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Lubrication Systems & Data
Elif H. Öztürk
Lubrication Systems & DataBRUSSELS, 04.10.2016
T2.5 - TAILORING LUBRICATION TO DUTY AND CLIMATE
• Under this task the rail-wheel lubrication andappropriateness for different density of operationswill be researched and tested.
• The task will consider on-board lubrications & track• The task will consider on-board lubrications & trackside lubrication to reduce rail wear.
• Different lubrication for different lines/trafficdensity and weather conditions.
T2.5 - TAILORINGLUBRICATION TO
DUTY AND CLIMATE
T2.5 - TAILORING LUBRICATION TO DUTY AND CLIMATE
T2.5.1 Lubricationsystems and data
(M4-M18)
T2.5.2 Tailoringlubrication to dutyand climate (M13-
M33)
T2.5.1 Lubrication systems and data (M4-M18)
Lead Partner:
Partners:
T2.5.1 Lubrication systems and data (M4-M18)
• INTADER: is leading the task based on the experienceand needs for lubrication on TCDD’s network.
• USFD is inputing expertise of the effect of lubricationon rail-wheel contact, especially wear rates of track andeffect of reliability in lubricant application on fatiguelife of rail steel.
• UIC is contributing knowledge of standards and theirapplication in rail-wheel interface management acrosstheir member countries.
• The project will consider also existing UIC Wheel RailConditioning project led by ProRail. The work willparticularly consider lubrication systems appropriatefor low density lines
Lubrication Questionnaire
CONTACT PERSON
TEL. NO.
FAX NO.
E-MAIL ADRESS
Please describe the railway operation
NAME OF THE RAILWAY
ORGANIZATION
NeTIRail-INFRA WP2 T2.5.1/T2.5.2
QUESTIONNAIRE FOR LUBRICATION
Please describe the railway operation
YES NO Environmental Conditions
Busy Capacity Limited Passenger Railway
Under Utilized Rural/ Secondary Line
A Freight Dominated Route
What is the total Length of Track in Question?
what is the axle loads in the range? ( TON)
What is the train speed range? (km/hr)
What is the tonnage annually?
(Million Gross Ton/year)
What is the number of passenger train annually?
What is the number of freight train annually?
Wet in General
Dry in General
Mixture
of Them
Minimum Ambient
Temperature °C?
Maximum Ambient
Temperature °C?
YES NO
Supplier ModelMaintenance
Interval
Do you use track-based lubricators on your railway?
Details of the Lubrication System
Hydrolic Type
Mechanical
Type
Electric
Powered Type
Comments
What do you lubricate rails for?
Lubrication Questionnaire-Track Side Lubrication
<200 <600 <1000
<2000
High
Rail
Low
RailBoth
What is the range of curve radius that you position the lubricator on track?
Curve Radius
(meter)
Straight
/Tangent
Track
<400
What rails do you lubricate?
<800 <1500>2000
What is the position relative to the start
of the
transition curve?
Usage per. year
Powered Type
Details of Lubricant
Supplier Name Comments
transition curve?
Please describe the cost benefits of lubrication
BenefitsApproximate
value annuallyComments
Rail wear reduction
Other reductions
Wheel wear reduction
Please indicate the cost of lubrication
CostsApproximate
value annuallyComments
Please describe the any other effects of the lubrication
Effects
Rolling contact
fatique cracking
Braking performance
Noise and vibration
Others
Lubricant
Other
Lubricator
maintenance
& replacement
YES NO
Supplier ModelMaintenance
Interval
Locomotives
Coaches
Multiple Units
Freight
wagons
Others
Do you use on-board lubricators on your railway?
Details of the Lubrication System
Total
Lubricated
Train Set
Comments
What do you lubricate wheels for?
Lubrication Questionnaire-Onboard LubricationPlease describe the cost benefits of lubrication
BenefitsApproximate
value annuallyComments
Rail wear reduction
Wheel wear reduction
Other reductions
Usage per. year
Solid Stick
/Sprey etc
Details of Lubricant
Supplier Name Comments
Please describe the method you preferred for the actuation in the case of continuous, or triggered
from track position or geometry?
Please indicate the cost of lubrication
Lubricator maintenance
& replacement
Please describe the impacts of the lubricationFactors Comments
Rolling contact
Braking performance
Noise and vibration
Others
Lubricant
Other
Approximate
value annuallyCosts Comments
FRICTION MODIFIERSYES NO
Please describe the cost benefits of lubrication
Please indicate the cost of lubrication
Do you use friction modifiers on your railway?
Do you apply friction modifiers to the wheels?
BenefitsApproximate
value annuallyComments
Rail wear reduction
Wheel wear reduction
Other reductions
CostsApproximate
value annuallyComments
Lubricator maintenance
& replacement
Lubricant
Other
Please describe the effects of the lubrication
Factors Comments
Others
If you use on board applicators for friction modifiers on your railway system, please proceed to
"Onboard-Applicators", If you use ontrack applicators for friction modifiers please proceed to
"Ontrack-Applicators".
