Roma, 1 december 2006

Rete Ferroviaria Italiana Track Maintenance

Ing. Matteo Triglia

2

Network and Situation

• 16.000 km of line, two third electrified and 6.300 km double-track line (with 22.000 km of main line)

• About 30.000 km of total track and 44.000 switches

• About 1.900 plants for the regulation of the trains circulation and 20.000 km of track equipped with systems of automatic block for the spacing of trains

• More then 1.500 km of tunnels, 530 km of bridges and viaducts, 9.000 km of power lines, 385 power station and substation

• Cost about 1 M. €/ year

Situation

• Increasing uncertainties on financing

• Effect turnover on the competences

• Discontinuity of perimeter: Entry of AV / AC network

• Discontinuity of content: insertion of new technologies

• increase of plants maintenance

Network

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• Containment of the costs• Improvement of the

reliability and the safety • Increase of the availability

of the track• Management of the new

technologies and the lines AV / AC

Attended impact

• Increase of the productivity of personal

• Reduction of maintenance cost of the traditional network for contracted activity

• Improvement of the indexes of unavailability of the infrastructure

• Increase of maintenance cost for new technologies and lines AV/AC

Assigned objectives

Objectives

4

16.000 km of line (6.300 double track)1.255 km of tunnels530 km of bridges and viaducts

9.000 km of power lines

385 stations and sub-stations

3 national workshops

Infrastructure Structure

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Type of line

Type A – Main Line with heavy traffic (intensity, speed and major maintenance standard)

Type B – Main Line (long distance line for national and international traffic)

Type C – secondary electrified line

Type D – not electrified line

Infrastructure Structure

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Infrastructure Structure

LINEkm LINE km TRACK

TYPE A 1.275 2.550TYPE B 5.120 9.320TYPE C 4.300 4.936TYPE D 5.325 5.362

TOTAL NETWORK 16.020 22.168

JUNCTION AND FREIGHT LINE 1.000OTHER TRACK 8.000

TOTAL TRACK 31.168

ELECTRIC POWER SUPPLY 3000 V c.c.

LINE ELECTRIFIED km 10.695 MAIN TRACK ELECTRIFIED km 16.086LINE NOT ELECTRIFIED km 5.395 MAIN TRACK NOT ELECTRIFIED km 5.362TOTAL km 16.020 TOTAL km22.168

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Infrastructure Structure

Km of LineKm of Line

0

2000

4000

6000

8000

10000

12000

double track

single track

double track 1256 4306 655 53 6270

single track 3 838 3884 4881 9606

LINE A

LINE B

LINE C

LINE D

TOT.

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Infrastructure Structure

Km Km Main Main LineLine

0

2000

4000

6000

8000

10000

12000

14000

double track

single track

Double track 2511 8611 1310 105 12537

Single track 3 838 3884 4881 9606

LINE A

LINE B

LINE C

LINE D

TOT.

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Infrastructure Structure

A B C D

4.848

TOTAL

14.388

12.792

16.970

44.150

2.092

991

1.765

TYPE OF LINE

TOTAL 3.476 22.830 12.996

6.976

6.971

8.883

3.622

3.920

5.454

SWITCHES ON SECONDARY LINE CENTRALISED (electrified + manual)

SWITCHES ON SECONDARY LINENOT CENTRALISED and FLATT SHUNTING(electrified + manual)

1.698

910

868

SWITCHES ON MAIN LINE(electrified + manual)

