1. Coal Line Longitudinal
Rail Stress Project
ENGINEERING & TECHNOLOGY

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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Outdated technology expensive to maintain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

8. 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

9. 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

10. DISPLAY

11. 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

12. Coal Line Pilot Installation Overview

13. Test Results: 15 days (Left Rail)
Date

14. iCOMS Main screen display
Normal
Warning
Alarm

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

16. 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

17. 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

18. HARDWARE

19. 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

20. Thank you for your attention
The End
Thank you for your attention

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

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

23. Measurement site breakdown

24. Coal Line Pilot Installation Overview

25. HARDWARE

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