April 2015

Rail Lifecycle Management Forum John Paff – Lead Track Engineer

Asset Standards Authority Purpose, priorities and progress | 1 16 September 2016

Track Engineering

John P aff Lead T rack Engineer

Nagajyothi Lolla Senior Engineer,

Track

Navneet Kaur Senior Engineer,

Track

David Brown Senior Surveyor

Graeme S hephard Principal Engineer, Alignment and Transit

Space

Dave Cooper Principal Engineer

Track Structure

Jack Tattersall A/Senior Engineer

Track Structure

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Purpose and objectives of today

• Engage with industry to enhance standard development

• ASA wants to listen to your ‘war stories’ on past railway activities that affect your day-to-day engineering tasks

• ASA wants to know if you like or dislike the content in any of our standards

• ASA encourages you to be open, honest and willing to participate

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Purpose and objectives of today • This forum is about rail lifecycle management • We have previously held similar technical forums

for design, construction and maintenance • For today, we can discuss associated activities and

other disciplines too. • Predominantly heavy rail but inclusive of light rail

and metro systems • This forum is for YOU!

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Why you are here • Self assurance primarily rests with you as

Authorised Engineering Organisations (AEOs). • As proven track engineers working on infrastructure

on behalf of TfNSW, you are best positioned to provide an informative review and feedback in relation to NSW standards you continuously comply with

• You are considered key stakeholders in the performance of our standards.

• To collaborate and promote common understanding

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Thi ngs to consider • Interdependencies • Discipline interfaces • Concept and planning works • Construction, maintenance and asset

management • Types of contract engagement • Client expectations • Appropriateness of standard content • Intelligent compliance

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April 2015

Discussion 1 – Rail Steel

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Rail Steel

Applicable standards and manuals: - AS 1085.1 Railway Track Material – Steel Rails - ESC 220 – Rail and Rail Joints - EN 13674-1 Vignole railway rails 46 kg/m and

above

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Rail Steel - Composition

Table E1 and E2 extracted from AS1085.1

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Rail Steel – Properties and Hardness

Table E3, E4 and E5 extracted from AS1085.1

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Discussion 2 – Selection of Rail

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Selection of Rail

Heat affected zone in HH rail – AS1085.1 extract

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Selection of Rail

Sydney’s light rail section 60kg rail – extracted from AS1085.1

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Selection of Rail

Technical Note - TN 057: 2016

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Revised requirements to ESC 220 Section 4.1.2.1 'Use of Head Hardened Rail' ofESC 220 shall be replaced in its entirety with

the following:

Head hardened 60kg/m rail shall be selected for use in accordance with the existing or proposed

track structure d ass detailed in Rail Corp standard ESC 200 and the following requirements:

• for tracks subject to more than 20 MGT per year of heavy axle load traffic (23 t axle load or

greater)

• for tracks where axle loads heavier than 25 tare to be used at levels greater than 1 MGT per

year

•

~. curves where the use of standard carbon rail would result in a predicted renewal cycle of 6

years or less

no other locations are permitted to be installed with head hardened 60H rail unless a

concession has been granted by the Asset Standards Authority (ASA)

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Background and site handling Where selection requires two steel types to be installed, common practice has been to select only

a single steel grade for ra il replacement, which has consistently resulted in the procurement and

installation of steel with the harder value. The view taken was that using the harder steel type for

an entire installation would result in reduced rail wear, longer service life, and enable more

simplified site placement and installation.

A negative consequence of having a reduced rate of ra il wear from head hardened rail (60H) is

the prevalence of rolling contact fatigue (RCF) propagation. Standard carbon rail steel (60S),

under similar circumstances wears at a relatively equal rate to the RCF defect types and

consequently does not permit a significant surface defect to become established.

The associated RCF surface micro-eracking also negates ultrasonic testing of the rails and

creates a safety significant issue of 'untestable rail'.

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April 2015

Discussion 3 – Rail Handling

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Rail Handling - Pending ASA “Good Practice Guide” contains a track element

and covers rail handling

New rail without bolt-holes Rail Train Hi-rail plant

Track Reconditioning

Excavator and grabs Rail manipulator

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April 2015

Discussion 4 – Turnouts

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TurnoutsESC 260

TURNOUTS ANO SPECIAL TRACKWORX

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TURNOUTS

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Discussion 5 – Installation and Adjustment

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Installation and Adjustment ~-

TMC 223

RAIL ADJUSTMENT

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Adjusted section Next section to be adjusted 4~~~~~~~~~~~~~~~~41~~~~~~~~~~~~~~~-~

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Step f Remove Anchor

Point here

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Next Adjustment Point

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Install Anchor Point here

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Discussion 5 – Welding

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Rail Welding

Youtube link: NWR’s mobile flash butt machine https://www.youtube.com/watch?v=vLNAaYxpp0Y

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Discussion 6 – Management, inspection methods and defect types

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Management, Inspection methods and defect types

- Five common defect types:

Squats Weld Defects Rail Joints

Transverse Vertical Splits

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Management, Inspection methods and defect types

- Applicable manuals

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Future Direction

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Future Direction

Youtube link: TfNSW’s new train unveiled https://www.youtube.com/watch?v=MY8KFJLYL8M

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