Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018

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Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Technological Advances in Heavy Rail
 28th March 2018
 Engineers Ireland - Irish Rail

Peter Smyth
Chief Mechanical Engineer
Irish Rail
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Technological Advances in Heavy Rail - Irish Rail

I will talk about:
• Technology, innovation and systems in use on
  Irish Rail and on the global Railway.
• Some of the latest innovations and ideas to
  optimise and improve maintenance.
• I will also look forward to the future to consider
  what might be - principally from a rolling stock
  operational and maintenance perspective
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Irish Rail CME – Key Numbers

                  500              Staff
                                                        80         €m Total Maintenance p.a

                  9       Depot Locations
                                                        30          €m Diesel p.a

                  800         New wheelsets p.a
                                                         200               Bogies p.a

                  Operating safe, customer-focused, sustainable services
                  across Intercity, DART and Commuter which benefit
                  our economy, communities and our customers
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Our Fleets
• Fleets from Japan, Korea, Spain, USA,
      Germany, France
•    EMU (Dublin)
•    DMU (Commuter / Intercity)
•    Locomotives & carriages – traditional train
•    A peak time railway
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Fleet Disposition
  TYPE       CLASS       BUILDER        COUNTRY         DATE      SETS VEHICLES       COMMENT          IN SERVICE   TOTAL

DMU           29000        CAF            Spain       2003-2005   29     116                              116
              2600       Tokyu Car        Japan         1994       8      16                              16
              2800       Tokyu Car        Japan         2000      10      20                              20
              2700        Alstom          Spain         2000      14      28            Stored
                                                                                                                     152
EMU           8100     LHB Siemens      Germany         1984      38      76                              76
              8500      Tokyu Car        Japan        2000-2005   17      68                              68
              8200       Alstom          Spain          2000       5      10            Stored
                                                                                                                     144
Intercity     MkIV          CAF           Spain         2006       8      67       (3 spare coaches)      67
              22000    Hyundai Rotem     Korea        2007-2012   63     234        (3/4/5 car sets)      234
            Enterprise   De Dietrich     France         1996       4      28      (14 owned by NIR)       14
                                                                                                                     315
Loco           201       GM-EMD        Canada / USA     1995              22         (+12 stored)         22
               71        GM-EMD            USA          1976              18                              18
                                                                                                                      40
                                                                                                                     651
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Passenger Numbers – Here we go again!!
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Fleet requirements

•   Passenger growth 8% - 10% per year
•   Peak availability really pushed
    •   DARTS 6/8 car all day, 10 min interval – 85% availability
    •   ICR fleet – 85%+ availability
    •   Commuter fleet – 90% availability
    •   All other fleets 75% - 80% availability
    Time for some technology optimised maintenance
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
• Improving the maintenance response through
  understanding system condition in real time

• Collect data, analyse it and report by
  exception
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
Traditional Maintenance Concept

                                    General
                                  Maintenance
                                  and Overhaul
                                    Manual
Engineers Ireland - Irish Rail - Technological Advances in Heavy Rail 28th March 2018
What's wrong with the OEM manual?

•   Not optimised for the maintainer – for cost, reliability or availability
•   Very generic content – not region specific
•   Intervals are not based on experience or actual usage e.g Km
Objectives for Application of Technology

                          Safety

     Availability                           Cost
                          ASSET

            Reliability            Efficiency
Maintenance Types

                      •Reactive
   Where we are

                      •Proactive

Where we want to be
                      •Predictive
Irish Rail 2018 – current systems in use

                            RailBam
      Nexala

                 W.I.L.D
Basic data system concept
Mobility solutions

• Mobility solution deployment 2018 / 2019
• Tablet solution connectivity
   • On site exam entry
   • Access to technical info
   • key data access (SAP, Nexala, WILD etc)
Remote Diagnostics

•   IE Network mainly single track and remote
•   Train failure recovery and prevention is key!
•   Complex new Hyundai Rotem fleet
•   234 vehicles in 63 trains
•   Major reliability challenge
•   TMS on board with 24 hour memory!!
•   Solution – remote diagnostics system
Remote diagnostics deployment

•   Competitive tender 2012
•   Nexala chosen
•   Hyundai Rotem fleet fitted 2012
•   €4m+ total costs (Capex and Opex) to 2018
    •   Retrofitted to 70% of fleets by end 2018:
    •   CAF DMUs Class 29000 - complete
    •   CAF MKIV Intercity carriages – in progress
    •   GM Class 201 Locomotive – in progress
NEXALA Diagnostics
Wheel slip hotspot activity by location during autumn
Who are the system users?

