Coal Line Longitudinal Rail Stress Project ENGINEERING & TECHNOLOGY

The Challenge Solution 50 – 60 % of all Perway train delays are stress related The Longitudinal Rail Stress Project provides a solution: to significantly reduce incidents and delays relating to rail stress and reduce required occupation time for testing and repair

A Solution is required for Early Detection of Rail Stress What is Rail Stress T E N S I O N Tension and Compression forces cause Rail Stress that may lead to a Rail Break or Kick Out A Solution is required for Early Detection of Rail Stress

Project Purpose To develop a wayside system that will monitor longitudinal rail stress in real time to enable better management of Continuously Welded Rail (CWR) The system should be able to warn against possible kick-outs and rail breaks The system should be a tool to plan and execute CWR maintenance The system should prevent… ……Derailments

CWR Measurement Methods currently in use 1. Cutting the Rail Accurate if measurements are done correctly Timeous operation –occupation is required Closure rail and welding is required Weakening the track structure 2. Lifting Frame Accurate if used properly Timeous procedure of loosening & fastening clips and requires occupation of selected section of line Only useable in tension conditions Frame upgraded to enhance accuracy and performance 3. Strain Gauging Extremely accurate with Digital measurements Usable in any stress condition High skill level required for initial installation Expensive

Olifants River Bridge – Ore Line Strain Gauging in use since early 80’s 16 Force measurement channels 2 Rail Temperature channels 2 Air Temperature channels 2 Concrete Temperature channels 4 Expansion gap deflection channels HBM UPM60 Scanning Unit

Olifants River Bridge – Ore Line Force & Temperature Continuous measurement of Rail Force and Air & Rail Temperatures Constant and Real Time monitoring allows operations to take action proactively – reduce train speeds or stop trains at alarm levels No derailments occurred since installation Outdated technology expensive to maintain Technological developments have improved Strain Gauge technology Enabled wayside recordings from multiple locations Improved methodology applied to Coal Line Pilot Project

Coal Line Pilot Site Selection Criteria Sites were selected on a priority basis: Tunnel entrances and exits Kick-out and Rail break areas Turnouts before/after deviations Long bridges Inside two tunnels (for comparison) Additional sites Site Selection Phase 1 Line 1: Vryheid – Richards Bay 98 Sites Line 1: Overvaal Tunnel 7 Sites Phase 2 Line 1: Ermelo – Vryheid Phase 3 Line 2: Remainder of Coal Line

Coal Line Pilot Wayside Intelligent Long Stress Management System Test Equipment Pilot Site Instruments covered with panels to protect against vandalism & on-track damage Operations takes action for train speeds and movement Infrastructure takes action for prioritising maintenance All the strain and temperature gauges are encapsulated for ease of application and re-usage Encapsulated gauges are manufactured by trained strain technicians adhering to strict QC measures ROCLA concrete cubicle containing Test Equipment Rail force and temperature measurement devices installed on tracks

DISPLAY

Installation / Rollout The Track Technology Centre is installing the system (start date: September 2006) A total of 26 Engineers and Technicians are utilized for the installation Coal Line Engineering Technicians are assisting and are trained in the operation and functionality of the system and its components A Coal Line signalling technician will be utilized for power supply purposes Target date for full operation of the system: July 2008

Coal Line Pilot Installation Overview

Test Results: 15 days (Left Rail) Date

iCOMS Main screen display Normal Warning Alarm

iCOMS Forecasting Prediction date Max air temp Est. Rail temp 24/06/2006 Max air temp 35°C Est. Rail temp 46°C

System Benefits Safety Assist in derailment prevention Warning system Rail break / kick-out detection Supporting data in the unfortunate event of an derailment Maintenance Intelligent maintenance Continuous CWR long stress measurements Maintenance management Maintenance cost savings Progress Continuous research possibilities due to system expandability Better understanding of track behaviour and CWR Expandability to instrument line 2 with minimal capital outlay Advantages to other maintenance actions (e.g. tamping & placing closures) System Users Coal Link Operations Centre Maintenance Managers Depot Engineers and Technicians Production Managers Technology Management (TTC) Viewer that will access data on the main server

Technological Development World first development : For future installations the Rocla concrete box is to be replaced by a smaller device mounted on mast poles or rail with own solar powered batteries

HARDWARE

Coal line project will be fully functional by July 2008 Decision Required Coal line project will be fully functional by July 2008 Require ROE and Regional Infrastructure participation in determining next priority routes / corridors for rollout in subsequent phases

Thank you for your attention The End Thank you for your attention

Measurement site breakdown Vryheid East Tintasdrift Dassieshoogte Lenjanedrift Engogweni Komvoorhoogte Bloubank Nhlazatshe Izolof Eqwasha Uloliwe T1 T2 T3 T4 T5 T6 T7

Measurement site breakdown Ulundi ILangakazi Intsamanzi Enqolothi Umunywana Isangoyana Emakwezini IDondotha Elubana Nsese RCB T10/11 T8 T12/13 T14/15 T16

Measurement site breakdown

Coal Line Pilot Installation Overview

HARDWARE

Maintaining WILMA Development of a complete maintenance plan Monitoring of warnings and alarms TTC and then NOC Maintenance of field equipment by contract