En 50126 Guide to the Application - PowerPoint by tea21332

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									                  INNOTRACK
Ett EU-projekt med totalt 38 deltagare varav 8 “banverk”




                                    Baserat på material
                                    presenterat av
                                       Björn Paulsson,
                                       John Amoore
                                       Jay Jaiswal
                                       Gunnar Baumann mfl
            INNOTRACK - Bakgrund
•   50-60 % av underhållskostnaden är relaterat till spår
    (BU, räl+skarvar, växlar)
•   Spegelvänt så kan merparten av
    underhållskostnaderna för trafikföretagen relateras
    till hjul/räl kontakt
•   Idag är budskapet att det inte kommer att finnas mer
    pengar till DoU av järnväg, snarare tvärtom
•   Samtidigt ställs nya krav:
      • Högre hastighet
      • Ökade axellaster
      • Ökad driftsäkerhet
      • Minskade trafikstörningar
                                Mål
• Minska LCC för järnvägsanläggningar med 30 %
• I linje med ERRAC; mål (European Rail Research Advisory Council )
• Minska tiden för att införa nya lösningar och produkter
• Göra det möjligt att jämföra mellan olika förvaltningar i
  syfte att lära av den som är bäst – allt i syfte att göra
  järnvägen mer konkurrenskraftig
• Bättre logistikupplägg
• Ta fram hjälpmedel för att åstadkomma detta
• Inte glömma att minskad LCC innebär att man inte
  tummar på RAMS
                        Vad är RAMS
• Reliability = Funktionssäkerhet Sannolikheten att en enhet kan
  utföra krävd funktion under givna förhållanden under ett angivet
  tidsintervall. (EN 50126:1999)
• Availability = Driftsäkerhet Förmågan hos en enhet att kunna utföra
  krävd funktion under angivna betingelser vid ett givet tillfälle eller
  under ett angivet tidsintervall, förutsatt att erforderliga stödfunktioner
  finns tillgängliga
• Maintainability = Underhållsmässighet Förmågan hos en enhet,
  som används enligt angivna betingelser, att vidmakthållas i, eller
  återställas till ett sådant tillstånd att den kan utföra krävd funktion,
  när underhållet utförs under angivna betingelser och under
  användning av fastställda förfaringssätt och resurser
• Safety = Säkerhet Status för ett tekniskt systems frihet från att
  leverera oacceptabla risker som medför skada
                   Tillvägagångssätt
• Fokusera på vad alla förvaltare av spåranläggare anser vara
  kostnadsdrivande:
   –   Spårunderbyggnad
   –   Växlar
   –   Räl och skarvar
   –   logistikupplägg
• Identifiera gemensamma problemområden och signifikanta
  spåravsnitt med dessa problem samt signifikanta fordon som
  orsakar dessa problem
• Identifiera hur detta följs upp och hur detta kan användas i LCC-
  kalkylering men med beaktan på att RAMS-villkor måste uppfyllas
• Implementera!
             Dagsläget, problem
• Banunderbyggnad
  – UK ”blöta underbyggnader”, F ”håligheter”,
  – S ”Sjunksvackor” --- OBS! ej trummor
• Spårväxlar
  – omläggning, korsning, tungor
• Räl
  – OFP, ytutmattning (RCF), slitage, vågbildning
  – isolerskarvar
                    Rail Life – Million Gross Tonnes
          BHPB    Banverket    Banverket    Ore line   Coal line   CVRD    CVRD    Jernbaneverke
Rail      MNJV    (Sweden)     (Sweden)                            EFVM     EFC          t
          68 kg   60 kg Rail   50 kg Rail    60 kg      60 kg      68 kg   68 kg      (Norway)

Life       Rail                               Rail       Rail       Rail    Rail     54 kg Rail




Tangent
          1,800 1,335          1,049        1,350 1,500            890     550        285
 Track
           Mgt   Mgt            Mgt          Mgt   Mgt             Mgt     Mgt        Mgt


  1
Degree
          1,200    611-         480-        1,200 1,000            722     548        228
Curves     Mgt     776          610          Mgt   Mgt             Mgt     Mgt        Mgt
                   Mgt          Mgt