•   Fleet technical support – shift / on call
•   Depot & fleet management
•   Fleet planners
•   Powertrain maintenance supplier
•   Nexala “Superuser” System development team
•   CTC (location, fleet status)
•   Safety
•   Operations
•   Infrastructure
Typical usage?

• Live fault and defect analysis – 800 data channels per vehicle
• Tracking Km run and Engine hours
• Root cause analysis
• Event recorder downloads
• Fleet location
Nexala rules

Building rules, alerts and managing output
•   From the root cause analysis investigations, rules can be built to monitor
    specific and multiple channels to alert users
•   For potential failures an email alert can be generated to alert of a sequence
    of events occurring on a train that is a “known” critical path to a failure.

This is the key reliability growth tool and allows Predictive Maintenance
Case study: Battery charger live fault
• This is a critical fault event
Case study: Battery charger live fault
• Rule generated email / SMS with actions required
Case study: Battery charger live fault
• Resent after 30 mins if fault still present
Case study: Transmission Temperature Alarm

Based on data - Maintenance decision to disconnect hydro brake to allow set remain in service. (324
transmission temp). Procedure developed for disconnecting the hydro brake to allow set to run in service
until set returns to maintenance Depot
Case study: Service affecting air pressure issue
Driver advised a full brake application received on approach to Heuston NFF. Nexala data was
reviewed & fault occurred so a repair was required.
Case study: HVAC passenger complaint
“Dear Sir/Madam
I recently was in contact with your call centre and was told to contact you by email to make a complaint. On Saturday 10th of
June I had the misfortune of travelling on the 13.25 service from Heuston to Galway. I was seated in the first carriage.
The temperature inside the train was very high. Myself and my fellow passengers expected the train to cool down once it started
moving. This was not the case however. It was so hot that I thought I was going to faint, there were many elderly passengers who
were in a lot of discomfort.
As there was no way of opening a window I decided to look for someone to Help. Not only was there no staff on board but there
was no one selling any drinks which would have been of some help (all the staff were on the next train which was joint on to our
train and there was no way to go between the trains). As the journey continued the heat became more and more unbearable.
This was now a serious health and safety concern. The man sat opposite me very kindly started sharing his water with myself and
the people around us. Eventually by the time we reached Athlone there was an announcement telling people to get off the train
and to go into the train in front. This resolved the problem. I could not believe this was allowed to happen. I explained that many
people on the train were near fainting and that you couldn't even get a drink of water to a member of staff in Athone. However
he just looked at me saying they were working on it.

At the very very least I expect my fare to be refunded and some compensation to be paid for the torture I had to put up with by
being an Irish Rail customer. I am prepared to send a copy of this correspondence to the media if my complaint is not dealt with
satisfactory.”
Case study: HVAC passenger complaint
•   Sets 22023 & 22003 were coupled. 22203 was the leading car. This passenger was on set 23. There was
    an engine isolated on car 22423, this means 2 x HVAC’s on reduced output so it will take longer to reach
    the required temp.
•   The temp was up at the start of the journey because the HVAC only started to work at 13:15hrs (10 mins
    before departure). Temp reached normal.
Case study: Passenger complaint doors not operating
•   19.35hrs Dublin to Galway on Friday 10/2/17. Passenger wanted to get off at Woodlawn (21.26hrs) Carriage C
    door did not operate. Passenger was over carried. Passenger got the 22.15hrs service from Galway back to
    Woodlawn. Passenger has requested an immediate reply

•   Set 48 was on the service. All doors were operating fine on this service. Set stopped in Woodlawn between
    21:45:30hrs & 21:46:15hrs (see below). Doors were enabled for this time giving a green light to all doors on the
    platform side only.
Case study: Passenger complaint doors not operating
•   When the set stopped in Woodlawn door B was opened (see below in yellow). Circled below in red indicates
    someone trying to open a non platform side door.
Predicative Maintenance Use