SINGLE AND DOUBLE TURNOUT

SwitchesSwitches

10

Steps of Maintenance Process

and Logistic

DW-MaintenanceBW-Pianning

Controllo

Tecnico

Annual

Planning

Attività Negoziale

Objects ofMaintenance

StandardActivity

State of Track

List ofMaterial

Diagnostic

Quartly

Programme

Weekly

ProgrammeExecution

Contract Management

Goods Entry - Store Management

Goods Management

SuppliersRegister

Advices

Form - PM

Form - MM

CdL

IntervalsSlowing down

Tech. Control

Economicalcontrol

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Plan the maintenance

Programme the resources

Manage spare parts and technical material

Study and remove the breakdowns

Informatics

system

The engineering of maintenance

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Evolution of maintenance

2. In the way of maintenance “on condition”

4. Relationship with suppliers of equipments and plants that are involved in the Maintenance during the life cycle.

3. Support with managerial informatics tools the visits to the work sites and the consequent technical relief's.

5. Certify the service.

1. Precise planning

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“Diagnostic" is the activity directed to determine “health condition" of the different components of the railway infrastructure in order to:

• guarantee the safety of the exercise

• prevent the breakdowns

• address maintenance resources where is recorded a degrade of geometric characteristics and/or of the infrastructure operation parameters incompatible with the desired service level (maintenance “on condition”)

Diagnostic

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The virtuous diagnostic circle - maintenance

Interventoimmediato o

Analisidati eimmissione nel SIM

Esecuzione medianteTronchi, Zone, Cantieri Meccanizzati,

Appalti

Programmazione tramite SIM

manutenzioneon condition

ATTIVITA DI DIAGNOSTICA

•Controllo completo infrastruttura linee A e principali B

•Rilievo geometria e usura binario e linea di contatto linee C e restanti B

•Rilevo geometria binario linee D

•Rilievo parametri geometrici binario e deviatoi

•Rilievi a US dei difetti interni alle rotaie

MEZZI DI MISURA

Treno Archimede

Talete-Aldebaran

PV7 , EM80

Carrellini informatizzati

Treno Galileo e rivelatoriportatili

Immediate interventionor

Analyse of data insertion in SIM

Execution By means ofTrunks, Zones, Mechanized work site,

Contracts

Programme with SIM

maintenance“on condition”

DIAGNOSTIC ACTIVITY

•Complete infrastructure control line A & mainly B

•Relief geometry & rail corrugation & Overhead line on line C & other B

•Relief geometry line D

•Reilief track geometric parameters & switches

•Relief with US of rails defects

MEASURING VEHICULES

Archimede Train

Talete-Aldebaran

PV7 , EM80

Informatics trolley

Galileo train & portableindicator

15

Operational flow for the Diagnostic of the Infrastructure

Planning -Programme

Work

Orders

Work

Orders

Pa

ram

eters re

gis

tratio

n

Diagnostic Trains

Uultrasonic reg.

Diagnostic System Advices

•Quality index•Track geometric registration•Track defects

DATAWAREHOUSEMAINTENANCE

COAMI

Visite Structures

PM

Reports Breakdown

PM

Measuring documents

SEDE TECNICA

SEDETECNICA

SEDETECNICA SEDE

TECNICA

SEDE TECNICA

Punto di MisuraPunto di Misura

Punto di MisuraPunto di Misura

PM

DMS

Transform the data in information

16

InfraManager System of decisional support for the infrastructure maintenance

17

Proposal of work M/R

Elaborate work orders

PLANNING

SCHEDULING EXECUTIONMONITORING

- Interventions-Work planning

Measuring

ANALISES

Evaluation of quality

- Breakdown- Defects- Quality index- RAM Indicator- Statistics data

- Track Geometry- Rail Profile- Ballast- Sleepers- Catenaries Geometry- Wear of OHL

- …

-AREA TO BE OPTIMIZED

Chain of maintenance management based on diagnostic

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Chain of maintenance management based on diagnostic

Proposal of work

Scenario ottimizzato

PIANNING EXECUTIONSCHEDULINGMONITOR

- Interventi- ScadenzaLavori

Measuring

ANALISI

- Velocità di degrado- Vetustà- Storicolavori- Efficacialavorazione- Frequenzainterventi- Costi- Traffico

quality

- Avarie- Difetti- IndiciQualità- IndicatoriRAM- Datistatistici-Avvisi

- GeometriaBinario- ProfiloRotaia- Ballast- Traverse- Geometriacatenaria- Usurafilo- …

