delivering turnout solutions - rtsa nz - 25052017.pdf · turnout design and integration developing...
TRANSCRIPT
DESIGN SUPPLY INSTALL MAINTAIN
Delivering Turnout
Solutions
Introduction
GLOBAL TURNOUT SOLUTIONS
Introduction
BROWNFIELD CONSTRUCTION SOLUTIONS
Introduction
MAJOR PROJECTS
Introduction
CRANE RAIL CONSTRUCTION
▪ Turnout design and integration
▪ Developing turnout technology
▪ Turnout supply management
▪ Critical junctions design and installation
▪ Turnout pre-assembly and installation
▪ Turnout installation staging solutions
▪ Turnout refurbishment and track reconditioning
▪ Crane rail specialist (supply and construct)
▪ Slab track construction
▪ Turnout and track inspections, maintenance and asset
management
Design – Supply – Install – Maintain
Introduction
We specialise in:
▪ Light rail
▪ Metro
▪ Passenger and freight
▪ Heavy haul
▪ High Axle Load Heavy Haul (HAL-HH)
▪ All gauges and rail profiles
Design – Supply – Install – Maintain
Introduction
Turnout range:
Projects
347 TURNOUTS SUPPLIED
SUPPLIED 51 BUFFER STOPS
CONTRACTED FOR THE SUPPLY OF 400+ TURNOUTS
60KM OF TRACK INSTALLED
33KM OF CRANE RAIL INSTALLED
INSTALLED 102 TURNOUTS
WE HAVE BEEN BUSY AT MARTINUS RAIL
Projects
▪ 22.5t axle load
▪ AS60 rail
▪ 200+ tangential turnouts
Kiwi Rail
Projects
Doha Education City – Qatar
▪ 96 Turnouts and Diamonds▪ 17t axle load▪ S49, 60R2 rail▪ Groove and full depth turnouts▪ Direct fix Vossloh▪ Edilon Sedra Encapsulation
Projects
Projects
Sydney Ports – Botany third line and yard upgrade
▪ 30t axle load
▪ 60E1 rail
▪ 26 Tangential turnouts
OneSteel – Whyalla – Iron Ore Project
▪ 32t axle load
▪ 60E1 rail
▪ 9 Tangential and conventional turnouts
▪ 54t axle load flangeway running diamond
Projects
ARTC – 30TAL Gunnedah
▪ 30t axle load
▪ AS60 rail
▪ 15 Tangential and conventional turnouts
Projects
ARTC – HRR & LTTSF Hexham
Projects
▪ 32.5t axle load
▪ AS60 rail
▪ 41 Tangential turnouts
▪ swing nose crossings
ARTC – Kooragang Island
32.5t axle loadAS60 rail
8 Tangential turnoutsMonoblock crossings
Projects
ARTC – Upper Hunter Valley
32.5t axle loadAS60 rail12 Tangential turnoutsMonoblock crossings
Projects
MBRL - Brisbane
Projects
• 30km of track• 19 turnouts
ARTC – East/West Productivity works turnout upgrade
Projects
PKCT
Projects
• Upgrade the 6km of rail system within the 1km long coal stockyard to facilitate the introduction of new stacker and reclaimer equipment in the yard.
Southpine bridge renewals
Projects
• 2 x 700m tracks along two bridges and an embankment, and was undertaken within a 168 hour rail closedown
Webb dock
Projects
• 1,304m of Gantrex Slab Track – Ship to Shore (STS)• 5,680m of Gantrex Ballasted – Automatic Stacking Crane (ASC) track
GCLR Stage 2
Projects
• Light rail turnouts (49E1 & 51R1)• Diamonds and scissor crossovers• 13km ballast track• 2km embedded track
Buffer stops
Projects
• NWRL (NRTIJV) – x23 stops• MBRL – x13 stops• SEQ Yards – x8 stops• Wickham – x5 stops• Perth stadium – x2 stops• Katoomba – x2 stops• MTM – x1 stop• GCLR – x2 stops
Factories
Manufacturing facility – Century, Australia
Factories
Manufacturing facility – DT, Czech Republic
Global Turnout Solutions
Factories
Manufacturing facility- GWQC, China
Global Turnout Solutions
Factories
Manufacturing facility- CRSBG, China
What is a turnout?
