Rolling Stock Monitoring based on the ASDEK/SSD system Experience on the Polish market

Transcription

1 Rolling Stock Monitoring based on the ASDEK/SSD system Experience on the Polish market I have pleasure to present you experience of our company associated with the diagnosis of the rolling stock on the Polish market. For over 25 years we are the supplier of such systems mainly in Poland but also in the Czech Republic and Slovakia.

2 Few words about our company History: Turnover: Staff : Activities: company was founded in 1990 r since 2006 it is owned by the voestalpine group mln PLN (~ 8-10 mln EUR) ~80 people, mainly engineers Design, production, installation and servicing of intelligent transport systems to support: diagnostics systems of rolling stock and railway infrastructure railway traffic control systems tram traffic control systems equipment to turnouts control axle counter systems new product line UniAC

3 Agenda Objectives of the rolling stock monitoring Functionality Information management Alarms management Maintenance model Summary

4 Why do we need to monitor the rolling stock? 4 4/19/2016

5 voestalpine SIGNALING Sopot On Sp. this z o.o. slide you can see the typical damage to the components of wheels and wagons: defective bearings, jammed /stucks brakes, deformation of the track wheels These damages directly affect on faults other parts of the wagon (eg. bogie)and also affect on destruction of the railway infrastructure (crack of rails, turnouts or sleepers)

6 Damage may be caused in an extreme case of derailment of the train (especially damage the axle bearings).

7 Derailments, damage to railway infrastructure, speed limit of the fault train directly affects the creation of delays in rail traffic and an increase in dissatisfaction of passengers and reduce the comfort of rail travel.

8 1. Objectives of the rolling stock monitoring Increase in safety warning concerning the risk of the rolling stock emergency state Increase in travel comfort efficient carriages, noise reduction, reduced delays Reduction of Infrastructure costs detection of wheels deformation causing cracks in rails and turnouts detection of defective brakes causing accelerated wear of the railway detection of damage axial bearings that might be a cause of railway accidents and damage to infrastructure detection of overloaded axles Support for the rolling stock (wagon/carriage) maintenance additional option for carriers

9 1. 2. Functionality Bearing temperature measurement (hot box detection) - GM Brake / wheel temperature measurement (hot wheel / brake detection) - GH A few words about the functions of diagnostic systems. The first group relates to the detection of temperature in axial bearings and wheels. The high temperature is very often a result of a damage bearing or jamming the brake system. Photos show the typical solution of temperature monitoring which is realize by ASDEK

10 Wheel Defect Detection PMZ/PM Weighing in Motion - OK Idealne koło i szyna Q Perfect wheel and rail Qst Koło i tor rzeczywisty Q Qst Actual wheel and track Qdyn Wheel or track damaged Koło (tor) uszkodzone Q Qdyn Udar Qst The second group function detects the deformation of the wheel (flat, out of roundness, difference in diameter wheels on the same axle) and detects the static and dynamic wheel pressures. These functions use the effect of loss contact between wheel and rail when wheel, axle or bogie is fault.

11 Generations of rolling stock monitoring systems 1st generation 70 s-90 s SERVO9000 ASDEK/GM/70/90 19 systems 2nd generation 90 s-00 s ASDEK/PMZ/GM/GH/ CYBERSCAN2000 ASDEK/GM/GH/ CYBERSCAN systems 3rd generation 00 s 10 s ASDEK/GM/GH/PHOENIX ASDEK/PMZ/GM/GH/PHOENIX ASDEK/PM/GM/GM/GH/OK/ PHOENIX/GOTCHA 136 systems Total amount > 200 monitoring systems Three generations of diagnostic rolling stock systems in Poland. The newest generation of devices - there is about 70% all monitoring systems. However there is a very large group of systems with outdated technology that is constantly modernized. The main reason is the very difficult access to spare parts.

