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
Aug 19, 2014
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
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Why do we maintain?
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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
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Basic Maintenance Theory
Modern method - systems whole of life
approach
Reliability Centred Maintenance
Then develop maintenance concept
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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
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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?
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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
Mil
lio
ns
CU
MM
UL
AT
IVE
MA
INT
EN
AN
CE
CO
ST
0
1
2
3
4
5
6
YEARS / AGE
CO
ND
ITIO
N
Cummulative Cost 1 Cummulative Cost 2 Turnout Condition 1A Turnout Condition 1B
Turnout Condition 1C Turnout Condition 1D Turnout Condition 2A Turnout Condition 2B
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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?
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OUTCOMES – Tools to achieve RCM
Technical Maintenance Plans (TMP’s)
Service schedule
• Safety Significant
• Safety Critical
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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
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Comparison of to TMP frequency
Level of maintenance to match desired outcome
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Service Schedules
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Critical Areas of a Turnout
Switches & Stockrails
Crossings (including checkrails)
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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
Defe
cts
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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
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Crossings
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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
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Critical Crossing Checks
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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
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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
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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 TO’s per year
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Average renewal vs actual and forecast
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Turnout Age Profiling ≈ Condition
Turnout Age Profile at 2011/12
<10 years old
>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)
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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
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Fit for Purpose
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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?
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Turnout Grinding / Turnout Tamping
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Turnout Refurbishment
Trailing
Facing
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Prioritised Turnout Maintenance
Now we know how many
how do we prioritise?
Consider
1. Asset Criticality
2. Asset Configuration
3. Asset Performance
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Suggested approach to priority
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• 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
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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
=
+
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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 xCrossing Facing
2 x
Asset Criticality
D
C
B
A
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Asset performance - elements
• Maintenance Cost
• Maintenance Compliance
• Incident / Failure rate
• Asset Age?
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Asset configuration - elements
• Rail Size
• Turnout Geometry
• Bearer Type
• Points Machine Type
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Performance L2
Given Asset Category based on it’s Criticality needs a defined Condition Level.
Req
uir
ed
Asset
Co
nd
itio
n
Measuring Outcomes
Asset Condition Matrix
Min =80
Max = 90
Target = 85
Asset Criticality
ASSET
CONDITION
Asset Target Score
Measure of
Performance
Asset
Configuration
=
+
• May not want top condition
• What can the asset sustain, rather
than what do I need to do to sustain
the asset?
• What does the customer want?
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NEED GOOD ASSET INFORMATION
• Critical to effective Asset Management and MPM
Planning.
• The first step in the AMP – What have I got?
• Information can include
– A record of the asset
– The configuration and age
– Work carried out
– defects recorded and repaired
– MTBF and condition monitoring
• Need improve this element, consider asset owner
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IN SUMMARY
•Turnouts are a critical safety and reliability
aspect of the rail network.
•Must be able to justify the amount and
location of expenditure
•Turnouts should be
– fit for purpose
– at lowest cost of maintenance
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IN SUMMARY
• Understanding average turnout life will support a
forward plan to support customer outcomes
• Criticality, condition, performance, configuration are
considerations for determining maintenance priority
• Need good asset information
•Complete the life cycle –
ask why is that turnout there?
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Next
Challenge