Eurailspeed Parallel Session D.1

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1 Eurailspeed Parallel Session D.1 Heinz Ossberger Head of Engineering and Design VAE Voest-Alpine 23 november 2005 Max Mustermann 1

2 Milano November 8, 2005 Presented by: Heinz OSSBERGER Head of Engineering and Design VAE GmbH Austria 2

3 What you see is not always what you get L ife C ycle C ost Look at Total Life Cycle of Components / Products 3

4 LCC calculations: The way of VAE to provide the maximum benefit Identification of the optimal product for each field of application (speed, loads etc.) regarding the LCC (identification of minimal LCC) costs Total Costs Costs during Service Life Purchasing Costs performance, quality 4

5 LCC calculations: The way of VAE to provide the maximum benefit Total Investment Operation Maintenance Disposal Standard Product New Product 5

6 LCC: Influence and Solutions LCC INFLUENCE Life Time Maintenance Installation Rail Material Turnout Design SOLUTIONS Modular Setting and Monitoring 6

7 Cost factor: Wear and RCF-Defects Higher Loads Corrugation Wear Higher speeds Increasing axle load Higher annual tonnage Noise RCFdefects Poor running behaviour Damage on rolling stock and superstructure Less service life of components Increase of life cycle cost 7

8 Trends in Rail Steel Development Hardness [BHN] R200 R320Cr Higher Wear - and RCF - resistance R260 DOBAIN 400UHC+ 370LHT R350HT / R350LHT m-al year Bainite, HT Microalloyed Hypereutectoid, HT Heat Treated (HT) Standard Carbon 8

9 Test results Wear: Improvement factors improvement ratio , ,7 R220 R HT/400UHC R350HT / HSH R320Cr R200 R220 R260 S900 R320Cr R350HT base grade Source: ERRI and European Rail Operators 9

10 Test results RCF-Cracks (Head Checks) depth of rail damage [mm/100mgt] 3,5 3,0 2,5 2,0 1,5 1,0 R220 R260 HSH (R350HT) 370LHT DOBAIN430 R260 R220 0,5 R350HT / HSH 370LHT DOBAIN 0, radius [m] 10

11 LCC considerations Better track performance of harder rail grades 3-times better wear-resistance & 3-times better RCF-resistance for R350HT compared to R260 Less corrugation (approx. 50 % of R350HT compared to R260) Decrease in rail maintenance 3-times longer rail machining cycles (R350HT vs. R260) or Less metal removal necessary Less Life Cycle Cost (LCC) Longer rail service life 3-times longer for R350HT compared to R260 11

12 LCC results example DB AG and ÖBB DB AG: Reduction of LCC by about 35 % Medium speed lines (up to 230 km/h) Curve radii approx m Load approx tons/day Period under consideration: 40 years ÖBB: 15 % annual cost saving for R350HT compared to R260 in tight curves. conservative assumption: 30 % longer life span of R350HT Less grinding needs Rate of return 5 % net 12

13 Conclusion LCC and rail grade strategy Load related application of Premium high strength Rails (HSH -type) and applying LCC optimized maintenance strategies will diminish rail damage, increases service life time of the system, saves costs and makes track operation more cost effective, reliable and safe. 13

14 VAS Outlook New high strengths premium rail grades (Wear? RCF?) Extensive track testing of the new rail grades. LCC reduction by optimization of load related rail grade application and maintenance strategies by using LCC models ( LCC RAIL ) Verification of the best track test practice rail grade strategy together with railways 14

15 LCC: Influence and Solutions LCC INFLUENCE Life Time Maintenance Installation Rail Material Turnout Design SOLUTIONS Modular Setting and Monitoring 15

16 Crossover Gallese Italy UIC /3000/15000-tg 0,026 16

Comparison of calculated and measured forces in turnouts 5 0-5 -10-15 -20-25 -30-35 Predicted

17 Comparison of calculated and measured forces in turnouts Predicted Lateral Wheel/Rail Force [kn] Optimised Non-Optimised Distance [meters] 17

18 Comparison Calculation - Measurement kn latfrc_178_rgt_wh_a4 Y41_Z29_Weg_F measured latfrc_178_lft_wh_a4 Y42_Z29_Weg_F calculated Lateral Force :17:56 Vergleich latfrc_178_axle4 mit Z29 (Tiefpaß mit 3Hz) km kn

19 LCC: Influence and Solutions LCC INFLUENCE Life Time Maintenance Installation Rail Material Turnout Design SOLUTIONS Modular Setting and Monitoring 19

20 Close Link between RAMS and LCC RAMS Reliability FTA RP/RA Maintainability RCM MA/MP Investment Maintenance Investment Analysis LCC-P/A Life Cycle Costing Safety HA SA FMECA Availability Operation LCA LCC 20

21 High Speed Rail Link Taiwan The actual largest BOT Project worldwide Lenghts: 345 km, 80 % on viaducts and in tunnels Speed 300/160 km/h 161 turnouts for High Speed 21

22 High Speed Rail Link Taiwan Turnout Monitoring System VAE Roadmaster 2000 All turnouts are equiped with VAE Monitoring System Roadmaster

23 Safety and Reliability Report Verification of the Performance of the RAMS Requirements according to EN The safety and reliability report is the final document with the summary of the findings of all activities during the RAMS process Including all analysis performed during the RAMS process Provides the evidence of achieving the RAMS requirements according to EN and the customer s specification 23

24 HYDROSTAR Innovative Switch Operating System 24

25 Hydraulic switch operating system HYDROSTAR HYDROSTAR fulfils four functions Driving (electro-hydraulic) Setting (hydraulic) Positive Locking Detection (electro-mechanic) 25

26 Functions of the HYDROSTAR - displayed at the HYDROSTAR ZV Drive Force transmission Locking device Tongue detector 26

27 Drive I Principle: All setting levels of the switch or the moveable point frog are driven by one hydraulic device only. This hydraulic device is normally integrated in the first hollow steel sleeper. With this hydraulic device, it is possible to set a multiplicity of setting levels only by one active unit. 27

28 Locking I Principle: At every setting level, there is a unit for setting and locking integrated into the hollow steel sleeper. These cylinders were set hydraulically. in theses cylinders a double form fitting locking at the end position of the tongue or the moveable point frog takes place. 28

29 Tongue detector I Principle: This device has the same function as a normal tongue detector of an conventional drive. The correct end position of the tongue or the moveable point frog will be monitored. 29

30 Force transmission I Principle: Force transmission between the setting levels is done by hydraulic pipes. These pipes are mounted between the rails at the tongue section or along the rails at the moveable point frog. The pipes are covered to protect them against damage. 30

31 Comparision of HYDROSTAR ZV with a conventional turnout with single drives 31

32 LCC: Influence and Solutions LCC INFLUENCE Life Time Maintenance Installation Rail Material Turnout Design SOLUTIONS Modular Setting and Monitoring 32

33 Railputler: Just-in-Time Delivery of Rails 33

34 Preassembled turnout with HYDROSTAR switch section prepared for shipping 34

35 Preassembled turnout HYDROSTAR loading of the switch section 35

36 Plug and Play: Installation of a preassembled turnout 36

37 LCC: The objective of voestalpine: What you see is what you get! Thank you for your attention 37

VIGNOLE TURNOUT SYSTEMS INNOVATIVE WEICHENSYSTEME

IMG_VAE VIG_VAE _2 VIGNOLE TURNOUT SYSTEMS INNOVATIVE WEICHENSYSTEME voestalpine VAE Führend bei Weichen und Signaltechnik Efficient turnouts for standard- and non standard-gauge railways and metros voestalpine