rails products
DESCRIPTION
Rails ProductsTRANSCRIPT
LUCCHINISeverStal
Rails and rolled productsfor railway applications
Our quality steel in your daily life
Lucchini, now part of the Severstal Group, is one of the world leaders in the manufacture of long products from quality and special steels. In the railway sector the Lucchini Group produces rails and track products in the Piombino plant and cast manganese crossings for railway points in the BFM plant in Bari. The rapid evolution of transport systems and the need for more and more sophisticated materials have required the creation of safe and efficient products suitable for high speed use. In this context of high technological demands Lucchini is one of the leading figures on an international level thanks to a balanced combination of competent human resources, an innovative engineering ability and an integrated plant system. The rails and railway equipment produced at Piombino have been used by the Italian State Railway and for the construction of the whole Italian network since 1908/09 when they were first rolled in the Piombino (LI) factory. The continuous modernisation of Piombino rails production line has allowed Lucchini to reach a leadership position on an international level and to become one of the most important business partners for the delivery of rails and railway equipment. By investing in research and technology and thus being able to use leading edge plants to deliver high quality and safe products Lucchini fulfils the steadily increasing requirements of the railway market. It does so in terms of standards, technique and quality and it facilitates cost reduction in direct
Railway products and services
intervention on the railway network. In the context of the company strategy technological innovation has taken into account the following important factors:
The development of high speed systems;•National and international technical standards, •ever more oriented satisfying safety, comfort and environmental issues;The directives of the European Union concerning •railway transport.
Continuous caster
Degassing PlantL.F. Converter Blast furnace
Wharf
Mineral yard
Rehating furnace
Break mill
2 Reversible stands
Horizontal and vertical straightness machines Samples
Cooling bed 108 m
Cut and drilling (on demand)
Straightness control
Inspection bed for client inspection and weight
Service center
Delivery
Horizontal finishing stand
Non destructive control system US and E.C.
Wharf
Manufacturing process
Steel production in the Piombino factory is based on integrated cycle. The raw material arrives by ship at the company’s private dock, where it is stored before converting into cast iron in a blast furnace with a daily production capacity of around 6.600 tons. The liquid cast-iron is transferred to the steelworks in torpedo cars with an average capacity of 150 tons. In this phase the cast-iron undergoes an initial treatment called HMD (Hot Metal Desulphurization) aimed at reducing the sulphur content.The transformation process takes place in three 120 ton oxygen converters (BOF - Basic Oxygen Furnace) of the LBE-CBS type (Lance Bubbling Equilibrium - Control Bottom Stirring). Suitable secondary metallurgy (LF) working practices
allow the completion of the steel before it is transferred to the degassing plant. The degassing plant used in the Piombino factory is a Tank Degasser. Degassing not only reduces the hydrogen and other gas value, it also permits significant internal cleaning due to the drawing of inclusions towards the surface of the bath. After degassing the steel is cast by the continuous casting process based on the most modern and precise control systems. The plant produces square section blooms with a 320 mm side or rectangular 340x245 mm blooms destined to rolled rails with high quality metallurgical characteristics.
Continuous caster Rail mill Coke plant
Blast furnace
Wire rod millBar millMineral yardCoal yardWharf
Steel plant
Management
Service center
From raw minerals to finished productCare and attention is paid from the selection of raw materials to the delivery of the finished product.
Rolling of Rails
The recently reconstructed rolling mill at the
Piombino factory is based on the most modern
technologies available in the field of rolling.
It is possible to produce rails from 27 to 70 kg/m in
finished bars up to 108 metres long with very strict
and uniform tolerances that satisfy European and
international standards and technical specifications.
This system guarantees maximum production
flexiblity and the satisfaction of the highest Customer
quality standards.
The reduction ratio of continuous cast blooms
through a series of rolling processes is higher than
the ratio required by the standards.
In this way the internal structure and homogeneity
of the finished product are improved, as well as the
mechanical characteristics (rails heavier than 50
kg/m are produced from a square 320 mm bloom).
The use of high definition video cameras and of
laser sources during the rolling phase allows the
constant measuring and monitoring of the profile
dimensions and of all the process data such as
product temperature, speed rolling rate, efficiency of
equipment and ID-tracking.
Furthermore during rolling, the whole rail section is
checked by means of a 6 high definition
cameras integrated system that is conveniently
positioned to control the presence of any surface
defect.
