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Roma, 1 december 2006. Rete Ferroviaria Italiana Track Maintenance. Ing. Matteo Triglia . Network. Situation. 16.000 km of line, two third electrified and 6.300 km double-track line (with 22.000 km of main line) About 30.000 km of total track and 44.000 switches - PowerPoint PPT Presentation
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Roma, 1 december 2006
Rete Ferroviaria Italiana Track Maintenance
Ing. Matteo Triglia
2
Network and Situation
• 16.000 km of line, two third electrified and 6.300 km double-track line (with 22.000 km of main line)
• About 30.000 km of total track and 44.000 switches
• About 1.900 plants for the regulation of the trains circulation and 20.000 km of track equipped with systems of automatic block for the spacing of trains
• More then 1.500 km of tunnels, 530 km of bridges and viaducts, 9.000 km of power lines, 385 power station and substation
• Cost about 1 M. €/ year
Situation
• Increasing uncertainties on financing
• Effect turnover on the competences
• Discontinuity of perimeter: Entry of AV / AC network
• Discontinuity of content: insertion of new technologies
• increase of plants maintenance
Network
3
• Containment of the costs• Improvement of the
reliability and the safety • Increase of the availability
of the track• Management of the new
technologies and the lines AV / AC
Attended impact
• Increase of the productivity of personal
• Reduction of maintenance cost of the traditional network for contracted activity
• Improvement of the indexes of unavailability of the infrastructure
• Increase of maintenance cost for new technologies and lines AV/AC
Assigned objectives
Objectives
4
16.000 km of line (6.300 double track)1.255 km of tunnels530 km of bridges and viaducts
9.000 km of power lines
385 stations and sub-stations
3 national workshops
Infrastructure Structure
5
Type of line
Type A – Main Line with heavy traffic (intensity, speed and major maintenance standard)
Type B – Main Line (long distance line for national and international traffic)
Type C – secondary electrified line
Type D – not electrified line
Infrastructure Structure
6
Infrastructure Structure
LINEkm LINE km TRACK
TYPE A 1.275 2.550TYPE B 5.120 9.320TYPE C 4.300 4.936TYPE D 5.325 5.362
TOTAL NETWORK 16.020 22.168
JUNCTION AND FREIGHT LINE 1.000OTHER TRACK 8.000
TOTAL TRACK 31.168
ELECTRIC POWER SUPPLY 3000 V c.c.
LINE ELECTRIFIED km 10.695 MAIN TRACK ELECTRIFIED km 16.086LINE NOT ELECTRIFIED km 5.395 MAIN TRACK NOT ELECTRIFIED km 5.362TOTAL km 16.020 TOTAL km22.168
7
Infrastructure Structure
Km of LineKm of Line
0
2000
4000
6000
8000
10000
12000
double track
single track
double track 1256 4306 655 53 6270
single track 3 838 3884 4881 9606
LINE A
LINE B
LINE C
LINE D
TOT.
8
Infrastructure Structure
Km Km Main Main LineLine
0
2000
4000
6000
8000
10000
12000
14000
double track
single track
Double track 2511 8611 1310 105 12537
Single track 3 838 3884 4881 9606
LINE A
LINE B
LINE C
LINE D
TOT.
9
Infrastructure Structure
A B C D
4.848
TOTAL
14.388
12.792
16.970
44.150
2.092
991
1.765
TYPE OF LINE
TOTAL 3.476 22.830 12.996
6.976
6.971
8.883
3.622
3.920
5.454
SWITCHES ON SECONDARY LINE CENTRALISED (electrified + manual)
SWITCHES ON SECONDARY LINENOT CENTRALISED and FLATT SHUNTING(electrified + manual)
1.698
910
868
SWITCHES ON MAIN LINE(electrified + manual)
