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RISSB : TURNOUT WORKSHOP
PLANNING OF TURNOUT MAINTENANCE
SOME PERSONAL EXPERIENCE
PETER MICENKO
MAY 2014
BRISBANE
CONTENTS
• INTRODUCTION
• BASIC ASSET MAINTENANCE 101
• EXPERIENCES over 30 years
– SOUTH AFRICA
– AUSTRALIA
• SUMMARY AND CONCLUSION
ASSET MAINTENANCE 101
• KNOW WHAT YOU HAVE– ASSET OR EQUIPMENT REGISTER
• INSPECT THE ASSETS– CONDITION
• PROTECT THE TRAFFIC
• ENTER THE CONDITION - WORKS MANGAGEMENT SYSTEM
• PLAN THE REPAIRS
• REPAIR/RENEW
• CLOSE OUT
SUMMARISING ASSET MAINTENANCE PROCESS
DETECT
CORRECT
INSPECT
PROTECT
RAILWAY COMMON ATTRIBUTES
• ALL DIFFERENT- tribes & teams
• SOME ASPECTS ARE EXCELLENT
• HAVE TO START SOMEWHERE
– TRY / TEST SOMETHING
– NORMALLY ANYTHING IS BETTER THAN
NOTHING
– REFINE-CONTINUOUS IMPROVEMENT
– PERFECTION TAKES TIME
EQUIPMENT REGISTER
• VARIES
– INDIVIDUAL NEEDS
– ORGANISATION NEEDS
– SUPPORT
• CAN VARY IN DETAIL BUT
– NEEDS TO BE CORRECT
– NEEDS TO BE KEPT CORRECT
EQUIPMENT REGISTER
SOME IMPORTANT CRITERIA CAN BE:-
• LINE CODE
• LOCATION/STATION
• POINTS NUMBER
• KM LOCATION
• SPEED / AXLE LOAD CAPABILITY
• DESCRIPTOR OF POINTS
USUALLY IN A SPREAD SHEET FORMAT
EQUIPMENT REGISTERFIELD OR DIAGRAMATIC
• GOOD FOR VISUALISING &
DISCUSSIONS
EQUIPMENT REGISTER
• DESCRIPTOR OF POINTS • TYPE I.E. 1:9, 1:12
• RAIL PROFILE I.E. 30kg/m…. 60 kg/m
• LEFT OR RIGHT
• TYPE OF CROSSING
• TYPE OF BLADES
• WELDED OR BOLTED
• TYPE OF BEARERS
• METHOD OF OPERATION- ELECTRIC, HYDRAULIC, MANUAL
MAINTENANCE PLANNING
turnout condition assessment
• TECHNICAL
• ECONOMIC
• OPERATIONAL
• ORGANISATIONAL
• WITHOUT ALL FOUR ASPECTS CONSIDERED WILL NOT
REALISE BENEFITS
MEASURE TO KNOW : MEASURE TO MANAGE
• INSPECTION BASED
• ESTABLISH THE CONDITION
• Use to
– PLAN THE REPAIR JOBS
– MAINTENANCE PRIORITY
• CRITCALITY of ASSET the BUSINESS
• “FILE SAVE”- KEEP RETRIEVABLE RECORDS
• ESTABLISH THE CONDITION AFTER WORKS
MAINTENANCE PLANNING
turnout condition assessment
• START WITH KNOWING WHAT ASSETS YOU HAVE -
EQUIPMENT REGISTER
• INSPECT YOUR ASSETS
• WHAT TO MEASURE
• OPINION
• TEMPLATES
• PHOTO GUIDE
AN EARLY TEMPLATE c1982• Nothing existing
• Developed by local PWI
• Simple & met needs
• Location: Station, points
number, points machine
number, road, km
• Type of
turnout:1:9,48kg/m,
monoblock, old switches,
timber,
• Used measurements for
Turnout gauge locations &
versine requirements &
• Personal appraisal
CAPE WESTERN. C. 1990TURNOUT ASSESSMENT
• FIELD ASSESSMENT
• MEASUREMENTS
• RELATES GEOMETRY STANDARD
• MEASURE &
• CALCULATES AN INDEX
A SCORING SYSTEM
KIMBERLEY INSPECTION c 1998
• BIGGER PICTURE VIEW
• Extend geometry measurements
QUEENSLAND RAILTURNOUT INSPECTION • HAS SOMETHING SIMILAR
• DEFINES THE TURNOUT
• MEASURES GEOMETRY &CONDITION