Products
Breakdown of a turnout
Products
1. Switch panel
2. Closure panel
3. Crossing panel
Breakdown of a turnout
Products
Breakdown of a turnout
Products
• Bearers
• Switch set
• Infill closure rails
• Crossing
• Check rail unit
• End infill closure rails
• Points machine
• Rodding
• Platework
• Jewellery
Different types of turnout
Products
▪ Similar flexure
▪ Contra flexure
▪ Crossover
▪ Diamond▪ Scissor crossover▪ Single slip▪ Double slip▪ Catchpoints
Conventional vs Tangential
Products
Conventional vs Tangential
Products
Conventional vs Tangential
Products
• Tangential = improved technology
– Reduced forces
– Increased speed
– Longer service life
– Improved ride quality
– Concrete bearers
– Asymmetric thick web switch
– Resilient fastened stock rail
– Raised adjustable check rails
Conventional vs Tangential
Products
Conventional vs Tangential
Products
Conventional vs Tangential
Products
Conventional vs Tangential
Products
Rail Bound Manganese (RBM)
Products
▪ Fully cast manganese insert
▪ Explosively hardened
▪ AS60 Wing rail
▪ CNC machined nose profile to suit
client wheel profile
▪ Life expectancy: 300MGT
Monoblock
Products
▪ Fully cast manganese
▪ Explosively hardened
▪ No bolts
▪ FBW 60kg Legs
▪ CNC machined WR & nose profile to suit
client wheel profile
▪ Life expectancy: 400MGT
Swing nose crossing
Products
▪ Rail type
▪ Frame type
▪ Manganese cradle
- Eliminates impact
- Reduced noise
- Suitable for longer rate
turnout (high speed)
- Life Expectancy: Greater
than 1000 MGT
High axle load (48T) heavy haul turnout
Products
Designs according to axle loads and speed
Products
Temporary Takeoff Turnout
The Temporary turnout creates a
temporary siding allowing track
machines to move on and off track at
will.
▪ Allows safe and easy removal of
track machines with up to 23T axle
loads from mainline
▪ Once the track machine is located
on the temporary siding it is as
simple as removing two switch
ramps and a crossing ramp,
weighing only 350kg each, in order
to restore mainline running
Products
Temporary Takeoff Turnout
PWI Ken EricksonInnovation Award Winners
Products
Points operation rodding
Products
Backdrive Crank
Drive Locking Bars
Detection Bars
Points Motor
Linking rods
Rear Drive Rod
Deflection Plates
Heel of Switch
Points of switch
Hydraulic points machine – Alstom CTS2
Products
Electric points machine - Siemens M3A/20A
Products
Electric points machine - Siemens D84M
Products
Track forms – Concrete bearers
Products
Track forms – Composite bearers
Products
Products
Expansion Switches
▪ Used for thermal and
subsidence management
▪ Moving Stockrail - gauge is
kept within tolerance
▪ Small Expansion – Up to
100mm
▪ Medium Expansion – Up to
330mm
▪ Long Expansion – Up to
600mm
Products
Buffer Stop systems – Friction Hydraulic
R&D
• New product development is key to ensure that Martinus Rail stays at the forefront of turnout technology and meets increasing network and operational demands from the client
• Martinus Rail carries out design validation (can be by an independent third party) to:– Ensure product conformance
– Ensure product suitability
– Ensure product life cycle
• Validation will include:– Engineering reports
– Design review
– Risk analysis review
R&D
• All new crossing designs are verified for performance using finite element analysis (FEA) techniques
• Tested up to 48T for both static and fatigue analysis
• Fatigue life tested for 2.4 x 107 cycles.
