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Track Asset Maintenance and Renewal Søren Boysen Director of Technical Operations, Rail Net Denmark

Presentation Cost Optimisation Track Maintenance & Renewals Congress 2012

• Rail Net Denmark (Banedanmark) – Key Figures

• Implementing The Asset Management Process

• Day to Day Maintenance – work smarter, not harder

• Long-term Maintenance and Renewal

– The Track Analysis Model

• Sum up

Agenda

•  We are a state-owned enterprise under the

Ministry of Transport

•  We own and manage the Danish state railway

network

•  2,200 employees

•  We do day-to-day maintenance, renewal, and large

projects – e.g. the Signalling Programme (3 billion

EURO)

•  Traffic Operation and passenger information

•  Train operation is done by DSB and private train

operators

About Rail Net Denmark – who we are and what we do

Facts Figures

Line length 2,323 km

Tracks 3,240 km

Bridges 2,342

Total area served 5,500 ha

About Rail Net Denmark

Agenda

• Rail Net Denmark (Banedanmark) – Key Figures • Implementing The Asset Management Process • Day to Day Maintenance

– work smarter, not harder • Long-term Maintenance and Renewal

– The Track Analysis Model • Sum up

Banedanmark has developed a comprehensive activity planning process for both maintenance and renewal

Best practice Asset Management Process

Agenda

• Rail Net Denmark (Banedanmark) – Key Figures • Implementing The Asset Management Process • Day to Day Maintenance

– work smarter, not harder • Long-term Maintenance and Renewal

– The Track Analysis Model • Sum up

Day to day maintenance

Daily maintenance

Mobile Data Capture

Yardstick Method

SAP PM • Link between activities

and money spend • System support

• Identical use of process • No paperwork in the track • Minimise potential failures

• Support individual in track

• Reduce variation

Elements in improving the process of day-to-day maintenance.

SAP PM (Plant Maintenance)

Register Masterdata on: >200 construction elements •  Through tracks •  Sidings •  Points •  Trackside signals •  Rectifier substation •  Level crossings

>2,000,000 pieces of single equipment •  Sleepers •  Rails •  Insulated Rail Joints •  Masts etc.

Mobile Data Capture

Presenting, capturing and registering data on location in the track. Inspections and control is handled in the track. Work orders are created directly in SAP when the inspection is done in the track.

Liste  over  billeder  vedhæftet  til  meddelelsen

Tag  billede

Kamera  søger

Tilbage  til  tilstands-­‐  meddelelsen

Slet  billede

Mobile Data Capture

• Eliminating double procedures • Eliminating double registration • Eliminating typing and paperwork • Submitting data directly to SAP • Automatic time registration

More quality time in the track!

Support tool: Yardstick Method Today: Variation in asset evaluation and requests for maintenance activities

Asset evaluation Asset condition reporting

Good

Functional

Poor

Asset Maintenance Requests

No maintenance/renewal needed

Maintenance/renewal needed by date/year

Maintenance / renewal needed now

Asset Condition Scale (1-4)

Asset Condition

2 3 4 1 Poor Functional Good

Average reported condition Variance in asset condition reporting of the same assets by different assessors results in variance in requests for maintenance/ renewal. Ultimately this may result in under-maintaining some sections of the infrastructure while over-maintaining others.

Yardstick Method Minimising variation in asset evaluation and requests for maintenance activities

The implementation of the yardstick method helps to reduce the variance (measured as standard deviation) in asset condition reporting by different assessors. This makes it possible to make better informed prioritization decisions regarding where and how to maintain and renew the asset infrastructure.

Implementing yardsticks in Asset evaluation Asset condition reporting Asset Maintenance Requests

Good

Good

Functional

No maintenance/renewal needed

No maintenance/renewal needed

Maintenance/renewal needed by date/year

Reduced variance (standard deviation)

Asset Condition Scale (1-4)

Asset Condition Poor Functional Good

3 2 1 4

Average reported condition

Agenda

• Rail Net Denmark (Banedanmark) – Key Figures • Implementing The Asset Management Process • Day to Day Maintenance

– work smarter, not harder • Long-term Maintenance and Renewal

– The Track Analysis Model • Sum up

Introduction – The Track Analysis Model

The Model Rail Net Denmark has developed a LCC model to support decisions and establish a forecast on track renewal

