending 20 or 30 mm (0.79 or 1.18 in) below.

Until 1946, a level crossing in Stockholm, Sweden connected the railway south of Stockholm Central Station and a tramway. The tramway operated on 600–700 V DC and the railway on 15 kV AC. In the Swiss village of Oberentfelden, the Menziken–Aarau–Schöftland line operating at 750 V DC crosses the SBB line at 15 kV AC; there used to be a similar crossing between the two lines at Suhr but this was replaced by an underpass in 2010. Some crossings between tramway/light rail and railways are extant in Germany. In Zürich, Switzerland, VBZ trolleybus line 32 has a level crossing with the 1,200 V DC Uetliberg railway line; at many places, trolleybus lines cross the tramway. In some cities, trolleybuses and trams shared a positive (feed) wire. In such cases, a normal trolleybus frog can be used.

Alternatively, section breaks can be sited at the crossing point, so that the crossing is electrically dead.

Australia

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Many cities had trams and trolleybuses using trolley poles. They used insulated crossovers, which required tram drivers to put the controller into neutral and coast through. Trolleybus drivers had to either lift off the accelerator or switch to auxiliary power.

In Melbourne, Victoria, tram drivers put the controller into neutral and coast through section insulators, indicated by insulator markings between the rails.

Melbourne has several remaining level crossings between electrified suburban railways and tram lines. They have mechanical switching arrangements (changeover switch) to switch the 1500 V DC overhead of the railway and the 650 V DC of the trams, called a Tram Square.[12] Several such crossings have been grade separated in recent years as part of the Level Crossing Removal Project.

Greece

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Athens has two crossings of tram and trolleybus wires, at Vas. Amalias Avenue and Vas. Olgas Avenue, and at Ardittou Street and Athanasiou Diakou Street. They use the above-mentioned solution.

Italy

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In Rome, at the crossing between Viale Regina Margherita and Via Nomentana, tram and trolleybus lines cross: tram on Viale Regina Margherita and trolleybus on Via Nomentana. The crossing is orthogonal, therefore the typical arrangement was not available.

In Milan, most tram lines cross its circular trolleybus line once or twice. Trolleybus and tram wires run parallel in streets such as viale Stelvio, viale Umbria and viale Tibaldi.

Multiple overhead lines

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Two overhead conductor rails for the same track. Left, 1,200 V DC for the Uetliberg railway (the pantograph is mounted asymmetrically to collect current from this rail); right, 15 kV AC for the Sihltal railway

Some railways used two or three overhead lines, usually to carry three-phase current. This is used only on the Gornergrat Railway and Jungfrau Railway in Switzerland, the Petit train de la Rhune in France, and the Corcovado Rack Railway in Brazil. Until 1976, it was widely used in Italy. On these railways, the two conductors are used for two different phases of the three-phase AC, while the rail was used for the third phase. The neutral was not used.

Some three-phase AC railways used three overhead wires. These were an experimental railway line of Siemens in Berlin-Lichtenberg in 1898 (length 1.8 kilometres (1.1 mi)), the military railway between Marienfelde and Zossen between 1901 and 1904 (length 23.4 kilometres (14.5 mi)) and an 800-metre (2,600 ft)-long section of a coal railway near Cologne between 1940 and 1949.

On DC systems, bipolar overhead lines were sometimes used to avoid galvanic corrosion of metallic parts near the railway, such as on the Chemin de fer de la Mure.

All systems with multiple overhead lines have a high risk of short circuits at switches and therefore tend to be impractical in use, especially when high voltages are used or when trains run through the points at high speed.

The Sihltal Zürich Uetliberg Bahn had two lines with different electrification. To be able to use different electric systems on shared tracks, the Sihltal line had its overhead wire right above the train, whilst the Uetliberg line had its overhead wire off to one side. This configuration was used up until summer 2022, since then the Uetliberg line has been switched to the standard 15kV 16.7 Hz configuration.[13]

Overhead catenary

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Catenary (upper photo) is suited to higher-speed rail vehicles. Trolley wire (lower photo) is suited to slower-speed trams (streetcars) and light rail vehicles.
Overhead feeding rail on the RER Line C trenches and tunnels in central Paris
Compound catenary equipment of JR West
An older rail bridge in Berwick-upon-Tweed, retrofitted to include overhead catenary lines

A catenary is a system of overhead wires used to supply electricity to a locomotive, tram (streetcar), or light rail vehicle that is equipped with a pantograph.

Gantry with old and new suspended equipment at Grivita railway station, Bucharest

Unlike simple overhead wires, in which the uninsulated wire is attached by clamps to closely spaced crosswires supported by poles, catenary systems use at least two wires. The catenary or messenger wire is hung at a specific tension between line structures, and a second wire is held in tension by the messenger wire, attached to it at frequent intervals by clamps and connecting wires known as droppers. The second wire is straight and level, parallel to the rail track, suspended over it as the roadway of a suspension bridge is over water.

Catenary systems are suited to high-speed operations whereas simple wire systems, which are less expensive to build and maintain, are common on light rail or tram (streetcar) lines, especially on city streets. Such vehicles can be fitted with either a pantograph or trolley pole.

Electrification support structures

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Various methods are used to support overhead line equipment. These must provide support (vertical position of catenary and contact wires) and registration (horizontal position of catenary and contact wires). The metal parts that provide OLE registration are typically designed to adjust in the vertical plane as the pantograph moves under it. These are often designed to allow mechanically independent registration, in which each contact and catenary wire for each track is mechanically independent from the adjacent wire runs.