Tradition and innovationLucchini has been producing rails for 100 years. Today the most modern available technologies are utilized in order to satisfy even the most demanding technical specifications.
Hot marking
The rail plant is equipped with two automatic hot
marking machines controlled by the information
system which manages the entire production line.
The machines have a revolving heads and can print
multiple markings on the rolled product moving on
the roller-way at the foreseen rolling speed.
This marking system guarantees the identification
of every single rail produced as required by the
international standards and/or by the Customer’s
technical specifications.
Cooling bed
Rails are trimmed at one end before leaving the
rolling stands and are positioned on the 120 metres
long cooling bed by means of 52 lifting conveyors.
The conveyors are each other independent moving
rails on the cooling bed. In this way the bars are
positioned with a curve which straightens out during
cooling. This facilitates their feeding into the cold
straightening plant.
All is aimed at reducing to a minimum the mechanical
pressures necessary for straightening and
consequently at reducing internal stresses.
The advancement of the rails is obtained by a
“walking-beam” system.
Advanced technologyThanks to the continuous modernisation of its production line Lucchini produces rails as long as 108 meters without welding.
Rail straightening
The straightening line has two straightening units positioned after the cooling bed. The straightening pressures are applied onto the relevant axis at the rail height for vertical straightening and onto the head sides for horizontal straightening.
Non-Destructive Tests
The increasing requirement for products with fewer surface defects derives from a variety of different reasons such as: safety in use, operational reliability, extension of life cycle, travel comfort, track geometry, increased speed, increased axial loads, increased railway traffic.For the above mentioned reasons and for the many requirements of product quality control, the rails produced in the Lucchini Piombino factory are analysed in an integrated “system” of Non-Destructive Tests (NDT). This testing system consists of Eddy current equipment and of ultrasonic equipment. The NDT system has been specifically developed and created for controlling all rail profiles required by the market.
Eddy Current Test
The Eddy Current test allows the continuous and automatic control of the head and of the feet of the rail at a speed of 1m/sec. The method is based on the operation of 6 rotating probes (for flat areas) and of 2 fixed probes (for
Non-destructive control systemSafety and reliability for railway applications.
gauge corner) and uses the magnetic permeability of
steel. All the probes transmit information concerning
the number of detected defects, their distance from
the ends and their position within the section.
The calibration of the Eddy Current system is carried
out with a sample rail with a length of 12 metres in
which defects of known position and dimensions are
artificially produced.
Ultrasonic Test
The Ultrasonic examination is carried out in a
continuous and automatic mode soon after the Eddy
current test. The system is equipped with 16 probes
of the “squirter” type (with water jet) without direct
contact with the rail that allow to check the whole
section of the rail for its entire length.
The defects detected by the Eddy current and
ultrasonic control systems are processed in real time
and signalled to the technicians both on monitors and
on inspection reports.
The defect detected is highlighted on the rail by
means of an automatic paint spray.
Cutting to length
After the checks with the NDT system the rails are
cut to length and drilled if required, by means of a
dedicated facility. Finishing operations can also be
carried out at the service centre (CSE).
High SpeedTechnological solutions for an expanding market.
Cold checking of straightness
Straightness is checked by means of a no-contact high definition cameras system. The system is completely static and does not require any electro-mechanical positioning. The processed data are recorded and a reporting is generated. The control is performed on the final rail length.
Finishing
After cold cutting and straightness control, the rails are transferred to the inspection bed for the final controls. A dedicated, automatic handling system - capable of managing lengths of up to 108 metres turns the rail on all four sides for the visual surface control. On request, this system can also weigh individual rails. Final material identification - conforming, non-conforming - is relyed to the application of an adhesive label with a bar code. When this label is read, all the information needed for successive operations is loaded into the warehouse management information system.
Straightness check systemEmploying a no-contact high definition camera system and laser sources.
Rail service centre
The rails are then transferred to the Service Centre (CSE) for warehousing in dedicated areas equipped to handle rails from 4 to 108 metres in length or for extra finishing operations requested by the Customer (cutting into smaller sizes, drilling, packing, etc.).
Shipment and logistics
Rails can be shipped from the Piombino plant either by rail or by sea using the plant’s own port facility. By managing its own fleet of wagons to transport rails up to 108 metres in length and via continuous innovation at the port for shipping rails up to 108 metres long Lucchini is able to operate in international markets with maximum flexibility. These systems also guarantee service quality and punctuality all the way to the destination indicated by the Customer. Internal and external handling operations are executed with special systems and equipment to guarantee maximum product integrity.
