ribbons of steel - railtex 2015 - presenting rails with extra life

Ribbons of Steel – Presenting rails with extra life

Together we make the difference

Daniel Pyke – Product Marketing Manager

2Ribbons of Steel SlideTata Steel

Scene setting

Broken Rails Levels decreased dramatically over last 10 years

• ~40% weld related• 10-15% corrosion related

Partial view

Weld

Corrosion and Foot Fatigue

Rail ends

Fatigue

Others

Weld

Rail

Corrosion and Foot Fatigue

Weld

Rail

Corrosion and FootFatigueRail ends

Rail Head

Fatigue

Others


Scene setting

Industry prevents rail failure by maintenance Maintenance cost comparisons across networks difficult Large costs directed at:

Fatigue management• Rolling Contact Fatigue• Squats

Wear Plastic flow / Lipping / end batter

Conflicting industry drivers Reduced maintenance cost Increased track availability


Contact Fatigue

Plastic flow

Corrosion

Foot Fatigue

Wear

Corrugation

Noise


Corrosion

Foot Fatigue

Wear

Wear

Contact FatigueNoise

Plastic flow

Corrugation


Contact Fatigue

Corrosion

Foot Fatigue

Wear

Noise

RCF

Plastic flow

Corrugation


Corrosion

Foot Fatigue

Wear

Noise

Foot corrosion

Crown corrosion

Contact Fatigue

Plastic flow

Corrugation


Contact Fatigue

Corrosion

Foot Fatigue

Wear

Noise

Foot Fatigue

Plastic flow

Corrugation


Contact Fatigue

Corrugation Corrosion

Foot Fatigue

Wear

Plastic flow

Noise

Plastic flow


Contact Fatigue

Corrosion

Foot Fatigue

Wear

Plastic flow

Noise

Corrugation

Corrugation


Contact Fatigue

Corrosion

Foot Fatigue

Wear

Noise

Noise

Plastic flow

Corrugation


Corrugation

Contact Fatigue

Corrosion

Foot Fatigue

Wear

Noise

Plastic flow


Contact fatigue (RCF) reduction case study

RCF initiates and propagates into the severe category within 8-12 months of installation in R260

3 monthly grinding of R260 enables ~5 year rail life HP335 installed in Jan 2011

Installation date: 21/1/11

Maximum line speed: 110mph

Curve radius: 1186m

Traffic type: Mixed passenger and freight

EMGTPA: ~38

R260 - 27mm surface crack length (3 months after grinding)


HP335 vs. R260

No grinding during this period


Life Cycle CostsCumulative Relative Rail Management Costs

0

0.2

0.4

0.6

0.8

1

1.2

0 1 2 3 4 5 6 7 8 9 10

Year

Rela

tive c

ost o

f rai

l man

agem

ent v

s R26

0 Gra

de

Payback in Year 3

Re-rail in Year 5 for R260

Data provided courtesy of Network RailSite details: 1186m radius, 37.5 EMGTPALinespeed 110mph

Over 40% life cycle cost saving


Contact fatigue (RCF) summary

Life extended by using HP335 More than doubled Lower RCF growth Lower wear rate

Maintenance reduced Reduced inspection requirements 2/3rds reduction in rail grinding requirements

Huge life cycle cost savings Over 40% reduction in rail management cost 10+ year view gives greater savings


Wear and corrugation reduction case study

Severe vertical wear and plastic deformation Corrugation on both the low and high rail Site re-railed approximately every 2½ years in R260 HP335 installed in April 2010

Installation date: April 2010

Maximum Line Speed:

15mph

Curve radius: 40m (150mm cant)

Traffic type: Light rail passenger vehiclesBi-directional

MGTPA: ~ 5


HP335 vs. R260

Wear

Wear rates significantly reduced Head wear

Low rail – 53% reduction High rail – 52% reduction

Side wear Low rail – N/A High rail – 90% reduction

Corrugation

Corrugation growth rate radically reduced

High Rail - 64% reduction Low Rail - 68% reduction

Life of HP335 rail has more than doubled compared to R260

Bold – R260 @ 3yrs

Feint – HP335 @ 5yrs


Contact Fatigue

Plastic flow

Corrosion

Foot Fatigue

Wear

Corrugation

Noise


Any questions?

Together we make the difference

ribbons of steel - railtex 2015 - presenting rails with extra life

Engineering