OPTIMIZATION

Scenario ottimizzato

Elaborate Work orders

WorkRegister

PL ESCHEDULMONITORING

- Intervention- Work Planning

M

ANALISES

- Degrade speed- Old age- Work register- Work Efficiency- Intervention frequency- Costs- Traffic

Evaluation of

- Breakdown- Defects- Quality Index- RAM Indicator- Statistics Data-Advices

- Track Geometry- Rail Profile- Ballast- Sleepers- OHL Geometry- Wear of OHL- …

OPTIMIZATION

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Finished work

Algorithms of work forecast:

- overcoming thresholds- Degrade speed

Track

Rail

Sleeper

Ballast

Algorithms of Technical and Economical Optimisation:- Grouping works on spatial and temporary base- elimination of ordinary intervention in proximity of renewal- Works distribution in accordance to the priorities and the ties of the railway exercise

Sceneries of intervention

Diagnostic Data

BasicData's

Executed work

Cost and bonds

ENTRY ELABORATION FINAL OUTPUT OPTIMISATIONOUTPUT

INTERMEDIATE

-Tamping-Ballast Cleaning-Rail renewal-Renewal ballast

Definition of Maintenance intervention

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Diagnostic

Diagnostic and extraordinary maintenance

The practice of track renewal is tied up to considerations on life duration of the track or to directives of technical standardization (ex.: 60 UNI, Pandrol fastening, elimination of wood sleepers, etc.). These considerations can always be additional to the results of the mobile diagnostic that these are considered on a sufficient long term (1-2 years).The analysis of these elements is facilitated by the recent insertion in the SIM.

21

Diagnostic

The internal defects registered with US

The consistence, registered on the network, of the rails inside defects pointed up with the ultrasounds furnishes an important element of evaluation on the necessities of extraordinary maintenance of one determined section of track.When in fact on a section of track are present many defects that exceeds a determined limit, it can economically result more convenient, from the point of view of the operational costs, to plan a generalized renewal of rails in that section.

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RFI main activity

inspection and control of the entire network with the “mobile diagnostic”

intervention in case of abnormality’

Intervention of ordinary maintenance

protection of work site

Intervention of maintenance (levelling and lining of track and switches, bush cutting, general overhaul, substitution of rails and sleepers)

Inspection of outsourced work

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Main activity of track work Contractors

Intervention of extraordinary maintenance and renewal

Intervention of ordinary and/or complete maintenance (rail grinding, levelling and lining of track and switches, bush cutting, general overhaul, extended to rail and sleepers substitution)

Urgent intervention

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RFI, for the outsourced track work, has organized two "contract type", both of more years validity: the one, with jurisdiction to level of the whole network, divided in one or more territorial lots, for the trust of important track work including, track renewal, systematic ballast cleaning, total sleepers substitution, etc.

the other one, with jurisdiction to level of Infrastructure Compartment Direction, for the trust of the track work of ordinary maintenance, finalized in containment of the normal defects (revision, leveling, etc.) ;

Outsourced Track Work

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Both contracts have the objective of:

• to avoid the fragmentation of the performers, giving responsibility to the contractors in terms of ability technical / executive and of business organization, with particular respect to the quality of the performed performances;

• to harmonies behaviors to the whole network; to plan middle term interventions through a single tender, guaranteeing to the trackwork contractors a stability of the orders and favoring, at the same time, the modernization of the equipments and the improvement of the business organization.

Outsourced Track Work

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For both contract type, the execution of the intervention is in quality assurance, accordingly to the standards ISO 9000 and in respect to the documents "Plain of Quality."For the performance quality, the contractor, during the operational phases and before reactivation to the exercise of the track under maintenance, must verify the quality of the performed work reporting the result on special forms released by RFI.

Outsourced Track Work

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The track works are contracted to subjects in possession of RFI qualification certificate to the "System of Qualification of the railway trackwork Contractors" and, if required to the "System of Qualification of Suppliers of concrete sleepers", that participates in an association of enterprises (ATI, constitute of trackwork Contractors and manufacturers of the materials). This in order to guarantee a coordination of the productivity and performance and of the oneness of the responsible interlocutor.

