Technical Strategy Leadership Group

Transcription

1 Agenda item: 4(a) MEETING: Technical Strategy Leadership Group DATE: 5 th June 2014 SUBJECT AUTHOR VT SIC Annual report Andy Doherty 1 Purpose 1.1 This paper presents a summary of the activities of the Vehicle/Track Systems Interface Committee (VT SIC) and its sub-groups in 2013 and early 2014 as well as the planned activities for the remainder of Issue 2.1 This paper forms the sixth annual report to be presented to TSLG from the Chair of the Vehicle/Track SIC. 3 Recommendations 3.1 TSLG is invited to note the progress being made by the VT SIC and its sub-groups. In particular, TSLG is invited to note: 3.2 The effort and hard work provided by experts and the support from their employing organisations from across the industry which continues to make the VT SIC an effective and powerful supporter of the UK railway. 3.3 The VT SIC continues to provide technical solutions and verified advice to industry to deliver economic benefit to its members 3.4 TSLG should be aware that in the last year there has been a problem to achieve affordable and viable contract arrangements for full scale evaluation tests to conclude 2 funded RSSB projects. RSSB is working to find a solution to this problem as it could have impact on many TSLG and SIC projects. 4 Headline Activity 4.1 VT SIC has continued to progress its 3 year strategic and broad based programme of research and application during 2013/4. This work is conducted by the subgroups of VT SIC; ARG, WMG, PPG (Permanent Project Group of the SIC) and by RSSB. 4.2 VT SIC continues to be strongly supported by experts from across the industry, who freely provide their time and expertise. 4.3 VT SIC continues to get top quality support for its work from RSSB and its people 4.4 The UK broken rail rate reduced to 126 in the year 13/14 (the lowest of record). Rail foot defects are now the highest causer of failure. As a result part of the VT SIC research programme will know focus on the causes and detection of this type of failure. 4.5 The VT SIC Annual Conference of technical reporting and dissemination was very well supported and again voted a success by the 100 or so attendees. Thank you to the hard work of the contributors and RSSB for the arrangements. 4(a)-Annual Report VT SIC Jun 14 Page 1 of 7

2 4.6 The production of; guidance notes, best practice advice, technical papers, training course and direct expert advice, to support and generate competence in the industry remains a high priority to VT SIC. 4.7 A number of quality learned technical papers has been produced by members of the VT SIC community, these have been presented at the WCRR in Sydney, and in a number of UK and European technical conferences. 4.8 The WMG was a major supporter of the recent Wheelset management Conference ran by the I Mech E in April. This successful conference has aided the knowledge transfer and dissemination of VT SIC work. 4.9 VT SIC has supported the development of the VTAC for CP The implementation of HALL bushes and P12 wheel profiles, and premium rail steel has become business as usual to the industry VT SIC has collaborated with railways from across the world to build understanding of rail STUDS (Squat type unknown defects). London Underground, NSW Australia, US Railroads all appear to have a similar defect which is linked to AC Traction drive systems. Papers and discussion have enabled a better understanding and control actions SNCF, DB, SBB and many other railways have sought wheel-rail advice from UK Railway engineers, demonstrating the expertise the UK railway now has in this subject 4.13 VT SIC and RSSB ran to an unexpected problem with obtaining reasonable quotes for full scale testing of the proposed outputs of the projects T797 Performance and installation criteria for sanding systems and T959 On-board Detection of Low adhesion. The problem was the attribution and compensation for the risk of wheel set damage. RSSB is working to find a solution to this problem, as it could have impact on many TSLG and SIC projects. 5 PPG Research 5.1 During the last year PPG has undertaken work in a number of areas. These have included: 5.1 Track-Ex continues to grow as a unique tool for assessing rolling contact fatigue (RCF), and the number of users has increased over the year. Over 550 engineers, from both Network Rail and the wider rail industry, have now been on a training course run by PPG Providing training to new and existing users remains an important part of the team s work. During the year 10 training courses were run with the purpose of both helping people use the software and to provide a good basic understanding of wheel/rail interaction and the causes of track damage. As well as training, development of the software tool itself has continued with enhancements and new features being developed in response to users needs Within the year Track-Ex has been used to support a number of track projects, the largest of which was the Midland Main Line linespeed improvement programme, where it was used to assess the impact of changes to the infrastructure on RCF. It has also been used to support the CrossRail project, and one of the training courses was run specifically for the CrossRail team Track-Ex wear model. Monitoring of changes in rail profile over time on a newly re-railed curve has been undertaken. This will be used to generate a new algorithm within Track-Ex to predict the optimum period for rail grinding, based on how quickly the rail profile will wear at different sites RCF models for premium rail steels. Monitoring of RCF development at a number of sites installed with premium grade rail steels has continued, and work started on using this to develop an RCF model for these steels. This will be integrated into Track-Ex so that the best sites for the use of these rail steels can be identified. 5.2 A major project was launched to analyse RCF and the impact of Desiro vehicles on the Wessex route. The objective was to help the Wessex team better understand the causes of RCF on the route and how that will change as the proportion of vehicles fitted with 4(a)-Annual Report VT SIC Jun 14 Page 2 of 7

