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November 2009
By Jeff Stagl, managing editor
Whether they're obtaining a power source for grade crossing gates, wayside signals or other C&S devices, railroads want reliable systems to ensure vital equipment continues to function at all times.
They're demanding battery, solar and back-up power systems that provide a high output and hold a charge a long time, but are affordable, easy to install and require minor maintenance.
"We also are seeing more requests for remote monitoring packages to provide immediate online system health information and performance data," said officials at solar-power system supplier Arthur N. Ulrich Co. in an email.
In addition, railroads want power systems that are tailored for every wayside application.
"We try to offer an array of solutions for any remote site need," Arthur N. Ulrich officials said. "In addition to solar-power systems, we offer wind generator systems, methanol fuel cells, thermoelectric generators, extended-run generators and packaged hybrid power systems combining any of these technologies."
Last month, Progressive Railroading contacted suppliers seeking details on the ways they're revamping and enhancing product lines to address railroads' power system needs. Four responded, and their emailed replies follow.
AMERESCO Solar provides engineered solar power supplies to the railroad, oil and gas, and telecommunications/telemetry markets. The systems include solar modules, mounting structures/poles, charge regulators/system controllers, batteries and enclosures, wiring harnesses, and complete documentation packages to ensure safe and reliable installations, company officials said in an email.
AMERESCO Solar's industrial sales support technicians now have served the rail industry for 18 years.
"Today's railroad customers expect quick delivery of quality-designed solar power supplies and the safest-possible installation methods," AMERESCO Solar officials said.
So, the company is "constantly reviewing and implementing all of the latest technologies" to ensure reliability, they said. For example, AMERESCO Solar is using ReliOn Inc. fuel cells in back-up or solar power supply designs to provide an "extremely reliable back-up to our power systems," company officials said.
AMERESCO Solar's engineering group also focuses on redundant power sources to ensure loads are maintained throughout the year and during the worst weather conditions. In addition, the company is incorporating the latest wind machine technologies to supplement its solar system.
"Shawnee DC Generators are also part of our strategy to provide back-up to our solar power supplies during extreme weather situations," AMERESCO Solar officials said.
In summer 2008, Exide Technologies-Industrial Power introduced the fifth-generation ABSOLYTE¨ battery, the ABSOLYTE¨ GP. The development of the ABSOLYTE¨ GP was the result of global "green" initiatives and customer expectations, according to officials at Exide Technologies-Industrial Power and Transportation Products Sales Co. (TPSC).
Since its introduction in the late 1970s by GNB Technologies, the ABSOLYTE® led the way in terms of product development with advanced features, such as improved post and cover seals, and increased product performance and advanced manufacturing processes, such as improved leak detection, Exide and TPSC officials said in an email. The ABSOLYTE® GP is Exide's first step toward an environmentally friendly lead-acid battery.
"Our objective was to reduce hazardous materials in the battery, utilize more recycled materials and improve the ease of recycling," Exide and TPSC officials said.
Exide achieved its first goal by utilizing its patented 2025 alloy. Prior to being used in the ABSOLYTE® GP, the alloy was used overseas for eight years and was installed in more than 150,000 cells. The 2025 alloy is free of cadmium yet still maintains the technical characteristics of the ABSOLYTE® IIP, such as a reduced maintenance design, high cycling and a 20-year design life in float applications. The 2025 alloy also reduces energy consumption with lower float currents.
Recycling of the ABSOLYTE® is much easier with the GP technology, Exide and TPSC officials said. The ABSOLYTE® GP now can be recycled at any lead acid recycler throughout the world. In addition to the alloy change, the ABSOLYTE® GP increased its utilization of recyclable material by switching to a recycled resin for its non-flame retardant jars and covers. The change is distinguishable from previous ABSOLYTE® models with new black covers.
In March, TESSCO Technologies Inc. and Kyocera Solar Inc. reached an agreement under which TESSCO became an official distribution partner for a new line of standard solar power systems targeted at the rail industry.
Through their strategic partnership, TESSCO and Kyocera Solar have redesigned a series of pre-engineered solar power systems designed to "make railroad solar simple," TESSCO officials said in an email.
The quick-to-deploy systems are properly configured to ensure optimal system integrity assurance for 24/7 up time and leverage existing signaling hut structures, according to TESSCO. Optimized for Ni-Cad battery technology, the power panel mounts on the wall of existing hut structures and features low-voltage alarming, DIN rail-mounted breakers, terminal blocks, and grounding that's completely pre-wired and ready to install.
In addition TESSCO and Kyocera Solar now offer an articulating mast for mounting solar panels to ease installation and maintenance at ground level.
TESSCO, which offers power and wireless communications equipment for signaling sites, long has been a "total source" provider of wireless communications products to the rail industry, according to the company. Since the agreement was forged with Kyocera Solar, TESSCO has been positioned to provide current railroad customers — including BNSF Railway Co., CN, CSX Transportation, Norfolk Southern Railway and Union Pacific Railroad — complete turn-key communications and signaling solutions, TESSCO officials said.
Most of the changes and enhancements to Arthur N. Ulrich's power systems are driven by customer feedback, ensuring products are tailored to their needs, according to the company, which manufactures and markets its power systems through subsidiary RedHawk Energy Systems.
For example, Arthur N. Ulrich developed the RP Series Retractable Mast to provide a safer way for service personnel to mount and maintain wayside solar-power systems. Solar module arrays, wind generators and communication antennas can be assembled and mounted to the pole structure from ground level. In areas exposed to hurricanes, the solar arrays can be lowered to reduce the potential for damage from high winds, company officials said in an email.
Arthur N. Ulrich also is attempting to increase its use of Maximum Power Point Tracking because new solar controller designs have evolved in recent years.
"These designs allow the solar array to be configured at voltages higher than the system battery," company officials said. "This enables more effective use of all the solar energy reaching the modules, while also reducing voltage and power losses in the connections between the arrays and the controller."
Recently, Arthur N. Ulrich also added a foldable/hinged design to its PV subarray systems, which feature a foldable panel rail configuration that facilitates easier handling and installation of the subarray, and provide a smaller shipping footprint. In addition, the company recently finished developing a small fuel-cell system for extended backup power requirements for wayside applications in conjunction with a major fuel-cell manufacturer. The "eco-friendly" system can be used in lieu of small generator sets or larger capacity battery systems for locations needing or desiring extended backup times, Arthur N. Ulrich officials said.
"The fuel cell can operate for days, weeks and even months during extended power outages without any maintenance, as compared to small engine generator sets that typically require maintenance every 25 to 48 hours of ongoing operation," they said.
The company currently provides power systems to virtually all major U.S. railroads, but is expanding its markets to the commercial and industrial sectors with designs that "originally were pioneered" in the rail industry, Arthur N. Ulrich officials said.
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