new zealand rtsa division

2

New Zealand RTSA DivisionPandrol

Craig Mulvay – Vortok Product Line and Equipment, APAC

Tim Hoare – Welding and Equipment, APAC

23/05/19

Content

1. Company Overview

2. Rail Stress Management

3. Aluminothermic Welding

Section 1: Company Overview

Company Structure

Innovative solutions dedicated to our activities 51% Family

Ownership:

Railways MetalsConductic

Operations #1

in their activities

worldwide

Railways

Company Structure

Railways

Company Structure

RailwaysRailways

Rail Stress Management Safety Barrier

Equipment – Vortok Product Line

Cable ManagementCoil

Equipment MountingConditional Monitoring

Clipping Machines

Equipment – Rosenqvist Product Line

Sleeper Replacement

Sleeper Handling

Sleeper Spreading

Rail Handling

Track Tools

Equipment – Railtech Product Lines

Section 2: Rail Stress Management

11

Rail Stress Management

Rail Stress Management is the active management of rail thermal forces to

prevent buckling in high temperatures or rail break in low temperatures.

Network Rail UK:

“The management of rail stress to prevent track buckles is one of the

highest track risks on the network.”

One of the foundations of managing the risk is by maintaining the

Stress Free Temperature (SFT) of the rail.

12

Rail Buckle – Real Time

Please Click Mouse To Run Video

13

Pull Apart – Rail Break

14

What is SFT

15

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:

Bolted Track

16

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:

Bolted Track

17

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:

Bolted Track

18

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:

Bolted Track CWR Track

19

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:


20

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:


21

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:


22

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:


Rail Stress

Rail Temperature

SFT

Compression Tension

Incre

ased

Tem

pera

ture

Decre

ased

Tem

pera

ture

What is SFT:

CWR Track

24

What is SFT:

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak

SFT

Compression Tension

Stress Free Temperature (SFT)

is the temperature at which the

rail is at zero axial thermal

loading.

That is; not in tension and not in

compression.

SFT = Neutral Temperature

25

What is Target SFT:

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak

Max. expected rail temperature

Min. expected rail temperature

Target SFT

Compression Tension

Target SFT is set by the Track Owner

26

VERSE

27

VERSE Overview – What is it?• VERSE – Vertical Rail

Stiffness Equipment

• Non-destructive method of

measuring Stress Free

Temperature (SFT) of

Continuously Welded Rail

(CWR)

• Recognised standard for

measuring risk of track

buckles and rail breaks

• Works on same principle

of ‘A-Frame’

28

VERSE Overview – When is it used?• As a routine Survey Tool

• As a spot check

• As a quality control tool

• To check mechanised

maintenance impact

29

VERSE Overview – Theory of Operation

• Rail is raised to form a simply supported beam section

• Rail is deflected in the centre of the beam and Force and Displacement is

measured

• Force vs Displacement result is proportional to Rail Tension

• Rail Tension with known rail temperature allows SFT to be calculated

• F(y) ∝ Rail Tension ∝ SFT

30

VERSE Overview – Theory of Operation

SFT ∝ F(y)

Inputs: Rail Temperature

Rail Stiffness - Rail Section Type

- Rail Wear

- Elastic Modulus (constant)

Beam Geometry - Inner Spans

- Outer Spans

Curve Versine (before and after unclipping)

Outputs: SFT of the Rail

31

What is SFT:

Rail Stress

Rail Temperature

Data Point

Compression Tension

Rail Temperature

Ra

il Te

nsio

n

32

What is SFT:

Rail Stress

Rail Temperature

Data Point

Compression Tension

Measured SFT

Rail Temperature

Ra

il Te

nsio

n

33

What if measured SFT is below Target?

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak



Target SFT

Compression Tension

Measured SFT

34

What if measured SFT is below Target?

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak



Target SFT

Compression Tension

Measured SFT

Action:- Add tension to the rail cutting out rail and rewelding

- Follow standard stressing procedures

35

What if measured SFT is above Target?

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak



Target SFT

Compression Tension

Measured SFT

36

What if measured SFT is above Target?

Rail Stress

Rail Temperature

Buckle

Rail

Bre

ak



Target SFT

Compression Tension

Measured SFT

Action:- Reduce tension by adding in rail (add a closure rail)

- Follow standard stressing procedures

37

Vortok Stressing Roller

(VSR)

38

How It WorksOver Centre

Lowered Raised

39

How It Works – Reason for using VSR

Force distribution along pull length(considering straight track for simplicity)

𝐹 𝑥 = 𝑃 − 𝜇𝐴𝑚𝑔𝑥Where;F(x) = Force in rail at point x from pull pointP = Tensor ForceμA= Vertical Coefficient of Frictionm = Mass/meter of railg = Gravity

40


Force distribution along pull length(considering straight track for simplicity)