12 3. Information management in ASDEK/SSD system OVER-RIDING LEVEL data collection and processing Superordinate, GSM IT network DECISION-MAKING LEVEL operating decisions BASIC LEVEL measurements TRAFFIC MANAGEMENT TRAFFIC CONTROLER Local IT network CARRIER LOCAL DISPATCHER OTHER SYSTEMS SIEĆ INFORMATYCZNA SIEĆ INFORMATYCZNA CENTRAL DATABASE SID NADRZĘDNA LOCAL TERMINAL LOCAL CONTROL CENTRE LST/LCS MAINTENANCE MANAGEMENT REGIONAL DISPATCHER LOKALNA (liniowa) ROLLING STOCK DIAGNOSTIC SYSTEMS ASDEK The third level - a central database, which has information of all diagnostic systems on the rail network. The data are sent from the local computer terminals to central base via a GSM devices. The Central base communicates with other systems PKP Railway. Access to data have regional dispatchers, maintenance staff and the carriers - directly through the web browser. MAINTENANCE SERVICES. The second level - local computer stations operated by traffic dispatchers. The one computer terminal present information from one to several diagnostic devices. In Poland there are over 150 terminals. The main groups of users are: traffic operators and dispatchers. The access to data have also maintenance workers and of course carriers through traffic operator (alarm). The first level - measuring devices. The transmission of information to the local IT network.. On this slide you can see how it manages information with diagnostic systems levels of information management.

13 Group of information about trains status: all locations date/time, length, speed, number of train type of carrier alarms information about multiple alarms associated with the same carriage/train on another ASDEK systems links to detail raport about particular train CENTRAL DATABASE SID A few slides presenting the group information in the database A very important possibility is to observe the multiple crossings of alarm by the same wagon.. The regional dispatcher can quickly detect wagon that moves on the PKP network from one to another diagnostic systems with damage and decide to off the voestalpine SIGNALING Sopot wagon Sp. or z o.o. to inform the carrier administration in writing form of the security risks. The regional dispatcher may request documents which will confirm that wagon was checked and repaired with all informations about tests and measurment protocol.

14 Group of information about all and particular axles in train: tempratures of hot boxes, wheels, overload, flat places, etc. data and graphic form of results information about number of carriage with alarm ability to analyze details about damages, problems in carriages information about operator (dispatcher) activities. CENTRAL DATABASE SID

15 Group of information about all and particular ASDEK systems: all locations data and graphic form of technical status links to details raport about particular diagnostic system historical data CENTRAL DATABASE SID This group of information is important for maintenance workers. Some of the data presented potential technical problem or defect which could happen in the near future and need for preventive activities.

16 4. Alarms management - PKP Polish Railways A few words about managing alarms. PKP has very precise guidelines and rules of procedure in case of alarm for traffic operator and dispatchers. Procedures are the same across the network stations.

17 Rolling stock monitoring Alarm Check train on the track or at station Decision by train operator: continue journey with/without speed limited or off the wagon voestalpine SIGNALING The Sopot main Sp. activities. z o.o. After an alarm the traffic operator or dispatcher stops train on the track or at the nearest station and request verification of potential damage by train operator. The train operator decides about journey continue with or without speed limited or turn off the wagon.

18 Hot box detection 2 alarm types: warning/stop Proceeding: stop the train by traffic dispatcher,check on track by train operator Decisions: speed limit or off the wagon or journey continuation Hot wheel / brake detection 2 alarm types: warning/stop Proceeding: stop the train by traffic dispatcher,check on track by train operator Decisions: speed limit, or off the wagon or journey continuation Wheel defect detection 2 alarm types: warning/stop Proceeding: information to train operator check on the station Decisions: speed limit or off the wagon or journey continuation Weighing in Motion 1 alarm type : overloaded Proceeding: information to train operator check on the station Decisions: speed limit, off the wagon, journey continuation procedures in progress Types of alarm.

19 Hot box detection Hot wheel / brake detection Wheel defect detection (PMZ) ~ alarms per year ~ alarms per year ~ alarms per year ~ 2-3 alarms/year/system ~ alarms/year/system ~ alarms/year/system Average amount of alarm for ASDEK systems in Poland.

20 Mainly issues that impact the efficiency : not enough knowledge, experiences on carrier s side, lack of completed check procedures after alarm (stop,warning) by train operator, lack of assurance that the control on track was made lack of enough equipment, tools, instructions to check axle, wheel after alarm in carrier staff, e.g. train operator - driver (is not a specialist) checks flat places (by hand? visually?), while the problem can be associated with roundness wheel, difference in diameter wheels on the same axle or damage bogie (truck). all decisions after alarm about next activities are on carrier s staff hands. ( except alarms associated with dynamic overloads >350 kn automatic off the wagon). more, more training and essential meetings with carriers

21 4. Maintenance model - PKP Polish Railways Technical maintenance outsourcing by internal company (voestalpine SIGNALING) Diagnostic maintenance (supervision) own resources ( PKP PLK) Maintenance model on PKP Polish Railway based on a clear division of responsibilities. Technical maintenance is carried out by an external company while PKP supervises the technical maintenance in the framework of the diagnostic.

