Esveld RAILPROF en Coenraad Full Screen

RAILPROF INSTRUMENTS
Background Information
RAILPROF BACKGROUND
Coenraad Esveld
Director of Esveld Consulting Services
www.railprof.com
ECS ORGANIZATION
Esveld Consulting Services
Consulting
Publications
Equipment
RAILPROF
Chair of Railway Engineering 1993-2006

www.railprof.com
MODERN RAILWAY TRACK
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Apple iTunes Stores
Amazon Stores
DAMAGE DUE TO POOR WELD GEOMETRY
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RAILPROF MEASURING PRINCIPLE

LCD
Vertical ASCII file

x
-600
-595
-590
-585
-580
vert
0.00
0.01
0.02
......
......
hor
0.00
0.02
0.03
.......
.......
Reference line
1000 mm
Sensors based on eddy current principle
www.railprof.com
RAILPROF WITH PDA
www.railprof.com
RAILPROF IN FLIGHT CASE
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MAIN CHARACTERISTICS OF THE RAILPROF

1.
Weight: less than 7 kg;
2.
Length: 116 cm;
3.
measurements controlled by PDA through wireless communication via Bluetooth;
4.
Measuring length: 1,000 mm in accordance with the CEN standards for weld geometry; sampling interval 5 mm;
5.
Measuring time: about 10 sec;
6.
Data transfer to PDA and analysis: about 6 sec;
7.
Data storage: unlimited on PDA internal memory or Secure Digital (SD) card;
8.
Data transfer to desktop PC via Active Sync, Windows Mobility Center, memory card, or network (GPRS, or wifi);
9.
Desktop software for presentation of results. Easy to generate reports in, for instance, pdf format;
10. High
a.
b.
c.
accuracy at ambient temperatures between - 5 C and + 40 C (PDA normally 0 C to + 40 C):

Vertical geometry: +/- 0.030 mm;
Lateral geometry: +/- 0.050 mm;
Inclination associated with QI: 0.180 mrad, accuracy +/- 5 %;
11. Measuring principle transducers: eddy current. Results not influenced by moisture, rust, dirt and the real metal
surface is measured;
12. Bottom of RAILPROF is resistant to temperatures up to 150 C;
www.railprof.com
MAIN APPLICATIONS
Checking and acceptance of flash butt welds, thermit welds and glued insulated
joints;
Positioning of rails before welding;
Production of glued insulated joints;

Assessment of corrugations;
Monitoring of grinding process;
Acceptance of grinding work;
Acceptance of rails for longitudinal geometry, including straightness of rail ends.
www.railprof.com
ANCIENT WELD GEOMETRY STANDARDS

Grind off top
p < 0.3 mm/1 m
Mostly used:
Versine: 0 < p < 0.3 mm
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10
FORCE-RELATED WELD STANDARDS

Dynamic contact force is function of inclination:
Fdyn = Constant * v 2 * Inclination
Inclination: High-Speed < 1.0 mrad

Conventional < 1.8 mrad
www.railprof.com
11
DYNAMIC CONTACT FORCE
9 % correlation
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91 % correlation
12
DEVELOPMENT OF THE QUALITY INDEX
QI
www.railprof.com
13
www.railprof.com
14
www.railprof.com
15
FORCE-BASED ASSESSMENT
OF
WELD GEOMETRY
www.railprof.com
16
QUALITY INDEX
Inclinationmax
QI =
1
Inclinationnorm
www.railprof.com
OK
17
WELD GEOMETRY STANDARDS

Standards
Vertical Rail Geometry
Speed [km/h] Inclination [mrad]
250 < V 300
1.0
200 < V 250
1.1
180 < V 200
1.3
160 < V 180
1.4
140 < V 160
1.6
120 < V 140
1.8
100 < V 120
2.0
90 < V 100
2.2
80 < V 90
2.3
70 < V 80
2.4
60 < V 70
2.6
50 < V 60
2.8
40 < V 50
3.0
V 40
3.2
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Standards
Lateral Rail Geometry
Speed [km/h] Versine p [mm]
80 < V 300
-0.5 p 0.5
40 < V 80
-0.7 p 0.7
V 40
-1.0 p 1.0
Standards applied at:

ProRail
Metro & Light Rail companies in NL
18
NEW STANDARDS VERTICAL

Advantages of new standards:
1. Also negative welds allowed;
2. Maximum versines at 140 km/h 2 times larger;
3. Speed dependant.
www.railprof.com
19
NEW VERSUS OLD NORM

2m
2z0
z0 0.3 mm
z z0 sin
2 x
dz 2
z0
dx
0.3 1.0 mrad

2
Velocity
Versine
[mm]
Inclination
[mrad]
40 km/h
1.02
3.2
80 km/h
0.76
2.4
140 km/h
0.57
1.8
200 km/h
0.41
1.3
300 km/h
0.29
1.0
Old Norm
0.30
1.0
For 80 km/h the new norm is 2.5 times more favorable than the old norm, provided
short waves have been ground off.
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20
HSL-SOUTH
INFRASPEED
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21
Short waves on HSL: welds
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In short-wave band: track quality on HSL-South determined by rail welds,

connecting the 120 m straightened rails from Voest;
Welds: mainly flash butt (2647), but also thermite (468);
22
Welds, GWM 550

On two sections, the initial weld quality after manual grinding was unsatisfactory.
These welds were ground with the Plasser GWM 550 grinding train.
1
95%
cumulative frequency
0.8
0.6
0.4
CDF of weld quality
welds with unsatisfactory initial quality
before GWM
after GWM
0.2
QI = 1 0.7 mrad
0
00
www.railprof.com
32
46
4 3
5
Quality Index QI (300 km/h)
10
23
Speno final grinding: effect on welds

Total HSL-South ground by Speno (RR 24/48). Effect on weld quality for a 6 km
representative double track test section:
1
95%
cumulative frequency
0.8
0.6
CDF of weld quality,
HSL-South, Northern part
test section
West, before Speno
West, after Speno
East, before Speno
East, after Speno
0.4
0.2
1.9
0
0
www.railprof.com
3.1
2
QI = 1 0.7 mrad
3.6
4
5
6
Quality Index QI (300 km/h)
10
24
24 kN
40 kN
46 kN
Fdyn = 0.22 V [kN, m/s, mrad]
According to simple S-N approach (fatigue):

3
Lifetimenew Forig.
Lifetimeorig. Fnew
Fwheel Fwheel, stat Fwheel, dyn
Life cycle extension:

- GWM spot grinding 4.9
- Speno finish grinding 1.7
Total lifetime extension (extra to ref. lifetime) (%)
Why is weld quality so important?

700
600
500
400
300
200
100
0
0
10
20
30
40
50
60
Total load reduction (% )
www.railprof.com
25
EXPECTED COST SAVINGS

Due to impact load reduction at welds:
20 40 % of annual maintenance budget;
ProRail budget in The Netherlands:
~ 250 mio for 4,500 single track;
Savings: 50 100 mio total,
or 10 20,000
per km single track.
Renewal
70 %
TOTAL MAINTENANCE AND

RENEWAL COST ON NS
Manual
maintenance
20 %
250 million per year

for 4.500 km track
Price level 2006
Mechanical
Maintenance 10 %
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26
Cumulative Frequency
0.8
0.6
SELECTION ON PRORAIL
81%
60%
100 welds per group
0.4
31%
Limit at 140 km/h (1.8 mrad)
0.2
Limit at 80 km/h (2.4 mrad)
CDF
Moerdijk - Dordrecht (VSRT)
Delft - Den Haag
Lage Zwaluwe - Hollands Diep
0
0
www.railprof.com
3
4
5
6
Weld Quality Index [-] (140 km/h)
9
27
OLD VERSUS NEW STANDARDS

New Standards
300
140 80 40 km/h
Cumulative Frequency
0.8
73%
0.6
Population 239 welds
58%
46%
0.4
Old Norm (0 0.3 mm)