In the heart of MediterraneanEfficient logistics for clients. Maximum flexibility and punctual service.
The rolling mill is designed to produce 108 metres rails without any welding, for conventional networks and for high speed ones (rails from 27 kg/m to 70 kg/m). The production range also includes: tongue bars, baseplates and check rails.
Lucchini is able to design and to produce all the profiles requested by the market in order to satisfy the Customer.
production range
Products for traditional applications and for High Speed marketLucchini is able to design and produce a wide range of profiles re-quested by the market
Quality grades % in weight ppm ppm MPa % HB
EN 13674 series C Mn Si Cr S P max 0 max H max Rm min A min
R200 0,40/0,60 0,70/1,20 0,15/0,58 0,15 max 0,008/0,035 0,035 20 3 680 14 200/240
R220 0,50/0,60 1,00/1,25 0,20/0,60 0,15 max 0,008/0,025 0,025 20 3 770 12 220/260
R260 0,62/0,80 0,70/1,20 0,15/0,58 0,15 max 0,008/0,025 0,025 20 2,5 880 10 260/300
R260Mn 0,55/0,75 1,30/1,70 0,15/0,60 0,15 max 0,008/0,025 0,025 20 2,5 880 10 260/300
R320Cr 0,60/0,80 0,80/1,20 0,50/1,10 0,80/1,20 0,008/0,025 0,02 20 2,5 1080 9 320/360
UIC 860.O
700 0,40/0,60 0,80/1,25 0,05/035 / 0,05 max 0,05 / / 680 14 /
900A 0,60/0,80 0,80/1,30 0,10/0,50 / 0,04 max 0,04 / / 880 10 /
900B 0,55/0,75 1,30/1,70 0,10/0,50 / 0,04 max 0,04 / / 880 10 /
1100 0,60/0,82 0,80/1,30 0,30/0,90 0,80/1,30 0,03 max 0,03 1080 9 /
AREMA
Standard carbon 0,74/0,84 0,75/1,25 0,10/0,60 0,25 max 0,020 max 0,02 / 1,5 982 9 300 min
IRS-T-12-96
880 0,60/0,80 0,80/1,30 0,10/0,50 / 0,035 0,035 / 3 880 10 260 min
SPecificationS Profile WeigHt (kg/m) H Wf Wt WH
AREMA141RE 69,83 188,91 152,40 17,46 77,79
136RE 67,44 185,74 152,40 17,46 74,61
UIC 860.O
60UIC 60,34 172,00 150,00 16,50 72,00
54UIC 54,43 159,00 140,00 16,00 70,00
54UIC E 53,81 161,00 125,00 16,00 67,00
UNI 3141
50UNI 49,85 148,00 135,00 14,00 66,88
46UNI 46,79 145,00 135,00 14,00 65,00
36UNI 36,19 130,00 100,00 14,00 60,00
27UNI 27,35 120,00 95,00 11,00 50,00
BS 11:85
BS113A 56,39 158,75 139,70 20,00 72,01
BS 100A 50,18 152,40 133,35 15,08 72,00
BS 90A 45,02 142,88 127,00 13,89 66,68
BS 80A 39,76 133,35 117,47 13,10 65,43
BS 80R 39,67 133,35 127,00 13,49 63,50
BS 70A 34,81 110,33 123,82 12,30 62,19
BS 60R 29,82 114,30 109,54 11,11 57,15
EN 13674-1
60E1 60,21 172,00 150,00 16,50 72,00
60E2 60,05 172,00 150,00 16,50 72,00
56E1 56,30 158,75 140,00 20,00 69,85
54E1 54,77 159,00 140,00 16,00 70,00
54E2 53,82 161,00 125,00 16,00 67,01
54E4 54,30 154,00 125,00 16,00 67,00
50E5 49,90 148,00 135,00 14,00 67,00
50E6 50,90 153,00 140,00 15,50 65,00
49E1 49,39 149,00 125,00 14,00 67,00
46E1 46,17 145,00 125,00 14,00 65,00
46E2 46,27 145,00 134,00 15,00 62,00
46E4 46,90 145,00 135,00 14,00 65,00
AFNOR NF 52-523U50 50,63 153,00 140,00 15,50 65,00
U33 46,30 145,00 134,00 15,00 62,01
DIN 5902
S49 49,43 149,00 125,00 14,00 67,00
S49A 49,05 148,00 125,00 14,00 67,00
S40 36,54 128,00 115,00 13,00 58,27
S33 31,18 126,00 105,00 11,00 58,00
GOST R 51685 - 2000 P65 64,84 180,00 150,00 18,00 75,00
Other Specifications
ER52 51,68 155,00 141,00 15,00 66,00
R48 48,00 150,00 127,00 14,00 68,00
