LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 1...
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Transcript of LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 1...
Gir
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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
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L ife
C ycle
C ost
Look at Total Life Cycle of Components / Products
What you see is not always what you get
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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
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LCC calculations:The way of VAE to provide the maximum benefit
TotalInvestment
OperationMaintenance
Disposal
New Product
Standard Product
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LCC: Influence and Solutions
LCC INFLUENCE
SOLUTIONS
Rail Material
TurnoutDesign
ModularSetting andMonitoring
Installation
Maintenance
Life Time
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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
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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
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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
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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]
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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)
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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
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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.
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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
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LCC: Influence and Solutions
LCC INFLUENCE
SOLUTIONS
Rail Material
TurnoutDesign
ModularSetting andMonitoring
Installation
Maintenance
Life Time
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Crossover Gallese – ItalyUIC60-7500/3000/15000-tg 0,026
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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
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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
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LCC: Influence and Solutions
LCC INFLUENCE
SOLUTIONS
Rail Material
TurnoutDesign
ModularSetting andMonitoring
Installation
Maintenance
Life Time
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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
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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
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All turnouts are equiped with VAE Monitoring System „Roadmaster 2000“
High Speed Rail Link TaiwanTurnout Monitoring System VAE Roadmaster 2000
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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
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HYDROSTAR®
Innovative Switch Operating System
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Hydraulic switch operating system HYDROSTAR®
HYDROSTAR fulfils four functions
Driving (electro-hydraulic)
Setting (hydraulic)
Positive Locking
Detection (electro-mechanic)
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Functions of the HYDROSTAR® - displayed at the HYDROSTAR® ZV
Drive
Tongue detector
Force transmission
Locking device
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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.
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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.
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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.
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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.
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Comparision of HYDROSTAR® ZV with a conventional turnout with single drives
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LCC: Influence and Solutions
LCC INFLUENCE
SOLUTIONS
Rail Material
TurnoutDesign
ModularSetting andMonitoring
Installation
Maintenance
Life Time
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Railputler:Just-in-Time Delivery of Rails
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Preassembled turnout with HYDROSTAR® switch section prepared for shipping
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Preassembled turnout HYDROSTAR® loading of the switch section
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Plug and Play:Installation of a preassembled turnout