coal line longitudinal rail stress projectglobalview.uic.org/cd-rom3_sans/wilma_hannes_maree.pdf ·...
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ENGINEERING & TECHNOLOGYENGINEERING & TECHNOLOGY
Coal Line Longitudinal Rail Stress Project
Coal Line Longitudinal Rail Stress Project
2
The Challenge
Perway Incidents 2006 (% of total minutes delayed / reason)
Animals4%
Block Joints4%
Broken Rail23%
Other3%
Sets13%
Ultrasonic28%
False Alarm2%
Fire0%
Geometry23%
50 – 60 % of all Perway train delays are stress relat ed
The Longitudinal Rail Stress Project provides a sol ution:• to significantly reduce incidents and delays relati ng to rail
stress and • reduce required occupation time for testing and rep air
Solution
3
What is Rail Stress
T E N S I O N
COMPRESSIONTension and Compression forces cause Rail Stress that may lead to a Rail Break or Kick Out
A Solution is required for Early Detection of Rail Stress
4
Project Purpose
• To develop a wayside system that will monitor longitudinal rail stress in real
time to enable better management of Continuously Welded Rail (CWR)
• The system should be able to warn against possible kick-outs and rail breaks
• The system should be a tool to plan and execute CWR maintenance
• The system should prevent…
……Derailments
5
CWR Measurement Methods currently in use
1. Cutting the Rail
2. Lifting Frame
3. Strain Gauging
• Accurate if measurements are done correctly• Timeous operation –occupation is required• Closure rail and welding is required• Weakening the track structure
• Extremely accurate with Digital measurements• Usable in any stress condition• High skill level required for initial installation• Expensive
• Accurate if used properly• Timeous procedure of loosening & fastening clips and requires occupation of selected section of line
• Only useable in tension conditions• Frame upgraded to enhance accuracy and performance
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Olifants River Bridge – Ore Line
Strain Gauging in use since early 80’s
HBM UPM60 Scanning Unit
• 16 Force measurement channels
• 2 Rail Temperature channels
• 2 Air Temperature channels
• 2 Concrete Temperature channels
• 4 Expansion gap deflection
channels
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Olifants River Bridge – Ore Line Force & Temperature
• Continuous measurement of Rail Force and Air & Rail Temperatures
• Constant and Real Time monitoring allows operations to take action proactively – reduce train speeds or stop trains at alarm levels
• No derailments occurred since installation
• Outdated technology expensive to maintain
• Technological developments have improved Strain Gauge technology• Enabled wayside recordings from multiple locations• Improved methodology applied to Coal Line Pilot Project
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Coal Line Pilot
Site Selection
• Phase 1
Line 1: Vryheid – Richards Bay
� 98 Sites
Line 1: Overvaal Tunnel
� 7 Sites
• Phase 2
Line 1: Ermelo – Vryheid
• Phase 3
Line 2: Remainder of Coal Line
Site Selection Criteria
Sites were selected on a priority
basis:
1. Tunnel entrances and exits
2. Kick-out and Rail break areas
3. Turnouts before/after deviations
4. Long bridges
5. Inside two tunnels (for
comparison)
6. Additional sites
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Coal Line PilotWayside Intelligent Long Stress Management System
ROCLA concrete cubicle containing Test Equipment
Rail force and temperature measurement devices installed on tracks
Instruments covered with panels to protect against vandalism & on-track damage
Test Equipment Pilot Site
Operations takes action for train speeds and movement
Infrastructure takes action for prioritising maintenance
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DISPLAY
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Installation / Rollout
• The Track Technology Centre is
installing the system (start date:
September 2006)
• A total of 26 Engineers and
Technicians are utilized for the
installation
• Coal Line Engineering Technicians are
assisting and are trained in the
operation and functionality of the
system and its components
• A Coal Line signalling technician will be
utilized for power supply purposes
• Target date for full operation of the
system: July 2008
12
Coal Line PilotInstallation Overview
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Test Results: 15 days (Left Rail)
Date
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iCOMS Main screen display
NormalWarningAlarm
15
iCOMS Forecasting
24/06/2006Prediction date 35°CMax air temp 46°CEst. Rail temp
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System Benefits
System Users
• Coal Link Operations
Centre
• Maintenance Managers
• Depot Engineers and
Technicians
• Production Managers
• Technology
Management (TTC)
• Viewer that will access
data on the main
server
Safety
• Assist in derailment prevention
• Warning system
• Rail break / kick-out detection
• Supporting data in the unfortunate event of an derailment
Maintenance
• Intelligent maintenance
• Continuous CWR long stress measurements
• Maintenance management
• Maintenance cost savings
Progress
• Continuous research possibilities due to system
expandability
• Better understanding of track behaviour and CWR
• Expandability to instrument line 2 with minimal capital
outlay
• Advantages to other maintenance actions (e.g. tamping &
placing closures)
17
Technological Development
World first development : For future installations the Rocla concrete box is to be replaced by a smaller device mounted on mast poles or rail with own solar powered batteries
18
HARDWARE
19
Decision Required
• Coal line project will be fully functional by July
• 2008
• Require ROE and Regional Infrastructure participation
in determining next priority routes / corridors for
rollout in subsequent phases
20
The End
Thank you for your attention
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0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105
Km Distance
Tunnels Dev Turnouts Open Track
Vryheid East
Tintasdrift
Dassieshoogte
Lenjanedrift
Engogweni
Komvoorhoogte
Bloubank
Nhlazatshe
IzolofUloliw
e
Eqwasha
Measurement site breakdown
T1 T2 T7T6T5T4T3
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Measurement site breakdown
105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
Km Distance
Tunnels Dev Turnouts Open Track
UlundiILangakazi
Intsamanzi
Enqolothi
Umunywana
Isangoyana
Emakwezini
IDondotha
Elubana
RCBNsese
T8
T10/11
T16T14/15T12/13
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Measurement site breakdown
Number of Longstress measurement sites per 10Km
2
4
3
5 5
4
6
8
6
4 4
7
6 6
5 5
4 4 4
3 3
0
1
2
3
4
5
6
7
8
9
km 0
-10
km 1
0-20
km 2
0-30
km 3
0-40
km 4
0-50
km 5
0-60
km 6
0-70
km 7
0-80
km 8
0-90
km 9
0-10
0
km 1
00-1
10
km 1
10-1
20
km 1
20-1
30
km 1
30-1
40
km 1
40-1
50
km 1
50-1
60
km 1
60-1
70
km 1
70-1
80
km 1
80-1
90
km 1
90-2
00
km 2
00-2
10
Nu
mb
er o
f st
atio
ns
24
Coal Line PilotInstallation Overview
25
HARDWARE
26
Maintaining WILMA
• Development of a complete maintenance plan
• Monitoring of warnings and alarms TTC and then NOC
• Maintenance of field equipment by contract