April 2015
Rail Lifecycle Management Forum John Paff – Lead Track Engineer
Asset Standards Authority Purpose, priorities and progress | 1 16 September 2016
Track Engineering
John P aff Lead T rack Engineer
Nagajyothi Lolla Senior Engineer,
Track
Navneet Kaur Senior Engineer,
Track
David Brown Senior Surveyor
Graeme S hephard Principal Engineer, Alignment and Transit
Space
Dave Cooper Principal Engineer
Track Structure
Jack Tattersall A/Senior Engineer
Track Structure
Asset Standards Authority | 2
Purpose and objectives of today
• Engage with industry to enhance standard development
• ASA wants to listen to your ‘war stories’ on past railway activities that affect your day-to-day engineering tasks
• ASA wants to know if you like or dislike the content in any of our standards
• ASA encourages you to be open, honest and willing to participate
Asset Standards Authority | 3
Purpose and objectives of today • This forum is about rail lifecycle management • We have previously held similar technical forums
for design, construction and maintenance • For today, we can discuss associated activities and
other disciplines too. • Predominantly heavy rail but inclusive of light rail
and metro systems • This forum is for YOU!
Asset Standards Authority | 4
Why you are here • Self assurance primarily rests with you as
Authorised Engineering Organisations (AEOs). • As proven track engineers working on infrastructure
on behalf of TfNSW, you are best positioned to provide an informative review and feedback in relation to NSW standards you continuously comply with
• You are considered key stakeholders in the performance of our standards.
• To collaborate and promote common understanding
Asset Standards Authority | 5
Thi ngs to consider • Interdependencies • Discipline interfaces • Concept and planning works • Construction, maintenance and asset
management • Types of contract engagement • Client expectations • Appropriateness of standard content • Intelligent compliance
Asset Standards Authority | 6
Rail Steel
Applicable standards and manuals: - AS 1085.1 Railway Track Material – Steel Rails - ESC 220 – Rail and Rail Joints - EN 13674-1 Vignole railway rails 46 kg/m and
above
Asset Standards Authority | 8
Rail Steel – Properties and Hardness
Table E3, E4 and E5 extracted from AS1085.1
Asset Standards Authority | 10
Selection of Rail
Sydney’s light rail section 60kg rail – extracted from AS1085.1
Asset Standards Authority | 13
Selection of Rail
Technical Note - TN 057: 2016
_... __ ,,,_ .. _,,,.._,. __ .................... _, __ .. ___ ., __ . =-~=-;o:,;:;:;;;:;.:.:;,.-:;.,;:;::· ··
·. (-------~- "'··-....... -----·----·- ·--- -----------· --· ·-- ··- ··--...--··
------··-·---·-- ·- --
Revised requirements to ESC 220 Section 4.1.2.1 'Use of Head Hardened Rail' ofESC 220 shall be replaced in its entirety with
the following:
Head hardened 60kg/m rail shall be selected for use in accordance with the existing or proposed
track structure d ass detailed in Rail Corp standard ESC 200 and the following requirements:
• for tracks subject to more than 20 MGT per year of heavy axle load traffic (23 t axle load or
greater)
• for tracks where axle loads heavier than 25 tare to be used at levels greater than 1 MGT per
year
•
~. curves where the use of standard carbon rail would result in a predicted renewal cycle of 6
years or less
no other locations are permitted to be installed with head hardened 60H rail unless a
concession has been granted by the Asset Standards Authority (ASA)
1·; :;;11-
~---=---·-··-··= I ---·- -·- ·- ···- -------· ··---~-·-. .,........... ----------·--·-·· .., ___ .... _ .. _. ...
Background and site handling Where selection requires two steel types to be installed, common practice has been to select only
a single steel grade for ra il replacement, which has consistently resulted in the procurement and
installation of steel with the harder value. The view taken was that using the harder steel type for
an entire installation would result in reduced rail wear, longer service life, and enable more
simplified site placement and installation.
A negative consequence of having a reduced rate of ra il wear from head hardened rail (60H) is
the prevalence of rolling contact fatigue (RCF) propagation. Standard carbon rail steel (60S),
under similar circumstances wears at a relatively equal rate to the RCF defect types and
consequently does not permit a significant surface defect to become established.
The associated RCF surface micro-eracking also negates ultrasonic testing of the rails and
creates a safety significant issue of 'untestable rail'.
Asset Standards Authority | 14
Rail Handling - Pending ASA “Good Practice Guide” contains a track element
and covers rail handling
New rail without bolt-holes Rail Train Hi-rail plant
Track Reconditioning
Excavator and grabs Rail manipulator
Asset Standards Authority | 16
TurnoutsESC 260
TURNOUTS ANO SPECIAL TRACKWORX
=-.. - .. ~-
TMC2S1
TURNOUTS
.. ::::::.-.. _ .. ____ .. i*.:Sr-=.~:::=:::-.=:E:!~=-~ .. :::':."'Z~'":".:=:=:J:=-·---
.:;.~-·=:-x.:=·- ... ·--
Asset Standards Authority | 18
Installation and Adjustment ~-
TMC 223
RAIL ADJUSTMENT
:=..-
Adjusted section Next section to be adjusted 4~~~~~~~~~~~~~~~~41~~~~~~~~~~~~~~~-~
l~I ,. A
I I
Step f Remove Anchor
Point here
B t c ,.,_,
I ", I "-
Steo 2 Steo 3 Install Anchor Remove Anchor
Point here Point here
Next Adjustment Point
1111111111111 < E II:\
\ Steo 4
Install Anchor Point here
Asset Standards Authority | 20
Rail Welding
Youtube link: NWR’s mobile flash butt machine https://www.youtube.com/watch?v=vLNAaYxpp0Y
Asset Standards Authority | 22
Discussion 6 – Management, inspection methods and defect types
April 2015 Asset Standards Authority | 23
Management, Inspection methods and defect types
- Five common defect types:
Squats Weld Defects Rail Joints
Transverse Vertical Splits
Asset Standards Authority | 24
Future Direction
Youtube link: TfNSW’s new train unveiled https://www.youtube.com/watch?v=MY8KFJLYL8M
Asset Standards Authority | 27