Toby Horstead, RailCorp - Major Periodic Maintenance; Asset Life, Criticality, Priority

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Toby Horstead, Senior Asset Planner Civil & Track, RailCorp delivered the presentation at the RISSB’s 2013 Rail Turnouts Workshop. The RISSB’s National Rail Turnouts Workshop 2013 gives all those involved an in-depth forum to consolidate and share the latest technical information for rail turnouts. Drawing on industry expertise, the workshop features technical and practical presentations that address key turnout functions in an every-day operational context. For more information about the event, please visit:

Text of Toby Horstead, RailCorp - Major Periodic Maintenance; Asset Life, Criticality, Priority

  • Commercial in confidence National Turnouts Workshop Newcastle, May 2013 Major Periodic Maintenance; asset life, criticality, priority Toby Horstead, Senior Asset Planner Civil & Track Asset Planning & Performance
  • 2Commercial in confidence Why do we maintain?
  • 3Commercial in confidence An industry concern Capital Works are exciting, but We all contribute to the ongoing maintenance. Maintenance Approach Engage you all in discussing maintenance Assessing life, criticality and priority Completing the lifecycle
  • 4Commercial in confidence Basic Maintenance Theory Modern method - systems whole of life approach Reliability Centred Maintenance Then develop maintenance concept
  • 5Commercial in confidence Turnout Maintenance All the problems of plain track and much more Every moving part is a reliability risk Every gap or discontinuity is a reliability and safety risk
  • 6Commercial in confidence Turnout Maintenance RM inspect and correct to hold safety and short term reliability How do we manage the long term performance and sustainability of Turnouts? Can I anticipate how much work each year or do I see what fails, then ask for funding?
  • 7Commercial in confidence Asset Life Cycle Curve $0 $0 $0 $1 $1 $1 $1 $1 $2 0 5 10 15 20 25 0 5 10 15 20 25 30 35 40 45 50 Millions CUMMULATIVEMAINTENANCE COST 0 1 2 3 4 5 6 YEARS / AGE CONDITION Cummulative Cost 1 Cummulative Cost 2 Turnout Condition 1A Turnout Condition 1B Turnout Condition 1C Turnout Condition 1D Turnout Condition 2A Turnout Condition 2B
  • 8Commercial in confidence WORKSHOP - MAINTENANCE A COMPLEX JUNCTION What are the likely turnout maintenance issues? What is critical, how would you know? Can you forecast the future level of maintenance?
  • 9Commercial in confidence OUTCOMES Tools to achieve RCM Technical Maintenance Plans (TMPs) Service schedule Safety Significant Safety Critical
  • 10Commercial in confidence Inspection Regimes Track Patrol general, looking for obvious critical failures, 2 per week Turnout inspection detailed checks and measurements yearly Others Ultrasonic conducted by hand for critical areas eg switches Engine asses track effects on rollingstock Signals FPLs prime example of other discipline
  • 11Commercial in confidence Comparison of to TMP frequency Level of maintenance to match desired outcome
  • 12Commercial in confidence Service Schedules
  • 13Commercial in confidence Critical Areas of a Turnout Switches & Stockrails Crossings (including checkrails)
  • 14Commercial in confidence Critical Areas of a Turnout Defects in Turnouts Found by KK by Type 0 20 40 60 80 100 120 140 160 crossings switches Other TOTAL Defects
  • 15Commercial in confidence Switches Safety critical to prevent derailment Critical for reliability especially related to signalling Moving parts complex interaction Costly repairs requiring access to track Without detailed and regular inspection and defect management, can lead to safety issues Greatest broken rail risk as rail is unrestrained
  • 16Commercial in confidence Crossings
  • 17Commercial in confidence Crossings Main safety concern is if wheel goes the wrong way past the crossing Also impact and damage from crossing noses Often speed restrictions, crossings may be difficult to replace on short notice
  • 18Commercial in confidence Critical Crossing Checks