R&D
• New crossing designs undergo wheel / rail interface design studies to ensure that new and hollow wheel profiles transfer through the crossing in the most efficient manner without causing impacts, wheel strikes or wear
R&D
• All products undergo rigorous QA testing and follow up analysis
Install
KR Supply
• Martinus Rail designed brand new tangential turnout design solutions in
collaboration with KiwiRail based around the in track conventional turnouts
currently installed in track. The following table displays current details of turnouts
in use in Kiwi Rail:
• Martinus Rail has reverted to turnout design fundamentals to provide a newly
designed suite of the turnout sizes to incorporate full tangential design and
features that will provide a turnout with an increased life cycle giving Total Cost
of Ownership (TCO) benefits for Kiwi Rail. Martinus Rail has designed the four new
layouts to the following details:
Crossing Rate (Strike) Crossing Angle (°) Speed (km/h)
1 in 7.5 7.59463 25
1 in 9 6.34019 30
1 in 12 4.76364 40
1 in 18 3.17983 60
Radius (m) Crossing Rate (Strike) Crossing Angle (°) Lead Length (m) Divergent Road
Speed (km/h)
R96 1 in 7.5 Straight 7.59463 14.675 28
R140 1 in 9 Straight 6.34019 17.386 33
R250 1 in 12 Straight 4.76364 22.393 42
R560 1 in 18 Straight 3.17983 34.487 66
Kiwi Rail – NZR50 Turnouts
KR Supply
Item Description Reference Document
Turnout Type Tangential – mixed trafficIn accordance with
AS1085 and EN 13232
Turnout
Radius96m, 140m, 250m, 560m
Crossing Rate 1 in 7.5, 1 in 9, 1 in 12, 1 in 18
Gauge 1068mm Kiwi Rail T151
Rail Size NZR50GB 2585-2007 &
Kiwi Rail dwg. 88323/1
Bearers Concrete / CompositeKiwi Rail T151, T160 &
AS1085.14
Turnout
Road SpeedAs per Table 7
Axle Load 22.5T Kiwi Rail T151
Wheel
ProfileNZ A,C & E series
Kiwi Rail dwg. 7604-11,-
13 & -15
Rail Cant in
TurnoutZero
Points
Operation
Suitable for M3A, CTS-2 & Racor
Lever
Yearly
Tonnage18 MGT P.A.
Kiwi Rail – NZR50 Turnouts
Design Criteria Dimension (mm)
Nominal track gauge 1068
Design wheelset back to back dimension 993 - 998
Check rail effectiveness 1026 - 1032
Crossing Flangeway width 41
Check rail gap 38
Maximum superelevation (cant) deficiency
through diverging track60
Switch rail toe / stock rail open throw
dimension≥ 115
Switch rail throat opening ≥ 50
Check rail flared end opening to gauge ≥ 80
Check rail height above the running rail 0
Flangeway depth clearance 45
KR Supply
Kiwi Rail – NZR50 Turnouts
Switch assembly – The switch assembly is fabricated from 50AT asymmetric switchblades and NZR50 head
hardened stockrail.
Asymmetric tangential switchblades – The switchblade is manufactured from 50AT rail. The last 500mm of the
switchblade is forged to the NZR50 profile for connection to the infill closure rails.
• Rail type 50AT, U71 V quality according to TB/T 3109-2005. Rail head is post CNC machined factory
pearlitized to produce a head hardened grade material
Stockrail – Manufactured from NZR50 head hardened (to HB 340) rail. Stock rails are drilled for locking device,
anti-creep device and switch stops.
• Rail type NZR50 quality U75V (HT) according to GB2585-2007
• Head of stockrail undercut to 1:3
Monoblock Crossing Assembly – Manufactured from cast austenitic manganese steel manufactured to TB/T
447-2004
• Explosively hardened within range 320 – 350 HB, all running surfaces up to 100mm from ends of
casting, 20mm from top of rail
• FBW Crossing legs NZR50 quality U75V (HT) according to GB2585-2007
KR Supply
Kiwi Rail – NZR50 Turnouts
Adjustable Check Rail - The check rail unit (two per turnout) comprises the check rail and the check rail
bracket. The check rail is bolted to the bracket using M24 x 80 fasteners. The ends of the check rail are flared to
allow gathering of the wheel flange.
• Check rail type 33C1 (UIC33) to EN 13674-3
• Closure rail clipped to the check rail plate using resilient clips
• Fully adjustable using shim set
Closure Rail - The infill closure rails (rails between the end of the switches and start of the crossing) are supplied
either straight or pre-curved from NZR50 quality U75V (HT) according to GB2585-2007.
Concrete Bearers – Prestressed concrete bearers to AS1085.14 with M24 Screwspike ferrules and Pandrol
shoulders
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
Quality Management Plans
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Risk management
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Quality Inspections
• Manufacturing inspection – In process inspection by the manufacturer
• Third party inspection - In process and post production inspection by a
third party expert
• FAT – Factory Acceptance Test carried out by Martinus Rail senior
engineers
• 100% inspection at factory – All products 100% inspected by Martinus
Rail prior to shipping
• 100% inspection on delivery– All products 100% inspected by Martinus
Rail on delivery
• Trial lay – First off article trial lay for KiwiRail proving
KR Supply
Quality Inspections
ITEM No.
