Optimisation of mechanised maintenance management of railway track infrastructure

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(2) OPTIMISATION OF MECHANISED MAINTENANCE MANAGEMENT OF RAILWAY TRACK INFRASTRUCTURE. A Thesis Submitted in Partial Fulfilment of the Degree of. DOCTOR OF PHILOSOPHY in. ENGINEERING MANAGEMENT at the. FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT of the. by Leon Zaayman 2017 SUPERVISOR: PROF. JHC PRETORIUS CO-SUPERVISOR: PROF. P VEIT (TECHNICAL UNIVERSITY GRAZ, AUSTRIA).

(3) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE. ABSTRACT Railway track infrastructure is a complex system consisting of various subsystems which require incremental maintenance from all engineering disciplines; all of whom are competing for the limited time and number of available maintenance windows. The constant demand for higher traffic volumes, increased train speeds and heavier axle loadings all result in an exponential increase in maintenance requirements but the time available for maintenance is as a result even further reduced. This requires a more scientific lifecycle approach to infrastructure maintenance management. It also requires increased performance from mechanised construction, maintenance and renewal machines to keep the infrastructure reliable, available, maintainable, affordable and safe within the short windows. The objectives of this thesis are to address the optimisation of infrastructure maintenance management and to provide a model with selection criteria for maintenance machinery and their features for the prevailing circumstances.. ii.

(4) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE. TABLE OF CONTENTS CHAPTER 1 – INTRODUCTION........................................................................................................... 1 PART 1 – OPTIMISATION OF MAINTENANCE MANAGEMENT ................................................................. 5 CHAPTER 2 – RAILWAY INFRASTRUCTURE DEFINED AS A SYSTEM ..................................................... 6 1. 2.. INTRODUCTION ...................................................................................................................... 6 RAILWAY INFRASTRUCTURE SYSTEM ...................................................................................... 6 2.1. System Level ............................................................................................................... 6 2.2. Subsystem Level .......................................................................................................... 7 2.3. Component Level .......................................................................................................... 8 2.3.1. 2.3.2.. Overhead Electrification Equipment (OHE) Components ......................................................... 8 Track (Superstructure and Substructure) Components ......................................................... 14. CHAPTER 3 – INFRASTRUCTURE LIFECYCLE .................................................................................... 18 1. 2. 3. 4.. INTRODUCTION .................................................................................................................... 18 A SYSTEMS ENGINEERING APPROACH TO INFRASTRUCTURE LIFECYCLE .................................... 18 PROJECT MANAGEMENT ....................................................................................................... 22 FEASIBILITY AND DESIGN PHASE ........................................................................................... 22 4.1. Introduction ............................................................................................................... 22 4.2. Need Identification and Scope – Owners Requirement Specification ................................... 23 4.3. Feasibility Study ......................................................................................................... 25 4.3.1. 4.3.2. 4.3.3.. 5.. 6.. 4.4. Project Execution – Detail Design Phase ......................................................................... 29 CONSTRUCTION AND COMMISSIONING PHASE ....................................................................... 29 5.1. Construction .............................................................................................................. 29 5.2. Commissioning ........................................................................................................... 30 OPERATION AND MAINTENANCE PHASE ................................................................................. 31 6.1. Operation and Maintenance .......................................................................................... 31 6.2. Track Life Stages ........................................................................................................ 31 6.2.1. 6.2.2. 6.2.3.. 7. 8.. Feasibility Study Phase 1 ................................................................................................. 26 Feasibility Study Phase 2 ................................................................................................. 27 Feasibility Study Phase 3 ................................................................................................. 28. Early Life Stage .............................................................................................................. 32 Mid-Life Stage................................................................................................................ 33 Late Life Stage ............................................................................................................... 34. RENEWAL PHASE ................................................................................................................. 35 LIFECYCLE COSTS AND COST ANALYSIS ................................................................................ 36 8.1. Introduction ............................................................................................................... 36 8.2. Cost of Maintenance ................................................................................................... 38 8.2.1. 8.2.2.. 8.3. 8.4. 8.5. 8.6. 8.7. 8.8.. Capital Costs ................................................................................................................. 38 Operational Costs ........................................................................................................... 39. Initial Quality of Construction ....................................................................................... 40 Traffic Characteristics ................................................................................................. 43 Infrastructure Configuration .......................................................................................... 43 The Effect of the Different Maintenance Tactics on Lifecycle Cost ..................................... 44 The Effect of Underinvestment in Maintenance on Lifecycle Cost ...................................... 46 External Uncontrollable Factors ..................................................................................... 49. CHAPTER 4 – INFRASTRUCTURE DETERIORATION AND FAILURE ........................................................ 50 1. 2.. 3.. INTRODUCTION .................................................................................................................... 50 CONDITION DETERIORATION ................................................................................................. 50 2.1. Hypothetical Track Deterioration Curve .......................................................................... 50 2.2. Causes of Condition Deterioration ................................................................................. 51 2.3. Condition Deterioration Rate ......................................................................................... 52 INFRASTRUCTURE CONDITION MEASURING AND RECORDING ................................................... 53 3.1. Measuring Systems ..................................................................................................... 53 3.2. Measurements ............................................................................................................ 57 3.2.1.. Absolute Measurements in Millimetres ............................................................................... 57 iii.

