Glenn Lorenz - Vossloh Cogifer Australia - Heavy haul turnout installation and maintenance
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Transcript of Glenn Lorenz - Vossloh Cogifer Australia - Heavy haul turnout installation and maintenance
Glenn Lorenz
Vossloh Cogifer Australia Pty Ltd
May 2014 Brisbane
Heavy Haul Turnouts
•Heavy Haul Turnouts are designed
and manufactured to meet the needs
of Heavy Haul rail systems and
networks.
•Vossloh Cogifer Australia (VCA) is a
designer and manufacture of Turnouts
and Rail component in Australia.
•VCA have supplied turnouts in all
heavy haul networks in Australia.
Contents:
• What is Heavy Haul?
• Who Uses Heavy Haul?
• Client Needs / Expectations.
• Heavy Haul geometries and
Configurations.
• Turnout Design.
• Turnout manufacture.
• Heavy Haul Turnout components.
• Turnout Installation &
Maintenance.
• Future for Heavy Haul Turnouts
•What is Heavy Haul Rail?
Any rail Haulage above 28 Tonne Axle
Load
Heavy Haul Sub Category :
Medium HH – 28 to 34 Tonne Axle Load.
Super HH – 35 to 42+ Tonne Axle Load.
Unit of Measure
Wagon single axle vertical load mass.
E.g. 120 gross tonne wagon ÷ 4 Axles =
30 Tonne Axle Load. (TAL).
North West
BHP Iron Ore
Rio Tinto
FMG
Mid – West
& OPR
Aurizon
NSW
Hunter Valley
ARTC
Who Uses Heavy Haul in Australia?
Heavy Haul Pilbara – WA
Standard Gauge
• BHP Billiton Iron Ore – 37TAL at
220 MT p.a.
• Newman, Yandi & Yarrie Networks
• To Port Hedland & Finucane Island.
• Rio Tinto / Pilbara Iron – 35TAL at
290 MT p.a.
• Paraburdoo, West Angelas,
Brockman & Yandicoogina to
Dampier & E. Intercourse Island.
• Robe River Network – Pannawonica,
Mesa J & Area C to Cape Lambert.
• Fortescue Metals Group – 42TAL
at 155 MT p.a.
• Single line parallel with Newman
Railroad.
• Christmas Creek & Cloudbreak to
FMG port at Finucane Island.
Christmas Creek &
Cloudbreak
FMG
BHP Billiton
Yarrie Line
BHP Billiton
Newman & Yandi Networks
Rio Tinto
Pilbara Iron Networks
Rio Tinto
Robe River Line
Mesa J & K
Heavy Haul – QLD Narrow Gauge
•30TAL at 120 MTpa shipping coking coal:
•Four Systems now operated by Aurizon
•Newlands System - Bowen Basin (non-elec)
•Feeds to Abbot Point
•Goonyella System (non-elec)
•Feeds to Hay Point & Dalrymple Bay
•Blackwater System (elec)
•Feeds to new port at Jilalan (near Rockhampton)
•Moura System (elec) - Feeds to Gladstone
•RG Tanna Coal Terminal; Barney Point
Heavy Haul – NSW
ARTC – Std Gauge
•32TAL at Over 90 MTpa shipping steaming coal
•Lower Hunter
•Mt. Thorley, Ravensworth, Bayswater
•Upper Hunter
•Ulan & Gulgong (Ulan Line)
•New England Ranges
•Gunnedah & Curlewis
•3 Ports at Newcastle
•Port Waratah Coal Services
•Kooragang Island
•Newcastle Coal Infrastructure Services
•Ability to handle extremely
heavy loads.
•Long Life Cycle.
•Component reliability.
•Minimal maintenance.
•Component interchangeability.
•Maintenance access within minimal
time frame, to suit increasingly
frequent train schedules.
•Provide technical support.
Client Needs –in HH Turnout design.
Heavy Haul geometries and Configurations.
•HH geometries differ little from non Heavy haul turnouts.
•Standard Secant and Tangential geometry.
•Geometry, turnout radius and angle is determined by the required
speed of the operator, both on diverge and mainline movements.
•Turnout angles generally range from 1:10 to 1:25
Turnout Design and Features:
•Understanding of clients technical requirements.