• GIVES SOME IDEA OF LIFE
EXPECTANCY
• INSPECTIONS
• DETERMINE THE CONDITION
• CRITCALITY IN THE NETWORK
• PLAN THE REPAIR JOBS
• “FILE SAVE” - KEEP RETRIEVABLE RECORDS
• KNOW THE CONDITION AFTER WORK
MAINTENANCE PRIORITY
KIMBERLEY INSPECTION c 1998• The importance of recording work
done
TRACK GEOMETRY VS TIME
POOR
CONDITION
WORK PERFORMED ON
TURNOUT
GOOD
CONDITION
TRACK CONDITION VS
MAINTENANCE INPUT
• THE EFFECT OF A CHANGE OF PHILOSOPHY
MANHOURSRED= CONDITION AS
TOTAL WORK
REQUIREMENTS
POOR
CONDITION
GOOD
CONDITION
Job prioritization in NSW c 2002• Model for rating jobs
– Due Diligence - Safety, Operating Environment
– Rail Safety, Reliability, Economic Benefit & Payback,
Environmental impact
– Condition- incidents, and rail safety
• All jobs in one pot- Limited budget for MPM- Not turnout specific
Due Diligence Programs Rail Safety Score Reliability Score Financial Score Environmental Score
Due Diligence Safety Due Diligence Environmental Other Cyclic MPM Strategic MPM
Ref Project No. of
persons
Injury
class
Ranking
Score
Prob. Customer Req
not met
Legislation
breach
Ranking
Score
Ranking
Score
Prob. Incident
Code
Incident
Score
Annual
Score
Ranking
Score
Prob. No. of
Failures
No. of
Speeds
Closure
Y/N
Trains
impacted
Ranking
Score
Prob. Payback
years
Ranking
Score
IRR Ranking
Score
Prob. Inside
corridor
Outside
corridor
Ranking
Score
TOTAL
SCORE
WEIGHTED
SCORE
M02-118 Cootamundra Yard. 429km Upgrade
yard-stage 1 Cootamundra North Fork /
M02-118
>100 F 10 10 10
M02-34 Joppa Junction to Junee. Resurface and
profile 180 km various locations / M02-
34
0 0 N 0 0 0 C 5 100 6 H 1 1 N 900 9 H 10 6 L 1 2 2 23 6.5
M02-35 Joppa Junction to Junee. WTSA
resurfacing 47 km various locations /
M02-35
0 0 N 0 0 0 C H 500 9 10 10 L 3 32 8.95
M02-37 Joppa Junction to Junee. Profile rail
grinding 65 km / M02-37
0 0 N 0 0 0 H B 800 5 M 1 1 N 450 7 H <5 8 L 3 3 3 23 6.15
M02-36 Joppa Junction to Junee. Ballast clean
12 km / M02-36
0 0 N 0 0 0 0 0
M02-38 Joppa Junction to Junee. Resurface 33
turnouts / M02-38
0 0 N 0 0 0 H K 50 200 4 H 2 N 900 9 H <5 8 L Y 1 22 6.2
M02-40 Joppa Junction to Junee. Renew 0.6 km
security fencing / M02-40
0 0
M02-39 Joppa Junction to Junee. Renew 25 km
stock fencing / M02-39
0 0 0 C N 50 250 6 L 1 N 5 1 L <15 2 L Y 1 10 3
W-125 Wallenbeen 414-416 km Down. Rerail
1.4 km Morrison's Hill / W-125
0 0 0 C B 800 9600 10 H Y 60 9 C 1 10 H Y Y 8 37 9.5
W-112 Cootamundra 431.65 km Up main
Upgrade turnout Strattons Mill - Croker
Carroll / W-112
0 0 N 0 0 0 H B 800 1600 8 H 1 1 N 900 9 H >15 5 L Y Y 2 24 6.95
W-118 Cootamundra 433.211 km Up main
1/12.1 SOTT-Replace 30 transoms / W-
118
>100 F 10 10 10
LOCAL QUEENSLAND APPROACH
• PREVIOUS
– LEGACY ISSUES
– YOUNG ORGANISATION
• DESIGN & MAUNUFACTURE LEAD TIMES
