Commercial in confidence
National Turnouts Workshop Newcastle, May 2013
Major Periodic Maintenance;
asset life, criticalit...
2Commercial in confidence
Why do we maintain?
3Commercial in confidence
An industry concern
Capital Works are exciting, but
We all contribute to the ongoing maintenance...
4Commercial in confidence
Basic Maintenance Theory
Modern method - systems whole of life
approach
Reliability Centred Ma...
5Commercial in confidence
Turnout Maintenance
All the problems of plain track and much more
Every moving part is a reliabi...
6Commercial in confidence
Turnout Maintenance
RM – inspect and correct to hold safety and
short term reliability
How do we...
7Commercial in confidence
Asset Life Cycle Curve
$0
$0
$0
$1
$1
$1
$1
$1
$2
0 5 10 15 20 25 0 5 10 15 20 25 30 35 40 45 50...
8Commercial in confidence
WORKSHOP - MAINTENANCE
• A COMPLEX JUNCTION
• What are the likely turnout maintenance issues?
• ...
9Commercial in confidence
OUTCOMES – Tools to achieve RCM
Technical Maintenance Plans (TMP’s)
Service schedule
• Safety ...
10Commercial in confidence
Inspection Regimes
• Track Patrol –
general, looking for obvious critical
failures, 2 per week
...
11Commercial in confidence
Comparison of to TMP frequency
Level of maintenance to match desired outcome
12Commercial in confidence
Service Schedules
13Commercial in confidence
Critical Areas of a Turnout
Switches & Stockrails
Crossings (including checkrails)
14Commercial in confidence
Critical Areas of a Turnout
Defects in Turnouts Found by KK by Type
0
20
40
60
80
100
120
140
1...
15Commercial in confidence
Switches
Safety critical to prevent derailment
Critical for reliability especially related to...
16Commercial in confidence
Crossings
17Commercial in confidence
Crossings
Main safety concern is if wheel goes the
wrong way past the crossing
Also impact an...
18Commercial in confidence
Critical Crossing Checks
19Commercial in confidence
Crossing Maintenance
Crossing is heavy impact point
Requires monitoring
Maintenance grinding...
20Commercial in confidence
Determining Average Major Maintenance
ASSET POPULATION
STEADY STATE =
AVG ECONOMIC LIFE
• Fit f...
21Commercial in confidence
The RailCorp experience
• Over 2,500 discrete turnout assets
• Varying age profile, configurati...
22Commercial in confidence
Average renewal vs actual and forecast
23Commercial in confidence
Turnout Age Profiling ≈ Condition
Turnout Age Profile at 2011/12
<10 years old
>10 years old, n...
24Commercial in confidence
Varying approaches to maintenance
• Availability of funding, access, resources and desired cust...
25Commercial in confidence
Fit for Purpose
26Commercial in confidence
Understanding avg economic life
• Renewal is based on replacing the entire turnout and can
be u...
27Commercial in confidence
Turnout Grinding / Turnout Tamping
28Commercial in confidence
Turnout Refurbishment
Trailing
Facing
29Commercial in confidence
Prioritised Turnout Maintenance
Now we know how many
how do we prioritise?
Consider
1. Asset Cr...
30Commercial in confidence
Suggested approach to priority
31Commercial in confidence
• The ideal is hindered by funding, resource and track
access limitations.
• Means the actual p...
32Commercial in confidence
Next Evolution
ASSET
CONDITION
Asset Target Score
Measure of
Performance
Asset
Configuration
Te...
33Commercial in confidence
Asset criticality - elements
• Weighted timetable usage
and impact on maintenance
priority
• Im...
34Commercial in confidence
35Commercial in confidence
Asset performance - elements
• Maintenance Cost
• Maintenance Compliance
• Incident / Failure r...
36Commercial in confidence
Asset configuration - elements
• Rail Size
• Turnout Geometry
• Bearer Type
• Points Machine Ty...
37Commercial in confidence
Performance L2
Given Asset Category based on it’s Criticality needs a defined Condition Level.
...
38Commercial in confidence
NEED GOOD ASSET INFORMATION
• Critical to effective Asset Management and MPM
Planning.
• The fi...
39Commercial in confidence
IN SUMMARY
•Turnouts are a critical safety and reliability
aspect of the rail network.
•Must be...
40Commercial in confidence
IN SUMMARY
• Understanding average turnout life will support a
forward plan to support customer...
41Commercial in confidence
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Toby Horstead, RailCorp - Major Periodic Maintenance; Asset Life, Criticality, Priority

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Toby Horstead, Senior Asset Planner Civil & Track, RailCorp delivered the presentation at the RISSB’s 2013 Rail Turnouts Workshop.

