Chapter V: Part II: Overhead Construction (1)

=Trolley Wire.= The trolley wire is suspended from the span wires or brackets in such a way as to permit of an uninterrupted passage of an upward pressing trolley wheel underneath it. The trolley wire itself may be either round, grooved, or figure 8 in section. Where a round wire is used, No. 00 B. & S. gauge is the most common size. Figure 8 wire, so called from its section, which is shown in Fig. 64, is designed to present a smooth under surface to the trolley wheel, which will not be interrupted by the clamps or ears used to support it. Clamps are fastened to the upper part of the figure 8. The grooved wire is rolled with grooves into which the supporting clamps fasten. This wire also presents a smooth under surface to the trolley wheel.

=Trolley-Wire Clamps and Ears.= The trolley is supported either by clamps or by soldered ears. One type of clamp grasps the wire by virtue of screw pressure. A soldered ear is shown at E, Fig. 65. This ear has small projections at each end, which are bent around the wire to assist the solder in holding the wire to the ear. Another form of ear, used to some extent, holds the wire by virtue of having the edges of the groove offset or riveted around the wire.

The ear or clamp screws to a bolt which is insulated from the metal ear through which passes the span wire. A cross-section through a common type of trolley-wire hanger is shown in Fig. 66. Here there is an outer shell of metal, which is adapted to hook to the span wire. In this shell is an insulating bolt, that is, a bolt surrounded with some form of insulating material which is very strong mechanically and not likely to be cracked by the hammering action of the passing trolley wheel. Most of the insulating compounds used in making trolley-wire insulators are trade secrets. Another kind of insulator called the “cap and cone” type is shown at C, Fig. 65. In these insulators, the metal part B which fastens to the span wire does not completely surround the insulation C. Wood has sometimes been used for the insulation of trolley-wire hangers.

=Span Wires.= In city streets, the trolley wire is commonly suspended from span wires stretched between poles located on both sides of the street. These span wires are of ¼-inch or ⅜-inch galvanized stranded steel cable. In order to add to the insulation between the trolley wire and the poles at the side of the street, what is called a _strain insulator_ is placed in the span wire. This is an insulator adapted to withstand the great tension put upon it by the span wire. One of these is shown in Fig. 67. Means are usually provided for tightening the span wires as they stretch and as the poles give under the strain. The insulator in Fig. 67 has a screw eye for that purpose.

=Brackets.= In the bracket type of overhead construction, a trolley wire is fastened to brackets placed on poles near the track. This construction is used on suburban and interurban lines where the presence of poles near the track is not objectionable. It has been found that a rigid connection of the trolley wire to a bracket is likely to result in the breaking of the trolley-wire insulators. For this reason the brackets now commonly used provide for a flexible suspension of the trolley-wire hanger from the bracket. A bracket employing such flexible construction, made by the Ohio Brass Company, is illustrated in Fig. 68.

An example of standard straight-line bracket construction is shown in Fig. 69.

=Feeders.= Where additional conductivity is needed beyond that furnished by the trolley wire itself, feeders are run on insulators along the poles at the side of the track. Such feeders are connected to the trolley wire at regular intervals. Where span-wire construction is used, the feed wire may be substituted for the span wire at the pole where the connection between feed wire and trolley wire is made. In such a case, of course, a trolley-wire hanger is used which has no insulator, so that the current feeds directly through the hanger. Another method is to run the feed connection parallel with a span wire and a short distance from it.

=Section Insulators.= Section insulators are usually placed in the trolley wire at regular intervals. Such a section insulator is shown in Fig. 70. Its purpose is to insulate one section of trolley wire from the next, so that in case the trolley wire of one section breaks, or is grounded in any other manner, that section can be disconnected and the other sections on either side kept in operation. In large city street-railway systems, each section of trolley wire usually has its own feeder or feeders, independent of the other sections. This feeder is supplied through an automatic circuit breaker at the power house. In case a certain section of trolley wire is grounded the large current that immediately flows will open the circuit breaker supplying that section; but, unless the ground contact is of an extremely low resistance, it will not affect the operation of the other feeders. Should it be of sufficiently low resistance to cause all the generator circuit breakers to open, it would, of course, interrupt the entire service temporarily; but usually the circuit breaker on any individual feeder will cut that feeder out before all the circuit breakers will open.

=High-Tension Lines.= Where high-tension alternating-current wires are run, as in the case where the road is of such length as to require the establishment of several substations, these high-tension circuits are usually carried some distance above the 500-volt direct-current trolley and feeders. An example of interurban overhead construction is shown in Fig. 69. Here the high-tension wires are carried on large porcelain insulators of a size necessary for 26,000 volts. These insulators are placed 35 inches apart. High-tension wires are kept so far apart because of the danger that arcs will in some way be started between the lines, as the high-tension current will maintain an extremely long arc. The blowing of green twigs across the lines, or birds of sufficient size flying into the lines, is likely to establish arcs which will temporarily short-circuit the line. The greater the distance apart of the wires, the less danger that such things will occur.