Independent of line speed
16 % passed
0.2
3%
0
www.railprof.com
5
6
7
8
9
10
11
12
13
14
. Inclination of Weld Geometry (25 mm base) [mrad]
Maximum Absolute
15
16
28
DESKTOP SOFTWARE
www.railprof.com
All data and graphs can be presented on PC;

Results can be sent in pdf format to Employer.
29
GRINDING SOFTWARE
www.railprof.com
Wavebands: 1-3 cm, 3-10 cm en 10-30 cm;

Per waveband maximum deviation to be set by user;
Calculation of GA, GG en GSD for these wavebands.
GA: Average amplitude;

GG; Average wavelength;
GSD: Average grinding depth.
30
EXAMPLE OF WELD HSL
www.railprof.com
1 mm
QI = 1 1 mrad
All welds of HSL-South were checked with RAILPROF
31
RAILPROF Customers
Volker Rail
BAM Rail
Metro Bilbao
AVE
Voest Railpro
Seoul Metro
Metro de Madrid
Strukton Rail
Equipment
Strukton NV
TUC Rail
Kelsan
Sersa
Rheda
2000/Infraspeed
Zagreb University
RailOK
www.railprof.com
Netherlands
Netherlands
Spain
Spain
Netherlands
Korea
Spain
Netherlands
Belgium
Belgium
UK
Switzerland
QR
TSTG Schienen
Technik (now Voest)
Sumitomo Metal
Technology
Spitzke
KORAIL
Southwest Jiaotong
University
Fortescue Metals
Group
Yapiray
Australia
Germany
Japan
Netherlands/
Germany
Korea
China
Australia
Turkey
Netherlands
Croatia
Netherlands
32

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Esveld RAILPROF en Coenraad Full Screen

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RAILPROF INSTRUMENTS

Chair of Railway Engineering 1993-2006

MODERN RAILWAY TRACK

DAMAGE DUE TO POOR WELD GEOMETRY

RAILPROF MEASURING PRINCIPLE

Vertical ASCII file

Sensors based on eddy current principle

RAILPROF WITH PDA

RAILPROF IN FLIGHT CASE

MAIN CHARACTERISTICS OF THE RAILPROF

Weight: less than 7 kg;

Length: 116 cm;

measurements controlled by PDA through wireless communication via Bluetooth;

Measuring time: about 10 sec;

Data transfer to PDA and analysis: about 6 sec;

accuracy at ambient temperatures between - 5 C and + 40 C (PDA normally 0 C to + 40 C):

Production of glued insulated joints;

ANCIENT WELD GEOMETRY STANDARDS

p < 0.3 mm/1 m

FORCE-RELATED WELD STANDARDS

Fdyn = Constant * v 2 * Inclination

Inclination: High-Speed < 1.0 mrad

DYNAMIC CONTACT FORCE

DEVELOPMENT OF THE QUALITY INDEX

WELD GEOMETRY STANDARDS

Standards applied at:

NEW STANDARDS VERTICAL

NEW VERSUS OLD NORM

0.3 1.0 mrad

Short waves on HSL: welds

In short-wave band: track quality on HSL-South determined by rail welds,

Welds, GWM 550

Speno final grinding: effect on welds

Fdyn = 0.22 V [kN, m/s, mrad]

According to simple S-N approach (fatigue):

Life cycle extension:

Total lifetime extension (extra to ref. lifetime) (%)

Why is weld quality so important?

Total load reduction (% )

EXPECTED COST SAVINGS

TOTAL MAINTENANCE AND

250 million per year

100 welds per group

Limit at 140 km/h (1.8 mrad)

Limit at 80 km/h (2.4 mrad)

OLD VERSUS NEW STANDARDS

Population 239 welds

Old Norm (0 0.3 mm)

All data and graphs can be presented on PC;

Wavebands: 1-3 cm, 3-10 cm en 10-30 cm;

GA: Average amplitude;

EXAMPLE OF WELD HSL

All welds of HSL-South were checked with RAILPROF

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