Heavy Haul Network Health

Using Technology and Innovation to Drive Efficiencies

August 2016

Presenter: Bazil Miller – General Manager

Speno Rail Maintenance Australia

Network Health

Understanding the condition of your network is critical for any network operator.

In a Heavy Haul environment where some network sections see in excess of 1 million gross tonnes per day, it is even more important.

Collecting the data to understand the condition of your network has become increasingly harder to obtain through traditional methods as network operators are looking for more ‘invisible’ maintenance practices so they can move more trains.

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Using Technology and Innovation

Speno have done this for one of our Heavy Haul clients in the Pilbara region of WA by building and supplying a Multi-Purpose Platform (MPP) to collect network health data.

This MPP is called US6 and it differs in several ways from the traditional TRV’s (Track Recording Vehicles) that most network operators use, own or have used. Traditionally a network owner would tow around or send out a TRV once or twice a year to gather Track Geometry data that they would then use for planning maintenance activities.

The US6 is fitted with an array of instrumentation to collect the following data. Track Geometry, Rail Head Loss, Rail Surface Condition, Hi Speed Ultrasonic Testing, Ballast condition and Sleeper and Clip irregularities.

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The data

All of this data is then fed into the client’s maintenance condition monitoring program every month.

US6 is able to travel at track speed of 80kph, tests at 60kph and covers the network in 2 x 1 week campaigns per month.

This cycle is driven by the network owner’s rail testing compliance standards.

Not only has this process improved the Rail Testing maintenance footprint by doing it at high speed, it has improved the network health knowledge by providing high quality, regular, reliable data that is used for maintenance planning.

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The benefits

The benefits to the network owner are as follows.

Less maintenance possession to collect critical data (Improved Productivity).

Repeatable, reliable, quality and regular data used for maintenance planning and budgeting (Reduced Costs and Improved Productivity).

Less people ‘on track’ carrying out track, switch and crossing inspections (Improved Safety and Productivity).

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Objectives of an integrated, high-speed single platform

An integrated, high-speed single platform that provides quality, repeatable and useable data that enables our clients to better manage their track.

Capable of:

- Locating rail defects – ultrasonic testing

- Measuring RCF, track geometry and rail profile,

- Full network coverage to inspection frequency, and

- Providing meaningful data / reporting of track condition and exceptions.

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Typical Track Inspection Systems

• Traditional High Speed Rail Ultrasonics System. Currently testing at 60kph and we are working on increasing it to 80kph and including Phased Array testing.

• Inertial Track Geometry Measurement System.

• Full Rail Profile Measuring System – Head-loss.

• Track Vision System V-Cube (which comprises)• Track Inspection System (TIS),• Track Head Inspection System (THIS-lite), and• Track Measurement System (TMS).

• Rail Head Inspection System (THIS).

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Ultrasonic Rail Flaw Detection

• Continuous Ultrasonic Testing at 60 km/h, and

• Confirmation of discontinuities performed separately.

Ultrasonic testing is conducted to mitigate risk of rail breaks, and ensure the quality of rail welding

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Ultrasonic Rail Flaw Detection Reporting

• Rail defect report daily, monthly and year to date,

• Rail surface condition summary report daily, monthly and year to date,

• Rail testing report, and

• Inputs into RAMSYS.

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Defect Number 1516052301 TD0

Defect Plot Head Height Plot

FCG

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How to Use Ultrasonics Data

• Rail defect deterioration analysis,

• Rail welding quality analysis,

• Rail defect removal plans,

• Re-railing plans,

• Ultrasonic testing compliance,

• Input to grinding plans, and

• Risk profiling of track sections.

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Track Geometry Inspection System

Measured Parameters• Track gauge,

• Horizontal alignment (versine),

• Vertical alignment (top),

• Track Cant, and

• Track Twist.

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Track Geometry Reporting

• Exception reporting,

• TQI listing – Top, line, twist, gauge,

• S – Curve/distribution of TQI, and

• Inputs into RAMSYS.

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How to Use Track Geometry

• Exception rectification plans,

• Track condition deterioration analysis,

• Track machine planning,

• Track machine work quality analysis,

• Track renewal planning, and

• Risk profiling of track sections.

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Rail Profile Inspection System (Head Loss)

Measured parameters• Track Gauge,

• Rail Profile and Head Loss,

• Rail Vertical Wear,

• Rail Transversal Wear, and

• User Defined Wear.

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Head Loss Reporting

• Exception listing

• Exception trending

• RAMSYS input/data reports

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How to Use Head Loss Data

• Exception rectification plans,

• Deterioration of rail,

• Re-rail plans, and

• Risk profiling of track sections.

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Track Vision Inspection Systems

• Track Measurement System – TMS,

• Track Inspection System –TIS,

• Track Head Inspection System – THIS lite, and

• Track Head Inspection System – THIS.

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Track Vision Inspection Systems

TMS - Excess or lack of ballast

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TIS

• Missing or rotated/shifted fastening clips

• Cracked sleepers

• Rail surface defects

Track Vision Inspection Systems

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Track Vision Inspection Systems

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THIS

• Gauge corner defect

• Rolling contact fatigue

Track Vision Inspection Systems

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• Exception rectification plans

• Track condition deterioration analysis

• Track machine and Resource planning

• Track renewal planning

• Risk profiling of track sections

How to Use Track Vision Inspection Systems

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• Reduction in track maintenance time,

• Better management of track maintenance data,

• Reduction in speed restrictions,

• Data is provided in format that can be imported into RAMSYS, and

• Better use of maintenance and planning resources.

Using Technology and Innovation to Drive Efficiencies

Benefits

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Track Vision Systems - a few ‘questionable’ results

Track Vision Inspection Systems…’Questionable’ Results