  • 19Commercial in confidence Crossing Maintenance Crossing is heavy impact point Requires monitoring Maintenance grinding of flow, requires access Weld repair or replace, some repairs can become impractical K crossings present special problems Blunter angle with higher impact Unchecked area Competing tolerances to be met
  • 20Commercial in confidence Determining Average Major Maintenance ASSET POPULATION STEADY STATE = AVG ECONOMIC LIFE Fit for purpose at lowest cost of maintenance Mix of fixed interval and condition based Organisations are reliant upon their own Engineering experts and industry experts
  • 21Commercial in confidence The RailCorp experience Over 2,500 discrete turnout assets Varying age profile, configuration, use, movements AMP based on SS, backlog identified TO life based on bearer; Concrete = 50yrs, Timber = 30yrs SS renewal level currently 56 mainline TOs per year
  • 22Commercial in confidence Average renewal vs actual and forecast
  • 23Commercial in confidence Turnout Age Profiling Condition Turnout Age Profile at 2011/12 10 years old, not within 10 years of avg asset life Within 10 years of avg asset life (due for renewal in next 10 years) Backlog (at or beyond avg asset life)
  • 24Commercial in confidence Varying approaches to maintenance Availability of funding, access, resources and desired customer outcomes can all have an influence on the maintenance strategy. Valid approaches can include: Upgrade in lieu of like for like renewal or refurbishment, gain benefits of reset life, increase inspection intervals, new technology, operational benefits Renew only like for like and refurbish Increase levels of refurbishment and corrective maintenance and delay the need for complete renewal or upgrading Fix on fail; identify defect, apply track speed and fix when funding and access allow Value for money scoping fit for purpose Greatest reliability improvement for RailCorp is concrete bearers
  • 25Commercial in confidence Fit for Purpose
  • 26Commercial in confidence Understanding avg economic life Renewal is based on replacing the entire turnout and can be underpinned by the long life component bearer life The more difficult question is then the economic life for: Turnout refurbishment Turnout resurfacing Turnout grinding (as a whole) Actual data has it been recorded, does it give a cycle? But what is the appropriate cycle?
  • 27Commercial in confidence Turnout Grinding / Turnout Tamping
  • 28Commercial in confidence Turnout Refurbishment Trailing Facing
  • 29Commercial in confidence Prioritised Turnout Maintenance Now we know how many how do we prioritise? Consider 1. Asset Criticality 2. Asset Configuration 3. Asset Performance
  • 30Commercial in confidence Suggested approach to priority
  • 31Commercial in confidence The ideal is hindered by funding, resource and track access limitations. Means the actual priority order is challenged. We do not deliver 1 through to 1,900 Must consider balance against other programs Suggested approach to priority
  • 32Commercial in confidence Next Evolution ASSET CONDITION Asset Target Score Measure of Performance Asset Configuration Test the Asset Condition against the determined Criticality for that asset Move to a Steady State for Asset Criticality band and prioritisation within the criticality band = +
  • 33Commercial in confidence Asset criticality - elements Weighted timetable usage and impact on maintenance priority Impact on On Time Running Accessibility Results in bands of criticality Through Facing 4 x Through Trailing 2 x Crossing Trailing 1 x Crossing Facing 2 x Asset Criticality D C B A
  • 34Commercial in confidence
  • 35Commercial in confidence Asset performance - elements Maintenance Cost Maintenance Compliance Incident / Failure rate Asset Age?
  • 36Commercial in confidence Asset configuration - elements Rail Size Turnout Geometry Bearer Type Points Machine Type
  • 37Commercial in confidence Performance L2 Given Asset Category based on its Criticality needs a defined Condition Level. RequiredAssetCondition Measuring Outcomes Asset Condition Matrix Min =80 Max = 90 Target = 85 Asset Criticality ASSET CONDITION Asset Target Score Measure of Performance Ass