PROCESS / OPERATION / DESCRIPTION VERIFYING
DOCUMENTS TARGET ACTUAL TOLERANCE
INSPECTED BY
COMMENTS
1.13
Gauge to Gauge Distance at A/B/C/D/E (Switch closed)
SG.NZR50-7.5-101
122
156
193
232
275
122.4
156.2
193.5
233
275.5
±1 mm (pass)
1<x<1.5mm (note)
x>1.5mm
(adjust with shim)
KJ
1.14 Switch assembly end opening SG.NZR50-7.5-101 427 426 ±1 mm KJ
1.15 Switch tip to end of stock rail SG.NZR50-7.5-101 1090 1090 ±3 mm KJ
1.16 Stockrail Drilling from End of Stockrail (diameter/distance/height from foot)
SG.NZR50-7.5-101 ø22 1500 63
22 1500 64
±0.5 mm ±2 mm ±1 mm
KJ
1.17 Switch Drilling Hole Diameter – Foot SG.NZR50-7.5-101 Ø32 32 ±0.5 mm KJ
1.18 Switch Drilling Hole Diameter – Web SG.NZR50-7.5-101 Ø22 22 ±0.5 mm KJ
1.19 Stock rail head machining clearance to switch tip SG.NZR50-7.5-101 40 39 ±10 mm KJ
1.20 Foot of the rail to the inside edge of the hole - 17 17.5 +2 mm -0 mm
KJ
1.21 From the foot relief to the bottom of the holes - 14 14 +2 mm -1mm
KJ
KR Supply
Quality InspectionsITEM No.
PROCESS / OPERATION / DESCRIPTION VERIFYING DOCUMENTS
TARGET ACTUAL TOLERANCE INSPECTED
BY COMMENTS
1.22
Switch Drilling from Toe of Switch
SG.NZR50-7.5-101
Ø32 Holes: 50, 117, 184, 690, Ø22 Holes: 294 +232 +253 +100 Check M20 Bolt Fit
Ø32 Holes: 49.7, 116.7, 184.5, 690, Ø22 Holes: 294.5 +232 +253 +100
Checked
±1 mm
KJ
1.23 Switch stops correctly positioned (gap between switch stop and rail web)
VISUAL 0 0 +2, -0 mm KJ
1.24
Length of plates under switch: 50-FLAT 50-SW/50-SWH 50-7.5-13-RH-RS/50-7.5-13-LH-LS 50-7.5-14-RH-RS/50-7.5-14-LH-LS 50-7.5-15-RH-RS/50-7.5-15-LH-LS 50-7.5-16-RH-RS/50-7.5-16-LH-LS
-
450
650
790
840
850
906 (Loose)
450
649
790
841
849
±2 mm (OK)
>2 mm (Check Hole to
Hole L-70mm, ±1)
KJ
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Quality Inspections
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Product Marking
ITEM DESCRIPTION
1 in
7.5
- L
eft
Han
d T
urn
ou
t
1 in
7.5
- R
igh
t H
an
d T
urn
ou
t
1 in
9 -
Le
ft H
and
Tu
rno
ut
1 in
9 -
Rig
ht
Han
d T
urn
ou
t
1 in
12
- L
eft
Han
d T
urn
ou
t
1 in
12
- R
igh
t H
and
Tu
rno
ut
1 in
18
- L
eft
Han
d T
urn
ou
t
1 in
18
- R
igh
t H
and
Tu
rno
ut
1 Left hand side - switch rail + stock rail * I * I * I * I
2 Right hand side - switch rail + stock rail * I * I * I * I
3 Crossing * I * I * I * I
4 Check rails – C * I * I * I * I
5 Check rails – K * I * I * I * I
6 Closure – C * I * I * I * I
7 Closure – K * I * I * I * I
8 Closure – F * I * I * I * I
9 Closure – D * I * I * I * I
10 Closure – A N/A N/A N/A N/A * I * I
11 Closure – H N/A N/A N/A N/A * I * I
12 Loose Items (Box) * I * I * I * I
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Delivery
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Logistics
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Trial Lay
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Trial Lay
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Trial Lay
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Trial Lay
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Installation
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Installation
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Points operation rodding
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Points operation rodding
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Teamwork
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Teamwork
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Summary
• Challenges
• Brand new turnout design
• New manufacturer
• Shipping rail from NZ
• Logistics of moving parts around the world
• Earthquake!
• Successes
• Turnouts on the ground
• Rodding installed
• Working relationships
• Manufacturing quality