SINGLE AND DOUBLE TURNOUT
SwitchesSwitches
10
Steps of Maintenance Process
and Logistic
DW-MaintenanceBW-Pianning
Controllo
Tecnico
Annual
Planning
Attività Negoziale
Objects ofMaintenance
StandardActivity
State of Track
List ofMaterial
Diagnostic
Quartly
Programme
Weekly
ProgrammeExecution
Contract Management
Goods Entry - Store Management
Goods Management
SuppliersRegister
Advices
Form - PM
Form - MM
CdL
IntervalsSlowing down
Tech. Control
Economicalcontrol
11
Plan the maintenance
Programme the resources
Manage spare parts and technical material
Study and remove the breakdowns
Informatics
system
The engineering of maintenance
12
Evolution of maintenance
2. In the way of maintenance “on condition”
4. Relationship with suppliers of equipments and plants that are involved in the Maintenance during the life cycle.
3. Support with managerial informatics tools the visits to the work sites and the consequent technical relief's.
5. Certify the service.
1. Precise planning
13
“Diagnostic" is the activity directed to determine “health condition" of the different components of the railway infrastructure in order to:
• guarantee the safety of the exercise
• prevent the breakdowns
• address maintenance resources where is recorded a degrade of geometric characteristics and/or of the infrastructure operation parameters incompatible with the desired service level (maintenance “on condition”)
Diagnostic
14
The virtuous diagnostic circle - maintenance
Interventoimmediato o
Analisidati eimmissione nel SIM
Esecuzione medianteTronchi, Zone, Cantieri Meccanizzati,
Appalti
Programmazione tramite SIM
manutenzioneon condition
ATTIVITA DI DIAGNOSTICA
•Controllo completo infrastruttura linee A e principali B
•Rilievo geometria e usura binario e linea di contatto linee C e restanti B
•Rilevo geometria binario linee D
•Rilievo parametri geometrici binario e deviatoi
•Rilievi a US dei difetti interni alle rotaie
MEZZI DI MISURA
Treno Archimede
Talete-Aldebaran
PV7 , EM80
Carrellini informatizzati
Treno Galileo e rivelatoriportatili
Immediate interventionor
Analyse of data insertion in SIM
Execution By means ofTrunks, Zones, Mechanized work site,
Contracts
Programme with SIM
maintenance“on condition”
DIAGNOSTIC ACTIVITY
•Complete infrastructure control line A & mainly B
•Relief geometry & rail corrugation & Overhead line on line C & other B
•Relief geometry line D
•Reilief track geometric parameters & switches
•Relief with US of rails defects
MEASURING VEHICULES
Archimede Train
Talete-Aldebaran
PV7 , EM80
Informatics trolley
Galileo train & portableindicator
15
Operational flow for the Diagnostic of the Infrastructure
Planning -Programme
Work
Orders
Work
Orders
Pa
ram
eters re
gis
tratio
n
Diagnostic Trains
Uultrasonic reg.
Diagnostic System Advices
•Quality index•Track geometric registration•Track defects
DATAWAREHOUSEMAINTENANCE
COAMI
Visite Structures
PM
Reports Breakdown
PM
Measuring documents
SEDE TECNICA
SEDETECNICA
SEDETECNICA SEDE
TECNICA
SEDE TECNICA
Punto di MisuraPunto di Misura
Punto di MisuraPunto di Misura
PM
DMS
Transform the data in information
16
InfraManager System of decisional support for the infrastructure maintenance
17
Proposal of work M/R
Elaborate work orders
PLANNING
SCHEDULING EXECUTIONMONITORING
- Interventions-Work planning
Measuring
ANALISES
Evaluation of quality
- Breakdown- Defects- Quality index- RAM Indicator- Statistics data
- Track Geometry- Rail Profile- Ballast- Sleepers- Catenaries Geometry- Wear of OHL
- …
-AREA TO BE OPTIMIZED
Chain of maintenance management based on diagnostic
18
Chain of maintenance management based on diagnostic
Proposal of work
Scenario ottimizzato
PIANNING EXECUTIONSCHEDULINGMONITOR
- Interventi- ScadenzaLavori
Measuring
ANALISI
- Velocità di degrado- Vetustà- Storicolavori- Efficacialavorazione- Frequenzainterventi- Costi- Traffico
quality
- Avarie- Difetti- IndiciQualità- IndicatoriRAM- Datistatistici-Avvisi
- GeometriaBinario- ProfiloRotaia- Ballast- Traverse- Geometriacatenaria- Usurafilo- …
OPTIMIZATION
Scenario ottimizzato
Elaborate Work orders
WorkRegister
PL ESCHEDULMONITORING
- Intervention- Work Planning
M
ANALISES