(5) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 3.2.2.. 3.3.. 3.3.1. 3.3.2.. 4. 5. 6. 7.. Condition Indices ............................................................................................................ 58. Reports ..................................................................................................................... 61 Real Time Reports .......................................................................................................... 61 Post Processed Reports ................................................................................................... 62. MAINTENANCE STANDARDS ................................................................................................. 67 THRESHOLD FOR MINIMUM ALLOWABLE TRACK CONDITION .................................................... 69 INITIAL QUALITY .................................................................................................................. 71 FAILURE .............................................................................................................................. 72 7.1. Introduction ............................................................................................................... 72 7.2. Potential and Functional Failure ..................................................................................... 73 7.3. Failure Probability Patterns ........................................................................................... 75 7.3.1. 7.3.2. 7.3.3. 7.3.4. 7.3.5. 7.3.6.. 7.4. 7.5.. Failure Rates .............................................................................................................. 80 Failure Mechanisms or Causes ...................................................................................... 80 7.5.1. 7.5.2. 7.5.3. 7.5.4.. 7.6. 7.7. 7.8.. Corrosion ...................................................................................................................... 81 Wear ............................................................................................................................ 81 Fatigue.......................................................................................................................... 82 Overload ....................................................................................................................... 82. Failure Modes ............................................................................................................. 83 Failure Detection......................................................................................................... 84 Reliability Analysis ...................................................................................................... 84 7.8.1. 7.8.2.. 7.9.. Infant Mortality Failure Pattern ......................................................................................... 77 Initial Break-in Period Pattern............................................................................................ 78 Random or Constant Failure Pattern .................................................................................. 78 Wear-Out Failure Pattern ................................................................................................. 78 Fatigue Failure Pattern..................................................................................................... 79 Bathtub Failure Pattern .................................................................................................... 79. Failure Mode and Effects Analysis (FMEA) ......................................................................... 85 Fault Tree Analysis (FTA) ................................................................................................ 88. Failure Analysis Methods ............................................................................................. 89. CHAPTER 5 – INFRASTRUCTURE MAINTENANCE MANAGEMENT........................................................ 90 1. 2.. INTRODUCTION .................................................................................................................... 90 INFRASTRUCTURE MAINTENANCE MANAGEMENT OVERVIEW ................................................... 90 2.1. Introduction ............................................................................................................... 90 2.2. Organisational Mission, Vision and Objectives ................................................................. 91 2.2.1. 2.2.2. 2.2.3.. 2.3.. Maintenance Strategy ................................................................................................. 92 2.3.1. 2.3.2. 2.3.3. 2.3.4. 2.3.5. 2.3.6. 2.3.7. 2.3.8. 2.3.9.. 2.4.. Reactive vs Pro-active Maintenance Strategy ..................................................................... 92 In-House Maintenance vs Contracting ............................................................................... 93 Maintenance Standards ................................................................................................... 93 Night-Working vs Daytime Working ................................................................................... 94 Centralization vs. Decentralization .................................................................................... 94 Level of Mechanisation vs Labour Intensive Methods........................................................... 94 Infrastructure Material Replacement Strategy ..................................................................... 94 Maintenance Windows .................................................................................................... 95 Detailed Maintenance Activity Strategies ........................................................................... 95. Maintenance Tactics ................................................................................................... 95 2.4.1. 2.4.2. 2.4.3. 2.4.4. 2.4.5.. 3.. Mission Statement .......................................................................................................... 91 Vision Statement ............................................................................................................ 91 Objectives ..................................................................................................................... 91. Introduction ................................................................................................................... 95 Emergency Maintenance (Unplanned Reactive Maintenance)................................................. 97 Preventive Maintenance (Planned Proactive Maintenance) .................................................... 99 Predictive Maintenance (Planned Proactive Maintenance) ................................................... 101 Corrective Maintenance (Planned Proactive Maintenance) .................................................. 101. 2.5. Maintenance Plan ..................................................................................................... 2.6. Maintenance Execution .............................................................................................. MAINTENANCE MANAGEMENT PROCESS .............................................................................. 3.1. Introduction ............................................................................................................. 3.2. Input in the Maintenance Process ................................................................................ 3.2.1. 3.2.2. 3.2.3.. 102 104 105 105 106. Introduction ................................................................................................................. 106 Knowledge Hierarchy .................................................................................................... 108 Infrastructure Architecture Knowledge ............................................................................ 109. iv.