The RISSB’s National Rail Turnouts Workshop 2013 gives all those involved an in-depth forum to consolidate and share the latest technical information for rail turnouts. Drawing on industry expertise, the workshop features technical and practical presentations that address key turnout functions in an every-day operational context.

For more information about the event, please visit: http://www.informa.com.au/railturnoutsworkshop13

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Toby Horstead, RailCorp - Major Periodic Maintenance; Asset Life, Criticality, Priority

  1. 1. Commercial in confidence National Turnouts Workshop Newcastle, May 2013 Major Periodic Maintenance; asset life, criticality, priority Toby Horstead, Senior Asset Planner Civil & Track Asset Planning & Performance
  2. 2. 2Commercial in confidence Why do we maintain?
  3. 3. 3Commercial in confidence An industry concern Capital Works are exciting, but We all contribute to the ongoing maintenance. • Maintenance Approach • Engage you all in discussing maintenance • Assessing life, criticality and priority • Completing the lifecycle
  4. 4. 4Commercial in confidence Basic Maintenance Theory Modern method - systems whole of life approach Reliability Centred Maintenance Then develop maintenance concept
  5. 5. 5Commercial in confidence Turnout Maintenance All the problems of plain track and much more Every moving part is a reliability risk Every gap or discontinuity is a reliability and safety risk
  6. 6. 6Commercial in confidence Turnout Maintenance RM – inspect and correct to hold safety and short term reliability How do we manage the long term performance and sustainability of Turnouts? Can I anticipate how much work each year or do I see what fails, then ask for funding?
  7. 7. 7Commercial in confidence Asset Life Cycle Curve $0 $0 $0 $1 $1 $1 $1 $1 $2 0 5 10 15 20 25 0 5 10 15 20 25 30 35 40 45 50 Millions CUMMULATIVEMAINTENANCE COST 0 1 2 3 4 5 6 YEARS / AGE CONDITION Cummulative Cost 1 Cummulative Cost 2 Turnout Condition 1A Turnout Condition 1B Turnout Condition 1C Turnout Condition 1D Turnout Condition 2A Turnout Condition 2B
  8. 8. 8Commercial in confidence WORKSHOP - MAINTENANCE • A COMPLEX JUNCTION • What are the likely turnout maintenance issues? • What is critical, how would you know? • Can you forecast the future level of maintenance?
  9. 9. 9Commercial in confidence OUTCOMES – Tools to achieve RCM Technical Maintenance Plans (TMP’s) Service schedule • Safety Significant • Safety Critical
  10. 10. 10Commercial in confidence Inspection Regimes • Track Patrol – general, looking for obvious critical failures, 2 per week • Turnout inspection – detailed checks and measurements yearly • Others – Ultrasonic – conducted by hand for critical areas eg switches – Engine – asses track effects on rollingstock – Signals FPLs – prime example of other discipline
  11. 11. 11Commercial in confidence Comparison of to TMP frequency Level of maintenance to match desired outcome
  12. 12. 12Commercial in confidence Service Schedules
  13. 13. 13Commercial in confidence Critical Areas of a Turnout Switches & Stockrails Crossings (including checkrails)
  14. 14. 14Commercial in confidence Critical Areas of a Turnout Defects in Turnouts Found by KK by Type 0 20 40 60 80 100 120 140 160 crossings switches Other TOTAL Defects
  15. 15. 15Commercial in confidence Switches Safety critical to prevent derailment Critical for reliability especially related to signalling Moving parts complex interaction Costly repairs requiring access to track Without detailed and regular inspection and defect management, can lead to safety issues Greatest broken rail risk as rail is unrestrained
  16. 16. 16Commercial in confidence Crossings
  17. 17. 17Commercial in confidence Crossings Main safety concern is if wheel goes the wrong way past the crossing Also impact and damage from crossing noses Often speed restrictions, crossings may be difficult to replace on short notice
  18. 18. 18Commercial in confidence Critical Crossing Checks
  19. 19. 19Commercial in confidence Crossing Maintenance Crossing is heavy impact point Requires monitoring Maintenance grinding of flow, requires access Weld repair or replace, some repairs can become impractical K crossings present special problems  Blunter angle with higher impact  Unchecked area  Competing tolerances to be met
  20. 20. 20Commercial in confidence Determining Average Major Maintenance ASSET POPULATION STEADY STATE = AVG ECONOMIC LIFE • Fit for purpose at lowest cost of maintenance • Mix of fixed interval and condition based • Organisations are reliant upon their own Engineering experts and industry experts
  21. 21. 21Commercial in confidence The RailCorp experience • Over 2,500 discrete turnout assets • Varying age profile, configuration, use, movements • AMP based on SS, backlog identified • TO life based on bearer; Concrete = 50yrs, Timber = 30yrs • SS renewal level currently 56 mainline TO’s per year