- Degrade speed- Old age- Work register- Work Efficiency- Intervention frequency- Costs- Traffic
Evaluation of
- Breakdown- Defects- Quality Index- RAM Indicator- Statistics Data-Advices
- Track Geometry- Rail Profile- Ballast- Sleepers- OHL Geometry- Wear of OHL- …
OPTIMIZATION
19
Finished work
Algorithms of work forecast:
- overcoming thresholds- Degrade speed
Track
Rail
Sleeper
Ballast
Algorithms of Technical and Economical Optimisation:- Grouping works on spatial and temporary base- elimination of ordinary intervention in proximity of renewal- Works distribution in accordance to the priorities and the ties of the railway exercise
Sceneries of intervention
Diagnostic Data
BasicData's
Executed work
Cost and bonds
ENTRY ELABORATION FINAL OUTPUT OPTIMISATIONOUTPUT
INTERMEDIATE
-Tamping-Ballast Cleaning-Rail renewal-Renewal ballast
Definition of Maintenance intervention
20
Diagnostic
Diagnostic and extraordinary maintenance
The practice of track renewal is tied up to considerations on life duration of the track or to directives of technical standardization (ex.: 60 UNI, Pandrol fastening, elimination of wood sleepers, etc.). These considerations can always be additional to the results of the mobile diagnostic that these are considered on a sufficient long term (1-2 years).The analysis of these elements is facilitated by the recent insertion in the SIM.
21
Diagnostic
The internal defects registered with US
The consistence, registered on the network, of the rails inside defects pointed up with the ultrasounds furnishes an important element of evaluation on the necessities of extraordinary maintenance of one determined section of track.When in fact on a section of track are present many defects that exceeds a determined limit, it can economically result more convenient, from the point of view of the operational costs, to plan a generalized renewal of rails in that section.
22
RFI main activity
inspection and control of the entire network with the “mobile diagnostic”
intervention in case of abnormality’
Intervention of ordinary maintenance
protection of work site
Intervention of maintenance (levelling and lining of track and switches, bush cutting, general overhaul, substitution of rails and sleepers)
Inspection of outsourced work
23
Main activity of track work Contractors
Intervention of extraordinary maintenance and renewal
Intervention of ordinary and/or complete maintenance (rail grinding, levelling and lining of track and switches, bush cutting, general overhaul, extended to rail and sleepers substitution)
Urgent intervention
24
RFI, for the outsourced track work, has organized two "contract type", both of more years validity: the one, with jurisdiction to level of the whole network, divided in one or more territorial lots, for the trust of important track work including, track renewal, systematic ballast cleaning, total sleepers substitution, etc.
the other one, with jurisdiction to level of Infrastructure Compartment Direction, for the trust of the track work of ordinary maintenance, finalized in containment of the normal defects (revision, leveling, etc.) ;
Outsourced Track Work
25
Both contracts have the objective of:
• to avoid the fragmentation of the performers, giving responsibility to the contractors in terms of ability technical / executive and of business organization, with particular respect to the quality of the performed performances;
• to harmonies behaviors to the whole network; to plan middle term interventions through a single tender, guaranteeing to the trackwork contractors a stability of the orders and favoring, at the same time, the modernization of the equipments and the improvement of the business organization.
Outsourced Track Work
26
For both contract type, the execution of the intervention is in quality assurance, accordingly to the standards ISO 9000 and in respect to the documents "Plain of Quality."For the performance quality, the contractor, during the operational phases and before reactivation to the exercise of the track under maintenance, must verify the quality of the performed work reporting the result on special forms released by RFI.