3 HALL bushes increases, and use Track-Ex to identify the best RCF control measures in the locations where the HALL bushes may not have a significant effect on reducing RCF. 5.3 Following the fitment of HALL bushes to the SWT fleet of Desiro vehicles PPG has undertaken work to identify the potential benefits of fitting the bushes to some other fleets. Following this the bushes are now being fitted to the Class 221 fleet. 5.4 P12 wheels. Potential new fleets have been considered for a trial of this wheel profile and PPG have provided assistance in these. 5.5 VTAC model. PPG have been involved in developing the Variable Usage Charge model for CP5. This model, together with a VUC calculator tool to allow VUC rates to be determined for new or modified vehicles has been implemented. 5.6 Conicity mapping. The University of Huddersfield were commissioned to develop a tool to determine equivalent conicity from rail profile and track geometry data collected from the new track inspection systems used by Network Rail. 5.7 Re-profiling wheels with thin flanges. A project was launched, and is continuing, to assess the potential benefits of allowing operators to re-profile wheels without the need to restore the full flange thickness specified in Railway Group Standards. 5.8 Track damage investigations have been undertaken at a number of locations, including problems identified with an expansion switch on HS1 and RCF in tunnel sections on WCML. 5.9 A number of presentations and papers have been made, including a technical paper on Track-Ex presented at the WCRR conference in Sydney. The V/T SIC paper on the effects of changing material hardness on wheel/rail wear has been presented at a number of PWI meetings and also at a wheelset colloquium organised by ATOC. 6 RSSB R&D programme 6.1 The past year has seen continued progress of the RSSB managed research projects in support of V/T SIC and its sub-groups; Adhesion Research Group (ARG) and Wheelset Management Group (WMG), and their planned workload. This has required the different parts of the GB rail industry to engage and work together. The following are examples of this co-operation. 6.2 T774 Investigating the value, reliability and effectiveness of axle inspection techniques This research investigated the human factors aspects of axle inspection and improved our understanding of human performance in these tasks. It has provided guidance on how human performance can be optimised and delivered guidance documents to be utilised by the GB rail industry. 6.3 T963 Improving wheelset life by better understanding the causes of wheel damage This research has investigated the relationships between wheel life, train configuration, route, track conditions, and maintenance practices. It has provided a good practice wheel tread damage guide for train operators and maintainers. The guidance includes definition of tread damage with illustrations and detailed description, potential mitigation for the different types of tread damage and case studies to optimise wheel life and thus minimise the associated costs. It includes illustrations of the damage types, what causes them, and methodologies for managing the damage. 6.4 T797 Performance and installation criteria for sanding systems This research examined the relevance of the existing sanding requirements and undertook development testing and research to propose and justify future changes to the criteria. The tests examined the performance of different sanding system configurations by measuring and comparing how much sand passes through the wheel rail interface. It found that there were a number of changes that could be made to sanders to increase the amount of sand entering the interface. A proposal has been made to revise Railway Group Standards to allow the use of dedicated traction sanders (where fitted) on single 4(a)-Annual Report VT SIC Jun 14 Page 3 of 7