The generic types of support structures are summarised below.[14]

Gantry structures to support overhead lines in Hyderabad, India
  • Single Cantilever
    • The most basic and common type of OLE structure that supports and registers one wire run above one track.
  • Double Cantilever
    • Similar to the previous but with two cantilever arms adjacent to each other on one mast. Often used where two wire runs converge.
  • Back to Back Cantilever
    • Two wire runs over two tracks supported and registered by one mast placed in the centre of the tracks with cantilever arms attached to opposite sides. Frequently used on tram and light rail systems but can appear on heavy rail lines.
  • Two Track Cantilever (TTC)
    • Two wire runs over two tracks supported by one mast with a boom structure extending over to the second track. TTCs typically provide mechanically independent registration, but subtypes exists called the "span-wire two track cantilever" which has both registration arms mechanically linked. TTCs are often used where there are poor ground conditions or obstructions on one side of a two track railway. They are also sometimes used to minimised piling since only one track must be taken out of service for this phase of construction.
  • Portals
    • Also known generically as "gantries", portals are large structures with masts on either side and a fixed steel beam between them. They are frequently used on sections of railway line with more than two tracks. Portals typically provide mechanically independent registration, however variants exist with registration span-wires that mechanically link adjacent wire runs. Portals are sometimes used on two track railways over bridges and viaducts or where ground conditions are poor. This is because portals inflict fewer rotational forces on their foundations.
  • Headspans
    • An alternative method to supporting multi-track areas, headspans consist of a mast at either side of the railway and various cables running horizontally between the two masts (called span wires) to support and register all wire runs at tension. Because the tension of all wire runs and span wires are required simultaneously to hold up the OLE wires, headspans by definition do not provide mechanically independent registration and a failure of one OLE or span wire will bring all wire runs out of geometric limits. Headspans are cheaper and less obtrusive than portals and so are well suited to low speed complex multitrack areas like stations, station approaches, depots and sidings, and areas where visual intrusion is an important consideration. They are also capable of supporting tracks with speeds up to 200km/h (125mph) but provide significant reliability disadvantages over portals or TTCs for this application.

Tunnels, low overbridges and other location specific features (retaining walls, adjacent rockfaces etc) frequently require bespoke OLE structures that may incorporate some features of the generic types above.

Overhead catenary systems in the United States

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Amtrak's Northeast Corridor in the United States has catenary over the 600 miles (970 km) between Boston, Massachusetts, and Washington, D.C., for inter-city trains. Commuter rail agencies including MARC, SEPTA, NJ Transit, and Metro-North Railroad use the catenary to provide local service.

In Cleveland, Ohio, interurban/light rail lines and a heavy rail line use the same overhead wires, due to a city ordinance intended to limit air pollution from the large number of steam trains that passed through Cleveland between the east coast and Chicago. Trains switched from steam to electric locomotives at the Collinwood railyards about 10 miles (16 km) east of Downtown and at Linndale on the west side. When Cleveland constructed its rapid transit (heavy rail) line between the airport, downtown, and beyond, it employed a similar catenary, using electrification equipment left over after railroads switched from steam to diesel. Light and heavy rail share trackage for about 3 miles (4.8 km) along the Cleveland Hopkins International Airport Red (heavy rail) line, Blue and Green interurban/light rail lines between Cleveland Union Terminal and just past East 55th Street station, where the lines separate.

Part of Boston's Blue Line through the northeast suburbs uses overhead lines, as does the Green Line.

The Yellow Line on the Chicago "L" used an overhead catenary system for the west half of the route, switching to third rail for the east half. This was discontinued in 2004 when the entire route was converted to third rail.[citation needed]

On the San Francisco peninsula in California, the Caltrain commuter rail system completed the installation of an overhead contact system (OCS) in 2023, to prepare for the conversion of its 160-year old San Francisco-to-San José Peninsula Corridor to fully electrified service in September 2024.[citation needed]

Problems with overhead equipment

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Overhead lines may be damaged by strong winds.[15] Lightning can hit overhead wires or supporting systems, stopping trains with a power surge.[16]

During cold or frosty weather, ice may coat overhead lines. This can result in poor electrical contact between the collector and the overhead line, resulting in electrical arcing and power surges.[17] Ice coatings also add extra weight, as well as increase their surface area exposed to wind, consequently increasing the load on the wires and their supports.

Lines may sag during hot weather and if a pantograph gets entangled, this can result in a dewirement. Similarly, in very cold weather they may contract and snap.

The installation of overhead lines may require reconstruction of bridges to provide safe electrical clearance.[18]

Overhead lines, like most electrified systems, require a greater capital expenditure when building the system than an equivalent non-electric system. While a unelectrified railway line requires only the grade, ballast, ties and rails, an overhead system also requires a complex system of support structures, lines, insulators, power-control systems and power lines, all of which require maintenance. This makes non-electrical systems more attractive in the short term, although electrical systems can pay for themselves eventually. Also, the added construction and maintenance cost-per-mile makes overhead systems less attractive on already existing long-distance railways, such as those found in North America, where the distances between cities are typically far greater than in Europe. Such long lines require enormous investment in overhead line equipment, which private rail companies are unlikely to be interested in, and major difficulties confront energizing long portions of overhead wire on a permanent basis, especially in areas where energy demand already outstrips supply.

Many people consider overhead lines to be "visual pollution", due to the many support structures and complicated system of wires and cables that fill the air. Such considerations have driven the move towards replacing overhead power and communications lines with buried cables where possible. The issue came to a head in the UK with the Great Western Main Line electrification scheme, especially through the Goring Gap. A protest group with their own website has been formed.[19]

The valuable copper conductor can also be subject to theft, as for example the Lahore-Khanewal line in Pakistan and the Gweru-Harare section of line in Zimbabwe.

Height

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The height of the overhead line can create hazards at level crossings, where it may be struck by road vehicles. Warning signs are placed on the approaches, advising drivers of the maximum safe height.

The wiring in most countries is too low to allow double-stack container trains. Exceptions include the Channel Tunnel, which has a higher overhead line to accommodate double-height car and truck transporters, and lines in China and India with higher wiring and pantographs to allow double-stack container trains.[20][21][22]

History

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The first tram with overhead lines was presented by Werner von Siemens at the 1881 International Exposition of Electricity in Paris: the installation was removed after that event. In October 1883, the first permanent tram service with overhead lines was on the Mödling and Hinterbrühl Tram in Austria. The trams had bipolar overhead lines, consisting of two U-pipes, in which the pantographs hung and ran like shuttles. From April to June 1882, Siemens had tested a similar system on his Electromote, an early precursor of the trolleybus.