Both glass and porcelain insulators are successfully used on lines of very high tension. Glass is the cheaper and porcelain has the greater mechanical strength.

High-tension wires are usually of hard-drawn copper or of aluminum made up in the form of a cable of several strands. Aluminum is lighter for a given conductivity than copper; and, at the market price controlling at the present time, is cheaper. It is, however, more subject to unevenness of composition, which leaves weak spots at certain points in the wire; and that is the reason why aluminum is now always used in the form of a stranded cable rather than as a single conductor. Aluminum, being considerably softer than copper and melting at a lower temperature, is more likely to be worn through as a result of abrasions or to be melted off by a temporary arc. These slight objections are balanced against its smaller first cost as compared with the cost of copper.

The calculation of the proper amount of feed wire for a given section of road is somewhat similar to the calculation of electric light and power wiring as already outlined. It is first necessary to estimate approximately the amount of current required at different portions of the line. The amount of drop to be allowed between the power house and cars must be decided arbitrarily by the engineer. A drop of 10 per cent is probably the one most commonly figured upon in designing feeding systems. The resistance in ohms of the copper feeders required to conduct a given current with a given loss in volts, can be calculated by dividing the volts lost by the current, according to Ohm’s law. By the aid of a table which gives the conductivity of various sizes of wire according to the methods outlined in connection with “Electric Wiring,” the proper number and size of the feeders can be determined. The most difficult thing to determine is the load that will be placed upon any section of the line. Of course, there will be times when cars are bunched together owing to blockades. It is out of the question to provide enough feeder copper to keep the loss in voltage within reasonable limits at such times. The ordinary load upon any feeder is used as the basis of calculation in most cases. The amount of current required per car depends on the weight of the car and the character of the service. This will be taken up later under the head of “Operation.”

THIRD RAIL.

=Location.= The third-rail system of conducting current to electric cars, as most commonly employed in the United States, follows the example set by the Metropolitan West Side Elevated Railway of Chicago. All the elevated roads in the United States are now operated by means of third rails located at one side of the track. The third rail is an ordinary T-rail and is located with the center of its head 20 inches outside of the gauge line of the nearest track rail, and 6³⁄₁₆ inches above the top of the track rail. On a few interurban roads this distance has been increased in order to accommodate certain steam railroad rolling stock which must at times be operated over the line.

=Insulators.= The third rail is supported every fifth tie on an insulator. These insulators on first construction were made of wooden blocks boiled in paraffine, but at the present time more substantial forms of insulation are being used.

One form of third-rail insulator, known as the “Gonzenbach,” has a base of cast iron resting on the tie. Over this is placed a cap of insulating material similar to that used in strain and trolley-wire insulators. Over this insulating material is another cast-iron cap upon which the third rail rests. The weight of the third rail holds it in position, and there is no clamping together of the various parts of the insulator.

Another form of third-rail insulator is made of what is called “reconstructed granite,” and another of vitrified clay. Fig. 71 shows one of the latter.

=Switches.= Where the third rail is used, a contact shoe is placed on each side of both trucks of the motor car. At switches it is necessary to omit the third rail for a short distance on one side of the track, and place a short section of third rail on the other side of the track so that the current supply to the car will be uninterrupted.

=At Highway Crossings.= Where the third-rail system is employed on interurban surface lines, it is necessary to omit a section of it at every highway crossing. If the crossing is too wide to be bridged across by a car, the car must have sufficient momentum to drift over such crossings when it comes to them. To connect across the break in the third rail at such points, an underground cable is generally used. This cable must be thoroughly protected against leakage of moisture into the insulation where it comes to the surface for connection to the third rail.

Another form of third rail, laid several years ago on some of the lines of the New York, New Haven & Hartford Railroad, was of an inverted V-shape, and was laid midway between the track rails with its top 1 inch above them and its bottom only 1⅝ inches above the ties. It was supported on wooden blocks. This location of the third rail has never been popular, because of the poor insulation with the rail located so close to the ties between the rails.

=Conductivity.= The conductivity of a steel rail varies considerably. A rail of the ordinary composition used on steam railroads is too high in carbon to give the best conductivity. Such a rail has about one-tenth the conductivity of the same cross-section of copper. Steel can easily be obtained, however, which will have one-seventh the conductivity of copper, and the additional cost of obtaining such special steel is quite low, so that the majority of roads installing the third-rail system have seen fit to pay the extra cost and thereby secure a softer rail than that usually employed in track rails.

=Cost.= The cost of the third-rail system is less than an overhead trolley system, provided enough copper is placed in the trolley feeders to make the conductivity of the trolley system equal to that of the third-rail system. It is very seldom, however, that a trolley system is so constructed on an interurban road; and hence the trolley system, as usually constructed, is cheaper than the third-rail system, because it is not of equal conductivity to a third-rail system.