4 and coupled multiple units, and the use of the sanders on each of the leading cars of coupled multiple units when an emergency brake is demanded and low adhesion is detected. 6.5 T959 On-board detection of low adhesion This research, sponsored by TSLG, has developed a new technique for detecting low adhesion conditions by monitoring running conditions on-board a vehicle. This is a predictive technique based upon measuring what is happening dynamically to the wheelsets and bogie during normal running, prior to braking. Although the research hasn t reached its full potential, the industry is working together to consider its options so that this work can be taken to the next level. 6.6 T888 DynoTRAIN This is a European wide rail industry collaboration in which the GB rail industry made significant contributions. The research looked at ways of reducing the costs and time taken to achieve trans-european rail vehicle certification in terms of railway vehicle dynamics and track interactions. The research concluded that the DynoTRAIN outputs can be included in a requirements framework for standards to enable virtual assessment and simulation for rolling stock certification for the purposes of interoperability. Going forward, proposals have been made to increasing the use of simulations as an alternative to tests, and improved application of the statistical techniques for incorporation into the current revision of EN14363 on dynamic approval testing of rolling stock The successful conclusion of this research has been greatly assisted by the collaboration of suppliers and representatives of the rail industry in achieving their objectives. 7 V/T SIC has been strongly supported by its sub groups; Technical Advisory Group (TAG), Wheelset Management Group (WMG) and Adhesion Research Group (ARG) 7.1 Technical Advisory Group (TAG) V/T SIC s Technical Advisory Group (V/T TAG) has continued to meet in support of the SIC itself. The membership has been strengthened with a number of new members being invited to join in order to increase the breadth of expertise. The group now includes experts drawn from Network Rail s track engineers and Permanent Project Group; vehicle manufacturers and other suppliers, operators and maintainers; infrastructure contractors; universities; government and regulator; and RSSB. They are able to contribute specialist knowledge and experience, including vehicle dynamics; vehicle track / interaction; infrastructure aspects; research, analysis, evaluation and application; standards and European influences During the year V/T TAG received presentations on several formal research projects and technical investigations, and provided peer group discussion and comment. These have included amongst others: a) T728 Impact of corrosion upon the high cycle fatigue properties of GB axle steel b) T996 Development of a categorisation system for the interface between track condition and the forces imposed by rail vehicles c) Interface between PPG work on track damage, the Track 21 project and VTISM d) Track-Ex developments e) Adjustment switch damage on HS1 f) Re-profiling wheels with thin flanges and use of alternative design flange thicknesses g) The virtual project team work in the International Collaborative Research Initiative RCF and wear of rails and wheels h) V/T SIC Future priorities i) The second generation development of track formation models 4(a)-Annual Report VT SIC Jun 14 Page 4 of 7

5 j) Plans for the University of Huddersfield s Innovation Centre k) Possible quick conicity assessment method for track or vehicle contributions l) PPG project on RCF on the Wessex routes m) Huddersfield PhD work on residual stress testing in railway wheels n) Wheel-rail interface issues for effective lubrication At the request of V/T SIC, it has also continued to function as a Working Group for the SIC on specific remitted subjects V/T TAG was briefed on the plans for chapter champions for the Rail Technical Strategy and noted that the forward programme will need to assist the SIC in supporting Network Rail as they progress the Infrastructure area V/T TAG has agreed to hold a special session to act as a detached peer review group for the update of the VTISM Technical Basis documentation. As there are potential IPR issues, those wishing to attend will confirm their acceptance of the necessary nondisclosure agreement Paul Harrison has retired as Chairman of V/T TAG and a new industry chairman is being sought. Paul s contribution has been significant and his steering of the various discussions has been a great support to the industry. RSSB has agreed to chair the V/T TAG on an interim basis. 7.2 Adhesion Research Group (ARG) ARG commissions and leads adhesion and train detection-related research proposals on behalf of V/T SIC and Adhesion Working Group (AWG). There are members and active support from train operators, Network Rail, LUL, ROSCOs and suppliers Research project T797 Performance & installation criteria for sanding systems is a near term R&D project to understand the assumptions underpinning the current sanding system railway group standard and design requirements. The first phase output has been delivered during the last year with the following outputs: recommendations for on-train sand delivery hose height and angle recommendations for on-train sand delivery nozzle diameter and material confirmation that the ideal sand delivery rates are between 1.5 & 2.0kg/min per wheel Recommendations for standards change to allow multiple location sanding along a unit/train formation, sand delivery at leading wheelsets etc Research project T959 On-board detection of low adhesion is a long term R&D project to develop and prototype a near real time on-train system for automatic detection and quantification of low adhesion, independent of whether the train is braking coasting or motoring. Computer modelling of modern DMU-type trailer bogies has been completed and gives confidence that a prototype fitted to a modern DMU or EMU could deliver quantified adhesion detection within 5-10 seconds of it being encountered under motoring and coasting conditions and potentially, in under 5 seconds under braking conditions Research project T1042 Investigation into the effect of moisture on rail adhesion this project aims to review and report on the GB and worldwide body of evidence associated with the wet rails phenomenon in line with National Task Force (NTF) and AWG requests. This project has been specified, tendered and completed during the last year and has delivered the following outputs: confirmed that the wet rail phenomenon is real and evidence-backed that slightly wet rails are worse than both dry and water soaked rails for adhesion that GB mainline rail does not have processes, or equipment in place today to effectively monitor and report on wet rails today confirmed that current poor adhesion mitigation techniques, e.g. sanders, TG60/sandite, vegetation management etc. are equally effective against wet rails as against 3rd body contaminated rails 4(a)-Annual Report VT SIC Jun 14 Page 5 of 7