(6) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 3.2.4. 3.2.5.. 3.3.. Resources ................................................................................................................ 115 3.3.1. 3.3.2. 3.3.3. 3.3.4. 3.3.5. 3.3.6.. 3.4.. Introduction ................................................................................................................. 126 Key Performance Indicators (KPI) .................................................................................... 127 Non-Conformance Reporting .......................................................................................... 129 Root Cause Failure Analysis ........................................................................................... 129 Maintenance Engineering ............................................................................................... 130. MAINTENANCE DOCUMENTATION ....................................................................................... 130 4.1. Introduction ............................................................................................................. 130 4.2. Manuals .................................................................................................................. 131 4.2.1. 4.2.2.. 5.. Introduction ................................................................................................................. 123 Reliability .................................................................................................................... 123 Availability................................................................................................................... 124 Maintainability.............................................................................................................. 124 Safety ......................................................................................................................... 124 Ride Comfort ............................................................................................................... 125 Noise and Vibrations ..................................................................................................... 125 Cost of Ownership........................................................................................................ 126. Performance Analysis ................................................................................................ 126 3.6.1. 3.6.2. 3.6.3. 3.6.4. 3.6.5.. 4.. Introduction ................................................................................................................. 117 Infrastructure Maintenance Requirement Analysis ............................................................. 118 Maintenance Planning ................................................................................................... 119 Maintenance Execution ................................................................................................. 120 Recording of Work Done................................................................................................ 122. Output .................................................................................................................... 123 3.5.1. 3.5.2. 3.5.3. 3.5.4. 3.5.5. 3.5.6. 3.5.7. 3.5.8.. 3.6.. Introduction ................................................................................................................. 115 Maintenance Budget (Finance) ........................................................................................ 115 Organisational Resources ............................................................................................... 116 Infrastructure Measuring and Recording Vehicles .............................................................. 116 Mechanised Maintenance Machinery ............................................................................... 116 Track Material .............................................................................................................. 117. Process ................................................................................................................... 117 3.4.1. 3.4.2. 3.4.3. 3.4.4. 3.4.5.. 3.5.. Operational Requirements Knowledge .............................................................................. 111 Infrastructure Condition Knowledge ................................................................................ 111. Quality Policy Manual .................................................................................................... 131 Maintenance Manual ..................................................................................................... 131. 4.3. Policies ................................................................................................................... 4.4. Procedures............................................................................................................... 4.5. Work Instructions ..................................................................................................... 4.6. Work Order (Job-Card) .............................................................................................. 4.7. Records ................................................................................................................... MAINTENANCE MANAGEMENT SYSTEMS ............................................................................. 5.1. Introduction ............................................................................................................. 5.2. Graphic Display Diagrams .......................................................................................... 5.3. Computerised Maintenance Management Systems (CMMS) ............................................. 131 132 132 132 132 133 133 133 134. CHAPTER 6 – MAINTENANCE WINDOWS ....................................................................................... 136 1. 2.. 3. 4.. 5. 6.. INTRODUCTION .................................................................................................................. TRAIN SLOTS VS MAINTENANCE SLOTS ................................................................................ 2.1. Train Slots ............................................................................................................... 2.2. Maintenance Slots .................................................................................................... THE INFLUENCE OF TRAIN OPERATIONS ON MAINTENANCE .................................................... ON-TRACK MAINTENANCE OPPORTUNITIES .......................................................................... 4.1. In-Between Train Working .......................................................................................... 4.2. Track Occupation (Possession) on Single Lines .............................................................. 4.3. Working in the ‚Shadow‛ of a Maintenance Window (Single Lines) .................................. 4.4. Working in Default Maintenance Window (Single Lines) .................................................. 4.5. Track Occupation (Possession) on Multiple Lines ........................................................... 4.6. Permit ..................................................................................................................... 4.7. Maintenance Shutdown ............................................................................................. 4.8. Working at Night ...................................................................................................... PRIORITY CRITERIA FOR THE LOCATION OF MAINTENANCE WINDOWS .................................... COSTS ASSOCIATED WITH MAINTENANCE WINDOWS ............................................................ 136 137 137 138 138 141 141 143 145 146 146 147 147 148 148 150 v.