 2-3+
Degree
          360       355          280           -        800         -        -        133
Curves    Mgt       Mgt          Mgt                    Mgt                           Mgt
                      INNOTRACK - projekt organisation
                         SP0       InnoTrack kordination
                                         UIC
                     SP2                                   SP4
       SP1                               SP3                                  Vehicle & track
                                                                              Characteristics
       Drift                                           Räls och              General model of
                   Under-                               skarvar
       NR                            Spårväxlar                             failure/degradation
                  byggnad
                                                         VAS/                SP6
LCC methodology      SNCF                 DB
RAMS technology                                         CORUS                LCC
  LCC models
                  Track subgrsde        Predictive                            DB
                   monitoring &       Models for S&C   Methodology for
                    assessment                         Duty conditions
      SP5                             Switch designs   Supported track     Best logistics practices
                  Evaluation and                            Form           New logistics processes
     Logistik         test of          Standards &       Rail steel      Cost effective methodologies
    ALSTOM        superstructure       LCC analysis       Material
                                                          Grinding
                   innovations
                                                        methodology


                  SP7       Implementering och utbildning
                                     UIC
                  Ekonomi
• Total kostnad för projektet är:
   €18 593 000
varav kommissionen bidrar med:
   € 10 000 000
                                          Current development process
  State of      Investi                      Verification
                                                            Final              National         Pilot                   Volume
                            Development           &                                                        Revisions
   the art      gations                                     design            acceptances      delivery                deliveries
                                                 tests


             The impact of the generated INCREASED KNOWLEDGE

  State of    Investi-                  Verification   Final     National         Pilot                Volume
                          Development                                                     Revisions
   the art    gations                     & tests      design   acceptances      delivery             deliveries

                        The impact of a                                                                        Time n-x
             COMMON EUROPEAN ACCEPTANCE PROCESS                                                                cost n-x

State of Investi-     Deve- Verification Final         European       Pilot              Volume
the art gations     lopment   & tests                                         Revisions
                                         design        acceptance    delivery           deliveries


                                                                                             Time n-x
                                                                                             cost n-x

             UNIFIED ACCEPTANCE CRITERIA
Year 1                                                                                                                      Year n
                         INN0TRACK Innovations
                                           Innovation
the translation of research & development into added value reduced LCC & improved RAMS

                 PRODUCTS                                             PROCESSES
     new subgrade treatments                              logistics processes
     optimised track components                           sensor technologies & signal processing
     innovative switch designs                            soil improvement methods
     improved driving and locking devices                 innovative grinding methods
     new rail steel materials                             improved welding techniques
     new cost effective track forms                       inspection techniques



                                         METHODOLOGIES
                        classification methods for track and vehicle characteristics
                        defining duty conditions from vehicle track interaction
                        assessment of technical and economical problems
                        Europe-wide accepted LCC and RAMS evaluations
           The “Drivers” for the need for
                   Improvement
• The participating IMs account for
  >185,000 km of track                                                 Approximate Total
                                              Participating IMs
                                                                       Track Length, km
• An annual rail requirement of over                  ADIF                          16800
  733,000t or >6000 km of track                       OBB                            7700
  renewal is predicted based on                      SNCF                           45500
  using 60kg/m rail and a 3.3%                         DB                           53750
                                                    PRORAIL                          4700
  renewal rate                                         BV                           11800
• Cost of rail is a small proportion of                NR                           33500
  the total track renewal costs and                    CD                           11400
                                          Total of 8 Participating IMs            185,150
  use of premium grade rails offers
  significant savings on maintenance
  to IMs
               The Complex Rail System



•   Rail is the HUB as it forms the interface between the Vehicle & Track
    Systems
•   Rail condition affects the integrity & life span of other components of
    system
•   Optimisation of system requires a range of disciplines
     – Vehicle dynamics, contact mechanics, civil/P’way engineering &
        Metallurgy
•   The Key DELIVERABLES from this SP are:
                                Employing Rail Metallurgy
                              Developments to Improve LCC
    Track forces and duty