=Advantages in Operation.= Where very heavy cars or trains are to be operated, the third-rail system is decidedly an advantage, for two reasons. In the first place, it affords the cheaper method of conducting a given heavy volume of current; and in the second place, the contact shoes that conduct the current from the third rail to the moving car or train are built to carry a much larger volume of current than the trolley wheel, which has only a small area of contact on the trolley wire. Ordinarily there are two of these contact shoes in multiple for every motor car.

Another advantage of the third rail over the trolley is that the trolley may leave the wire at high speeds or in passing switches. On well-constructed roads, where the trolley wire is kept in good alignment and the track is smooth, there is little trouble from this source; but it is undoubtedly a convenience to be able to operate cars or trains without giving any attention to a trolley pole.

CONDUIT SYSTEMS.

The underground conduit system, in which the conductors conveying the current to the cars are located in a conduit under the tracks, is in use in two cities of the United States—New York City and Washington, D. C. The cost of this system, and the danger of interruption of the service where the drainage is not excellent, have prevented its more extensive adoption.

The New York type of conduit is a good example of this construction. The conductors consist of T-bars (CC) of steel supported from porcelain cup insulators located 15 feet apart in the conduit. A cross-section of the conduit is shown in Fig. 72. At each insulator a handhole is provided (Fig. 73), so that access may be had to the insulator from the street surface. Manholes are provided at intervals of about 150 feet, so that the dirt which collects in the conduit can be scraped into these manholes and removed at intervals. The manholes also serve as points of drainage to the sewer system.

=Contact Plow.= Current is conducted to the car through a pair of contact shoes commonly called a _plow_ (Fig. 74). This plow has the two shoes insulated from each other, and from the frame of the plow. They are provided with flat springs that hold the shoes against the conducting bars in the conduit. The shank of the plow is thin enough (⁹⁄₁₆ inch) to enter the slot of the conduit. The conductors pass up through the middle. These plows can, of course, be removed only when the car is over an open pit.

=Cost.= A conduit system of this kind is very expensive to build because of the fact that a very deep excavation must be made in the street to accommodate the conduit. The track rails, slot rails, and sheet-steel conduit lining are held in alignment by cast-iron yokes placed 5 feet apart. The entire space around and underneath these yokes is filled with concrete in order to give rigidity and a permanent track. Three expensive items, therefore, enter into the construction of a conduit road—namely, the deep excavation, which may call for the changing of other underground pipes or conduits in the street; the large amount of iron and steel needed for the yokes and slot rails; and the large amount of concrete needed.

On American conduit roads the slot and conduit are placed under the middle of the track. Some of these roads are simply reconstructed cable-conduit roads in which the old cable conduit has been used for electrical conductors. In the conduit road at Buda-Pest, Hungary, the slot is placed alongside one of the track rails.

=Current Leakage.= The leakage on an underground conduit road is considerable, because the insulators are necessarily located in a damp, dirty place, which causes leakage over the surface of the insulators. This leakage, however, is not prohibitive so long as the conductor rails are not under water. If on account of poor drainage the conductor rails become submerged, the leakage becomes so great that it is impossible to operate the road.

It will be noticed that the conduit system as illustrated here employs two conductor rails—one for the positive side of the circuit and the other for the negative. The track rails, therefore, are not used as conductors, and one side of the circuit is not grounded as in the ordinary trolley system, although the leakage to ground may be considerable from one or both conductor rails.

TRACK CONSTRUCTION.

=Girder Rail.= A great variety of track rails are used in electric railways. The most common at one time was the girder, a typical section of which, with joint, is illustrated in Fig. 75. This is an outgrowth of the old tram rail used on horse railways. It has a tram alongside of the head, on which vehicles may be driven. Its chief advantage from the standpoint of the railway company is that there is plenty of room for dirt and snow to be pushed away by the flanges of the cars. If the company maintains the paving, it may be to its advantage to have teams use the steel track rather than the paving, although this advantage in maintenance is probably more than compensated for by the delay of cars through the regular use of the track by teams.

=Trilby Groove Rail.= A modification of the girder rail, known as the _Trilby_, and sometimes as the _grooved girder_, is shown in Fig. 76. A rail similar to this is used in several large cities of the United States. It has a groove of such a shape that the flanges of the car wheels will force snow and dirt out of it instead of packing it into the bottom of the groove, as in the case of the regular European narrow-grooved rail. A narrow-grooved rail in which the grooves correspond closely to the shape of the car-wheel flanges is sure to make trouble in localities where there is snow and ice, as the grooves become packed and derail the cars.

=Shanghai T-Rail.= In some systems a T-rail is used. Where the T-rail is to be used with paving, the popular form is the Shanghai T, shown in Fig. 77. This rail is high enough to permit the use of high paving blocks around it.

=Common T-Rail.= The T-rail used by steam railroads is known as the A. S. C. E. standard T-rail, because it follows the standard dimensions recommended for T-rails by the American Society of Civil Engineers. A standard 65-pound T-rail of this kind is shown in Fig. 78. Other weights of this rail have the same relative proportions. Such a rail is used for interurban roads, and for suburban lines in streets where there is no block paving. The high rails are used to facilitate paving with high paving blocks.