(7) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 6.1. 6.2.. Direct Costs Associated with Maintenance Windows ..................................................... 150 Indirect Costs Associated with Maintenance Windows ................................................... 151 6.2.1. 6.2.2. 6.2.3. 6.2.4. 6.2.5.. 6.3.. Inefficient Management of the Maintenance Window ........................................................ 151 Machine Availability ...................................................................................................... 152 Quality of Work Produced by the Machine ....................................................................... 153 Machine Performance.................................................................................................... 153 Working at Night .......................................................................................................... 154. Hypothetical Example ................................................................................................ 154 6.3.1. 6.3.2. 6.3.3.. Background ................................................................................................................. 154 Minimum Tamping Production Required ........................................................................... 156 Machine Comparison..................................................................................................... 156. PART 2 - INFRASTRUCTURE MAINTENANCE ACTIVITIES ................................................................... 158 CHAPTER 7 – INFRASTRUCTURE MAINTENANCE ACTIVITIES ........................................................... 159 1. 2. 3.. 4.. 5. 6. 7.. 8.. 9. 10.. 11.. 12. 13.. INTRODUCTION .................................................................................................................. MATERIAL TRAINS ............................................................................................................. INFRASTRUCTURE INSPECTION, MEASURING AND RECORDING ............................................... 3.1. Introduction ............................................................................................................. 3.2. Track and OHE Geometry and Rail and Ballast Profile Measurements ................................ 3.3. Ultrasonic Rail Flaw Detection .................................................................................... 3.4. Management Trolley Inspections and Visual Inspections ................................................. 3.5. Ground Penetrating Radar .......................................................................................... RAIL .................................................................................................................................. 4.1. Introduction ............................................................................................................. 4.2. Rail Transportation, Offloading and Loading .................................................................. 4.3. Rail Replacement (Installation) .................................................................................... 4.4. Rail Profiling ............................................................................................................. 4.5. Rail Destressing ........................................................................................................ RAIL FASTENINGS AND INSULATORS ................................................................................... RAIL PADS ......................................................................................................................... SLEEPERS .......................................................................................................................... 7.1. Introduction ............................................................................................................. 7.2. Sleeper Transportation ............................................................................................... 7.3. Sleeper Replacement ................................................................................................. BALLAST ........................................................................................................................... 8.1. Introduction ............................................................................................................. 8.2. Ballast Cleaning ........................................................................................................ 8.3. Ballast Tamping ........................................................................................................ 8.4. Ballast Regulating ..................................................................................................... 8.5. Ballast Transportation and Offloading .......................................................................... FORMATION ...................................................................................................................... TURNOUTS, SLIPS AND CROSSINGS (SETS) ........................................................................... 10.1. Transportation of Sets ............................................................................................... 10.2. Set Replacement ...................................................................................................... 10.3. Set Component Replacement ...................................................................................... 10.4. Set Grinding ............................................................................................................. OVERHEAD EQUIPMENT ...................................................................................................... 11.1. Introduction ............................................................................................................. 11.2. Phase Break and Section Insulator Balancing and Replacement ........................................ 11.3. Substation and Booster Transformer Maintenance ......................................................... 11.4. Electrification Structure Inspection, Adjustments and Replacement .................................. 11.5. Contact Wire Replacement ......................................................................................... 11.6. Setting Contact Wire Stagger ..................................................................................... 11.7. Tensioning Device Maintenance .................................................................................. 11.8. Insulator Cleaning and Replacement ............................................................................ 11.9. Mast Pole Replacement ............................................................................................. 11.10. Electric Third Rail ...................................................................................................... SIGNALLING INFRASTRUCTURE ........................................................................................... BRIDGES, CULVERTS AND TUNNELS ...................................................................................... 159 159 162 162 162 163 163 164 164 164 164 165 167 168 169 170 171 171 171 171 172 172 173 173 174 174 176 176 176 177 177 178 179 179 179 179 180 180 181 181 181 182 182 183 183 vi.

(8) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 14. CUTTINGS AND EMBANKMENTS .......................................................................................... 15. COLLECTOR DRAINAGE SYSTEMS CLEANING ........................................................................ 16. OTHER WAYSIDE (LINESIDE) MAINTENANCE .......................................................................... 16.1. Vegetation Control .................................................................................................... 16.2. Level Crossings ......................................................................................................... 184 185 188 188 189. PART 3 – SELECTION CRITERIA OF MECHANISED INFRASTRUCTURE MAINTENANCE MACHINES .......... 190 CHAPTER 8 – INFRASTRUCTURE CRITERIA .................................................................................... 191 1. 2.. 3.. 4.. INTRODUCTION .................................................................................................................. INFRASTRUCTURE MATERIAL .............................................................................................. 2.1. Introduction ............................................................................................................. 2.2. Rails ....................................................................................................................... 2.3. Fastenings ............................................................................................................... 2.4. Rail Pads ................................................................................................................. 2.5. Sleepers .................................................................................................................. 2.6. Ballast ..................................................................................................................... 2.7. Turnouts, Slips and Crossing (Sets) ............................................................................. 2.8. Formation ................................................................................................................ INFRASTRUCTURE DESIGN .................................................................................................. 3.1. General Design Features ............................................................................................ 3.2. Vehicle Structure Gauge ............................................................................................ 3.3. Gauge ..................................................................................................................... 3.4. Dual Gauge .............................................................................................................. 3.5. Single vs Multiple Lines ............................................................................................. 3.6. Branch Lines ............................................................................................................ NETWORK FEATURES ......................................................................................................... 4.1. Track Length ............................................................................................................ 4.2. Topography ............................................................................................................. 4.2.1. 4.2.2. 4.2.3.. 4.3.. Curves ........................................................................................................................ 203 Grades ........................................................................................................................ 204 Mountainous or Remote Areas ....................................................................................... 205. Turnouts, Slips and Crossings (Sets)............................................................................ 205 4.3.1. 4.3.2. 4.3.3. 4.3.4.. 5.. 191 191 191 191 192 192 193 193 194 195 195 195 196 196 197 198 199 199 199 203. The Number of Sets on a Section ................................................................................... 205 Switch Blade Curvature ................................................................................................. 206 Turnout Entry and Take-Off Angles ................................................................................. 206 Sets on Timber or Concrete Sleepers............................................................................... 207. 4.4. Passing Loops and Stations ........................................................................................ 4.5. Off-Tracking Spurs for Maintenance Machinery and Material Trains .................................. 4.6. Level Crossings ........................................................................................................ 4.7. Service Roads .......................................................................................................... INFRASTRUCTURE CONDITION............................................................................................. 5.1. Track Deterioration ................................................................................................... 5.2. Measuring Infrastructure Condition .............................................................................. 5.3. Effect of the Value of the Intervention Level on Machine Selection .................................. 5.4. Effect of the Track Condition on Machine Selection ....................................................... 5.4.1. 5.4.2. 5.4.3. 5.4.4. 5.4.5. 5.4.6.. 207 208 209 209 209 209 209 210 210. Rails ........................................................................................................................... 211 Sleepers ...................................................................................................................... 211 Rail Fastenings and Rail Pads ......................................................................................... 212 Ballast......................................................................................................................... 212 Formation .................................................................................................................... 213 Turnouts, Slips and Crossings (Sets) ............................................................................... 214. CHAPTER 9 – OPERATING CRITERIA .............................................................................................. 215 1. 2.. 3.. INTRODUCTION .................................................................................................................. SIGNALLING SYSTEMS ........................................................................................................ 2.1. Mechanical (Semaphore) Signal................................................................................... 2.2. Colour Light Signal .................................................................................................... TRAIN OPERATING METHODS .............................................................................................. 3.1. Timetable Operation .................................................................................................. 3.2. Block Operation ......................................................................................................... 215 216 216 217 218 218 220 vii.