Origin The model is developed by Prognoz (IT platform) and Civity (conceptual input). Consultants selected through European tender process

Model input •  Data on asset components (as in SAP PM) •  Traffic data •  Prices from more than 120 renewal projects •  Prices from last years maintenance activities

Model output •  Reinvestment plan for up to 60 years •  Economic needs for maintenance in the same period •  Consequences on traffic performance

Mapping

Models of deterioration

Activities

Optimisation and prioritisation

DATA INPUT

Geographic location

Deterioration

Maintenance and renewal

Economic optimisation and prioritisation

Asset data

Traffic data

Output

Cost levels

Model structure

Mapping

Rail Detail (rail, sleeper and ballast)

Point Detail (switches and crossings)

Rail Wear (measuring wagons)

Geometrical Track Quality (measuring wagons)

Route Section (single equipment location)

Line Section (administrative units)

Traffic data (time table related units)

Cost data (administrative units)

Mapping

Input data for modelling

Information about the tracks (SAP PM)

Other sources

Deterioration

17 variations of rail service life: •  Rails (8) •  Sleepers (4) •  Ballast (1) •  Switches (4)

The service life is as recommended by the UIC with minor adjustments to the Danish conditions

-

200

400

600

800

1.000

1.200

1.400

0 5 10 15 20 25 30 35 40 45 50 55 60

Cumulative Equivalent Mill. Gross Tonnes (cemgt)

Equivalent Mill. Gross Tonnes (emgt)

Rail service life for rails of the type UIC60

Line section 10 ("Kystbanen")

Technical rail service life: 62,5 år

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Maintenance and renewal

In case of postponed renewal: •  Increased maintenance costs •  Increased renewal costs •  Risk of temporary speed reductions (traffic hindrance costs)

Costs

Optimal  time  of  renewal

Costs

LifetimeOptimal  time  of  renewal

Renewal  costs

Maintenance  costs

Postponed  time  of  renewal

Postponed renewal Costs  

LifetimeTime  of  investment/reinvestment

Optimal  time  of  investment/reinvestment

The Bath tub-model

Maintenance is executed in order to secure the full lifetime of the assets Description of the maintenance - by the ’bath tub-model’

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Activities modelled

Renewal activities

Renewal of rails

Renewal of sleepers

Renewal of ballast

Renewal of rails and sleepers

Renewal of rails, ballast, drain, and subgrade

Renewal of sleepers, ballast, drain, and subgrade

Renewal of rails, sleepers, ballast, drain, and subgrade

Renewal of switches

Renewal of ballast, drain, and subgrade

Renewal of rails, ballast, and subgrade

Renewal of sleepers, ballast, and subgrade

Renewal of rails, sleepers, ballast, and subgrade

Renewal of ballast, and drain

Renewal of rails, ballast, and drain

Renewal of sleepers, ballast, and drain

Renewal of rails, sleepers, ballast, and drain

 

Maintenance activities

Rail grinding

Tamping

Condition based maintenance activities

Norm based maintenance activities

 

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Economic optimisation and prioritisation

•  Bundling of renewal activities

•  Increasing condition based maintenance costs

for track components used after exceeded

service life

•  Increasing socio-economic costs caused by

temporary speed reduction in the track due to

using components after exceeded service life

•  Penalty for renewal of components before

reached end of life

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Short-term and long-term planning

•  The markings with LCC Tracks- and Bridges (gray boxes) indicates the optimal time for renewal

•  The marking with Tracks/Bridges (blue box) indicates the suggested renewal

•  Markings with Out of time and Signalling Programme are periods where renewal is not possible

Year 2013 2014 2015 2016 2017 2018 2019 2020 202111bHøje  Taastrup  -­‐  Roskilde

RenewalRenewalOut of  Time

Tracks  /  BridgesLCC  Bridges

LCC  Tracks

Signalling  Programme  

Example: Line section Høje Taastup – Roskilde.

The Track Analysis Model – use and development

Results used for political decision on funding

for the period 2015-2020, and as input for

the renewal plan (every 3-year).

With the renewal plan on track (and bridges)

we can plan other activities in the same

closures.

Complete overview of all master data on all pieces of equipment

Unified reporting and prioritisation

LCC model on long-term investments

Sum up

Thank you for your attention