Glenn Lorenz - Vossloh Cogifer Australia - Heavy haul turnout installation and maintenance


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Glenn Lorenz delivered the presentation at 2014 RISSB National Rail Turnouts Workshop.

The RISSB National Rail Turnouts Workshop gives all those involved an in-depth forum for discussion and the sharing of expertise. A key element of this workshop is participation and knowledge sharing from audience as well as the workshop leaders. It is a chance for you to bring your experience and to take away new approaches for best practice.

For more information about the event, please visit:

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Glenn Lorenz - Vossloh Cogifer Australia - Heavy haul turnout installation and maintenance

  1. 1. Glenn Lorenz Vossloh Cogifer Australia Pty Ltd May 2014 Brisbane Heavy Haul Turnouts
  2. 2. •Heavy Haul Turnouts are designed and manufactured to meet the needs of Heavy Haul rail systems and networks. •Vossloh Cogifer Australia (VCA) is a designer and manufacture of Turnouts and Rail component in Australia. •VCA have supplied turnouts in all heavy haul networks in Australia.
  3. 3. Contents: • What is Heavy Haul? • Who Uses Heavy Haul? • Client Needs / Expectations. • Heavy Haul geometries and Configurations. • Turnout Design. • Turnout manufacture. • Heavy Haul Turnout components. • Turnout Installation & Maintenance. • Future for Heavy Haul Turnouts
  4. 4. •What is Heavy Haul Rail? Any rail Haulage above 28 Tonne Axle Load Heavy Haul Sub Category : Medium HH – 28 to 34 Tonne Axle Load. Super HH – 35 to 42+ Tonne Axle Load. Unit of Measure Wagon single axle vertical load mass. E.g. 120 gross tonne wagon ÷ 4 Axles = 30 Tonne Axle Load. (TAL).
  5. 5. North West BHP Iron Ore Rio Tinto FMG Mid – West & OPR Aurizon NSW Hunter Valley ARTC Who Uses Heavy Haul in Australia?
  6. 6. Heavy Haul Pilbara – WA Standard Gauge • BHP Billiton Iron Ore – 37TAL at 220 MT p.a. • Newman, Yandi & Yarrie Networks • To Port Hedland & Finucane Island. • Rio Tinto / Pilbara Iron – 35TAL at 290 MT p.a. • Paraburdoo, West Angelas, Brockman & Yandicoogina to Dampier & E. Intercourse Island. • Robe River Network – Pannawonica, Mesa J & Area C to Cape Lambert. • Fortescue Metals Group – 42TAL at 155 MT p.a. • Single line parallel with Newman Railroad. • Christmas Creek & Cloudbreak to FMG port at Finucane Island. Christmas Creek & Cloudbreak FMG BHP Billiton Yarrie Line BHP Billiton Newman & Yandi Networks Rio Tinto Pilbara Iron Networks Rio Tinto Robe River Line Mesa J & K
  7. 7. Heavy Haul – QLD Narrow Gauge •30TAL at 120 MTpa shipping coking coal: •Four Systems now operated by Aurizon •Newlands System - Bowen Basin (non-elec) •Feeds to Abbot Point •Goonyella System (non-elec) •Feeds to Hay Point & Dalrymple Bay •Blackwater System (elec) •Feeds to new port at Jilalan (near Rockhampton) •Moura System (elec) - Feeds to Gladstone •RG Tanna Coal Terminal; Barney Point
  8. 8. Heavy Haul – NSW ARTC – Std Gauge •32TAL at Over 90 MTpa shipping steaming coal •Lower Hunter •Mt. Thorley, Ravensworth, Bayswater •Upper Hunter •Ulan & Gulgong (Ulan Line) •New England Ranges •Gunnedah & Curlewis •3 Ports at Newcastle •Port Waratah Coal Services •Kooragang Island •Newcastle Coal Infrastructure Services
  9. 9. •Ability to handle extremely heavy loads. •Long Life Cycle. •Component reliability. •Minimal maintenance. •Component interchangeability. •Maintenance access within minimal time frame, to suit increasingly frequent train schedules. •Provide technical support. Client Needs –in HH Turnout design.
  10. 10. Heavy Haul geometries and Configurations. •HH geometries differ little from non Heavy haul turnouts. •Standard Secant and Tangential geometry. •Geometry, turnout radius and angle is determined by the required speed of the operator, both on diverge and mainline movements. •Turnout angles generally range from 1:10 to 1:25