=Track Support.= The greater portion of track is laid on wooden ties. These ties, in the most substantial wooden tie construction, are 6 inches by 8 inches in section, and 8 feet long. They are spaced two feet between centers. Sometimes smaller ties, spaced farther apart, are used in cheaper forms of construction; but the foregoing figures are those of the best construction known in American railway practice. In paved streets, ties are usually employed, although sometimes what is known as “concrete stringer” construction is used instead of ties to support the rails. A strip of concrete about 12 inches deep is laid under each rail, and the rails are held to gauge by ties or tie rods placed at frequent intervals. Sometimes the concrete is made a continuous bed under the entire track. In most large cities the concrete foundation is used under all paving; and consequently, when concrete is used instead of ties to support the rails, this concrete is simply a continuation of the paving foundation. Where ties are used, they are laid sometimes in gravel, crushed stone, or sand, although frequently, in the largest cities, they are embedded in concrete. Sometimes this concrete is extended under the ties, and sometimes it is simply put around the ties.

=Ballast.= A ballast of gravel, broken stone, cinders, or other material which is self draining and which will pack to form a solid bed under the ties, should be used to get the best results under all forms of tie construction, whether in paved streets or on a private right of way, as on an interurban road. Of course, if concrete is placed under the ties, the gravel or rock ballast is not necessary. If ties are placed directly in soft earth, which forms mud when wet, they will work up and down under the weight of passing trains, and an insecure foundation for the track will be the result.

=Joints.= The matter of securing a proper joint for fastening together the ends of rails so as to make a smooth riding track without appreciable jar or jolt when the wheels pass a joint, has been given much study by electric railway engineers. A section through an ordinary bolted angle-bar joint is shown in Fig. 75. This joint is formed by bolting a couple of bars, one on each side of the rails. The edges of these bars are made accurately to such an angle that they will wedge in between the head and base of the rail as the bolts are tightened; hence the name _angle bars_. This is the form of joint generally used on steam railroads and on electric roads in exposed track, or in track where the joints are easily accessible, as in dirt streets. In paved streets, the undesirability of tearing up the pavement frequently to tighten the bolts on such joints, has led to the invention of several other types, which will be described later. Nevertheless very good results have been obtained in recent years with bolted joints laid in paved streets where care has been given to details in laying the track, and where the joints have been tightened several times before the paving is finally laid around them.

=Welded Joints.= Several forms of welded joints are in use. All these welded joints fasten the ends of the rails together so that the rail is practically continuous—just as if there were no joints—so far as the running surface of the rail is concerned. It was thought at one time that a continuous rail would be an impossibility because of the contraction and expansion of the rail under heat and cold, which, it was thought, would tend to pull the rails apart in cold weather and to cause them to bend and buckle out of line in hot weather. Experience has conclusively shown, however, that contraction and expansion are not to be feared when the track is laid in a street where it is covered with paving material or dirt. The paving tends to hold the track in line, and to protect it from extremes of heat and cold. The reason that contraction and expansion do not work havoc on track with welded joints, is probably that the rails have enough elasticity to provide for the contraction and expansion without breaking.

It is found that the best results are secured by welding rail joints during cool weather, so that the effect of contraction in the coldest weather will be minimum. In this case, of course, there will be considerable expansion of the track in the hottest weather, but this does not cause serious bending of the rails; whereas occasionally, if the track is welded in very hot weather, the contraction in winter will cause the joint to break.

=Cast-Welded Joints.= The process of cast-welding joints consists in pouring very hot cast iron into a mould placed around the ends of the rails. These moulds are of iron; and to prevent their sticking to the joint when it is cast, they are painted inside with a mixture of linseed oil and graphite. Iron is usually poured so hot that, before it cools, the base of the rail in the center of the molten joint becomes partially melted, thus causing a true union of the steel rail and cast-iron joint. This makes the joint solid mechanically and a good electrical conductor. To supply melted cast iron during the process of cast-welding joints on the street, a small portable cupola on wheels is employed. Fig. 79 gives an idea of the process of making cast-welded joints.

=Electrically Welded Joints.= An electrically welded joint is made by welding steel blocks to the rail ends. A steel block is placed on each side of the joint, and current of very large volume is passed through from one block to the other. This current is so large that the electrical resistance between the rail and steel block causes that point to become molten. Current is then shut off, and the joint allowed to cool. There is in this case a true weld between the steel blocks and the rails and joint. An electric welding outfit being expensive to maintain and operate, this process is used only where a large amount of welding can be done at once. Current is taken from the trolley wire. A rotary converter set takes 500-volt direct current from the trolley wire, and converts it into alternating current. This alternating current is taken to a static transformer which reduces the voltage and gives a current of great quantity at low voltage, the latter current being passed through the blocks and rails in the welding process. A massive pair of clamps is used to hold the blocks against the rails, and to conduct the current to and from the joint while it is being welded. These clamps are water-cooled by having water circulated through them so that they will not become overheated at the point of contact with the steel blocks.