(9) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 3.2.1. 3.2.2. 3.2.3. 3.2.4.. 4.. 5.. TRAIN DETECTION SYSTEMS ............................................................................................... 4.1. Track Circuits ........................................................................................................... 4.2. Axle Counters .......................................................................................................... TRANSPORT SERVICE TYPE ................................................................................................. 5.1. Structured Service .................................................................................................... 5.1.1. 5.1.2.. 6. 7. 8. 9. 10. 11.. Fixed Block .................................................................................................................. 221 Permissive Block .......................................................................................................... 221 Automatic Block ........................................................................................................... 222 Moving Block ............................................................................................................... 222. 223 223 224 224 224. Supply Driven .............................................................................................................. 225 Demand Driven ............................................................................................................ 226. 5.2. Ad-Hoc Service ........................................................................................................ TRAIN OPERATING ON DOUBLE AND SINGLE LINES ................................................................ TRACK UNAVAILABILITY ..................................................................................................... SPEED OF TRAINS ............................................................................................................... TRAFFIC ENTERING AND EXITING THE TRACK SECTION .......................................................... DELAY OF TRAINS .............................................................................................................. TIME BETWEEN TRAINS (HEADWAY)...................................................................................... 226 227 228 229 230 230 231. CHAPTER 10 – THROUGHPUT CRITERIA .......................................................................................... 233 1. 2. 3.. 4.. 5.. INTRODUCTION .................................................................................................................. CONSTRUCTION OF ADDITIONAL LINES ................................................................................ SHORTER HEADWAY BETWEEN TRAINS ................................................................................ 3.1. Introduction ............................................................................................................. 3.2. Effect on Infrastructure Requirements .......................................................................... 3.3. Effect on Track Deterioration and Maintenance Machinery Selection ................................ INCREASING TRAIN LENGTHS .............................................................................................. 4.1. Introduction ............................................................................................................. 4.2. Effect of Long Trains on Curve Deterioration................................................................. 4.3. Effect of Distributed Power Technology on Track Deterioration ....................................... 4.4. Effect of Long Trains on Track Maintenance Machinery Selection .................................... INCREASING AXLE LOADING ................................................................................................ 5.1. Introduction ............................................................................................................. 5.2. Effect of Increasing Axle Loads on Operating Costs ....................................................... 5.3. Effect of Increasing Axle Loads on Track Deterioration ................................................... 5.3.1. 5.3.2. 5.3.3. 5.3.4.. 5.4. 5.5.. Rails ........................................................................................................................... 241 Sleepers ...................................................................................................................... 242 Rail to Sleeper Fastenings .............................................................................................. 243 Substructure ................................................................................................................ 243. Economic Effect of Increasing Axle Loads .................................................................... 244 Effect of Increasing Axle Loads on Track Maintenance Machinery Selection ...................... 245 5.5.1. 5.5.2. 5.5.3. 5.5.4. 5.5.5. 5.5.6. 5.5.7. 5.5.8. 5.5.9.. 6.. 233 233 234 234 234 234 235 235 235 236 237 237 237 238 239. Measuring and Recording............................................................................................... 245 Tamping ...................................................................................................................... 245 Dynamic Track Stabilisation ........................................................................................... 245 Rail Maintenance .......................................................................................................... 245 Rail Pad Replacement .................................................................................................... 248 Sleeper Maintenance ..................................................................................................... 248 Rail to Sleeper Fastenings and Insulators ......................................................................... 249 Ballast Maintenance ...................................................................................................... 249 Turnout, Slip and Crossing (Set) Maintenance .................................................................. 251. SPEED OF TRAINS ............................................................................................................... 251. CHAPTER 11 – ENVIRONMENTAL CRITERIA ..................................................................................... 253 1. 2. 3. 4.. INTRODUCTION .................................................................................................................. ENVIRONMENT AND SUSTAINABLE DEVELOPMENT ................................................................ WASTE PRODUCTS AND SOURCES ....................................................................................... REDUCE, REPAIR, RECYCLE ................................................................................................. 4.1. Prevent ................................................................................................................... 4.2. Containment and Clean-Up ......................................................................................... 4.3. Reduce .................................................................................................................... 4.3.1.. 253 254 254 255 255 256 257. Reducing Energy Consumption ....................................................................................... 257 viii.

