Gir

sch

1

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

MilanoNovember 8, 2005

Presented by:Heinz OSSBERGERHead of Engineering and DesignVAE GmbH Austria

LCC and RAMS Based Track Work Technologyfor the Economical Benefit of High Speed Railways

Gir

sch

2

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

L ife

C ycle

C ost

Look at Total Life Cycle of Components / Products

What you see is not always what you get

Gir

sch

3

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC calculations:The way of VAE to provide the maximum benefit

Identification of the optimal product for each field of application (speed, loads etc.) regarding the LCC (identification of minimal LCC)

Costs during Service Life

Purchasing Costs

Total Costs

performance, quality

costs

Gir

sch

4

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC calculations:The way of VAE to provide the maximum benefit

TotalInvestment

OperationMaintenance

Disposal

New Product

Standard Product

Gir

sch

5

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC: Influence and Solutions

LCC INFLUENCE

SOLUTIONS

Rail Material

TurnoutDesign

ModularSetting andMonitoring

Installation

Maintenance

Life Time

6

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Cost factor: Wear and RCF-Defects

Wear

RCF-defects

Corrugation

Higher speeds

Increasing axle load

Higher annual tonnage

Higher Loads

Poor running

behaviour

Damage on

rolling stock and

superstructure

Less service life

of components

Noise

Increase of

life cycle cost

Gir

sch

7

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Trends in Rail Steel Development

200

260

230

290

370

320

350

400

430

460

1960 1970 20101980 1990 2000year

19501940

Hardness [BHN]

R200

R260

R320Cr

R350HT / R350LHT

Micro-alloyed

Heat Treated (HT)

400UHC+Hyper-eutectoid, HT

StandardCarbon

DOBAIN®Bainite, HT

Higher Wear-

and RCF- r

esistance

370LHT

-al

Gir

sch

8

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Test results – Wear: Improvement factors

10

7

5

4

3

2

1

R200 R220 S900 R320Cr R350HT

base grade

imp

rov

eme

nt

rati

o

R260

8,5

R350HT / HSH

5

R320Cr1,7 R200

R220

3

Source: ERRI and European Rail Operators

370HT/400UHC

Gir

sch

9

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Test results – RCF-Cracks (Head Checks)

100 1000 100000,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

DOBAIN370LHT

R220

R350HT / HSH

R260

R220 R260 HSH (R350HT) 370LHT DOBAIN430

dep

th o

f ra

il d

amag

e [m

m/1

00M

GT

]

radius [m]

Gir

sch

10

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC considerations

Better track performance of harder rail grades

3-times better wear-resistance & 3-times better RCF-resistance

for R350HT compared to R260

Less corrugation (approx. 50 % of R350HT compared to R260)

Decrease in rail maintenance

3-times longer rail machining

cycles (R350HT vs. R260) or

Less metal removal necessary

Longer rail service life

3-times longer for R350HT

compared to R260

Less Life Cycle Cost (LCC)

Gir

sch

11

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC results – example DB AG and ÖBB

DB AG: Reduction of LCC by about 35 %

Medium speed lines (up to 230 km/h)

Curve radii approx. 3000 m

Load approx. 90.000 tons/day

Period under consideration: 40 years

ÖBB: 15 % annual cost saving for R350HT

compared to R260 in tight curves.

conservative assumption: 30 % longer life span of R350HT

Less grinding needs

Rate of return 5 % net

Gir

sch

12

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Conclusion – LCC and rail grade strategy

Premium high strength Rails (HSH®-type)

Load related application of

and applying

LCC optimized maintenance strategies

will diminish rail damage,

increases service life time of the system,

saves costs and

makes track operation more cost effective,

reliable and safe.

Gir

sch

13

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

VAS Outlook

New high strengths premium rail grades

(Wear ↓ RCF↓)

Extensive track testing of the new rail grades.

LCC reduction by optimization of load related rail

grade application and maintenance strategies by

using LCC models (“LCC RAIL”)

Verification of the best track test practice rail grade

strategy together with railways

Gir

sch

14

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC: Influence and Solutions

LCC INFLUENCE

SOLUTIONS

Rail Material

TurnoutDesign

ModularSetting andMonitoring

Installation

Maintenance

Life Time

Gir

sch

15

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Crossover Gallese – ItalyUIC60-7500/3000/15000-tg 0,026

Gir

sch

16

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Predicted Lateral Wheel/Rail Force [kN]

-35

-30

-25

-20

-15

-10

-5

0

5

0 50 100 150 200 250 300

Distance [meters]

OptimisedNon-Optimised

Predicted Lateral Wheel/Rail Force [kN]