𝐹 𝑥 = 𝑃 − 𝜇𝐴𝑚𝑔𝑥Where;F(x) = Force in rail at point x from pull pointP = Tensor ForceμA= Vertical Coefficient of Frictionm = Mass/meter of railg = Gravity

41


Force distribution along pull length – Pulling over pads vs VSR

Input DataTr = 10°C (Rail Temperature)Tt = 32°C (Target SFT)m = 50kg/m (Rail Mass)μp= 0.3 (Steel to HDPE Coefficient of Friction)*μVSR= 0.04 (VSR Coefficient of Friction)**

*Theoretical value for Coefficient of Friction based on typical material performance

**Lab testing of VSR with 10kN vertical load per VSR resulted in:

μs= 0.02 (Static Coefficient of Friction)μd= 0.005 (Dynamic Coefficient of Friction)

42


SFT distribution along pull length – Pulling over pads vs VSR

43

SFT Monitor

44

SFT Monitor

Remote conditional monitoring of SFT

• Target Maintenace

• Enhance Safety

• Extend Operational

Availability

• Track Trials Commencing

Soon....

Section 3: ATW

46

What is Aluminothermic Welding (ATW)?

• The focus is often on the

process being used.

• What can we do to improve

the outcome without

changing the process?

47

Core of ATW Process

One-Shot Crucible

Aluminothermic Portion

Sand Moulds to suit rail

profile

48

Introductions in new Technology

• Consistent Ignition

• Pre Heating

• Head Repair Weld

• Relief of Residual Stress

• Monitoring and Recording

49

Consistent Ignition

Pandrol Startwel®

50

Startwel®

• Consistent Ignition

• Reliable

• Safe – no DG requirement

51

VIDEO STARTWEL®

https://www.pandrol.com/product/startwel-ignition-system/

https://www.pandrol.com/product/startwel-ignition-system/

52

Pre Heating Advancements

High Flow Preheater

53

Pre Heating – High Flow Preheater

• Optimized nozzle

• Homogeneous preheating

• No flame adjustment

• Automatic stop / start

• Preheating time controlled

via a built-in timer

54

Why Pre-Heating Parameters and Weld Gap are

important

• Lack of fusion resulting from

insufficient pre-heating

55

2012 – First trial welds in

the Channel Tunnel2018 – Field testing of Optimised Product

56

Importance of pre-heating = gap parameters

To

Specification

57


58


59

Video HFP

https://www.youtube.com/watch?v=tGgQFgKYLFY

https://www.youtube.com/watch?v=tGgQFgKYLFY

60

Head Repair Weld

61

Aluminothermic Head Repair Solution

• The HWR provides a

cost-effective and quick

solution to repair rail-head

defects and significantly

decreases the

maintenance cost of

modern rail networks.

68

Video HWR

https://www.pandrol.com/product/head-

wash-repair-hwr-process/

https://www.pandrol.com/product/head-wash-repair-hwr-process/

69

Relief of residual stress

71

Relief of Stresses

Aim

Our shot peening impact hammer was developed to

improve the fatigue behaviour of AluminoThermic Welds.

It is extremely common for defects to propagate from the weld

collar area:

- The Under head radius

- At the top of the foot

Shot peening locally lowers the amount of residual stress in the weld,

and is intended to reduce initiation and propagation of fatigue cracks.

72

Fatigue failure initiated under the head

73

Fatigue failure initiated at the foot

74 Non contractual picture

75

RAILTECH’s Shot Peening Impact Hammer

Shot peening is performed when the weld is below 300 . Use

safety protections for:

- EYES

- EARS

- HANDS

- NOSE

76

Side n°1 Side n°2

Interface n°1 Interface n°2 Interface n°3 Interface n°4

77

Results

In Europe for over 5 years, all of the welds in track that have been

correctly shot-peened are still in service. No weld failures have been

experienced.

In certain extreme conditions, where the welds could fail after 3 months

of service (less than 20 million tonnes), they have, due to the benefits of shot-

peening, been exposed to over 320 million tonnes without failure.

In the laboratory, fatique failures initiate within the parent rail, outside of

the shot-peened weld area

78

Testing of 68kg Rail with shot peening

• Some fatigue tests were realised to :

• 68K PLK CK 25 grade 345 with shot

peening realised 30 minutes after the end of

the tapping

79

Video Shot Peening

80

Recording and Monitoring

Advancements

81

Recording and Monitoring

Pandrol Connect

• Recording of in track conditions

• Condition monitoring

• End to End reporting

82

MODULES

Back office

Configuration

interface

Monitoring WebApp

Management of the

welds by supervisers

Mobile App

Record and check

welds on location

83

ONLINE WELD MONITORING

84

PDF WELD CERTIFICATE

85

ONLINE ADMINISTRATION TOOL

86

DATA EXPORTATION

87

App Video

https://www.pandrol.com/product/pandrol-connect-welding-app/

https://www.pandrol.com/product/pandrol-connect-welding-app/

Thank You

new zealand rtsa division

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