  22. 22. 22Commercial in confidence Average renewal vs actual and forecast
  23. 23. 23Commercial in confidence Turnout Age Profiling ≈ Condition Turnout Age Profile at 2011/12 <10 years old >10 years old, not within 10 years of avg asset life Within 10 years of avg asset life (due for renewal in next 10 years) Backlog (at or beyond avg asset life)
  24. 24. 24Commercial in confidence Varying approaches to maintenance • Availability of funding, access, resources and desired customer outcomes can all have an influence on the maintenance strategy. • Valid approaches can include: – Upgrade in lieu of ‘like for like’ renewal or refurbishment, gain benefits of reset life, increase inspection intervals, new technology, operational benefits – Renew only ‘like for like’ and refurbish – Increase levels of refurbishment and corrective maintenance and delay the need for complete renewal or upgrading – Fix on fail; identify defect, apply track speed and fix when funding and access allow • Value for money scoping – fit for purpose • Greatest reliability improvement for RailCorp is concrete bearers
  25. 25. 25Commercial in confidence Fit for Purpose
  26. 26. 26Commercial in confidence Understanding avg economic life • Renewal is based on replacing the entire turnout and can be underpinned by the long life component – bearer life • The more difficult question is then the economic life for: – Turnout refurbishment – Turnout resurfacing – Turnout grinding (as a whole) • Actual data – has it been recorded, does it give a cycle? • But what is the appropriate cycle?
  27. 27. 27Commercial in confidence Turnout Grinding / Turnout Tamping
  28. 28. 28Commercial in confidence Turnout Refurbishment Trailing Facing
  29. 29. 29Commercial in confidence Prioritised Turnout Maintenance Now we know how many how do we prioritise? Consider 1. Asset Criticality 2. Asset Configuration 3. Asset Performance
  30. 30. 30Commercial in confidence Suggested approach to priority
  31. 31. 31Commercial in confidence • The ideal is hindered by funding, resource and track access limitations. • Means the actual priority order is challenged. • We do not deliver 1 through to 1,900 • Must consider balance against other programs Suggested approach to priority
  32. 32. 32Commercial in confidence Next Evolution ASSET CONDITION Asset Target Score Measure of Performance Asset Configuration Test the Asset Condition against the determined Criticality for that asset Move to a Steady State for Asset Criticality band and prioritisation within the criticality band = +
  33. 33. 33Commercial in confidence Asset criticality - elements • Weighted timetable usage and impact on maintenance priority • Impact on On Time Running • Accessibility • Results in bands of criticality Through Facing 4 x Through Trailing 2 x Crossing Trailing 1 x Crossing Facing 2 x Asset Criticality D C B A
  34. 34. 34Commercial in confidence
  35. 35. 35Commercial in confidence Asset performance - elements • Maintenance Cost • Maintenance Compliance • Incident / Failure rate • Asset Age?
  36. 36. 36Commercial in confidence Asset configuration - elements • Rail Size • Turnout Geometry • Bearer Type • Points Machine Type
  37. 37. 37Commercial in confidence Performance L2 Given Asset Category based on it’s Criticality needs a defined Condition Level. RequiredAssetCondition Measuring Outcomes Asset Condition Matrix Min =80 Max = 90 Target = 85 Asset Criticality ASSET CONDITION Asset Target Score Measure of Performance Asset Configuration = + • May not want top condition • What can the asset sustain, rather than what do I need to do to sustain the asset? • What does the customer want?
  38. 38. 38Commercial in confidence NEED GOOD ASSET INFORMATION • Critical to effective Asset Management and MPM Planning. • The first step in the AMP – What have I got? • Information can include – A record of the asset – The configuration and age – Work carried out – defects recorded and repaired – MTBF and condition monitoring • Need improve this element, consider asset owner
  39. 39. 39Commercial in confidence IN SUMMARY •Turnouts are a critical safety and reliability aspect of the rail network. •Must be able to justify the amount and location of expenditure •Turnouts should be – fit for purpose – at lowest cost of maintenance
  40. 40. 40Commercial in confidence IN SUMMARY • Understanding average turnout life will support a forward plan to support customer outcomes • Criticality, condition, performance, configuration are considerations for determining maintenance priority • Need good asset information •Complete the life cycle – ask why is that turnout there?
  41. 41. 41Commercial in confidence Next Challenge
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