Tracks in the Sky
Flexicon has supplied over 40km of flexible conduit to protect both internal and external cabling on 361 high altitude carriages for the world’s highest railway in Tibet.
Rising to an altitude of 5000 metres above sea level, the conduit and fittings have to withstand temperatures down to -50ºC. It also needs to protect the cabling from water, snow, grit and dirt, sandstorms, high impact damage from stones thrown up by the wheels and ball lighting.
The company had to develop and supply bespoke conduit and fittings at very short notice since locally sourced products could not meet the requirements from such harsh conditions. Says Jeremy Curtis, export manager for Flexicon: “Such was the urgency for a conduit solution that could cope with this harsh environment that we had to air freight over 7 tonnes of conduit and fittings to the train builder in the Far East. Train production was in danger of being held up until we developed this bespoke solution.”
The flexible conduit has a metal interior to provide strength and a special low temperature plastic outer covering. The system also required a high IP rating since it is often immersed in freezing water with driving rain and the build up of snow. Special metal compression fittings provide both a high mechanical strength
and water and dust ingress protection. The high altitude carriages have enriched oxygen and UV protection systems since the air has up to 40% less oxygen than at sea level. The railway has several oxygen
factories along its length of rail to replenish this internal environment for the carriages. In addition, the water in the toilets must be heated to avoid freezing.
Of these carriages 308 are standard cars with 53 special tourist cars. The tourist carriages have sleeping rooms with showers plus entertainment and dining. Says Jeremy Curtis, export manager for Flexicon: “Clearly it is vital to protect the cabling for such high altitude carriages. Without power or lighting passengers would become very uncomfortable. “It is rare to come across quite such harsh conditions as those experienced in the Himalayas. This project clearly demonstrates our ability to turn around product design and test programmes at short notice.”
Flexicon’s manufacturing facility in Birmingham can manufacture special products in steel, stainless steel, brass and high specification polymers to protect cabling from extremes of temperature, ingress protection and mechanical forces. Using CAD-CAM technology and in house testing facilities allows the company
to retain full control of product development, even for the most demanding of applications.
The 1,100km Qinghai-Tibet railway has been built through some of the most difficult terrain on earth, and rises at one point to 5,072m (16,600ft) above sea level. Because of the region's extreme temperatures and unstable permafrost, long sections of track have been elevated to improve stability.
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