(10) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 4.3.2.. Reducing Waste ........................................................................................................... 258. 4.4. Repair ..................................................................................................................... 4.5. Recycle and Reuse .................................................................................................... 4.6. Dispose ................................................................................................................... 5. VISUAL POLLUTION ............................................................................................................ 6. SOIL POLLUTION ................................................................................................................ 7. WATER POLLUTION ............................................................................................................ 8. AIR POLLUTION .................................................................................................................. 8.1. Exhaust Gasses ........................................................................................................ 8.2. Dust from Open Wagons............................................................................................ 8.3. Dust from Maintenance Activities................................................................................ 8.4. Working in Tunnels ................................................................................................... 9. NOISE AND VIBRATION ....................................................................................................... 10. CLIMATOLOGICAL CONDITIONS ........................................................................................... 10.1. Lightning Density ...................................................................................................... 10.2. Arid Areas ............................................................................................................... 10.3. High Rainfall and Coastal Areas .................................................................................. 10.4. Extreme Temperatures ............................................................................................... 11. EFFECT OF ENVIRONMENTAL STANDARDS ON CONTRACTORS ................................................ 258 258 260 260 261 261 262 262 263 263 264 265 267 267 267 267 268 268. CHAPTER 12 – SAFETY CRITERIA ................................................................................................... 269 1. 2.. INTRODUCTION .................................................................................................................. RISK MANAGEMENT ........................................................................................................... 2.1. Introduction ............................................................................................................. 2.2. Identifying Hazards ................................................................................................... 2.3. Risk Evaluation ......................................................................................................... 2.4. Controlling Safety Risks ............................................................................................. 2.4.1. 2.4.2. 2.4.3. 2.4.4. 2.4.5. 2.4.6.. 3. 4.. Elimination ................................................................................................................... 271 Substitution ................................................................................................................. 274 Isolation ...................................................................................................................... 274 Engineering Control....................................................................................................... 275 Administrative Controls ................................................................................................. 277 Personal Protective Equipment (PPE) ............................................................................... 278. 2.5. Monitoring ............................................................................................................... RESPONSIBILITY FOR SAFETY .............................................................................................. OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM .............................................. 4.1. Health and Safety Policies, Procedures and Standards .................................................... 4.2. Legal, Site Specific and Railway Specific Requirements .................................................. 4.3. Hazard Identification, Risk Assessment and Risk Control ................................................ 4.4. Accidents and Incidents Emergency Response .............................................................. 4.5. Health and Safety Communication and Consultative Processes ........................................ 4.6. Health and Safety Training and Competency ................................................................. 4.6.1. 4.6.2. 4.6.3.. 4.7.. Competency Training .................................................................................................... 284 Induction Training ......................................................................................................... 284 Health and Safety Related Appointments Training ............................................................. 285 Safety Manager ............................................................................................................ 285 Safety Officer .............................................................................................................. 285 Health and Safety Representatives .................................................................................. 286 Incident & Accident Investigator ..................................................................................... 287 Risk Assessor .............................................................................................................. 287 First Aiders .................................................................................................................. 287. Health and Safety Performance Measurements and Reporting ......................................... 287 Safety Related Meetings ............................................................................................ 287 4.9.1. 4.9.2. 4.9.3.. 4.10. 4.11. 4.12. 4.13.. 278 278 280 281 282 282 283 283 284. Health and Safety Related Appointments...................................................................... 285 4.7.1. 4.7.2. 4.7.3. 4.7.4. 4.7.5. 4.7.6.. 4.8. 4.9.. 269 269 269 270 271 271. Daily Pre-Start Meetings ................................................................................................ 287 Safety Review Meetings ................................................................................................ 288 Formal Safety Meetings ................................................................................................. 288. Medical Fitness ........................................................................................................ Debilitating Substances Use ....................................................................................... Safety Equipment ..................................................................................................... Health and Safety Auditing ......................................................................................... 288 289 289 289 ix.

