sersa flash butt welding & destressing system presented by martin benkler member of the board...
TRANSCRIPT
![Page 1: Sersa Flash Butt Welding & Destressing System Presented by Martin Benkler Member of the Board Sersa(UK)Ltd](https://reader036.vdocuments.site/reader036/viewer/2022062422/56649e7c5503460f94b7d604/html5/thumbnails/1.jpg)
Sersa Flash Butt Welding & Destressing System
Presented by
Martin Benkler
Member of the Board Sersa(UK)Ltd
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Cost reductions and push for higher productivity
• High output industrial type approach
• Integration of individual processes
• Concentration of various activities in the same time slots
• Reduction of amount of possesions and better usage
• Introduction of high quality and repeatable processes
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Solution
• Welding and Destressing in one process
Animation Serstar
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Loosening the rail fasteners
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Preparation of the joints
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Positioning of the Joints
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Welding machine
• Highly mobile Road/Rail machines
• Ready to weld within minutes
• Hight output (up to 8 welds per hour or more)
• High precision and fast alignment system
• Recording of welding parameters of each weld
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Serstar Mobile Flash Butt Welding System
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Serstar Mobile Flash Butt Welding System in Operation including rough grinding
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Clamping and Alignment
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Recording of weld parameters
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Temperature measurement and calculation of required elongation
Calculation according to•the stressfree temperature•rail temperature•the lenght of rail to be destressed
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Marking of the required elongation
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Operation of Sersa Destressing Equipment
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Passing over of Serstar mobile flash butt welder
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Retightening of rail fasteners
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Final grinding and marking of welds
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Recording
• Weld Inspection Form
• Destressing FormFlashbuttWeldingInspectionformSersaUKLogo30-8-04.pdf
DestressingFormsSersaUK15-9-04.pdf
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Personnel on worksite
Working teams
Amount of operators Responsibility Remarques
1 2 Loosening of rail fasteners and provisional clamps
1 Person in Charge for Destressing (SERSA) 2 Inspectors from the German Federal Railways (DB) for welding and destressing1 Lookout
Total Personnel on worksiteProductive Sersa 15+1Supervision German (DB) 3
2 2 Preparation of rail ends
3 2 Positioning of rails
4 2 Operation of Sersa Destressing Equipment
5 2 Flash butt welding and rough grinding
6 4 Retightening of fasteners
7 1 + Team 1 Final grinding and marking of welds
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Average site productivity
Basis
• Rail Length 120m
• Rail Profile UIC 60 E 2 Grade 260
• Temperature Difference average 7 ° C
• Rail Fasteners Type Vossloh
• Monobloc concrete sleepers
• Track ballasted and tamped(at least first tamping)
Productivity
2,5 to 3 hours for
1 km of track welded and destressed
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Conclusion
A high productivity and thus lower cost can be
achieved by
• a production line approach
• an integration of various processes
• Use of high output machinery and processes
• Use of reproducable and as much as possible operator independant processes
• Very precise & thorough site planning and organisation