Much simpler and more functional was an overhead wire in combination with a pantograph borne by the vehicle and pressed at the line from below. This system, for rail traffic with a unipolar line, was invented by Frank J. Sprague in 1888. From 1889 it was used at the Richmond Union Passenger Railway in Richmond, Virginia, pioneering electric traction.

See also

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References

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Further reading

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An overhead line is a structure used in and distribution, as well as , to carry by suspending conductors from support structures such as poles or towers, with air serving as the primary insulator. These lines are used for both high-voltage transmission (typically above 69 kV) and lower-voltage distribution (e.g., 4–35 kV), utilizing specialized conductors like aluminum conductor steel-reinforced (ACSR) cables that combine high conductivity with mechanical strength to withstand environmental stresses. The development of overhead lines traces back to the late 19th century, coinciding with the advent of alternating current (AC) systems that enabled efficient long-distance transmission. A pivotal early milestone was on June 3, 1889, when the first long-distance transmission line (using direct current) delivered power from Willamette Falls to Portland, Oregon, spanning 14 miles at 4 kV. This was followed by George Westinghouse's 1896 installation of an 11 kV AC line from Niagara Falls to Buffalo, New York, covering 20 miles and marking the beginning of widespread high-voltage overhead networks. By the early 20th century, overhead lines formed the backbone of regional electrical grids, evolving into interconnected supergrids by mid-century to support growing energy demands and integrate power generation from distant sources. Key components of overhead lines include conductors, which transport the current; insulators, typically made of , , or to prevent unwanted electrical flow; and support structures such as wooden poles for lower voltages or steel lattice towers for high-voltage transmission. Additional elements encompass ground wires for protection, cross-arms to secure insulators, and guy wires or anchors for stability against and tension. These components are designed to optimize electrical performance while minimizing losses, with bundle conductors often used in extra-high-voltage lines to reduce and improve efficiency. Overhead lines offer significant advantages over underground cables, including substantially lower installation costs—often 3 to 5 times less—and simpler and repairs due to easy access. They also allow for quicker deployment and higher capacity in rural or open areas, though they are more vulnerable to weather-related disruptions like storms or tree falls. Despite these trade-offs, overhead systems remain the dominant choice for bulk worldwide, supporting grid reliability and the integration of sources over vast distances.

Fundamentals

Definition and applications

An overhead line, also known as an or overhead wire, consists of uninsulated or insulated electrical conductors suspended above the ground by support structures to transmit over long distances. These lines are primarily employed in and distribution systems, as well as , where they serve as the primary means of delivering electrical energy efficiently. In power grids, overhead lines facilitate the bulk transfer of from generation sites to load centers, while in rail systems, they supply power to locomotives and multiple units through contact devices like pantographs. The primary applications of overhead lines include high-voltage (AC) transmission for interconnecting power plants with urban and industrial consumers over hundreds of kilometers, often operating at voltages ranging from 115 kV to 765 kV. In railway electrification, they enable emission-free train operation by providing (DC) or , commonly in configurations such as systems that maintain consistent contact with moving vehicles. Compared to underground cables, overhead lines offer significant advantages in cost-effectiveness, with installation and maintenance expenses typically 5 to 10 times lower due to simpler construction and accessibility, though they require designs resilient to environmental factors. Basic principles of overhead lines emphasize high electrical conductivity to minimize energy losses, achieved through materials like aluminum or aluminum-steel composites (ACSR) that balance conductivity and mechanical strength for sagging under load. These systems operate predominantly in three-phase AC for transmission grids, with some high-voltage direct current (HVDC) applications for ultra-long distances to reduce losses, and are exposed to weather elements like , , and , necessitating robust insulation via air gaps and protective shielding. Typical span lengths between supports range from 30 to 500 meters, depending on terrain and voltage, allowing economical coverage while managing conductor tension and sag.

Historical development

The earliest precursors to overhead lines emerged in 18th-century experiments with , where scientists like Stephen Gray demonstrated conduction over distances using suspended silk threads and brass wires to transmit charges, laying the groundwork for elevated wire systems. In the , overhead telegraph lines served as direct forerunners to electrical , with the first commercial lines constructed in in 1837 and the in 1844, utilizing insulated copper wires strung on poles to carry low-voltage signals over long distances. The practical introduction of overhead lines for electric power began in the 1880s with applications in railways, notably by Werner von Siemens, who developed the world's first electric tramway in Berlin's Lichterfelde suburb in 1881, using rail conduction to supply direct current at 180 volts. This innovation marked the beginning of electric rail transport, paving the way for elevated contact systems in subsequent developments. By the 1890s, overhead lines expanded rapidly in urban tram networks, as seen in the United States where Frank J. Sprague's 1888 installation in Richmond, Virginia, spurred widespread adoption, enabling city growth through efficient electric transit. In , early 20th-century adoption accelerated, with constructing the world's first 110 kV overhead in 1912 between and to interconnect power plants. In the United States, the 1930s saw significant rural expansion via the (TVA), established in 1933, which built extensive overhead networks to electrify farms and villages, increasing rural access from under 10% to over 30% by 1940. Technological advancements included the transition from simple copper wires to aluminum conductor steel-reinforced (ACSR) composites in the early 1900s, driven by copper shortages during , which improved strength and reduced costs for longer spans. systems, featuring a suspended messenger wire supporting contact wires, gained adoption for electric rail in the , enhancing reliability for higher speeds on mainlines like those in by the 1930s. Post-World War II, a boom in high-voltage transmission occurred, exemplified by the ' first 345 kV lines commissioned in 1953 by to meet growing demand for long-distance power transfer. Early innovations like mechanical tensioning methods also emerged in the late to maintain wire sag under varying loads, ensuring operational stability.