-35

-30

-25

-20

-15

-10

-5

0

5

0 50 100 150 200 250 300

Distance [meters]

OptimisedNon-Optimised

Predicted Lateral Wheel/Rail Force [kN]

-35

-30

-25

-20

-15

-10

-5

0

5

0 50 100 150 200 250 300

Distance [meters]

OptimisedNon-Optimised

Comparison of calculated and measuredforces in turnouts

Gir

sch

17

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Comparison Calculation - Measurement

latfrc_178_rgt_Wh_A4 latfrc_178_lft_Wh_A4Y41_Z29_Weg_F Y42_Z29_Weg_F

-15

-10

-5

0

5

10

15

20

25kN

-15

-10

-5

0

5

10

15

20

25kN

7.25 7.30 7.35 7.40 7.45 7.50 7.55 7.60 7.65

km

14.03.01 13:17:56 V ergleic h latf rc _178_A x le4 mit Z 29 (Tiefpaß mit 3Hz )

Lateral Force

measured

calculated

Gir

sch

18

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC: Influence and Solutions

LCC INFLUENCE

SOLUTIONS

Rail Material

TurnoutDesign

ModularSetting andMonitoring

Installation

Maintenance

Life Time

Gir

sch

19

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Close Link between RAMS and LCC

LCCLife Cycle Costing

RAMSSafety

Availability

Reliability

Maintainability

FMECA

RCM

FTA

HA

MA/MP

RP/RA SA

OperationMaintenanceInvestment

LCALCC-P/AInvestment Analysis

Gir

sch

20

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

High Speed Rail Link Taiwan

The actual largest BOT Project worldwide

Lenghts: 345 km,80 % on viaducts and in tunnels

Speed 300/160 km/h

161 turnouts for High Speed

Gir

sch

21

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

All turnouts are equiped with VAE Monitoring System „Roadmaster 2000“

High Speed Rail Link TaiwanTurnout Monitoring System VAE Roadmaster 2000

Gir

sch

22

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Safety and Reliability Report – Verification of the Performance of the RAMS Requirements according to EN 50126

The safety and reliability report is the final document with the summary of the findings of all activities during the RAMS process

Including all analysis performed during the RAMS process

Provides the evidence of achieving the RAMS requirements according to EN 50126 and the customer´s specification

Gir

sch

23

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

HYDROSTAR®

Innovative Switch Operating System

Gir

sch

24

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Hydraulic switch operating system HYDROSTAR®

HYDROSTAR fulfils four functions

Driving (electro-hydraulic)

Setting (hydraulic)

Positive Locking

Detection (electro-mechanic)

Gir

sch

25

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Functions of the HYDROSTAR® - displayed at the HYDROSTAR® ZV

Drive

Tongue detector

Force transmission

Locking device

Gir

sch

26

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Drive I

Principle: All setting levels of the switch or the moveable point frog are driven by one hydraulic device only. This hydraulic device is normally integrated in the first hollow steel sleeper. With this hydraulic device, it is possible to set a multiplicity of setting levels only by one active unit.

Gir

sch

27

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Locking I

Principle:

At every setting level, there is a unit for setting and locking integrated into the hollow steel sleeper. These cylinders were set hydraulically. in theses cylinders a double form fitting locking at the end position of the tongue or the moveable point frog takes place.

Gir

sch

28

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Tongue detector I

Principle:This device has the same function as a normal tongue detector of an conventional drive. The correct end position of the tongue or the moveable point frog will be monitored.

Gir

sch

29

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Force transmission I

Principle:Force transmission between the setting levels is done by hydraulic pipes. These pipes are mounted between the rails at the tongue section or along the rails at the moveable point frog. The pipes are covered to protect them against damage.

Gir

sch

30

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Comparision of HYDROSTAR® ZV with a conventional turnout with single drives

Gir

sch

31

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC: Influence and Solutions

LCC INFLUENCE

SOLUTIONS

Rail Material

TurnoutDesign

ModularSetting andMonitoring

Installation

Maintenance

Life Time

Gir

sch

32

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Railputler:Just-in-Time Delivery of Rails

Gir

sch

33

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Preassembled turnout with HYDROSTAR® switch section prepared for shipping

Gir

sch

34

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Preassembled turnout HYDROSTAR® loading of the switch section

Gir

sch

35

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

Plug and Play:Installation of a preassembled turnout

Gir

sch

36

LC

C a

nd R

AM

S B

ase

d T

rack

Wor

k T

ech

nolo

gy

for

the

Eco

nom

ical

Ben

efit

of H

igh

Spe

ed R

ailw

ays

LCC: The objective of voestalpine:

What you see is what you get!

Thank you for your attention