                            Track Radii Gradient/Axle Load/Vehicle
                            Type/Traffic Density Track Condition


•           Wide range of duty conditions & Wide range of existing higher performance
            rail steels
•           Selecting optimum rail metallurgy to match duty conditions will lower LCC
            and improve RAMS characteristics
•           SP4 will deliver a definitive guide to the selection of rail grades as a function
            of duty conditions based on a scientific understanding of rail degradation
                    SP 4: RCF Control




•   Grinding is key tool for the management of Rolling Contact Fatigue
•   SP4 aims to demonstrate that the use of Innovative Grinding techniques
    combined with optimised rail metallurgy & track quality will enhance Rail
    Life
        SP 4: Laboratory Tests for RCF
•   Rolling Contact Fatigue is the
    major cause of rail
    degradation & replacement
    throughout the railway world
•   None of the properties
    included in European or
    International Specifications for
    rails include a test for RCF
    resistance
•   SP4 will develop rail steel
    material property tests that
    more closely reflect the in-
    service performance
           SP 4 – Minimum Action Rules




•   A significant number of rail breaks & defectives occur in all networks
•   Knowledge of criticality of defects is essential for effective planned
    maintenance
•   SP4 aims to develop “minimum action rules” based on problem
    oriented application of fracture mechanics principles for selected
    defects – Such rules will reduce unplanned maintenance costs
       150
                                                                 340 - 360 HB

                                                                 310 - 340 HB

       mm                                                        280 - 310 HB

       100
             High Performance Weld


                                       Standard SkV-Weld

                                                                 260 - 280 HB

        50




         0
          200                        300                   400
                                       HB

•   Use of Premium Grade Rail Steels requires Innovation in track
    welding. The hardness distribution of High Performance Welds
    offers improved track integrity around welds and therefore
    enhances rail life
•   Innotrack SP4 will demonstrate the benefits to Rail life using
    Innovative Aluminothermic welding techniques
        SP 4 Improved Integrity Welds




•   Discrete track irregularities such as those at welds are a source of
    increased dynamic track forces and hence promote track
    degradation
•   SP4 aims to demonstrate the benefits of narrow HAZ and improved
    geometry welds in improving and maintaining high track integrity
    SP 4 Improved Integrity Track Welds




•   Alumino-thermic weld breaks and defectives account for a large proportion
    of all breaks & defectives in any network
•   Introduction of cost effective solid phase welding techniques will reduce
    weld failures in the future.
•   SP4 will build on the research already undertaken to develop a modified
    gas pressure welding unit suitable for European practices
    INNOTRACK - In-depth example - input from Eurobalt II
Eurobalt II
- theories concerning measuring of
   track stiffness were developed
- prototype measuring vehicle was
   developed

Today
- theories from Eurobalt II are
   verified
- operational measuring vehicle
   developed and in use

INNOTRACK
- developed theories and vehicle are
   used in SP2 to support the
   development of innovative solutions
   to cut costs
    The Cost drivers in S&C´s are:
          - Damage and wear

                                     Damages due to severe duty conditions

                                     • Axle loads
                                     • Speed
Wear                                 • Boogies
                                     • Power units with slip control
                                     • Discontinuous track
                                                               Surface spalling
Rail breaks in                                                 Severe wear
the spring area


                                                               RCF, eg
                                                               head checks

Severe head checks
Spalling
The Cost drivers in S&C´s are:
   - Malfunction and Non-availability of Driving & Locking devices




                                       Which construction have the
                                       best LCC ?
                                              - Low investment
                                              - High availability
                                              - Low Maintemance
  The Cost drivers in S&C´s are:
        - Not optimised maintenance processes




-Wrong grinding of the rail in the area of tongue
                 SP 3 delivers Innovations in
                    locking device



       driving
       device
                                                moveable frog,
                 monitoring system              optimised contact area,
                                                Improved materials

• Definitive guide for selection of switch system depending on
  operational conditions by LCC Assessment
• Optimization of design and contact areas for low maintenance switch
• Innovative maintenance strategies and techniques
• High effective Monitoring Systems with Standard “Plug & Play”
Strategiska forskningsområden

								
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