Outsourced Track Work
27
The track works are contracted to subjects in possession of RFI qualification certificate to the "System of Qualification of the railway trackwork Contractors" and, if required to the "System of Qualification of Suppliers of concrete sleepers", that participates in an association of enterprises (ATI, constitute of trackwork Contractors and manufacturers of the materials). This in order to guarantee a coordination of the productivity and performance and of the oneness of the responsible interlocutor.
Outsourced Track Work
28
Furthermore, to the level of whole Network with a three year contract, are performed interventions of rail grinding, type corrective, for about 700 km/year of track on lines of group A, B and C for elimination of defects of short and long wave. Such interventions are performed in programmed possession of track of about 3 hours. The quality of the performed work is valued through a quality index that foresees the remaking of intervention in case it is not satisfied.
Outsourced Track Work
29
Quantity of work performed in the years 1999 to 2006 in extraordinary maintenance
Outsourced Track Work
7005601999
9001.1502000
8601.1002001
8001.0502002
670
440
800
560
km BINARIO
6502006
7502005
7302004
7002003
N° DEVIATOIANNO
7005601999
9001.1502000
8601.1002001
8001.0502002
670
440
800
560
km TRACK
6502006
7502005
7302004
7002003
N°SWITCHESYEAR
30
Amount of planned track renewal for the years 2007, 2008 and 2009
in extraordinary maintenance
Planned track work
6504502008
450
500
km BINARIO
6002009
6002007
N° DEVIATOIANNO
6504502008
450
500
km TRACK
6002009
6002007
N°SWITCHESYEAR
31
Special actions have been taken in the following sectors:
improvement of the competences of the personnel of the contractors;
certification of the performed work;
establishment of a systematic inspection activity on the track work site.
Control of Contractors track work
32
The qualification of the Contractors personnel that operates in maintenance activity of the railway infrastructure has been organized in only one system:
COMPETENCES OF CONTRACTORS PERSONNEL
Control of Contractors track work
ABILITAZIONI PERSONALE IMPRESE APPALTATRICI settore
MANSIONI ESECUTIVE DELLA PROTEZIONE CANTIERI TUTTI
“Saldatura alluminotermica” definita nella Circolare DI.TCAR.CI.AR.07.001.A del 21 marzo 2000 – “Abilitazione per l’esecuzione di saldature alluminotermiche di rotaie per il personale
dipendenti da Imprese Appaltatrici”. ARM
GUIDA DEI MEZZI D’OPERA DI PROPRIETA’ DELLE I.A. TUTTI
ARMDITTE (Proc. RFI DMA- DTC PS IFS 012 A del 03.03.2004) ARM
nuova
QUALIFICATION OF CONTRACTORS PERSONNEL sector
EXECUTIVE FUNCTION OF WORK SITE PROTECTION ALL
“alluminotermic welding” according ProcedureDI.TCAR.CI.AR.07.001.A of 21 march 2000 – “Qualification of Contractors Alluminotermic welders”
ARM
DRIVERS OF CONTRACTORS TRACKWORK MACHINES . ALL
ARMDITTE (Proc. RFI DMA-DTC PS IFS 012 A of 03.03.2004) ARM
new
33
CERTIFICATION OF THE PERFORMED WORK
The Terms of Contract for work in presence of the railway exercise prescribes that the contractor must perform the Quality Control of the work before the reactivation of the track to the exercise, with particular attention to those work that have importance with the Safety of the exercise.
Such controls must be documented through specific forms for the followings work: Renewal of track/total substitution of sleepers Ballast cleaning Renewal of switches and crossings
Control of Contractors track work
34
Considering the high investments in the activity of track work, RFI considers of fundamental importance the relationship with l’Associazione Nazionale Imprese Armamento Ferroviarie (ANIAF).
A major reason with the European Federation of Track Work Contractors (EFRTC)
Relationship with Contractors Association
35
Relationship with the Association allows to: better comprehension between client and supplier increase capacity/potentiality in carrying out of work seek/increase methodology for a better quality of the executed work Optimise the track work cost reduce the subjections to the railway exercise, in terms of time possession improve the safety of the railway exercise and the personnel involved in the work site promote use of high performance machines
Relationship with Contractors Association