Construction and components

Support structures

Support structures for overhead lines are essential frameworks designed to elevate and secure conductors above the ground, ensuring reliable or while withstanding environmental loads. For high-voltage transmission lines, lattice towers are commonly employed due to their strength and ability to support long spans and heavy conductor bundles. These structures consist of interconnected members forming a triangular or square base with cross-arms for insulator attachment, providing high rigidity against wind and mechanical stresses. In contrast, pole structures—such as wooden, , or poles—are typically used for lower-voltage distribution lines, railway catenaries, and urban applications where is limited. Wooden poles offer cost-effective installation in rural settings, while and poles provide greater durability in harsher conditions. The evolution of materials for these support structures reflects advancements in engineering and sustainability needs. In the , wooden poles dominated early telegraph and power lines, leveraging abundant natural resources for straightforward erection. By the early , steel lattice towers emerged for high-voltage applications, offering superior strength-to-weight ratios and resistance to decay. Today, corrosion-resistant remains prevalent, but composite materials—combining , polymers, and recycled fibers— are increasingly adopted for their , lighter weight, and reduced maintenance, particularly in coastal or fire-prone areas. Design factors for support structures prioritize structural integrity under dynamic loads, including , , and conductor tension. Wind loading calculations are critical, as gusts can induce significant lateral forces; standards require structures to withstand specified wind speeds, often using aerodynamic coefficients to model drag on towers and guys. Span optimization balances cost and reliability, with typical distances between supports ranging from 150 to 400 meters for high-voltage lines to minimize sagging while avoiding excessive foundation costs. Foundations vary by type: self-supporting lattice towers rely on deep footings for stability, whereas guyed poles or masts use anchorages and tensioned cables to distribute loads, reducing material use in soft soils. Installation of support structures involves methodical erection to ensure safety and alignment. Common methods for lattice towers include the build-up (piecemeal) approach, where sections are assembled incrementally using cranes and gin poles, or the section method, lifting pre-assembled modules into place. For poles, installation typically entails auguring holes, setting the base with , and raising via mobile cranes or helicopters in remote terrains. Structures are spaced according to terrain and load requirements, generally 200-500 meters apart for transmission to optimize . In seismically active regions, designs incorporate ductile materials and base isolators to absorb ground motions, with performance evaluated through dynamic analysis to prevent collapse under earthquakes up to magnitude 7 or higher.

Conductors and wire types

Overhead line conductors are primarily designed to balance electrical conductivity, mechanical strength, and environmental durability while minimizing losses and sagging under load. The most common material composition for high-voltage transmission lines is aluminum conductor steel-reinforced (ACSR), which consists of a central core for tensile strength surrounded by layers of aluminum strands for electrical conductivity. This hybrid design allows ACSR to withstand significant mechanical stresses from , , and tension while maintaining low electrical resistance. For applications requiring enhanced resistance, particularly in coastal or polluted environments, all-aluminum conductors (AAAC) are used, featuring aluminum alloys like 6201 that provide both conductivity and improved strength without a core. In early low-voltage distribution systems, solid conductors were prevalent due to their superior conductivity, though they have largely been replaced by aluminum-based options for cost and weight reasons. Conductors are typically stranded rather than to enhance flexibility and resistance to from and . Stranded designs consist of multiple aluminum or wires twisted around a central core, allowing the conductor to bend during installation and operation without cracking. For high-voltage lines above 230 kV, bundle conductors—such as twin, triple, or quad arrangements of sub-conductors spaced apart by spacers—are employed to increase the effective surface area, thereby reducing the corona effect, which causes energy loss and audible noise through of surrounding air. These bundles also improve thermal dissipation and compared to single conductors of equivalent cross-section. Key mechanical and electrical properties of overhead conductors include their sag-tension behavior and current-carrying capacity, or . Sag-tension curves describe how conductor elongation and vertical sag vary with temperature changes, ice accumulation, and wind loads; for instance, rising temperatures cause that increases sag unless tension is adjusted, while ice adds weight that amplifies tension and potential breakage. , determined by conductor diameter, material resistivity, and ambient conditions, represents the maximum continuous current a conductor can carry without exceeding its operating temperature limit, typically calculated using standards that account for solar heating and convective cooling. Aluminum's resistivity, around 2.83 × 10^{-8} Ω·m at 20°C, allows larger diameters to achieve higher ampacities, often up to 1,000 A or more for transmission lines, though this is limited by thermal sag risks. Modern advancements in conductor design include carbon-fiber core composites, such as aluminum conductor composite core (ACCC) types, which replace the steel core with a lightweight, high-strength carbon or composite. These enable operation at elevated temperatures up to 200°C without excessive sag, allowing up to double the of traditional ACSR on existing structures and reducing line losses in hot climates. The composite core's low coefficient minimizes sag under heat, supporting higher power transfer capacities while maintaining structural integrity.

Tensioning procedures

Tensioning procedures in overhead lines aim to balance mechanical stresses arising from the conductor's weight, wind loads, and temperature fluctuations, thereby maintaining sufficient ground clearance and optimizing . Proper tensioning prevents excessive sag that could compromise while avoiding undue stress that might exceed limits. Several methods are employed to achieve and sustain appropriate tension. Fixed-end terminations involve securing the conductor at anchors with a specific initial tension during installation, which is suitable for shorter spans where environmental variations have minimal impact. Automatic tensioning systems, often using suspended weights or springs, allow the conductor length to adjust dynamically, maintaining near-constant tension despite or contraction. For extended spans, hydraulic tensioning systems apply controlled force during stringing to achieve precise tension before final attachment. Calculations for sag and tension rely on approximations of the curve, such as the parabolic formula for low-sag conditions:
D=wL28TD = \frac{w L^2}{8 T}
where DD is the sag at mid-span, ww is the conductor weight per unit , LL is the span , and TT is the horizontal tension. These computations incorporate seasonal adjustments to model changes in tension due to temperature-induced elongation, pressure, and potential loading, ensuring year-round compliance with design parameters.
Key equipment includes turnbuckles for fine manual adjustments during installation, hydraulic tensioners for applying and verifying tension in the field, and monitoring tools such as strain gauges to continuously assess and regulate conductor stress. Tension requirements can vary based on conductor material properties, influencing the selection of these methods and equipment.

