Innovation for Modular Drainage Ben Shaw (Scheme Project Manager) Andrew Clark (Drainage Improvement Specialist) Special Projects, Doncaster 24 th

Transcription

1 Innovation for Modular Drainage Ben Shaw (Scheme Project Manager) Andrew Clark (Drainage Improvement Specialist) Special Projects, Doncaster 24 th June 2016 (v9) 1

2 Contents The Team The Industry Challenge Business Opportunity Solution for Modular Drainage Process Excavation using machine control Pipe Installation Self Discharging wagons/power cars (pea gravel & ballast) Commercial Safety/Risk Risk Long Term Development 2

3 The Team Richard Cunningham, Network Rail - Programme Manager Steve Jackson, Network Rail - Business Development Manager Andrew Lunn, Network Rail - Works Delivery Manager John Anderson, Network Rail - Project Engineer (Delivery) Frankie Rogalski Project Engineer (Drainage LNE/EM) Andy Clark, Network Rail - Drainage Improvement Specialist Andy Greaves, Network Rail - High Output (Track) Ben Shaw, Network Rail Scheme Project Manager Dave Allen/Peter Brooks/Neil Smith SITECH - Technical support (GPS) Milton Keynes Mona Sihota & Team James Browning & Team - Balfour Beatty Plant (Hither Green) 3

4 The Industry Challange Increase productivity and reduce the unit rate: Improving performance and costs, through efficiency gains and increased drainage targets for CP5 and onwards. With successful trials In February 2016 at Tyne yard and Sherburn In-Elmet May 2016 The business case and Implementation plan, to increase drainage installation by a minimum of % in the same track access Environmental Using trains to remove spoil and deliver granular material. Eliminate haulage for RRV s. 4

5 Business opportunity Experienced track/drainage renewals staff within Special Projects, Doncaster - We have a clear goal! Preliminary development PC138 machine controlled RRV s (bendy boom), able to work in any condition i.e. tunnels, platforms, cuttings etc.1 metre clearance from R.E to counterweight in work mode. Develop and Executive plan Autoppers/Sidetippers in rakes of 5 for drainage (equates to 300t ballast) the problem statement, we are unable to excavate the volume to justify these wagons! With machine controlled RRV s, good excavation rates can be achieved to utilise Autohoppers/Sidetippers, interim until we have MSF wagons 5

6 Business opportunity Preliminary Business case and long term Implementation plan, On proving the concept! The aim is to build up to x4 RRV s with machine control & MSF self discharging wagons with the capacity to delivery a 480 metre (16 x30 metre runs) installation in 8 hours. National unit rate is 800 per/metre (p/m), aim to reduce between p/m 6

7 Solution using Modular drainage Drainage renewals: By CP6, having proved the concept! Desirable x4 excavator s fitted with machine control Utilise MSF +MSF/SB wagons for drainage using x2 power cars for pea gravel & ballast 7

8 Preparation/Process for pipe installation Survey using Total Station: Design in CAD (in house) Design excavation corridor using Trimble Business Centre, to create machine files removing operator error, faster process for the excavation and enhances the skills of staff. Providing a compliant and professional drainage installation for the client No verification surveys required prior to construction We have the choice of installation material layer based on ground conditions : Excavate the trench to design level and install pipes with 150mm wheels fitted (simulating pea gravel) Excavate to design trench base within 25mm, install base pea gravel layer and trim to design (method TBC from trial holes) 8

9 Excavation using 3D control Design data installed into the machine as a 3D model, to increase accuracy to within 20mm for trench base Faster process as it removes the need for constant checking manually of trench depth As the cut/fill operations progress, the design string is updated in real time, allowing engineers and the more importantly the client to view without visiting the site 9

10 Excavation at Tyne Yard, February 2016 using machine control Design data installed into the machine as a 3D model, to increase accuracy to within 20mm for trench base Faster process as it removes the need for constant checking manually of trench depth 90 metres excavated in 2 hours 15 minutes using x1 machine. The trench base/catch pit locations excavated within the design tolerance of 20mm. 10

11 Pipe Installation Pipes assembled during a preparation shift and installed in 30 metre sections, laid on the design trench base as part of the design material layer. 11

12 Self discharging wagons (MSF/SB) Aim to increase pea gravel & ballast installation by 400% v conventional 50 yards p/h per machine using open wagons. 12

13 Desirable-power car(s) required working in conjunction with MSF wagons Expected increase in pea gravel/ballast installation 480 metre p/h installation. Based current High Output track discharge rates Require a modification by Plasser & Theurer for discharge offset for pea gravel and ballast 13

14 Commercial Current installation rates using conventional methods of metres in a standard 9 hour ROR possession Expectations of a % volume increase within the same track access as RRV s will be eliminated for backfill activity Increased accuracy on trench base/or the option of a base pea gravel layer. The trial attyne yard in February 2016, highlighted a 30-40% saving in material from over dig 3D control v conventional. As built using Total Station, GPS rover or operator in the machine to record at any location, reducing additional cost to revisit site. Large improvement in quality; right first time 14

15 Safety/Risk Eliminating staff working in an open excavation. Reducing staff exposure as the base pea gravel material layer installed using 3D machine control, RRV to install pipe lengths Reduction in staff exposure working near open excavations (harness training/fall arrest). Reducing staff exposure (FWI s) Eliminating the risk of damage to OHL equipment during backfill activities by using MSF wagons 15

16 Long Term Development 1.8 metre offset machines required working with Komatsu & Balfour Beatty plant Pea gravel layer power car required to remove the need for a service machine MSF wagons/power car for ballast required Utilise Autohoppers/Sidetippers for the interim period based on increased volumes using machine controlled RRV s Lifting system for an RRV for the 30 metres pipe sections Edge protection for site engineer checking levels Open trench length, TBC from investigations/lab tests of ground conditions/experience from previous sites Aim to standardise drainage nationally 16