46 SBBI 46,16 145,00 125,00 14,00 65,00
R45 45,40 150,80 127,00 13,80 67,47
DAN 45 45,46 141,00 126,00 13,76 72,20
81lb/yd 40,31 127,00 127,00 13,89 63,50
R31 31,58 125,00 106,00 12,00 56,00
Rails
Vignole Rails
WH
WH
Wf Wf
Wt
Wt
H
H
Bars for Points
Unlimited availability upon request
SPecificationS Profile WeigHt (kg/m) H Wf Wt WH
Italian Railway SpecificationA 60UNI 69,09 134,00 140,00 40,00 72,00
A 50UNI 61,04 148,00 135,00 28,00 66,88
EN 13674-260E1A2 69,04 134,00 140,00 40,00 72,00
50E1T1 60,96 148,00 135,00 28,00 67,00
SPecificationS Profile WeigHt (kg/m) a b c d
Italian Railway Specification60 P4U 58,384 370 152 15,5 29,5
60 P5U 58,384 370 152 15,5 29,5
UNI 3551
50 UNI 1/20 59,648 355 137 14 33
60 UNI 1/20 64,187 370 152 15 33
50S UNI 55,153 390 137 14 33
60S UNI 55,153 390 152 14 33
Other Specifications PB 68 68,42 360 142 20 33
Baseplates
Tongue Bars
db
a Wf
WtH
c
Baseplates in Bars Check Rails
Tongue bars are turnouts components which, after machining operations, are transformed into blades and used in switch.
Baseplates are used on track to secure the rail to the underneath sleepers.
Unlimited availability upon request
SPecificationS Profile WeigHt (kg/m) H Wf Wt
Italian Railway SpecificationCr 1 - 60U 40,03 192,00 72,00 18,00
Cr 4 - 60U 47,34 222,00 72,00 18,00
EN 13674-340C1 39,89 192,00 72,00 18,00
47C1 47,07 222,00 72,00 18,00
Check Rails
check rails are used to guide the flange of the wheel while the train runs trought the switch.
Unlimited availability upon request
Unlimited availability upon request
research and development
In this field, Lucchini dominates thanks to a whole series of implemented process and product development programs, aimed at increasing the reliability, life, and safety of its products and the range of products. Innovative products have been studied, perfected and tested such as: rails with improved mechanicals properties specifically studied to reduce rolling contact fatigue phenomena in Phalesia 110 steel grade. This allows Lucchini to reach extremely high quality standards in terms of the performance and life of the products it offers.
The innovative steel: higher strength and reliability
®
Quality directed to the futureProduct and process development programs aimed towards higher quality standards.
www.lucchini.com
Lucchini S.P.A.Headquarters25128 Brescia Italy
Via Oberdan 1/a
Tel. +39 030 39921
Fax +39 030 3992517
E-mail: [email protected]
Piombino Plant - Rail Business57025 Piombino (Livorno) - Italy
Largo Caduti sul Lavoro, 21
Tel. +39 0565 64111
Fax +39 0565 64133
E-mail: [email protected]
Lucchini UK LtdWheel Forge Way
Trafford Park - Manchester
M17 1EH
Tel +44 161 8860340
Fax +44 161 8722895
Lucchini IberiaAv. Josep Tarradellas 84-88
08029 Barcelona - Spain
Tel. +34 93 3691973
Fax +34 93 4197064
Lucchini Asia Pacific21 Tan Quee Lan Street
02-10 Heritage Place
188108 Singapur
Tel. +65 6 3346775
Fax +65 6 3347015
Lucchini SiderprodukteGrindlenstrasse 5
8954 Geroldswil - Switzerland
Tel. +41 44 749 2111
Fax +41 44 748 4710
www.siprosthal.ch
Lucchini USA660 White Plains Road
10591 Tarrytown - NY
Tel. +1 914 3327550
Fax +1 914 3327551
LUCCHINISeverStal