System configurations

Parallel and multiple overhead lines

Parallel and multiple overhead lines involve configurations where two or more transmission circuits share the same support structures to enhance power capacity without requiring additional towers. Twin or double-circuit lines, the most common setup, feature two independent three-phase circuits mounted on a single tower, while triple and quadruple circuits extend this to three or four circuits for even higher throughput in constrained areas. These arrangements optimize by consolidating , allowing transmission of greater power volumes over shared rights-of-way. Phase arrangements in multiple circuits are carefully designed to minimize , such as between adjacent lines. Optimal configurations often include transposition of phases—rotating their positions along the line—or specific geometries like horizontal, vertical, or delta layouts to balance electric and magnetic fields, reducing mutual impedance and improving system stability. For double-circuit lines, flat or triangular phase positioning helps mitigate these effects while accommodating shared supports. Spacing between phases and circuits is essential to prevent and ensure electrical clearance. Minimum phase-to-phase distances generally range from 7 to 10 meters for voltages around 230-500 kV, scaled according to insulation coordination standards to account for air and conditions. In ultra-high voltage lines exceeding 500 kV, bundle conductors—typically two to four sub-conductors per phase spaced 0.3-0.45 meters apart—are used to lower the , enabling reduced overall spacing while suppressing corona losses. Support structures for multiple circuits must provide robust separation to handle these requirements without compromising mechanical integrity. These configurations offer key advantages, including substantial cost savings in right-of-way acquisition and civil works, as shared towers and corridors minimize land needs and expenses in densely populated or environmentally sensitive grids. They enable capacity upgrades on existing alignments, supporting reliable power delivery to high-demand regions without expansive new builds. Challenges include heightened wind-induced aeolian vibrations, where low-speed winds create that amplifies oscillations across coupled conductors, potentially causing fatigue damage at clamps and requiring specialized dampers. complexity also increases due to the need for precise tension balancing, alignment, and against mutual faults in multi-circuit setups.

Overhead conductor rails

Overhead conductor rails, also known as rigid overhead contact systems (ROCS), consist of extruded aluminum profiles that serve as the primary conductor, often featuring a or carbon contact strip for interaction. These rails are mounted on or composite insulators to maintain electrical isolation and provide a constant height above the track, eliminating the need for tensioning mechanisms found in flexible wire systems. The design typically includes modular sections of 10-12 meters in length, connected via interlocking joints that accommodate without compromising conductivity. These systems are primarily applied in metro networks and where space constraints make traditional installations impractical due to sag requirements. For instance, the RER E line's EOLE extension incorporates 16 kilometers of rigid overhead conductor rails in a new linking Haussmann–Saint-Lazare and –La Folie stations, enabling efficient in a low-clearance environment. Similarly, the Metro's Violet Line and Ballabgarh sections utilize ROCS for underground segments, while the UK's (now ) employs it in sections like the Stanton Tunnel to support high-frequency urban services. Key advantages include minimized pantograph wear from the absence of wire sway and vibration, enhanced stability in confined spaces with installation heights as low as 4.5 meters, and the potential for higher speeds up to 80 km/h without dynamic . The tension-free configuration reduces maintenance needs by up to 50% compared to tensioned systems, as there is no risk of wire breakage or de-wirement, and it allows for simpler integration at stations with improved electrical clearances. Section breaks are adapted using insulated overlap sections to manage phase transitions without interrupting . Installation involves bracket mounting directly onto tunnel walls, ceilings, or lightweight support structures such as arms spaced 5-12 meters apart, secured via cast-in or mechanical anchors. Electrical continuity is ensured through flexible jumper leads at joints and transitions, with the facilitating rapid assembly—often completed in weeks for tunnel segments—while minimizing track possession times. Protective PVC sheathing on the aluminum profiles guards against , supporting operational voltages from 750 V DC to 25 kV AC.

Catenary systems

A catenary system in consists of a suspended arrangement of wires that forms a curve to deliver electrical power to trains via pantographs, enabling efficient contact at high speeds. This configuration supports the contact wire under tension while accommodating and dynamic loads from passing trains. Unlike rigid overhead conductor rails, catenary systems provide flexibility for open-track applications, maintaining consistent height and alignment over long spans. The primary components include the messenger wire, which bears the structural tension and is anchored between support structures; the contact wire, positioned below it for direct engagement; and droppers, which are vertical spacers connecting the messenger to the contact wire at regular intervals to ensure uniform spacing and load distribution. Auto-tensioning devices, such as or spring mechanisms, are integrated to automatically adjust wire tension in response to temperature variations, preventing excessive sag or stiffness that could disrupt contact. Stitch wires may also connect adjacent spans for smoother transitions, while overlaps at section ends allow continuous without interruption. The geometry of the follows the natural curve of a uniformly loaded hanging chain, described by the equation y=Twcosh(wxT)Twy = \frac{T}{w} \cosh\left(\frac{w x}{T}\right) - \frac{T}{w}, where TT is the horizontal tension, ww is the weight per unit length, and xx is the horizontal distance from the lowest point. This shape minimizes stress concentrations and ensures the contact wire remains nearly horizontal for stable interaction. In practice, spans are designed with specific sag and tension to limit vertical oscillations, with stitch and overlap arrangements providing seamless continuity across supports. Catenary systems are classified as simple or based on complexity and speed requirements. A simple uses a single wire supporting the contact wire directly via droppers, suitable for speeds up to approximately 200 km/h and cost-effective for standard . Compound catenaries incorporate an additional auxiliary wire between the messenger and contact layers, enhancing and reducing wave propagation for high-speed operations up to 350 km/h or more. Adaptations for DC systems (typically 1.5–3 kV) emphasize higher current capacity through heavier wires and closer spacing, while AC systems (25 kV) prioritize insulation and longer spans to minimize substation needs. Tensioning procedures are integrated to maintain optimal preload in both types. These systems are widely applied in high-speed rail networks, such as France's lines, which employ compound catenaries for reliable performance at 320 km/h, and Japan's , utilizing advanced simple catenaries capable of 360 km/h with minimal contact loss. Support designs include headspan configurations, where transverse wires span between opposite-side masts for multi-track setups, and portal structures, which use cross-track frames for stability in constrained areas. Both ensure adequate clearance and alignment for operation.