22 Technical Maintenance outsoursing Technical inspections Remove failures Disassembly and assembly Remote monitoring Upgrade software Training for customer staff Technical advice, analysis consulting Preventive activities 22 4/19/2016 The main activities included in the technical maintenance.

23 23 4/19/2016 Technical Maintenance outsoursing central services agreements Main assumptions of cooperation PKP Railway - voestalpine Long-term agreement (3-5 year), all systems during warranty and after warranty period. Technical inspections - in accordance with schedule, depending on the type of system: from 2 (new generation) to 8 (older systems) times per year Preventive activities (remote monitoring, additional corrections, inspections, reduce of false alarms, etc.) Time to repair up to 48h from reporting, logistic time is included. Repair means to restore the functionality of devices ( not all problems cause loss of functionality eg. UPS, disruptions during single train ride). Penalties associated with repair delays. Settlement - a lump sum per month, cost of materials is included. number of delays to remove faults in the average number of faults/year/system in MTBF - mean time between failure - 0,5 year A - Availability functionality enabled > 98,5 %

24 Technical Maintenance before central service agreement (before 2010) Technical inspections - only part of technical inspections were realized by voestalpine. Activities associated with basic maintenace (e.g conservation on older systems) were realized by PKP staff (in theory). Preventive activities not impemented. Time to repair dependent on local requirments (from 72 hours to 30 days). Settlement - a lump sum per month or rather after each service. Cost of materials was included only in part of local agreements/orders. the average number of faults/year/system before - > 4 MTBF - mean time between failure - < 0,25 year A - Availability functionality enabled < 90 % (in location when were only orders with time to repair over 14 days < 80%!!!) 24 4/19/2016

25 Services Department voestalpine SIGNALING organization Service Desk Service center Expert center Dispatcher Service engineers and technicians team Few slide about organization of the service in our company. First line are service dispatchers who receive notification of the failure of or damage voestalpine SIGNALING Sopot from Sp. z the o.o. dispatcher PKP Railway. They are receive it through the IT system via 25 or electronic fax. Additional voestalpine dispatchers monitors technical condition of devices on the network online. After that they organize all activities which are need to Experts

26 Services Department voestalpine SIGNALING organization Utrzymanie urządzeń DSAT 26 Map of service points in Poland.

27 3.3 IT tools support for maintenance activities Remote access to systems, devices - UpRage (computers, mobile phones) remote inspections quick check and identification problems after unexpected failures and loss of functionality better aproach which couse availability increase. preparation to technical inspection on the ground automatic upgrades of software 27

28 3.4 IT tools support for maintenance activities Grapfic maps of technical condition systems - MUT online correct work problems additional infos about disruption in systems work 28

29 3.5 IT tools support for maintenance activities Additional info about problems Support service staff in assessment were is problem in the interface track(rail) or rolling stock 29 Access to central base PKP Railway

30 Diagnostic Maintenance own resoursces Diagnostic inspections (yearly) Supervision of technical maintenance 30 4/19/2016 Activities PKP Railway are limited to the supervision of the proper performance of the service contract and annual review of diagnostic devices under the rules of the internal and external procedures.

31 Guidelines for use and maintenance Railway instructions and norms Technical documentation of systems Other formal regulations Guidelines for the maintenance of rolling stock diagnostic devices are also well described and are found in the instructions railway regulations and technical documentation of equipment.

32 5. Summary Benefits: Safety increase Travel comfort increase Infrastructure costs reduction Support for the maintenance of rolling stock new possibility for better communication and cooperation with carriers Key success factor: long-term cooperation between customer and supplier on many levels clear rules, responsibilities service agreement regular maintanance ( > MTBF) remote access, monitoring, preventive activities (> Availability) more knowledge, experience and formal regulation on the carrier side

33 Thank you for your attention MSc. Artur Nowak Head of Projects & Services voestalpine SIGNALING Sopot Sp z o.o. ul. Jana z Kolna 26c, Sopot, Poland tel , artur.nowak@voestalpine.com