=Thermit Welding.= A process of welding rail joints which was developed after the cast-welding and electric-welding processes, is known as the _Goldschmidt process_, which makes use of a material called “thermit” for supplying heat to make the weld. A mould is placed around the joint and the thermit is put in this mould and ignited. The heat produced by the thermit is so intense as to reduce the iron in the thermit mixture and make a welded joint. The thermit consists of a mixture of finely powdered aluminum and iron oxide. When this is ignited, the aluminum oxidizes, that is, absorbs oxygen so rapidly that an intense heat is the result. In the process of oxidation, the aluminum takes the oxygen from the oxide of iron, leaving molten metallic iron, which metallic iron makes the weld by union with the molten rail ends. This process has the advantage over other welding processes, of not requiring an elaborate apparatus and a large crew of men to operate it; and consequently it can be used where but a few joints are to be welded.

=Bonding and Return Circuits.= When the track rails are used as the conductors, as is usually the case, it is necessary to see that the electrical conductivity of the rail joints does not offer too high a resistance to the passage of the current. For this reason, when bolted or angle-bar joints are used, the rails are bonded together by means of copper bonds. It was soon found after electric roads were in use a short time, that unless the rail ends were so bonded, the resistance of the joints was so great as to cause great loss of power in the track. First, small iron bonds were used; but these bonds were so insufficient that large copper-wire bonds soon began to be used; and at the present time, on large roads, bonds of heavy copper cable are common. The resistance of a steel rail, such as used in city streets, is about eleven times that of copper. In order to secure as great carrying capacity at the rail joint as is afforded by the unbroken rail, it is therefore necessary to install bonds having a total cross-section ¹⁄₁₁ that of the rail. Where welded joints are used, bonding is unnecessary, except at crossings and switches where bolted joints are employed. Where track is welded, however, cross bonds should be put in at frequent intervals from one rail to another, and, if the track is double, from one track to the other, so that if one of the track rails breaks at a joint there will be a path around the break for the current.

A great many schemes have been devised to insure good contact between the copper bond and the rail, as the terminal is the weak point in any bond. One of the earliest and most efficient of small bonds was made by the use of channel pins, Fig. 80. This bond consisted of a piece of copper wire having its ends placed in the holes in the rail ends. Alongside this wire, a channel pin was driven in. The objection to the channel pin was the small area of contact between the copper bond and rail.

Next after the channel pin came the Chicago type of bond, Fig. 81, which is a piece of heavy copper wire with thimbles forged on the ends. These thimbles were placed in accurately fitted holes in the rail ends, and a wedge-shaped steel pin was driven into the thimbles to expand them tightly into the hole in the rail. Several other bonds using modifications of this principle are in use.

A type of bond in very common use consists of solid copper rivet-shaped terminals, Fig. 82. Between these terminals is a piece of flexible stranded copper cable, made flat to go under the angle bars. In one type the terminal lugs are cast around the ends of the cables, and in another type the cables are forged at their ends into solid rivet-like terminals. These terminal rivets were first applied as any other rivets, with the use of a riveting hammer. Because of the difficulty of thoroughly expanding such large rivets into the holes made for them in the rails, it has become customary to compress these rivets either with a screw press or a portable hydraulic press, which brings such great pressure to bear on the opposite ends of the rivet that it is forced to expand itself so as to fill the hole in the rail completely. This expansion is made possible by the ductile character of the copper. This great ductility characteristic of copper, however, has been the source of one of the difficulties in connection with rail bonding, because the soft copper terminal has a tendency to work loose in the hole made for it in the rail. It is practically impossible to maintain good bonding where the rail joints are so loose as to allow considerable motion between the rail ends.

Several types of bonds have been introduced, in which the contact between the rail and bond is made by an extra piece or thimble.

Another method of expanding bond terminals into the holes made to receive them, is that employed in the General Electric Company’s bond. In it a soft pin in the center of the terminal is expanded by compression of the terminal so that it forces the copper surrounding it outward. The copper terminal, in expanding to fill the hole, is therefore backed by the steel center pin.

All types of bonds must be installed with great care if they are to be efficient. Unless the bond terminal thoroughly fills the hole and is tightly expanded into it, moisture will creep into the space between the copper and the iron, and the copper will become coated with a non-conducting scale which destroys the conductivity of the contact. The _plastic_ rail bond, so called because it depends for the contact between the rail and the bond upon a plastic, putty-like alloy of mercury and some other metal, is applied in a number of different ways. One form consists of a strip of copper held by a spring against the rail ends under the fish-plate. The rail ends at the point of contact with this strip of copper are amalgamated and made bright by the use of a mercury compound similar to the plastic alloy. These points of contact are then daubed with plastic alloy, and the copper bond plate applied. It is not necessary, with any form of plastic bond, that the mechanical contact be unyielding, as the amalgamated surfaces with the aid of the plastic alloy between them, maintain a good conductivity in spite of any slight motion. The plastic alloy can be applied in a number of other ways, one of which is to drill a hole forming a small cup in the rail base in adjacent rail ends, fill these cups with plastic alloy, and bridge the space between them with a short copper bond having its ends projecting down into the cups.