Rolling contact
Braking performance
Noise and vibration
Friction Modifiers- On Board Applicators
Supplier ModelMaintenance
Interval
Loco.
Coaches
Multiple Units
Freight Wagons
Others
Please describe the reason for applying friction modifiers to the wheels.
Total Train
Set with
Applicator
Comments
Details of the Applicator for Friction Modifiers
Usage per. year
Solid Stick
/Sprey etc
Details of Friction Modifier
Supplier Name Comments
Please describe the method you preffered for the actuation in the case of continuous, or triggered from track
position or geometry?
Friction Modifiers- On Track Applicators
Supplier ModelMaintenance
Interval<200 <600 <1000 <2000
Please describe the reason for applying friction modifiers to the rail.
Details of the Lubrication System for Friction Modifiers
Hydrolic Type
Mechanical Type
Electric Powered
Type
Comments
What is the range of curve radius that you position the applicator on track?
Curve Radius
(meter)
Straight
/Tangent
Track
<400 <800 <1500 >2000
Please describe the details of friction modifier
Supplier Name
Please describe the criteria you preffered for the frequency of actuation in the case of
electrically operated lubricators
Comments
What is the position relative to the start of the transition curve?
Benefits of Effective Rail Lubrication
Rail/ Wheel Wear
Flange noise
Derailment
RCF Development
Cost Benefits
Methods Of Rail-wheel Lubrication
Application
Track-side On-board Hi-Rail
Track Side Lubrication
Track side lubrication strategies;
Wayside lubrication
Spray lubrication
Drilled rail lubrication
Wayside Lubrication
Components;
• Distribution hoses
• Application bars
• DC or AC power
Features:
• Multiple distribution ports
• Application to running orrestraining rails• DC or AC power
• Tank
• Control System
• Pump/motor
• Wheel/train sensor
• Easy to install
• Easy to maintain
Spray System
Application =>>>The Wheel or rail head
Application by nozzles
• Wall mounted• Wall mounted
• Pole mounted
• Controls
• Pump and reservoir
Drilled Rail: Application => holes drilled in
• Wall mounted
• Pole mounted
• Controls
• The head of the rail
• Suitable for embeddedtrack
• Controls
• Pump
• Reservoir
• Sections
• Gauge, restraining rail,u‐rail
On- Board Lubrication
Spray Systems
• Commonlyused in Europe
• Singleapplication per
Solid Sticks
• Large install• Singleapplication pertrain
• Fine tunedcontrols
• Large install
• Large volumesof engineering& performancedata
• no tread/TORmigration
• Simple
• Clean system
• Easy tomaintain
CORRECT LUBRICANT
Lubricants
Track Side
Grease Oils
Mobile
Solid Stick Oils
ON BOARD LUBRICANTS
On Board Spray
May contain oil solubleadditives or solid lubricants
• Generally single grade
• Biodegradable varietiesavailable
Solid Lubricant Sticks
• Contains no liquid/ oil
• No contemination totread/TOR
• No contamination of thetrack structure, vehicleavailable
• Multiple suppliers
track structure, vehicleballast
• Sticks are self extinguishingand nontoxic
Trackside Grease
Characteristics:
• Compositional components
• Stability and consistency
• Retentivity/carry down is a key feature for• Retentivity/carry down is a key feature forperformance
• Functional temperature range
• Manufacturing consistency
Trackside Grease:Ultra High Performance
Excellent carry down at low application rates, widetemperature range
It is expensive
Petroleum Based:
Good performance at intermediate priceGood performance at intermediate price
Wide range of qualities, seasonal temperature range
Bio Based:
Ranges of biodegradability
Carry down performance, seasonal temperaturerange
Experiences & Needs
NEXT STEPS
SZ ;Site test for different types and methods of lubrications.
Input to GIS mapping (T2.1), to identify which lubrication worksbest in different climate areas (some lab tests, somemanufacturers data)
Input this to WP6 Decision Support to create a map able to showthe appropriate type of lubricant for different locations based onmax/min temperature, rainfall levels, and any other factors foundto be important.
Novel aspects include testing under climate conditions relevant toSouthern Europe and testing new eco-friendly lubrication (Manyolder track grease products are carcinogenic and must bewithdrawn. New products often behave very differently).
This Research Answers The Questions:
Doesit have differentneeds to a high -density line?
Would on-board lubricationsystems be better for the caseof long track distances with
low traffic?
What type oflubrication is bestfor a low-densityline?
The task duration is chosen to allow
all periods of the year to be considered to
understand climatic effects on lubrication,
grease which fails in hot/cold conditions.