(11) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE 5. MACHINE SAFETY FEATURES .............................................................................................. 289 6. EUROPEAN STANDARDS FOR MECHANISED INFRASTRUCTURE MAINTENANCE RELATING TO SAFETY .................................................................................................................................... 292 CHAPTER 13 – MACHINE OWNERSHIP ............................................................................................. 295 1. 2.. 3.. 4.. INTRODUCTION .................................................................................................................. TYPE OF MACHINE OWNERSHIP ........................................................................................... 2.1. Machines owned, operated and maintained by the railways: ........................................... 2.2. Machines owned operated and maintained by the contractor: .......................................... 2.3. The machine is owned and operated by the railway but maintained and supported by the original equipment manufacturer (OEM) or a contractor: ........................................................... 2.4. The machine is owned by the railway but operated and maintained by two different contractors: ....................................................................................................................... 2.5. The machine is owned by the OEM but contracted to the railway by a civil engineering contractor: ......................................................................................................................... CONSIDERATIONS FOR MACHINE OWNERSHIP ...................................................................... 3.1. Availability of a Competitive Outsourcing Market ........................................................... 3.2. Location of the OEM ................................................................................................. 3.3. OEM Reputation for Quality and Support ...................................................................... 3.4. Range of Machines Offered by the OEM ....................................................................... 3.5. Availability of Suitably Qualified Machine Staff ............................................................. 3.6. Training ................................................................................................................... 3.7. Spare Parts Holding ................................................................................................... 3.8. Machine Maintenance ................................................................................................ 3.9. Technical Support ..................................................................................................... 3.10. Standards ................................................................................................................ 3.11. Conventions ............................................................................................................. COSTS OF MACHINE OWNERSHIP ......................................................................................... 295 295 295 297 299 299 300 300 300 300 301 301 301 302 303 304 305 306 306 306. CHAPTER 14 – INFLUENCE OF THE MAINTENANCE ORGANISATIONAL STRUCTURE ............................. 309 1. 2.. INTRODUCTION .................................................................................................................. CONSIDERATIONS FOR ORGANISATIONAL STRUCTURE .......................................................... 2.1. Asset Ownership, Maintenance and Operations ............................................................. 2.2. Asset Life Phases ..................................................................................................... 2.3. Engineering Disciplines .............................................................................................. 2.4. Size and Characteristics of the Railway Infrastructure .................................................... 2.5. Geographic Layout .................................................................................................... 2.6. Maintenance Planning and Execution Functions ............................................................. 2.7. Centralised or Decentralised Decision Making ................................................................ 2.7.1. 2.7.2. 2.7.3.. 2.8.. 309 309 309 310 311 314 315 317 317. Centralisation ............................................................................................................... 317 Decentralisation ........................................................................................................... 319 Combining Centralisation and Decentralisation .................................................................. 319. In-House or Outsourced Maintenance .......................................................................... 320 2.8.1. 2.8.2. 2.8.3.. Machines Owned, Operated and Maintained by the Railway ............................................... 320 Machines Owned, Operated and Maintained by Contractors ............................................... 321 Mixed Responsibility for Ownership, Operating and Maintenance of Machines ...................... 321. CHAPTER 15 – DECISION MAKING MODEL ....................................................................................... 323 1. 2. 3.. INTRODUCTION .................................................................................................................. 323 MACHINE SELECTION MODEL .............................................................................................. 324 CONCLUSION ..................................................................................................................... 341. CHAPTER 16 – FINAL CONCLUSIONS AND SUBJECT CONTRIBUTION ................................................. 342 1. 2. 3.. FINAL CONCLUSION............................................................................................................ 342 ACADEMIC CONTRIBUTION TO THE SCIENCE......................................................................... 348 RECOMMENDATIONS FOR FURTHER RESEARCH .................................................................... 348. REFERENCES ............................................................................................................................... 349. x.

(12) OPTIMISING MECHANISED MAINTENANCE OF RAILWAY TRACK INFRASTRUCTURE. TABLE OF FIGURES FIGURE 1: THE RAILWAY INFRASTRUCTURE SYSTEM (ADAPTED FROM ZAAYMAN, 2016) ......................................................................................7 FIGURE 2: RAILWAY INFRASTRUCTURE SUBSYSTEMS ......................................................................................................................................7 FIGURE 3: BRIDGE INSPECTION TRACK MOTOR VEHICLE.................................................................................................................................8 FIGURE 4: COMPLEX OHE SYSTEM (50 KV) ................................................................................................................................................9 FIGURE 5: OHE COMPONENTS ...............................................................................................................................................................10 FIGURE 6: CONTACT WIRE HORN CONTACT ON PANTOGRAPH ......................................................................................................................11 FIGURE 7: PHASE BREAK OR SECTION INSULATOR .......................................................................................................................................12 FIGURE 8: PHASE BREAK BETWEEN TWO SUBSTATIONS................................................................................................................................12 FIGURE 9: SECTION INSULATORS AND TRACK SECTION SWITCHES ...................................................................................................................13 FIGURE 