RISSB : TURNOUT WORKSHOP

PLANNING OF TURNOUT MAINTENANCE

SOME PERSONAL EXPERIENCE

PETER MICENKO

MAY 2014

BRISBANE

CONTENTS

• INTRODUCTION

• BASIC ASSET MAINTENANCE 101

• EXPERIENCES over 30 years

– SOUTH AFRICA

– AUSTRALIA

• SUMMARY AND CONCLUSION

ASSET MAINTENANCE 101

• KNOW WHAT YOU HAVE– ASSET OR EQUIPMENT REGISTER

• INSPECT THE ASSETS– CONDITION

• PROTECT THE TRAFFIC

• ENTER THE CONDITION - WORKS MANGAGEMENT SYSTEM

• PLAN THE REPAIRS

• REPAIR/RENEW

• CLOSE OUT

SUMMARISING ASSET MAINTENANCE PROCESS

DETECT

CORRECT

INSPECT

PROTECT

RAILWAY COMMON ATTRIBUTES

• ALL DIFFERENT- tribes & teams

• SOME ASPECTS ARE EXCELLENT

• HAVE TO START SOMEWHERE

– TRY / TEST SOMETHING

– NORMALLY ANYTHING IS BETTER THAN

NOTHING

– REFINE-CONTINUOUS IMPROVEMENT

– PERFECTION TAKES TIME

EQUIPMENT REGISTER

• VARIES

– INDIVIDUAL NEEDS

– ORGANISATION NEEDS

– SUPPORT

• CAN VARY IN DETAIL BUT

– NEEDS TO BE CORRECT

– NEEDS TO BE KEPT CORRECT

EQUIPMENT REGISTER

SOME IMPORTANT CRITERIA CAN BE:-

• LINE CODE

• LOCATION/STATION

• POINTS NUMBER

• KM LOCATION

• SPEED / AXLE LOAD CAPABILITY

• DESCRIPTOR OF POINTS

USUALLY IN A SPREAD SHEET FORMAT

EQUIPMENT REGISTERFIELD OR DIAGRAMATIC

• GOOD FOR VISUALISING &

DISCUSSIONS

EQUIPMENT REGISTER

• DESCRIPTOR OF POINTS • TYPE I.E. 1:9, 1:12

• RAIL PROFILE I.E. 30kg/m…. 60 kg/m

• LEFT OR RIGHT

• TYPE OF CROSSING

• TYPE OF BLADES

• WELDED OR BOLTED

• TYPE OF BEARERS

• METHOD OF OPERATION- ELECTRIC, HYDRAULIC, MANUAL

MAINTENANCE PLANNING

turnout condition assessment

• TECHNICAL

• ECONOMIC

• OPERATIONAL

• ORGANISATIONAL

• WITHOUT ALL FOUR ASPECTS CONSIDERED WILL NOT

REALISE BENEFITS

MEASURE TO KNOW : MEASURE TO MANAGE

• INSPECTION BASED

• ESTABLISH THE CONDITION

• Use to

– PLAN THE REPAIR JOBS

– MAINTENANCE PRIORITY

• CRITCALITY of ASSET the BUSINESS

• “FILE SAVE”- KEEP RETRIEVABLE RECORDS

• ESTABLISH THE CONDITION AFTER WORKS

MAINTENANCE PLANNING

turnout condition assessment

• START WITH KNOWING WHAT ASSETS YOU HAVE -

EQUIPMENT REGISTER

• INSPECT YOUR ASSETS

• WHAT TO MEASURE

• OPINION

• TEMPLATES

• PHOTO GUIDE

AN EARLY TEMPLATE c1982• Nothing existing

• Developed by local PWI

• Simple & met needs

• Location: Station, points

number, points machine

number, road, km

• Type of

turnout:1:9,48kg/m,

monoblock, old switches,

timber,

• Used measurements for

Turnout gauge locations &

versine requirements &

• Personal appraisal

CAPE WESTERN. C. 1990TURNOUT ASSESSMENT

• FIELD ASSESSMENT

• MEASUREMENTS

• RELATES GEOMETRY STANDARD

• MEASURE &

• CALCULATES AN INDEX

A SCORING SYSTEM

KIMBERLEY INSPECTION c 1998

• BIGGER PICTURE VIEW

• Extend geometry measurements

QUEENSLAND RAILTURNOUT INSPECTION • HAS SOMETHING SIMILAR

• DEFINES THE TURNOUT

• MEASURES GEOMETRY &CONDITION

• GIVES SOME IDEA OF LIFE

EXPECTANCY

• INSPECTIONS

• DETERMINE THE CONDITION

• CRITCALITY IN THE NETWORK

• PLAN THE REPAIR JOBS

• “FILE SAVE” - KEEP RETRIEVABLE RECORDS

• KNOW THE CONDITION AFTER WORK

MAINTENANCE PRIORITY

KIMBERLEY INSPECTION c 1998• The importance of recording work

done

TRACK GEOMETRY VS TIME

POOR

CONDITION

WORK PERFORMED ON

TURNOUT

GOOD

CONDITION

TRACK CONDITION VS

MAINTENANCE INPUT

• THE EFFECT OF A CHANGE OF PHILOSOPHY

MANHOURSRED= CONDITION AS

TOTAL WORK

REQUIREMENTS

POOR

CONDITION

GOOD

CONDITION

Job prioritization in NSW c 2002• Model for rating jobs

– Due Diligence - Safety, Operating Environment

– Rail Safety, Reliability, Economic Benefit & Payback,

Environmental impact

– Condition- incidents, and rail safety

• All jobs in one pot- Limited budget for MPM- Not turnout specific

Due Diligence Programs Rail Safety Score Reliability Score Financial Score Environmental Score