  11. 11. Turnout Design and Features: •Understanding of clients technical requirements. Axle loads, Speeds, Interfacing, Gauge, Wheel profile, signalling…… •Selection of appropriate components and material must be significantly robust to handle the load requirements. •Rail Type – Size, Hardness •Switch type – Full Depth, Mang tipped, Thick web, Asymm. •Crossing Type - SNX, RBM, Fabricated. •Bearer type – Concrete, Timber, Steel, Composite. •Plating – Cast, Braced, Fabricated. •Fastening System - Resilient, Screwed. •Cast Components – Material selection.
  12. 12. Turnout Manufacture: •Achievement of High tolerance Repeatability in manufacture is critical to ensure consistent and high quality product. •The use of 3D software and numerically controlled machines for manufacture provides high tolerance and repeatability. •Use of jigs to ensure quality, consistency and replication of product and assemblies.
  13. 13. Heavy Haul components. •Fastenings: •Complete resilient fastening systems. •Removal of screw spikes into bearers. •Removal of conventional screws and bolts and replace with swage lock bolting and elastic type fasteners. Traditional fastening system Resilient fastening system
  14. 14. RE68 /136RE Rail, & RE136TW Switch Rail AS 60 Rail 60E1A1 Switch Rail U 33 Guard Rail Rail Section Height (mm) Mass (kg/m) Izz x 106mm4 Zhead x 103mm3 RE 68 / 136 RE 185.7 67.5 39.4 391.7 RE 136 TW 185.7 87.8 41.9 415.5 AS 60 170.0 60.6 29.3 322.4 60 E1 A1 134.0 73.0 17.3 229.9
  15. 15. •Full Depth Manganese tip Switchblade Heavy Haul components. Switches: •Asymmetric section Switchblades. •Through Hardened Thick Web Switch Rail Section.
  16. 16. • Asymmetric Switchblades • 60 E1 A1 (or variants) for switchblades – usually heat-treated • Used with 60E1 or AS 60 stockrails and running rails – also heat-treated • Up to 32.5 tonnes / axle; Up to 100 km / hour loaded • IBAV / ISRB Resiliently fastened stockrails • Improved lateral stiffness – for design of operating equipment / backdrives • However, reduced bearer spacing (500 mm) for HAL applications. • Full – Depth Switchblades • May be over-riding, or flat-bottomed (with cut-away stockrails)Depends of the stockrail locators & supports – rail braces • AREMA Standards – reinforced, with Austenitic Manganese Steel tips • RE 68 / 136 RE – HT / HH recommended for HAL applications • Use of Thick-Web rail allows for tangential switch geometry and improved lateral stiffness. Characteristics of Switchblades
  17. 17. •Swing Nose Crossings – Mang Steel Cradle. Heavy Haul components. •Manganese Steel Fixed nose Crossings. •Crossings: •Swing Nose Crossings – Rail Steel
  18. 18. Crossing Selection.
  19. 19. Installation & Maintenance: Hunting marks Dip in stockrail •Correct installation and Maintenance is critical to ensure increased turnout life: •Solid substructure and Track alignment is essential. Both within the turnout and entering the turnout, to prevent corrugation and “Hunting”. •Early grinding to remove metal flow will ensure Switch and Crossing material stabilizes. Thus reducing future grinding frequencies. •Lubrication of moving parts. •Ensure all bolts and fastenings are correctly tightened and installed. Metal Flow
  20. 20. Future for Heavy Haul Turnouts •All swing nose Crossings. •In bearer Rodding for both switches and SNX for tamping access. •Use of Switch roller plates to reduce friction of Switchblades. •Metallurgical inputs for Material improvements to achieve longer life from wearing parts. i.e. Use of harder stronger rail steels, special alloyed steels for crossings and switch blades.
  21. 21. Future for Heavy Haul Turnouts •Boltless and Screwless assemblies ton ensure elastic toe load is consistant. •Concrete Bearers •More acute angle Turnouts with greater radii to increase diverge speed. •Component interchangeability of wearing parts for quick changeout. •Turnout design should have provision to optimize rail welding techniques.
  22. 22. Vossloh - AusRail Sydney Nov 2013
  23. 23. “Not So” Heavy Haul Application
  24. 24. 24 Thank you for your attention