6 An issue has arisen this year out of both T797 and T959, which will be taken to TSLG, in that further work was planned for both these research projects involving on-track testing. We have attempted to tender on-track testing for a T959 prototype adhesion detection system twice unsuccessfully and for T797 confirmatory on-track testing once unsuccessfully, where this latter exercise included T959 as an optional additional costed work package. The reasons for this lack of success included insufficient budget allocation, which could have been resolved, together with lack of willingness by industry parties to release suitable rolling stock for testing and unwillingness by both vehicle owners/operators and potential test service providers to financially underwrite any possible wheelset damage incurred during testing. As a consequence, ARG has agreed to recommend closure of research project T959 and to retender on-track testing of T797 once more, where the tenderers will be asked to provide core testing and reporting services only, with ARG/V/T SIC/TSLG using their best efforts to procure suitable rolling stock and arrange for agreements on possible wheelset damage to be agreed in advance Proposed future R&D overseen by ARG includes: T1046 Optimising the ability of industry to deal with low adhesion wheel/rail interface and the use of sanders this project has been tendered and will shortly go into procurement T1050 Emergency braking under low adhesion conditions this project was proposed by AWG and has recently been authorised for tendering research stemming from the outputs of T1042 as follows: laboratory studies to investigate underlying mechanisms for slightly wet rail adhesion performance laboratory studies to investigate the transient adhesion performance of rails drying and rails wetting investigation into better and more granular lineside and on-train weather, humidity, adhesion measurement and data collection and transmission techniques Additionally, RRUKA held a Solving the Adhesion Riddle event at RSSB on 24th January 2014 which a large number of academics and researchers attended. As a consequence of the proposals received after this event, 3 blue sky adhesion-related research proposals and 2 icase adhesion-related PhD scholarships have been agreed for award. 7.3 Wheelset Management Group (WMG) WMG is an industry forum to develop, share and promote wheelset management best practice. It seeks to understand the technical and commercial issues in the supply chain, promote wheelset maintenance best practice, share wheelset knowledge across the industry and sponsors research to develop improved practices. This year has seen the long standing chairman retire and the chairmanship is now shared by representatives from TOC s and Network Rail rolling stock specialist, due to demands on participants There is continued good support from all stakeholder groups in the industry: passenger and freight operators; Network Rail; London Underground; RSSB; owners; manufacturers; overhaul suppliers; technical specialists The 2013 / 2014 programme has included a number of presentations on technical developments that can extend wheelset life and reduce the maintenance burden without increasing risk. This includes presentations from manufacturers and Network Rail relating to rail lubrication and wheelset related research projects WMG is sponsoring a number of RSSB managed research projects and the common theme is the development of engineering knowledge to inform decisions on reducing wheelset whole life costs without an adverse impact on safety risk. This includes T774 which will deliver a process that enables TOCs to eliminate or reduce in-service axle inspection. The group has participated in directing this project to achieve practical guidance on the influence of human factors on the axle inspection. Further work will develop case studies to assist TOCs in applying the knowledge from this and other allied 4(a)-Annual Report VT SIC Jun 14 Page 6 of 7

7 projects to support decisions on the optimisation of axle overhaul, maintenance and nondestructive testing To maintain the technical knowledge within the industry WMG actively promotes the dissemination of lessons learned from incidents and research projects. It participates in external events such as the wheelset seminar run by the Institution of Mechanical Engineers where several papers were presented by WMG members Going forward the new chairmen intend to form sub-groups of interested members to investigate key issues and potential areas for future research that the group identify in order to increase the contribution of its members. 8 Communications 8.1 Many of the VT SIC publications and research papers have been loaded onto SPARKS 8.2 VT SIC is working on a second edition of the Wheel Rail Best Practice Handbook. The new edition will include all the recent work and developments of the VT SIC. The Handbook will be published as a hard copy book and as an e-book also available within SPARKS. A DOHERTY - Chairman, VT SIC 4(a)-Annual Report VT SIC Jun 14 Page 7 of 7