Sersa Flash Butt Welding & Destressing System

Presented by

Martin Benkler

Member of the Board Sersa(UK)Ltd

Cost reductions and push for higher productivity

• High output industrial type approach

• Integration of individual processes

• Concentration of various activities in the same time slots

• Reduction of amount of possesions and better usage

• Introduction of high quality and repeatable processes

Solution

• Welding and Destressing in one process

Animation Serstar

Loosening the rail fasteners

Preparation of the joints

Positioning of the Joints

Welding machine

• Highly mobile Road/Rail machines

• Ready to weld within minutes

• Hight output (up to 8 welds per hour or more)

• High precision and fast alignment system

• Recording of welding parameters of each weld

Serstar Mobile Flash Butt Welding System

Serstar Mobile Flash Butt Welding System in Operation including rough grinding

Clamping and Alignment

Recording of weld parameters

Temperature measurement and calculation of required elongation

Calculation according to•the stressfree temperature•rail temperature•the lenght of rail to be destressed

Marking of the required elongation

Operation of Sersa Destressing Equipment

Passing over of Serstar mobile flash butt welder

Retightening of rail fasteners

Final grinding and marking of welds

Recording

• Weld Inspection Form

• Destressing FormFlashbuttWeldingInspectionformSersaUKLogo30-8-04.pdf

DestressingFormsSersaUK15-9-04.pdf

Personnel on worksite

Working teams

Amount of operators Responsibility Remarques

1 2 Loosening of rail fasteners and provisional clamps

1 Person in Charge for Destressing (SERSA) 2 Inspectors from the German Federal Railways (DB) for welding and destressing1 Lookout

Total Personnel on worksiteProductive Sersa 15+1Supervision German (DB) 3

2 2 Preparation of rail ends

3 2 Positioning of rails

4 2 Operation of Sersa Destressing Equipment

5 2 Flash butt welding and rough grinding

6 4 Retightening of fasteners

7 1 + Team 1 Final grinding and marking of welds

Average site productivity

Basis

• Rail Length 120m

• Rail Profile UIC 60 E 2 Grade 260

• Temperature Difference average 7 ° C

• Rail Fasteners Type Vossloh

• Monobloc concrete sleepers

• Track ballasted and tamped(at least first tamping)

Productivity

2,5 to 3 hours for

1 km of track welded and destressed

Conclusion

A high productivity and thus lower cost can be

achieved by

• a production line approach

• an integration of various processes

• Use of high output machinery and processes

• Use of reproducable and as much as possible operator independant processes

• Very precise & thorough site planning and organisation