Operational elements

Section breaks and insulators

In overhead line systems for railway electrification, section breaks are essential divisions that allow for electrical isolation, , or without disrupting the entire network. Section breaks for isolation, often implemented using section insulators, enable specific segments of the overhead line to be de-energized for repairs or modifications while maintaining to adjacent areas. Neutral sections serve as dead zones between (AC) phases, preventing short circuits that could occur if a pantograph bridges two out-of-phase supplies; these are typically formed by inserting non-conductive elements into the contact wire. Dead sections, which are unpowered portions designated for ongoing repairs, function similarly to isolated breaks but remain permanently de-energized until work is complete, ensuring worker during . Insulators are critical components placed at support structures, such as masts and portals, to electrically isolate live conductors from grounded elements and prevent ground faults that could lead to system failures or hazards. Common types include insulators, valued for their durability and high ; insulators, which offer visibility for damage detection; and (composite) insulators, preferred for their lightweight design, resistance to contamination, and flexibility in harsh environments. These insulators are strategically positioned along the and contact wires to support tension while maintaining electrical separation, with designs often incorporating creepage distances to withstand and moisture. The functionality of section breaks relies on coordinated procedures for pantograph passage to ensure seamless operation. In neutral sections, trains coast through the dead zone with power disconnected automatically via onboard circuit breakers or relays, allowing the pantograph to slide under the insulated wire without arcing; this process is triggered by trackside beacons or train automation to open the main circuit before entry and restore it upon exit. Overlap gaps, where contact wires from adjacent sections extend parallel for a short distance (typically insulated in breaks), provide mechanical continuity for the pantograph, minimizing wear and ensuring uninterrupted current collection during transitions. Safety features are integrated to mitigate risks during passage through these breaks. Warning signs, such as neutral section indication boards placed approximately 1-2 km in advance, alert drivers to prepare for power interruption, while automatic control systems prevent unintended arcing. Circuit breakers at substations and on provide rapid isolation, and neutral sections often incorporate earthed segments to safely discharge any residual voltage. Typical for neutral sections range from 10-50 meters in short configurations for phase breaks, though longer spans up to 400 meters may be used depending on system design and length.

Crossings and transitions

Overhead lines at road and rail crossings require specialized configurations to ensure safe passage of vehicles and trains while maintaining electrical continuity and required clearances. Insulated overlaps are commonly employed at such crossings to electrically isolate sections of the contact wire, preventing unintended arcing or short circuits where tracks intersect. In these setups, separate insulated lengths of contact wire overlap between normal sections, connected via insulated droppers, allowing the to transition smoothly without loss of contact. crossovers, used in space-constrained rail junctions, feature independent overhead wiring with auto-tensioned crossover wires via spring devices to accommodate the intersecting and ensure reliable interaction. Height adjustments at level crossings are achieved through gradual ramps in the contact wire, enabling the overhead line to dip to minimum safe levels for road traffic while the adapts dynamically. Bridge integrations for overhead lines involve mounting special supports directly on the structure to minimize additional and handle load distribution. These supports, such as brackets or gantries attached to bridge girders, position the system to follow the bridge's alignment, with droppers and registration equipment adjusted for any structural deflections. Dynamic adaptations are critical here, as the pantograph's spring-loaded design compensates for unevenness caused by bridge vibrations or , maintaining consistent contact pressure up to 160 km/h on conventional lines and higher on high-speed routes. For movable bridges, such as swing or bascule spans, rotary overlaps with motorized conductor sections ensure seamless transitions when the bridge closes, allowing the pantograph to ride across both fixed and moving wire segments. Transitions in overhead lines occur at points of phase or voltage changes, often at national borders or substation boundaries, where neutral sections with insulated overlaps prevent phase mixing. These sections incorporate cut-in insulators in the and contact wire to separate electrical phases, with the passing through a short dead zone—typically 2-3 meters—while coasting. Gap designs at transitions prioritize maintaining contact through extended overlap spans or auxiliary wires, reducing uplift forces and arcing risks; for instance, in high-speed lines like the French TGV network, optimized overlap geometries limit contact force variations to under 20% during passage. Section breaks may be integrated at some transitions for electrical segmentation. International standards govern minimum clearances to ensure safety at crossings. In , the overhead line must provide at least 5.5 meters of clearance over roads to accommodate vehicles, with higher values for high-load routes, as specified in railway infrastructure guidelines aligned with EU Technical Specifications for (TSI). On high-speed lines, such as those exceeding 250 km/h, these clearances are enhanced to account for aerodynamic effects, with contact wire heights dynamically adjusted via ramps to comply while supporting speeds up to 320 km/h.

Height and clearance requirements

Overhead lines must maintain specified minimum heights to prevent contact with vehicles, structures, or personnel, ensuring safe operation and compliance with . For systems, the contact wire typically requires a nominal of 5.0 to 6.5 meters above the top of the rail to accommodate standard pantograph heights, which range from 1.8 to 3.0 meters depending on the train type. This provides a vertical clearance of at least 4.5 to 7.0 meters between the pantograph and ground level under normal conditions. In contrast, overhead power lines crossing roads or highways must adhere to vertical clearances of 5.5 to 6.7 meters (18 to 22 feet) above the road surface for voltages up to 50 kV, increasing to 7.0 to 12.0 meters for higher voltages or areas with oversized traffic to account for potential load swings. These standards vary by voltage class and location, with international guidelines like those from the (IEC) emphasizing location-specific adjustments for urban versus rural settings. Several environmental and mechanical factors influence the effective height of overhead lines, primarily through their impact on conductor sag and deflection. Under maximum load conditions, such as high temperatures or heavy current draw, conductors can sag by 1 to 3 meters over typical spans, reducing ground clearance and necessitating higher nominal installation heights. buildup, particularly in cold climates, adds significant weight; design standards often account for radial accretion of 50 to 100 mm, which can increase sag by 20 to 50% and requires reinforced tensioning to maintain clearances. deflection is limited to 0.5 to 1.5 meters horizontally and vertically under gusts up to 40 m/s to avoid excessive sway that could compromise adjacent clearances. Tensioning procedures play a critical role here, as proper stringing minimizes sag while allowing for . Vertical clearance is calculated as the difference between the nominal installation and the maximum anticipated sag, ensuring the lowest point of the conductor remains above required thresholds even under worst-case loading. The formula for basic clearance is Clearance=HnSmax\text{Clearance} = H_n - S_{\max}, where HnH_n is the nominal at supports and SmaxS_{\max} is the maximum sag, determined from equations incorporating span length, conductor weight, tension, and environmental loads. Compliance testing involves on-site measurements using sag scopes or surveys during peak load and weather simulations to verify that clearances exceed minimums by a margin, typically 0.3 to 0.5 meters. In areas with height constraints, such as urban environments or bridges, variable height systems allow contact wires to adjust between 4.5 and 7.0 meters using auto-tensioning or profile-specific designs, preventing wear on pantographs while maintaining . For freight railways accommodating double-stack trains, overhead lines must be elevated to at least 8.0 meters to provide clearance over loads up to 6.1 meters high, influencing route planning and structure modifications.