=Resistance of the Track.= The resistance of the return circuit is usually much higher than it should be owing to the bad contact of the bonds. The resistance of rails varies greatly with the proportions of carbon, manganese and phosphorus. The following figures, however, may be regarded as the average.

Weight per Yard. Resistance Single Rail per Mile.
50 .0253 ohms
60 .0211 ”
70 .0180 ”
80 .0159 ”
90 .014 ”

A track laid with continuous rails as in the case of welded joints, would have one-half the resistance given since there are two rails to be considered.

Tests of new unbonded track constructed with rails 60 feet long show that the joints cause an increase of .25 ohms or more per mile.

Several roads in testing bonds consider a bond good when the bond and one foot of the rail over it have a resistance equal to five feet of the solid rail.

=Supplementary Return Feeders.= On some large roads it is necessary to run additional return feeders from the power house to various points on the system, to supplement the conductivity of the rails. Otherwise the track rails near the power house would have to carry all the current, and in some cases there are not enough such lines of track passing the power house to do this properly. Sometimes these feeders are laid underground in troughs; sometimes they are laid bare in the ground, and sometimes on overhead pole lines. When laid in the ground, frequently old rails are used instead of copper or aluminum cables. The old rails are, of course, thoroughly bonded together with bonds giving a conductivity nearly equal to that of the unbroken rail.

FEEDER SYSTEMS.

There are two general schemes of direct current feeding in common use. One of these is shown in Fig. 83. Here the trolley wire is continuous and is fed into at different points. The long feeders supplying the more distant portion of the road are larger than those supplying the trolley near by, so as to maintain as nearly as is feasible the same potential the entire length of the line. With such a system of feeding, in order to maintain absolutely the same voltage at all points, it would be necessary to have just one trolley feeder and that feeding into the extreme end of the line farthest from the power station and further to make the resistance per 1,000 ft. of trolley and feeder the same as the resistance per 1,000 ft. of the track return circuit. The plan shown in Fig. 83 evidently does not fully carry out these rather impracticable requirements but is in the nature of a compromise, giving a higher potential near the power station than at distant points but nevertheless much more even potential than if the heaviest feeders were feeding into the trolley near the power house.

The other plan, shown in Fig. 84, divides the trolley wire into sections and feeds each section through a separate feeder which is calculated of such size as to maintain the same voltage on all the sections with the ordinary load.

In calculating a feeder system a certain probable load is assumed at certain points along the line. This load will manifestly depend on the size and number of cars in operation, grades and many local conditions.

Drop in rail
section 3.1 Volts 2.1 Volts 1.05 Volts
Total drop in
rail 3.1 ” 5.2 ” 6.25 ”
Drop in trolley 20.5 ” 20.5 ” 20.5 ”
Drop in feeder 36.4 ” 34.3 ” 33.25 ”
Resistance
feeder .728 Ohms .686 Ohms .665 Ohms
Feet per ohm 7253 23000 39700
Size of wire No. 1 250,000 C. M. 420,000 C. M.]

The following example will show the method pursued. The figures resulting from the calculations are placed immediately below the sections to which they refer in Fig. 84. The rails are assumed to be 70 pound to the yard. These have a resistance of about .018 ohms per mile. Adding one-sixth for additional resistance of bonds gives .021 and since the track is composed of two rails the resistance of the track will be one-half of this or .0105 ohms per mile.

The maximum drop in any section occurs when the car is farthest from the power house. Each car is assumed to take 50 amperes and the feeders are to be so designed as to allow a 10 per cent or 60 volts drop.

The current in the two miles of track nearest the power house is 150 amperes, in the next section 100 amperes, and in the last section 50 amperes. The drop in each section is as shown. The drop in the trolley which is 00 wire is, in each section, 20.5 volts. Subtracting from 60 volts the drop in the return circuit and trolley, gives the allowable drop in the feeder.

The resistance of each feeder can be calculated, since the current in each one is 50 amperes. The first feeder is one mile long, the second 3 miles and the third 5 miles, and with these figures the feet per ohm can be computed. The size of wire may be obtained by reference to a table of copper wire resistances.

BLOCK SIGNALS FOR ELECTRIC RAILWAYS.

The simplest block signal used by electric roads is a hand-operated one constructed on the principle shown in the diagram Fig. 85. A double throw switch is placed at each terminal of the section of track that is to be protected.

The switches have no central position, the knife blade always making contact with one or the other of the terminals shown. If the lamps are lighted, throwing either one of the switches will put them out. If they are not burning, they will be lighted by throwing either one of the switches.

A motorman on reaching a section of track finding the lamps not burning throws the switch. Lamps now burn in each switch box and show that the section is in use. On arriving at the other terminal of the block the switch is thrown, extinguishing the lights and showing that the block is clear.