Due Diligence Safety Due Diligence Environmental Other Cyclic MPM Strategic MPM

Ref Project No. of

persons

Injury

class

Ranking

Score

Prob. Customer Req

not met

Legislation

breach

Ranking

Score

Ranking

Score

Prob. Incident

Code

Incident

Score

Annual

Score

Ranking

Score

Prob. No. of

Failures

No. of

Speeds

Closure

Y/N

Trains

impacted

Ranking

Score

Prob. Payback

years

Ranking

Score

IRR Ranking

Score

Prob. Inside

corridor

Outside

corridor

Ranking

Score

TOTAL

SCORE

WEIGHTED

SCORE

M02-118 Cootamundra Yard. 429km Upgrade

yard-stage 1 Cootamundra North Fork /

M02-118

>100 F 10 10 10

M02-34 Joppa Junction to Junee. Resurface and

profile 180 km various locations / M02-

34

0 0 N 0 0 0 C 5 100 6 H 1 1 N 900 9 H 10 6 L 1 2 2 23 6.5

M02-35 Joppa Junction to Junee. WTSA

resurfacing 47 km various locations /

M02-35

0 0 N 0 0 0 C H 500 9 10 10 L 3 32 8.95

M02-37 Joppa Junction to Junee. Profile rail

grinding 65 km / M02-37

0 0 N 0 0 0 H B 800 5 M 1 1 N 450 7 H <5 8 L 3 3 3 23 6.15

M02-36 Joppa Junction to Junee. Ballast clean

12 km / M02-36

0 0 N 0 0 0 0 0

M02-38 Joppa Junction to Junee. Resurface 33

turnouts / M02-38

0 0 N 0 0 0 H K 50 200 4 H 2 N 900 9 H <5 8 L Y 1 22 6.2

M02-40 Joppa Junction to Junee. Renew 0.6 km

security fencing / M02-40

0 0

M02-39 Joppa Junction to Junee. Renew 25 km

stock fencing / M02-39

0 0 0 C N 50 250 6 L 1 N 5 1 L <15 2 L Y 1 10 3

W-125 Wallenbeen 414-416 km Down. Rerail

1.4 km Morrison's Hill / W-125

0 0 0 C B 800 9600 10 H Y 60 9 C 1 10 H Y Y 8 37 9.5

W-112 Cootamundra 431.65 km Up main

Upgrade turnout Strattons Mill - Croker

Carroll / W-112

0 0 N 0 0 0 H B 800 1600 8 H 1 1 N 900 9 H >15 5 L Y Y 2 24 6.95

W-118 Cootamundra 433.211 km Up main

1/12.1 SOTT-Replace 30 transoms / W-

118

>100 F 10 10 10

LOCAL QUEENSLAND APPROACH

• PREVIOUS

– LEGACY ISSUES

– YOUNG ORGANISATION

• DESIGN & MAUNUFACTURE LEAD TIMES

• POSSESSION LIMITATIONS

• MULTIPLE DISCIPLINES

• ASPECTS WERE GOOD

A BETTER MOUSETRAP

• CONCEPT BASED ON APPROACH TO LEVEL CROSSINGS

• LIST WHAT WE HAVE- 991 TURNOUTS ON CQCN

• VERIFY THEIR EXISTENCE

• DEVELOP A CONDITION ASSESSMENT

• LINK PROGRAMS TO TRAFFIC REQUIREMENTS

• BEGIN AND CONTINUE THE INSPECTIONS

– DOCUMENT THE RESULTS

– TRAIN FOR UNIFORMITY

– EATING THE ELEPHANT

– CONTINUOUS IMPROVEMENT

• STICK TO IT