Regional and specialized variations

Systems in the United States

In the , overhead line systems for railways primarily utilize configurations to deliver , with Amtrak's and other electrified routes employing a 25 kV AC standard at 60 Hz for efficient long-distance operation. This voltage level supports high-speed passenger services by minimizing transmission losses, and the system often incorporates arrangements to maintain consistent power delivery over extended distances. Hybrid setups combining overhead with systems are used in transitional zones, such as on Metro-North's , where handles higher-speed sections while third rail serves urban tunnels to avoid clearance issues. Support structures for railway in the vary by terrain and track configuration, with single poles common in single- or double-track rural areas for , while gantries or headspan arrangements are preferred in multi-track urban corridors to span wider alignments and reduce visual impact. For instance, Amtrak's on the predominantly uses pole-mounted supports in open sections, transitioning to gantry systems near stations and complex junctions. These designs ensure reliable contact with pantographs while adhering to safety clearances. For power transmission, overhead lines in the extensively employ wood poles, particularly in rural areas where their availability, ease of installation, and natural insulating properties make them economical for distribution and sub-transmission up to 69 kV. The USDA endorses wood poles for such applications, citing their durability under typical loading conditions when properly treated against decay and insects. In high-voltage scenarios exceeding 500 kV, bundle conductors—typically consisting of multiple sub-conductors per phase—are standard to reduce and losses; for example, the , a ±500 kV HVDC line spanning from to , utilizes bundled configurations on its lattice towers to handle up to 3,100 MW of power transfer from hydroelectric sources in the Northwest. Regulations governing overhead lines emphasize safety and reliability, with the (NESC), published by the IEEE, setting minimum clearances for overhead conductors—such as 18.5 feet over roads and 24 feet over railroad tracks (for supply conductors up to 35 kV, per NESC Table 232-1)—to prevent accidental contact and ensure worker protection. For railway applications, the (FRA) enforces safety standards under 49 CFR Part 229, which includes requirements for locomotive interaction with overhead lines and personnel protections against hazards, such as prohibiting work on energized without grounding. These rules integrate with broader FRA guidelines on for electrification projects to mitigate and system failure risks. Unique to US implementations, overhead lines often integrate with legacy diesel infrastructure through dual-mode locomotives or phased electrification, allowing seamless transitions on mixed corridors like those shared with freight operators. Recent upgrades for high-speed rail, such as California's High-Speed Rail project, involve designing 25 kV AC catenary compatible with existing Caltrain electrification, including reinforced supports and feeder systems to accommodate future 220 mph operations while minimizing disruptions to commuter services. This approach addresses historical under-electrification by prioritizing interoperability with aging networks.

Systems in Australia, Greece, and Italy

In , overhead line systems for railway electrification primarily operate at 25 kV AC, a standard adopted for mainline and high-speed routes to ensure efficient power delivery over long distances. Headspan wires are commonly used to support systems on broad-gauge tracks, such as those in and Victoria, where they span between masts to accommodate multiple tracks and varying alignments without excessive structural complexity. In rural areas prone to bushfires, designs incorporate fire-resistant features, including poles instead of timber, insulated conductors, and elevated clearances to reduce ignition risks from ground fires, with regular inspections mandated under national safety protocols. Greece's overhead line configurations, managed by the (OSE), also favor 25 kV AC electrification for modernized lines, including the Athens-Thessaloniki corridor, to support higher speeds and . Adaptations to the country's mountainous terrain involve shorter spans—typically 40-50 meters compared to 60 meters on flat ground—to manage steep gradients, wind loads, and uneven topography, reducing sag and mechanical stress on supports. Seismic reinforcements, such as flexible foundations and damped systems, are integrated into designs to comply with Eurocode 8 standards, given Greece's high risk, ensuring resilience during events like the 2021 Crete tremors. In , predominantly uses 3 kV DC for urban and legacy networks, enabling compact, high-density installations in densely populated areas like and , where space constraints demand low-profile wires and minimal visual impact. These systems integrate seamlessly with viaducts on high-speed lines, such as the Turin-Milan route, using rigid or semi-rigid catenaries to maintain stability under aerodynamic forces and . Post-2000 EU harmonization efforts, driven by Technical Specifications for (TSI), have standardized components like contact wire profiles and auto-tensioning mechanisms, facilitating upgrades from legacy DC to hybrid AC/DC sections for cross-border compatibility. Greece and Italy share Mediterranean climate challenges affecting overhead lines, including high urban pollution that accelerates insulator degradation through conductive dust accumulation, necessitating composite materials for better hydrophobicity and longevity. Wet events, increasingly frequent due to variability, cause conductor icing and added loads up to 10 kg/m, prompting monitoring systems and de-icing protocols in both countries. Cross-border rail initiatives, such as the Greece-Italy links evolving toward direct EU-standard alignments, emphasize unified TSI for to ease transitions at interfaces like Adriatic ports. In Italy, designs on viaducts briefly reference level crossings with insulated overlaps for safe DC/AC switches.

