new zealand rtsa division
TRANSCRIPT
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New Zealand RTSA DivisionPandrol
Craig Mulvay – Vortok Product Line and Equipment, APAC
Tim Hoare – Welding and Equipment, APAC
23/05/19
Content
1. Company Overview
2. Rail Stress Management
3. Aluminothermic Welding
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Section 1: Company Overview
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Company Structure
Innovative solutions dedicated to our activities 51% Family
Ownership:
Railways MetalsConductic
Operations #1
in their activities
worldwide
Railways
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Company Structure
Railways
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Company Structure
RailwaysRailways
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Rail Stress Management Safety Barrier
Equipment – Vortok Product Line
Cable ManagementCoil
Equipment MountingConditional Monitoring
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Clipping Machines
Equipment – Rosenqvist Product Line
Sleeper Replacement
Sleeper Handling
Sleeper Spreading
Rail Handling
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Track Tools
Equipment – Railtech Product Lines
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Section 2: Rail Stress Management
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Rail Stress Management
Rail Stress Management is the active management of rail thermal forces to
prevent buckling in high temperatures or rail break in low temperatures.
Network Rail UK:
“The management of rail stress to prevent track buckles is one of the
highest track risks on the network.”
One of the foundations of managing the risk is by maintaining the
Stress Free Temperature (SFT) of the rail.
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Rail Buckle – Real Time
Please Click Mouse To Run Video
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Pull Apart – Rail Break
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What is SFT
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track CWR Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track CWR Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track CWR Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track CWR Track
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Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
Bolted Track CWR Track
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Rail Stress
Rail Temperature
SFT
Compression Tension
Incre
ased
Tem
pera
ture
Decre
ased
Tem
pera
ture
What is SFT:
CWR Track
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What is SFT:
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
SFT
Compression Tension
Stress Free Temperature (SFT)
is the temperature at which the
rail is at zero axial thermal
loading.
That is; not in tension and not in
compression.
SFT = Neutral Temperature
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What is Target SFT:
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
Max. expected rail temperature
Min. expected rail temperature
Target SFT
Compression Tension
Target SFT is set by the Track Owner
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VERSE
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VERSE Overview – What is it?• VERSE – Vertical Rail
Stiffness Equipment
• Non-destructive method of
measuring Stress Free
Temperature (SFT) of
Continuously Welded Rail
(CWR)
• Recognised standard for
measuring risk of track
buckles and rail breaks
• Works on same principle
of ‘A-Frame’
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VERSE Overview – When is it used?• As a routine Survey Tool
• As a spot check
• As a quality control tool
• To check mechanised
maintenance impact
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VERSE Overview – Theory of Operation
• Rail is raised to form a simply supported beam section
• Rail is deflected in the centre of the beam and Force and Displacement is
measured
• Force vs Displacement result is proportional to Rail Tension
• Rail Tension with known rail temperature allows SFT to be calculated
• F(y) ∝ Rail Tension ∝ SFT
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VERSE Overview – Theory of Operation
SFT ∝ F(y)
Inputs: Rail Temperature
Rail Stiffness - Rail Section Type
- Rail Wear
- Elastic Modulus (constant)
Beam Geometry - Inner Spans
- Outer Spans
Curve Versine (before and after unclipping)
Outputs: SFT of the Rail
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What is SFT:
Rail Stress
Rail Temperature
Data Point
Compression Tension
Rail Temperature
Ra
il Te
nsio
n
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What is SFT:
Rail Stress
Rail Temperature
Data Point
Compression Tension
Measured SFT
Rail Temperature
Ra
il Te
nsio
n
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What if measured SFT is below Target?
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
Max. expected rail temperature
Min. expected rail temperature
Target SFT
Compression Tension
Measured SFT
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What if measured SFT is below Target?
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
Max. expected rail temperature
Min. expected rail temperature
Target SFT
Compression Tension
Measured SFT
Action:- Add tension to the rail cutting out rail and rewelding
- Follow standard stressing procedures
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What if measured SFT is above Target?
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
Max. expected rail temperature
Min. expected rail temperature
Target SFT
Compression Tension
Measured SFT
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What if measured SFT is above Target?