• USE THE RESULTS

TEMPLATE AND ASSESSMENT CRITERIA

• IDENTIFY THE ASSET

• ASSESS CONDITION

• BUSINESS NEEDS

• CURRENT USE– WORK IN PROGRESS

– MAJOR YARD COMPLETE

– EXPANDED TO 3 SUPT’S

– PROPOSE TO EXPAND TO ALL SUPT’S

SOURCE OF INPUT

condition assessment

USE APPROPRIATE ASPECTS

• ASSET REGISTER

• DEFECT DATA BASE

• FIELD MEASUREMENTS

• FIELD EVALUATION

• COMMENTS

• PRODUCE AN INDEX

USE FOR JOB &ACTION PRIORITY

IDENTIFY THE ASSET

• Line NC, CL…………….Section (Yard / N/A)

• Km (000.000km please)

• Turnout Number / Points Number

• Elec / Manual operation

• Rail Weight 60kg, 53kg, 50kg, 47kg

• LH / RH / Catch Points / Other

• Points Protector

• Ties (Con, timber)

• V - Type (FAB, RBM, SNX or Swing wing)

• Angle (1:8, 1:8.25, 1:10, 1:12, 1:16…….)

• Installation date (Approximate age)

ASSESS THE CONDITION

• Vee Condition ( 1 = Excellent / 10 = Red Board )

• Guard rails Condition ( 1 = Excellent / 10 = Red Board )

• Fastenings Condition ( 1 = Excellent / 10 = Red Board )

• Sleepers Condition ( 1 = Excellent / 10 = Red Board )

• Ballast Condition ( 1 = Excellent / 10 = Red Board )

• Formation Condition ( 1 = Excellent / 10 = Red Board )

• Drainage Condition ( 1 = Excellent / 10 = Red Board )

• GENERAL CONDITION RATING

INCLUDE BUSINESS NEEDS

• Next Ballast Undercut Date Quarter :

• Asset Renewal Year (based on above inspection) Quarter :

• Criticality To Business

• 4 = High (Main-Line (Designated Golden Asset))

• 3 = Moderate MGT's (Low Class Line)

• 2 = Yard (Low Speed, Low MGT's)

• 1 = Very Little Use

• Actions required to extend Asset Life and improve General

condition rating.

SUMMARY

• KNOW WHAT YOU HAVE

• MEASURE TO MANAGE- APPLICABLE MEASUREMENT

• CONDITION REPOSITORY

• PRIORITISE

• SHORT, MEDIUM LONG TERM EFFORTS

• LEAD TIMES /PROGRAMS

• QUALITY

• CONFIGURATION CHANGE/RECORDS

BIBLIOGRAPHY & ACKNOWLEDGEMENTS

The following reference sources to illustrate and support this

presentation is acknowledged with thanks.–“QR DETAILED TURNOUT INSPECTION” Template

–AURIZON, Draft turnout prioritisation template. D. Judge

–Various ex Transnet Freight Rail

•SOUTH AFRICAN TRANSPORT SERVICES Permanent Way Instructions

1984 and subsequent revisions.

•“Western cape switch tamper our experience”. E.S.Redman September 91”

•“Produksiebestuurderkursus, 24 maart 1999”. Johan Bekker

–POST GRAD THESIS- D. JUDGE