10: CONTACT WIRE TENSIONING SYSTEM ......................................................................................................................................14 FIGURE 11: TRACK COMPONENTS (ZAAYMAN 0) ........................................................................................................................................15 FIGURE 12: INFRASTRUCTURE LIFECYCLE PHASES ........................................................................................................................................18 FIGURE 13: SYSTEMS ENGINEERING BASIC V-MODEL ..................................................................................................................................19 FIGURE 14: V-MODEL ADAPTED FOR INFRASTRUCTURE LIFECYCLE (DETAILED) .................................................................................................21 FIGURE 15: OPERATIONS AND MAINTENANCE LIFE STAGES ..........................................................................................................................32 FIGURE 16: POTENTIAL FAILURE OF THE FORMATION INDICATES END OF TRACK LIFE .........................................................................................35 FIGURE 17: LIFECYCLE PHASES AND LIFECYCLE COSTS ..................................................................................................................................37 FIGURE 18: LIFECYCLE COST TREE............................................................................................................................................................38 FIGURE 19: INFLUENCE OF DECISIONS MADE DURING THE FEASIBILITY,............................................................................................................42 FIGURE 20 : THE EFFECT OF INITIAL QUALITY IN CONSTRUCTION ON THE DETERIORATION CURVE.........................................................................43 FIGURE 21: MAINTENANCE COST DISTRIBUTION DURING LIFECYCLE PHASES ....................................................................................................45 FIGURE 22 : TRACK DETERIORATION CURVE WITH INADEQUATE FINANCIAL INVESTMENT ...................................................................................47 FIGURE 23 : MAINTENANCE COST CURVE (FROM RT-CAP PROJECT, ZAAYMAN, 2016) ....................................................................................48 FIGURE 24: HYPOTHETICAL TRACK DETERIORATION CURVE (ADAPTED FROM ZAAYMAN, 2016)..........................................................................50 FIGURE 25: LARGE RANGE OF INFRASTRUCTURE MEASURING AND RECORDING ................................................................................................54 FIGURE 26: THE DIFFERENTIAL GPS CONCEPT ...........................................................................................................................................56 FIGURE 27: SYMMETRICAL HORIZONTAL ALIGNMENT MEASUREMENT ............................................................................................................57 FIGURE 28: EXAMPLE OF TRACK QUALITY INDEX REPORT .............................................................................................................................59 FIGURE 29: EXAMPLE OF A STRIP CHART (COURTESY PLASSER SOUTH AFRICA) .................................................................................................61 FIGURE 30: EXAMPLE OF THE S-CURVE OF A ZONE REPORT ..........................................................................................................................65 FIGURE 31: EXAMPLE OF A TRACK STANDARD (ADAPTED FROM TRANSNET FREIGHT RAIL, 2012)........................................................................68 FIGURE 32: EXCEPTIONS REPORT PRODUCED BY AN INFRASTRUCTURE MEASURING AND RECORDING VEHICLE .......................................................69 FIGURE 33 : SUMMARY OF THE EFFECT OF MAINTENANCE DUE TO THRESHOLD................................................................................................70 FIGURE 34 : THE EFFECT OF THE VARIOUS THRESHOLDS ON LIFECYCLE ............................................................................................................71 FIGURE 35 : THE EFFECT OF INITIAL QUALITY IN CONSTRUCTION ON THE DETERIORATION CURVE.........................................................................72 FIGURE 36: P-F INTERVAL (ADAPTED FROM MOUBRAY 1997) .....................................................................................................................73 FIGURE 37: P-F INTERVAL MAINTAINABLE COMPONENTS ............................................................................................................................74 FIGURE 38: P-F INTERVAL REPLACEABLE COMPONENTS...............................................................................................................................75 FIGURE 39: THE SIX FAILURE PROBABILITY PATTERNS ILLUSTRATED (ADAPTED FROM NOWLAN & HEAP, 1978) ....................................................76 FIGURE 40: INFANT MORTALITY FAILURE PATTERN .....................................................................................................................................77 FIGURE 41: INITIAL BREAK-IN PERIOD PATTERN .........................................................................................................................................78 FIGURE 42: RANDOM FAILURE PATTERN...................................................................................................................................................78 FIGURE 43: WEAR-OUT FAILURE PATTERN ...............................................................................................................................................79 FIGURE 44: FATIGUE FAILURE PATTERN ....................................................................................................................................................79 FIGURE 45: BATHTUB FAILURE PATTERN ..................................................................................................................................................79 FIGURE 46: DETERIORATING CAPACITY .....................................................................................................................................................83 FIGURE 47: FMEA TABLE......................................................................................................................................................................86 FIGURE 48: SIMPLE EXAMPLE OF A FAULT TREE .........................................................................................................................................88 FIGURE 49: MANAGEMENT AND STRATEGY HIERARCHY ...............................................................................................................................90 FIGURE 50: MAINTENANCE TACTICS ........................................................................................................................................................96 FIGURE 51: EXPANSION OF THE HYPOTHETICAL TRACK DETERIORATION CURVE ................................................................................................97 FIGURE 52: EXPANSION OF THE P-F INTERVAL CURVE .................................................................................................................................97 FIGURE 53: TIME BASED PREVENTIVE MAINTENANCE (1) ......................................................................................................................... 100 FIGURE 54: TIME BASED PREVENTIVE MAINTENANCE (2) ......................................................................................................................... 101 FIGURE 55: ASSET MANAGEMENT ........................................................................................................................................................ 105 FIGURE 56: PROCESS APPROACH TO MAINTENANCE MANAGEMENT ........................................................................................................... 106 xi.

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