Rail Stress
Rail Temperature
Buckle
Rail
Bre
ak
Max. expected rail temperature
Min. expected rail temperature
Target SFT
Compression Tension
Measured SFT
Action:- Reduce tension by adding in rail (add a closure rail)
- Follow standard stressing procedures
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Vortok Stressing Roller
(VSR)
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How It WorksOver Centre
Lowered Raised
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How It Works – Reason for using VSR
Force distribution along pull length(considering straight track for simplicity)
𝐹 𝑥 = 𝑃 − 𝜇𝐴𝑚𝑔𝑥Where;F(x) = Force in rail at point x from pull pointP = Tensor ForceμA= Vertical Coefficient of Frictionm = Mass/meter of railg = Gravity
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How It Works – Reason for using VSR
Force distribution along pull length(considering straight track for simplicity)
𝐹 𝑥 = 𝑃 − 𝜇𝐴𝑚𝑔𝑥Where;F(x) = Force in rail at point x from pull pointP = Tensor ForceμA= Vertical Coefficient of Frictionm = Mass/meter of railg = Gravity
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How It Works – Reason for using VSR
Force distribution along pull length – Pulling over pads vs VSR
Input DataTr = 10°C (Rail Temperature)Tt = 32°C (Target SFT)m = 50kg/m (Rail Mass)μp= 0.3 (Steel to HDPE Coefficient of Friction)*μVSR= 0.04 (VSR Coefficient of Friction)**
*Theoretical value for Coefficient of Friction based on typical material performance
**Lab testing of VSR with 10kN vertical load per VSR resulted in:
μs= 0.02 (Static Coefficient of Friction)μd= 0.005 (Dynamic Coefficient of Friction)
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How It Works – Reason for using VSR
SFT distribution along pull length – Pulling over pads vs VSR
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SFT Monitor
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SFT Monitor
Remote conditional monitoring of SFT
• Target Maintenace
• Enhance Safety
• Extend Operational
Availability
• Track Trials Commencing
Soon....
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Section 3: ATW
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What is Aluminothermic Welding (ATW)?
• The focus is often on the
process being used.
• What can we do to improve
the outcome without
changing the process?
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Core of ATW Process
One-Shot Crucible
Aluminothermic Portion
Sand Moulds to suit rail
profile
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Introductions in new Technology
• Consistent Ignition
• Pre Heating
• Head Repair Weld
• Relief of Residual Stress
• Monitoring and Recording
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Consistent Ignition
Pandrol Startwel®
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Startwel®
• Consistent Ignition
• Reliable
• Safe – no DG requirement
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VIDEO STARTWEL®
https://www.pandrol.com/product/startwel-ignition-system/
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Pre Heating Advancements
High Flow Preheater
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Pre Heating – High Flow Preheater
• Optimized nozzle
• Homogeneous preheating
• No flame adjustment
• Automatic stop / start
• Preheating time controlled
via a built-in timer
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Why Pre-Heating Parameters and Weld Gap are
important
• Lack of fusion resulting from
insufficient pre-heating
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2012 – First trial welds in
the Channel Tunnel2018 – Field testing of Optimised Product
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Importance of pre-heating = gap parameters
To
Specification
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Importance of pre-heating = gap parameters
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Importance of pre-heating = gap parameters
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Video HFP
https://www.youtube.com/watch?v=tGgQFgKYLFY
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Head Repair Weld
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Aluminothermic Head Repair Solution
• The HWR provides a
cost-effective and quick
solution to repair rail-head
defects and significantly
decreases the
maintenance cost of
modern rail networks.
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Video HWR
https://www.pandrol.com/product/head-
wash-repair-hwr-process/
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Relief of residual stress
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Relief of Stresses
Aim
Our shot peening impact hammer was developed to
improve the fatigue behaviour of AluminoThermic Welds.
It is extremely common for defects to propagate from the weld
collar area:
- The Under head radius
- At the top of the foot
Shot peening locally lowers the amount of residual stress in the weld,
and is intended to reduce initiation and propagation of fatigue cracks.
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Fatigue failure initiated under the head
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Fatigue failure initiated at the foot
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74 Non contractual picture
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RAILTECH’s Shot Peening Impact Hammer
Shot peening is performed when the weld is below 300 . Use
safety protections for:
- EYES
- EARS
- HANDS
- NOSE
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Side n°1 Side n°2
Interface n°1 Interface n°2 Interface n°3 Interface n°4
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Results
In Europe for over 5 years, all of the welds in track that have been
correctly shot-peened are still in service. No weld failures have been
experienced.
In certain extreme conditions, where the welds could fail after 3 months
of service (less than 20 million tonnes), they have, due to the benefits of shot-
peening, been exposed to over 320 million tonnes without failure.
In the laboratory, fatique failures initiate within the parent rail, outside of
the shot-peened weld area
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Testing of 68kg Rail with shot peening
• Some fatigue tests were realised to :
• 68K PLK CK 25 grade 345 with shot
peening realised 30 minutes after the end of
the tapping
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Video Shot Peening
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Recording and Monitoring
Advancements
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Recording and Monitoring
Pandrol Connect
• Recording of in track conditions
• Condition monitoring
• End to End reporting
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MODULES
Back office
Configuration
interface
Monitoring WebApp
Management of the
welds by supervisers
Mobile App
Record and check
welds on location
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ONLINE WELD MONITORING
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PDF WELD CERTIFICATE
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ONLINE ADMINISTRATION TOOL
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DATA EXPORTATION
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App Video
https://www.pandrol.com/product/pandrol-connect-welding-app/
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Thank You