Wayside Acoustic Detection Device RailBAM Wayside Acoustic Detection Device For Vehicle Condition Monitoring CORE 2004 This presentation provides an introduction to VIPAC’s automated acoustic sensing bearing fault detection system, RailBAM®, and current & evolving operational practices. Supported by Australian National (1993) – Whyalla trials With extensive trials at Pueblo (TTC) in 1996, system placed in field in 1998, upgraded with ARTC support in 2000, operational since 2001 and a recent upgrade in May 2004 to new acquisition system and faster processor. Key elements: Trackside cabinets Optical wheel sensors to measure diameter and speed Wakeup sensors at +/- 40m Wayside Hut with Comms (128kbaud) and Power (500W) Malcolm Owens (ARTC) & Mirek Vesely (Vipac Engineers & Scientists Ltd) Vipac Engineers

Wayside Acoustic Detection Devices Objectives: To improve operational safety by reducing maintenance costs & derailments Fundamental Principle: To reliably identify developing bearing faults of rolling stock So the developing faults can be monitored and bearing removal planned with minimal impact on train scheduling To spot prematurely failing bearings Improved maintenance strategies through SAFELY maximizing bearing life 14th IWSC 2004

Australian Acoustic Installations RailBAM Australian Acoustic Installations CORE 2004 Darwin Sydney Perth Adelaide Existing RailBAM units Proposed RailBAM units TTCI BHPB – 1 RailBAM WestNetRail 5 RailBAM’s We are in all of the same office locations that our big customers are…so we can have strong alliances, strong service. yet no one client coy “ownes” more than 5% of our turnover…we are very independent. ARTC – 1 RailBAM 14th IWSC 2004 Vipac Engineers

Future Acoustic Bearing Detectors At Nov 2004: Australia – 7 RailBAM units operational China – 1 RailBAM unit operational By June 2005: USA – 1 RailBAM unit operational Australia – 3 more RailBAM installations 12 total installations operating 14th IWSC 2004

Single & Dual Track Installation RailBAM CORE 2004 Single & Dual Track Installation Speed Sensor Wayside Hut Trackside Cabinets Single and dual tracks configurations Mixed gauge installation Slim-line cabinet design for closely spaced tracks incorporating new shutter mechanisms that is also suitable for freezing rain / snow conditions: environmental testing is to commence in July. Mixed Gauge 14th IWSC 2004 Vipac Engineers

Hampton Installation Tag Reader RailBAM CORE 2004 Hampton Installation Trackside Cabinet – open shutter collecting data Tag Reader 14th IWSC 2004 Vipac Engineers

Fault Types in Package Bearing Units Running Surface Faults - Cups & Cones - Rollers Looseness / Fretting Faults - Wear - Corrosion - Maintenance errors 14th IWSC 2004

Running Surface Faults Identified RailBAM Running Surface Faults Identified CORE 2004 Cup & Cone Faults 14th IWSC 2004 Vipac Engineers

Cup fault precedes roller fault Comparison of Acoustic Signal Levels for Cup and Roller Faults in an E-class PBU Cup fault precedes roller fault Increasing richness of bearing faults indicates increasing failure risk. Note-: Hot Box detectors range is 20 to 50 kms from detection to derail. 14th IWSC 2004

Looseness / Fretting in Package Bearing Units Small axle flexure leads to wear on internal bearing surfaces and results in looseness and fretting Rubbing & wear generates axial & radial looseness Looseness / fretting results in heat generation and overheated bearings 14th IWSC 2004

Looseness / Fretting Faults Identified RailBAM CORE 2004 Looseness / Fretting Faults Identified Looseness / Fretting Examples of fretting of material from cone inner surface associated with cone slipping on journal, prior to initiation of a spun cone. Cone back face material wear 14th IWSC 2004 Vipac Engineers

Bearing Fault Statistics Tapered Roller Package Bearings - mostly removed due to: Spalling on raceways Fretting wear on the cone back face, backing ring or seal wear ring. Axle Box Bearings - mostly removed due to: Excessive wear or looseness. Algorithm enhancements an on-going process and may be bearing type specific. Note Hot Box detectors can only alert after there is a total failure within the bearing and the thermal run away has escalated the external bearing temp 60 degree above normal temps. 14th IWSC 2004

Bearing Faults Preceded by Wheel Faults Wheel fault noted early April (A) Acoustic “wheel flats” in May (B) High “Looseness and Fretting” early June (C) No evidence of bearing running surface fault Rapidly worsening wheel defect during this time Wheels and bearings pulled (350kN impact) TBOGI/ WheelSpec? 14th IWSC 2004

False Economy (cont’d) Looseness Noisy Fretting A B C 6 months (A) Wheel skid (loading) (B) Impacts >200 kN (C) Looseness/Fretting seen Continued High level Looseness, Acoustic Wheel Flats, Impacts Not repaired because of “useful” life remaining in vehicle (D) Vehicle left in service until derailment - $$$ False Economy 14th IWSC 2004

Damage Potential Model RCF Creep Forces 14th IWSC 2004

ARTC Plans for Wayside Detection Integrated Sensors across network, with data trended by Vehicle Monitoring System. Data available to all operators Two Supersites (RailBAM, WCM, AoA & Wheel Profile) Located on North-South & East-West corridor Co-located Sensors (RailBAM, WCM, AoA) Located on Melbourne-Adelaide Adelaide-Perth Sydney-Port Pirie Melbourne-Sydney-Brisbane 14th IWSC 2004

Proposed Wayside Sensor Locations RailBAM Proposed Wayside Sensor Locations CORE 2004 Darwin Sydney Perth Adelaide WestNetRail 5 RailBAM’s RailBAM WCM Existing Sensors Proposed Sensors Wheel Profile AoA & TP RailSQAD We are in all of the same office locations that our big customers are…so we can have strong alliances, strong service. yet no one client coy “ownes” more than 5% of our turnover…we are very independent. 14th IWSC 2004 Vipac Engineers

Reduced Number of Derailments Installation of Wheel Impact Detector and RailBAM Systems 14th IWSC 2004

Evolving Benefits Summary Freight Operators: Optimised Bearing Maintenance based on bearing condition, via trending and targetting worst condition bearings. Extended Bearing Life & hence improved asset utilisation Reduced Train Stops & hence improved asset utilisation 14th IWSC 2004