Outsourced Track Work

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Furthermore, to the level of whole Network with a three year contract, are performed interventions of rail grinding, type corrective, for about 700 km/year of track on lines of group A, B and C for elimination of defects of short and long wave. Such interventions are performed in programmed possession of track of about 3 hours. The quality of the performed work is valued through a quality index that foresees the remaking of intervention in case it is not satisfied.

Outsourced Track Work

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Quantity of work performed in the years 1999 to 2006 in extraordinary maintenance

Outsourced Track Work

7005601999

9001.1502000

8601.1002001

8001.0502002

670

440

800

560

km BINARIO

6502006

7502005

7302004

7002003

N° DEVIATOIANNO

7005601999

9001.1502000

8601.1002001

8001.0502002

670

440

800

560

km TRACK

6502006

7502005

7302004

7002003

N°SWITCHESYEAR

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Amount of planned track renewal for the years 2007, 2008 and 2009

in extraordinary maintenance

Planned track work

6504502008

450

500

km BINARIO

6002009

6002007

N° DEVIATOIANNO

6504502008

450

500

km TRACK

6002009

6002007

N°SWITCHESYEAR

31

Special actions have been taken in the following sectors:

improvement of the competences of the personnel of the contractors;

certification of the performed work;

establishment of a systematic inspection activity on the track work site.

Control of Contractors track work

32

The qualification of the Contractors personnel that operates in maintenance activity of the railway infrastructure has been organized in only one system:

COMPETENCES OF CONTRACTORS PERSONNEL

Control of Contractors track work

ABILITAZIONI PERSONALE IMPRESE APPALTATRICI settore

MANSIONI ESECUTIVE DELLA PROTEZIONE CANTIERI TUTTI

“Saldatura alluminotermica” definita nella Circolare DI.TCAR.CI.AR.07.001.A del 21 marzo 2000 – “Abilitazione per l’esecuzione di saldature alluminotermiche di rotaie per il personale

dipendenti da Imprese Appaltatrici”. ARM

GUIDA DEI MEZZI D’OPERA DI PROPRIETA’ DELLE I.A. TUTTI

ARMDITTE (Proc. RFI DMA- DTC PS IFS 012 A del 03.03.2004) ARM

nuova

QUALIFICATION OF CONTRACTORS PERSONNEL sector

EXECUTIVE FUNCTION OF WORK SITE PROTECTION ALL

“alluminotermic welding” according ProcedureDI.TCAR.CI.AR.07.001.A of 21 march 2000 – “Qualification of Contractors Alluminotermic welders”

ARM

DRIVERS OF CONTRACTORS TRACKWORK MACHINES . ALL

ARMDITTE (Proc. RFI DMA-DTC PS IFS 012 A of 03.03.2004) ARM

new

33

CERTIFICATION OF THE PERFORMED WORK

The Terms of Contract for work in presence of the railway exercise prescribes that the contractor must perform the Quality Control of the work before the reactivation of the track to the exercise, with particular attention to those work that have importance with the Safety of the exercise.

Such controls must be documented through specific forms for the followings work: Renewal of track/total substitution of sleepers Ballast cleaning Renewal of switches and crossings

Control of Contractors track work

34

Considering the high investments in the activity of track work, RFI considers of fundamental importance the relationship with l’Associazione Nazionale Imprese Armamento Ferroviarie (ANIAF).

A major reason with the European Federation of Track Work Contractors (EFRTC)

Relationship with Contractors Association

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Relationship with the Association allows to: better comprehension between client and supplier increase capacity/potentiality in carrying out of work seek/increase methodology for a better quality of the executed work Optimise the track work cost reduce the subjections to the railway exercise, in terms of time possession improve the safety of the railway exercise and the personnel involved in the work site promote use of high performance machines

Relationship with Contractors Association