• POSSESSION LIMITATIONS
• MULTIPLE DISCIPLINES
• ASPECTS WERE GOOD
A BETTER MOUSETRAP
• CONCEPT BASED ON APPROACH TO LEVEL CROSSINGS
• LIST WHAT WE HAVE- 991 TURNOUTS ON CQCN
• VERIFY THEIR EXISTENCE
• DEVELOP A CONDITION ASSESSMENT
• LINK PROGRAMS TO TRAFFIC REQUIREMENTS
• BEGIN AND CONTINUE THE INSPECTIONS
– DOCUMENT THE RESULTS
– TRAIN FOR UNIFORMITY
– EATING THE ELEPHANT
– CONTINUOUS IMPROVEMENT
• STICK TO IT
• USE THE RESULTS
TEMPLATE AND ASSESSMENT CRITERIA
• IDENTIFY THE ASSET
• ASSESS CONDITION
• BUSINESS NEEDS
• CURRENT USE– WORK IN PROGRESS
– MAJOR YARD COMPLETE
– EXPANDED TO 3 SUPT’S
– PROPOSE TO EXPAND TO ALL SUPT’S
SOURCE OF INPUT
condition assessment
USE APPROPRIATE ASPECTS
• ASSET REGISTER
• DEFECT DATA BASE
• FIELD MEASUREMENTS
• FIELD EVALUATION
• COMMENTS
• PRODUCE AN INDEX
USE FOR JOB &ACTION PRIORITY
IDENTIFY THE ASSET
• Line NC, CL…………….Section (Yard / N/A)
• Km (000.000km please)
• Turnout Number / Points Number
• Elec / Manual operation
• Rail Weight 60kg, 53kg, 50kg, 47kg
• LH / RH / Catch Points / Other
• Points Protector
• Ties (Con, timber)
• V - Type (FAB, RBM, SNX or Swing wing)
• Angle (1:8, 1:8.25, 1:10, 1:12, 1:16…….)
• Installation date (Approximate age)
ASSESS THE CONDITION
• Vee Condition ( 1 = Excellent / 10 = Red Board )
• Guard rails Condition ( 1 = Excellent / 10 = Red Board )
• Fastenings Condition ( 1 = Excellent / 10 = Red Board )
• Sleepers Condition ( 1 = Excellent / 10 = Red Board )
• Ballast Condition ( 1 = Excellent / 10 = Red Board )
• Formation Condition ( 1 = Excellent / 10 = Red Board )
• Drainage Condition ( 1 = Excellent / 10 = Red Board )
• GENERAL CONDITION RATING
INCLUDE BUSINESS NEEDS
• Next Ballast Undercut Date Quarter :
• Asset Renewal Year (based on above inspection) Quarter :
• Criticality To Business
• 4 = High (Main-Line (Designated Golden Asset))
• 3 = Moderate MGT's (Low Class Line)
• 2 = Yard (Low Speed, Low MGT's)
• 1 = Very Little Use
• Actions required to extend Asset Life and improve General
condition rating.
SUMMARY
• KNOW WHAT YOU HAVE
• MEASURE TO MANAGE- APPLICABLE MEASUREMENT
• CONDITION REPOSITORY
• PRIORITISE
• SHORT, MEDIUM LONG TERM EFFORTS
• LEAD TIMES /PROGRAMS
• QUALITY
• CONFIGURATION CHANGE/RECORDS
BIBLIOGRAPHY & ACKNOWLEDGEMENTS
The following reference sources to illustrate and support this
presentation is acknowledged with thanks.–“QR DETAILED TURNOUT INSPECTION” Template
–AURIZON, Draft turnout prioritisation template. D. Judge
–Various ex Transnet Freight Rail
•SOUTH AFRICAN TRANSPORT SERVICES Permanent Way Instructions
1984 and subsequent revisions.
•“Western cape switch tamper our experience”. E.S.Redman September 91”
•“Produksiebestuurderkursus, 24 maart 1999”. Johan Bekker
–POST GRAD THESIS- D. JUDGE