Axle loads, Speeds, Interfacing, Gauge, Wheel profile,
signalling……
•Selection of appropriate components and material
must be significantly robust to handle the load
requirements.
•Rail Type – Size, Hardness
•Switch type – Full Depth, Mang tipped, Thick web,
Asymm.
•Crossing Type - SNX, RBM, Fabricated.
•Bearer type – Concrete, Timber, Steel, Composite.
•Plating – Cast, Braced, Fabricated.
•Fastening System - Resilient, Screwed.
•Cast Components – Material selection.
Turnout Manufacture:
•Achievement of High tolerance
Repeatability in manufacture is
critical to ensure consistent and
high quality product.
•The use of 3D software and
numerically controlled machines
for manufacture provides high
tolerance and repeatability.
•Use of jigs to ensure quality,
consistency and replication of
product and assemblies.
Heavy Haul components.•Fastenings:
•Complete resilient fastening systems.
•Removal of screw spikes into bearers.
•Removal of conventional screws and bolts and
replace with swage lock bolting and elastic type
fasteners.
Traditional fastening system Resilient fastening system
RE68 /136RE Rail, &
RE136TW Switch Rail
AS 60 Rail
60E1A1 Switch Rail
U 33 Guard Rail
Rail Section Height (mm) Mass (kg/m) Izz x 106mm4 Zhead x 103mm3
RE 68 / 136 RE 185.7 67.5 39.4 391.7
RE 136 TW 185.7 87.8 41.9 415.5
AS 60 170.0 60.6 29.3 322.4
60 E1 A1 134.0 73.0 17.3 229.9
•Full Depth Manganese
tip Switchblade
Heavy Haul components.Switches:
•Asymmetric section Switchblades.
•Through Hardened
Thick Web Switch
Rail Section.
• Asymmetric Switchblades
• 60 E1 A1 (or variants) for switchblades – usually heat-treated
• Used with 60E1 or AS 60 stockrails and running rails – also heat-treated
• Up to 32.5 tonnes / axle; Up to 100 km / hour loaded
• IBAV / ISRB Resiliently fastened stockrails
• Improved lateral stiffness – for design of operating equipment / backdrives
• However, reduced bearer spacing (500 mm) for HAL applications.
• Full – Depth Switchblades
• May be over-riding, or flat-bottomed (with cut-away stockrails)Depends
of the stockrail locators & supports – rail braces
• AREMA Standards – reinforced, with Austenitic Manganese Steel tips
• RE 68 / 136 RE – HT / HH recommended for HAL applications
• Use of Thick-Web rail allows for tangential switch geometry and
improved lateral stiffness.
Characteristics of Switchblades
•Swing Nose
Crossings – Mang
Steel Cradle.
Heavy Haul components.
•Manganese
Steel Fixed nose
Crossings.
•Crossings:•Swing Nose
Crossings – Rail
Steel
Crossing Selection.
Installation & Maintenance:
Hunting
marks
Dip in
stockrail
•Correct installation and Maintenance
is critical to ensure increased turnout
life:
•Solid substructure and Track alignment
is essential. Both within the turnout and
entering the turnout, to prevent
corrugation and “Hunting”.
•Early grinding to remove metal flow will
ensure Switch and Crossing material
stabilizes. Thus reducing future grinding
frequencies.
•Lubrication of moving parts.
•Ensure all bolts and fastenings are
correctly tightened and installed.
Metal Flow
Future for Heavy Haul Turnouts
•All swing nose Crossings.
•In bearer Rodding for both switches
and SNX for tamping access.
•Use of Switch roller plates to reduce
friction of Switchblades.
•Metallurgical inputs for Material
improvements to achieve longer life
from wearing parts.
i.e. Use of harder stronger rail steels,
special alloyed steels for crossings
and switch blades.
Future for Heavy Haul Turnouts
•Boltless and Screwless assemblies
ton ensure elastic toe load is
consistant.
•Concrete Bearers
•More acute angle Turnouts with
greater radii to increase diverge
speed.
•Component interchangeability of
wearing parts for quick changeout.
•Turnout design should have provision
to optimize rail welding techniques.
Vossloh - AusRail Sydney Nov 2013
“Not So” Heavy Haul Application
24
Thank you for your attention