Automatic signal systems have been devised on the same principle, in which magnets, operated by contacts made by the passage of the trolley wheel, cause the lamps to be lighted and extinguished automatically.

ELECTROLYSIS.

Much has been said about the possibilities of electrolysis of underground metal by the action of the return current of electric railways, when such railways are operated with grounded circuits, as they usually are. If electric current is passed through a liquid from one metal electrode to another, electrolysis will take place; that is, metal will be deposited on the negative pole, and the positive pole or electrode will be dissolved by becoming oxidized from the action of the oxygen collecting at that pole.

In an electric-railway return circuit, there is necessarily a difference of potential between the rails at outlying parts of the system and the rails and other buried pieces of metal located near the power house. Just what this total difference of potential is, depends on the loss of voltage in the return circuit. Thus, suppose there is 25 volts drop in the return circuit between a certain point on the system and the power station. There is, therefore, a pressure of 25 volts tending to force the current through the moist earth from the rails at distant portions of the line, to the rails, water pipes, and other connected metallic structures located in the earth near the power station. The amount of current that will thus flow to earth in preference to remaining in the rails, depends on the relative resistance of the rails, the earth, and the other paths offered to the current to return to the power house.

To take a very simple case, let us suppose a single-track road, Fig. 86, with a power house at one end, and a parallel line of water pipe on the same street passing the power house. If the positive terminals of the generators are connected to the trolley wire, the current passes, as indicated by the arrows, out over the trolley wire through the cars and to the rails. When it has reached the rails it has the choice of two paths back to the power house. One is through the rails and bonding; the other is through the moist earth to the line of water pipe and back to the power house, leaving the pipe for the rails, at the power house. Should the bonding of the rails be very defective, considerable current might pass through the earth to the water pipe.

Remembering now the principles of electrolysis, we see that the oxidizing action of this flow of current from the rails to the water pipes at the distant portion of the road will tend to destroy the rails, but will not harm the water pipe at that point, as it will tend to deposit metal upon it. When, however, the current arrives at the power house, it must in some way leave this water pipe to get back to the rails, and so to the negative terminals of the generators.

Here we see that there is a chance for electrolysis of the water pipe, because at this point the water pipe forms the positive electrode, which is the one likely to be oxidized and destroyed. This very simple case is taken merely for illustration. In actual practice the conditions are never so simple as this, for there are various pipes located in the ground running in various directions, which complicate the case very much; but we can see from this simple example that the principal place electrolysis of water pipe is to be feared is at points where a large volume of current is leaving the water pipe to take to some other conductor.

As an indication of how much current is likely to be leaving the water pipes at various points, it is customary to measure the voltage between the water pipes and the electric railway track and rails. When this voltage is high, it does not necessarily mean that a large volume of current is leaving the water pipes at the point where these pipes are several volts positive with reference to the rails; but such voltage readings indicate that, if there is a path of sufficiently low resistance through the earth, and if the moisture in the earth is sufficiently impregnated with salts or acids, there will be trouble from an electrolytic action due to a large flow of current. There is obviously no method of measuring exactly the amount of current leaving a water pipe at any given point, since the pipe is buried in the earth. Voltmeter readings between pipes and rails simply serve to give an indication as to where there is likely to be trouble from electrolysis. The danger to underground pipes and other metallic structures from electrolysis has been much overestimated by some people, as the trouble can be overcome by proper care and attention to the return circuit. Trouble from electrolysis, however, is sure to occur unless such care is given.

=Prevention of Electrolysis.= Remedies for electrolysis may be classified under two heads—general and specific. The general remedy is obviously to make the resistance of the circuit through the rails and supplementary return feeders so low that there will be but little tendency for the current to seek other conductors, such as water and gas pipes and the lead covering of underground cables. This remedy consists in heavy bonding, in ample connections, around switches and special work where the bonding is especially liable to injury, and in additional return conductors at points near the power house to supplement the conductivity of the rails.

It is important that all rail bonds be tested at intervals of six months to one year in order that defective bonds may be located and renewed, as a few defective bonds can greatly lower the efficiency of an otherwise low-resistance circuit.

The specific remedy for electrolysis which may be applied to reduce electrolytic action at certain specific points, consists in connecting the water pipe at the point where electrolysis is taking place, with the rail or other conductor to which the current is flowing. Thus, for example, if it is found that a large amount of current is leaving a water pipe and flowing to the rails or to the negative return feeders at the power house, the electrolytic action at this point can obviously be stopped by connecting the water pipe with the rails by means of a low-resistance copper wire or cable, thereby short-circuiting the points between which electrolytic action is taking place. There are certain cases in which it is advisable to adopt such a specific remedy. It should be remembered, however, that a low-resistance connection of this kind, while it reduces electrolysis at points near the power house, is an added inducement to the current to take to the water pipes at points distant from the power house, because of the decrease in resistance of the water-pipe path to the power house resulting from the introduction of the connection between the water pipe and the negative return feeder at the power house. With the water pipes connected to the return feeders in the vicinity of the power house, the current which flows from the rails to the water pipes at points distant from the power house will obviously cause electrolysis of the rails but not of the water pipes, since the current is passing from the earth to the pipe, and the pipe is negative to the earth. In this case the principal danger is that the high resistance of the joints between the lengths of water pipe will cause current to flow through the earth around each joint, as indicated on some of the joints, Fig. 86, and will cause electrolytic action at each joint. It is evident, however, that the conditions of the track circuit and bonding must be very bad if current would flow over a line of water pipe, with its high-resistance joints, in sufficient volume to cause electrolysis, in preference to the rail-return circuit, especially since ordinarily the resistance offered to the flow of current over the water pipes back to the power house must include the resistance of the earth between the tracks and water pipes.