Electrification support structures

Electrification support structures in railway systems are specialized engineering components designed to hold the overhead contact system (OCS) wires, ensuring reliable power delivery to trains while withstanding environmental and operational loads. These structures, often referred to as masts, portals, or brackets, are distinct from general utility poles and are engineered for the dynamic conditions of rail corridors, including vibration from passing trains and varying track geometries. They primarily support catenary systems by anchoring and tensioning the contact and messenger wires. The primary types of electrification support structures include portal (cross-span), headspan (lateral), and brackets. Portal structures consist of a spanning across multiple tracks between two masts, providing balanced support for adjacent tracks and minimizing the number of needed in multi-track sections. Headspan structures extend laterally from a mast over one or more tracks using span wires, offering flexibility for urban or constrained alignments but requiring periodic tension adjustments. Cantilever brackets, protruding from a single mast, are commonly used for single tracks or curved sections where portals are impractical, as they allow for adjustable registration of wires to maintain contact with the during train passage. Design considerations for these structures emphasize load distribution, particularly in multi-track configurations, where portals and headspans evenly share the weight of wires, , and forces across tracks to prevent uneven stress on foundations. Stability against aerodynamic effects, such as galloping induced by on iced wires, is assessed through testing to determine coefficients for drag, lift, and , ensuring the structures resist oscillations that could disrupt . Materials for electrification support structures typically include galvanized for its high tensile strength and resistance in outdoor environments, often formed into lattice or tubular masts to reduce weight while maintaining rigidity. Aluminum alloys are employed in lighter components, such as brackets, to minimize foundation requirements and ease installation, though they necessitate careful to handle lower yield strengths. For , anti-climb features—such as barbed guards or enclosures—are integrated into masts where voltages exceed 650 , preventing unauthorized access and reducing safety risks. Recent advancements focus on modular prefabricated units, which consist of pre-assembled or composite sections that enable rapid on-site installation, reducing construction time by up to 30% compared to traditional welded assemblies. These units often incorporate integration with signaling masts, combining OCS supports with signal mounting points in a single to optimize and lower maintenance costs in dense rail corridors.

Challenges and maintenance

Common operational problems

Overhead lines in railway systems are susceptible to wire breaks, which can occur due to material from repeated mechanical stresses during contact or from events like storms and high winds that cause excessive tension or whipping of the wires. in contact wires often results from cyclic loading as s pass, leading to and eventual fracture, particularly in high-speed or high-traffic corridors where over 220,000 interactions per year exacerbate the risk. Storms contribute by generating gusts that misalign wires or cause structural overload, as seen in hurricane-induced failures of overhead line equipment. Another critical failure mode is arcing, where intermittent loss of contact produces electrical arcs that and pit the contact wire, accelerating crack and potentially leading to burnout or complete wire severance. These failures stem from various causes, including and accumulation, which adds weight and alters wire , leading to overloading, increased sag, and heightened arcing risk during pantograph passage. Bird strikes or perching can damage insulators or cause short circuits by bridging conductive parts, while , such as throwing objects at lines or cutting components, directly severs or weakens wires, as evidenced by incidents damaging over 200 meters of cabling. Overload from demand spikes, though less common in dedicated railway systems, can occur during peak operations or faults, causing and sagging that strains connections. In overhead power transmission lines, common issues include conductor sagging due to thermal expansion from high temperatures or solar heating, which can reduce clearances and increase fault risks if not managed through proper tensioning. Insulator flashovers often result from contamination by , salt, or industrial dust, leading to partial discharges and eventual failure under wet conditions. Vegetation encroachment or tree contact causes the majority of momentary outages, while interactions, such as squirrels or birds, can trigger faults by bridging phases. Detection of these issues relies on visual inspections, where trained personnel walk or ride along tracks to identify wear, breaks, or anomalies like arcing marks on wires. Drone monitoring has emerged as an efficient alternative, using UAVs equipped with cameras to survey hard-to-reach sections for damage, ice buildup, or bird activity without disrupting service. Fault locators, including automated systems like pantograph-mounted sensors or along lines, pinpoint breaks or arcs in real-time by detecting vibrations, electrical faults, or events. Immediate responses prioritize safety and restoration, beginning with isolation of the affected section to de-energize the line and prevent further arcing or hazards. Repair crews are then dispatched to splice broken wires or replace damaged components, often using section breaks to limit the outage scope during fixes. through parallel feeders or alternative power routes helps maintain service on unaffected tracks, allowing rerouting of trains while repairs proceed. Overhead power lines are susceptible to corrosion accelerated by environmental pollutants such as , , harmful gases, salt , and humid or hot weather conditions, which can lead to chemical, electrochemical, and biological degradation of conductors. In marine environments, exposure to saline air further exacerbates this , potentially causing line failures and power disruptions. Wildfire risks are heightened by overhead lines, particularly through sparks or faults that ignite dry vegetation; for instance, Pacific Gas & Electric's transmission lines were determined to have caused the 2018 Camp Fire in , the state's deadliest wildfire, resulting in 85 deaths and widespread destruction. Bird collisions with overhead lines represent a significant ecological concern, especially for large migratory , but can be mitigated by installing high-visibility markers on groundwires and conductors, which studies have shown reduce collision rates by up to 50-90% in tested areas. Height-related challenges arise from urban encroachment, where growing development and growth encroach on rights-of-way, reducing required vertical clearances and increasing fault risks from contact or proximity. Near airports, overhead lines pose hazards due to potential collisions during low-altitude flights, governed by (FAA) regulations that mandate minimum clearances and obstruction marking for lines within approach zones. To address these issues, covered conductors with insulating layers are deployed to minimize flashovers from or animals, reducing outage rates by 0.19-0.29 per kilometer per year in high-risk areas. In flood-prone zones, elevated pole designs using taller structures or reinforced foundations keep lines above expected water levels, enhancing resilience against submersion and erosion. For protection against electromagnetic pulses (EMP) and , overhead ground wires and surge arresters are installed to shield lines from induced overvoltages, preventing widespread outages. Regulatory frameworks require environmental impact assessments (EIAs) for new overhead line projects, evaluating effects on , landscapes, and communities to ensure compliance and minimize harm. Life-cycle assessments indicate that overhead lines often have a lower than underground alternatives in rural areas due to reduced use and excavation, though results vary in urban environments.

References

  1. https://www.[researchgate](/page/ResearchGate).net/publication/349673232_Electric_and_Magnetic_Field_Minimization_using_Optimal_Phase_Arrangement_Techniques_for_MEA_Overhead_Power_Transmission_Lines
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