It is usually considered inadvisable to connect tracks and water pipes at points distant from the power house, because of the danger of electrolysis at water-pipe joints, as just explained.

Methods of testing rail bonds in the track will be explained under the head of “Tests.”

POWER SUPPLY AND DISTRIBUTION.

=Direct-Current Feeding.= As already explained, the majority of electric railways are operated on a 500-volt constant-potential direct-current system with a ground return. A constant potential of 450 to 550 volts is maintained between the trolley wire and track. Where the trolley wire is not sufficient, additional feeders are run from the power house and connected to the trolley wire, the number of feeders depending on the distance from the power house and the traffic.

=Booster Feeding.= Boosters are sometimes used on long feeder lines where there is a heavy load only a small portion of the time. These boosters are direct-current dynamos that are connected in series with the feeder upon which the voltage is to be raised above the regular power-house voltage. The booster may be driven either by a small steam engine or by an electric motor. The simplest form of booster is a series-wound dynamo. A booster armature must, of course, be of sufficient current capacity to pass all the current that will be required on its feeder. The voltage yielded by this dynamo, plus the power-station voltage, is the voltage of the boosted feeder as it leaves the power house. Supposing that a series-wound booster will give 125 volts at full load; it is obvious that being series-wound it will give no voltage at no load. The voltage will increase approximately as the load on the feeder increases; and since the drop in voltage on the feeder for which the booster is to compensate also varies with the load, the action of the booster is simply to add sufficient voltage to its feeder at any instant to compensate for the line loss upon that feeder and to maintain approximately constant potential at the far end of the feeder. Boosters raising the power-station voltage of a feeder more than 250 volts above the normal power-station voltage, are not common, though cases are on record where a feeder has been boosted as high as 1,100 volts above the power-station voltage. Since all the power used in driving a booster is wasted in line loss, this method of feeding is not economical; but where used only a few days out of the year it is sometimes to be preferred to a heavy investment in feeders. The investment in feeders might involve more interest charges than the cost of power wasted in booster feeding would amount to.

=Alternating-Current Transmission.= High-tension alternating-current transmission _to_ substations, with direct-current distribution _from_ substations, is extensively used on long interurban roads, and on large city street-railway systems where power is to be distributed over a wide area. In such cases the power house is equipped with alternating-current dynamos supplying high-tension three-phase alternating current to high-tension transmission lines or feeders. These high-tension feeders are taken to substations located at various points on the road, where the voltage is reduced by step-down transformers; and these transformers supply current to operate rotary converters, which convert from alternating to direct current for use on the trolley.

The advantage of this system of high-tension distribution is that, owing to the high transmission voltage, there is but a small loss in the high-tension lines, which lines can be made very small, and will thus involve but little copper investment. The substations can be located at frequent intervals, so that the distance the 500-volt direct-current must be conducted to supply the cars is not great. Current from one power house can thus be distributed over a very large system in cases where, if the 500-volt direct-current system of distribution were used, the cost of feeders for distributing such a low-voltage current would be prohibitive. Were the alternating-current high-tension scheme of distribution not used, it would be necessary to have a number of small power houses at various points on the system instead of one large power house. The cost of operation of several small power plants per kilowatt output, is likely to be much greater than that of one large power plant. The first cost of the alternating-current distributing system, including power house and substations, is likely to be considerably higher than would be the cost of a number of small power houses; but in cases where alternating-current distribution has been installed, it has been figured that the cost of operation of the central power house with alternating-current distribution would be sufficiently low as compared with several small ones to pay more than the interest on this extra investment.

=A System of Distribution for an Interurban Railway.= The typical features of a high tension system of distribution for an extensive interurban railway system are shown in Fig. 87, which represents the electrical transmission and distribution system of the Indiana Union Traction Company. The central power station at Anderson feeds into thirteen rotary converter substations from 7 to 65 miles distant from the power house. The substations east of Indianapolis are fed at 16,000 volts and are placed about 11 miles apart. The substations due north of Indianapolis are located at intervals of about 17 miles and are fed at 30,000 volts.

The power station at Anderson has a total capacity of 5,000 K. W. The substations vary in capacity from 250 to 1,500 K. W.