• Rules / algorithms can be run regularly. About 150 “rules” running
  for Rotem fleet currently
• Use output to predict when maintenance intervention needed. E.g
  • Air leaks – Monitor compressor run time. Outside norm = leak
  • Doors – Monitor opening / closing times. Outside norm = likely failure
  • Battery charger – Monitor key events and alarms
  • Transmission temp – regularly above 125degC = likely failure
Results – NEXALA R2M

• Balanced maintenance 2 weekly exam now 5 weekly (Km)
• System supports distance based maintenance regime
• Service affecting failures down > 50%
• Huge increase in engine and train reliability
• Tech issues addressed without disruption
• Customer issues diagnosed and addressed
• Added benefits
Results – NEXALA R2M
Engine Reliability Improvement

              NEXALA
              FITMENT
Behind the scenes………..

• Icomera Wi-Fi gateway “hosts” our
  Nexala Remote diagnostics
  system on ICR fleet
• Remote uploading of timetable
  databases, PIS databases
• Seat reservation system manifest
  connectivity
Passenger Wi-Fi
   Solution Overview- Train components
                      • Icomera X6 / X4 main gateway
                      • Acksys or HP access points
                      • Huber & Suhner roof antennae
                  Antennas+ GPS

                       Access Point                       Access Point

Gateway
 Router
                                      Network   Network
RailBAM Bearing Acoustic Monitor

•   Expected bearing life approx 3m Km (= Major cost €€)
•   Premature bearing failures at
RailBAM Acoustic Monitor
•    3 x Lineside acoustic systems installed 2015 - cost €3m
•    Acoustic monitoring of axle bearings
RailBAM Site Overview
RailBAM System Video

                       41
System principles
                              Bearing develops a
                                    defect

                         Vibration in the bearing structure
                             generates acoustic noise

      Noise Frequency                                         Noise amplitude
       determines the                                           determines
         fault types                                          damage severity

                                     Alert

                        Maintenance decision.
Fault Categorisation
FAULT

                       SEVERITY
        Roller                    Severe
        Cup                       Moderate
        Cone                      Minor
        Multiple
        Extended
Types of fault detected
 Cup/Cone        Roller   Multiple   Extended
Acoustic signature of failing bearing

                                 Site Recording and value
Inspections of 2 x bearings following alerts

22331    10 Consistent RS1_p alerts   22222    10 Consistent RS1_p & e alerts
         Inner race fault                      Inner race Fault
RailBAM Web Portal – vehicle mimic

                                     • System reports alarms
                                     • Data can be interrogated
                                     • Web mimic highlights
                                       areas for investigation
                                     • Example shows RS3
                                       faults

                                            David Pender
                                            CME Projects   47
                                               Dept.
Results – RailBAM

•    Successful early detection of axle bearing failures
•    14 alarms on ICR fleet = 10 damaged bearings (since Nov 2015)
•    Greater confidence for fleet operation
•    Consider using system output to drive future overhaul plan
•    Note - Hot box detector system still has a role in network safety
Wheel Impact Load Detector - W.I.LD

                               • Co-located with Railbam
                               • Data reported in same system
                               • System of load cells measures
                                 rolling wheel force in kN
                               • Also measures % axle imbalance
                               • Captures wheel flats early –
                                 reduces damage to wheel & rail

 Wheel Impact Load Detectors
                                                                  49
W.I.L.D alarm levels – per fleet type
W.I.LD Wheel damage example

Wheel damage measured over the site by high readings - Actual damage to the wheel

 Trend analysis Impact vs time
 Shows the condition of the wheel flat progressing
Wheel damage
Wheel measurement
Current wheel measurement tools

                                        AAR gauge
  Profile gauge
                            ORE gauge
Wheel measurement
•   Manual inspect and measurement – 3 / 6 month typically (Tolerance +/- 3mm)
•   South West Trains UK – 3 / 4 mm variance between staff measuring the same wheel!!
•   Human Error potential well documented in engineering industry
•   IE fleet wheel life ranges from 18 months – 5 years (scope for savings)
•   Track based systems can inspect and measure several times a day to 0.5mm
    tolerance
Automatic wheel inspection
Vehicle inspection systems
Aurizon – Queensland Coal Freight

Aurizon – Coal train operator
• 6300 wagons, 300 Locomotives
• Trains 2.4km – Cargo Aus $2m
• “Parting” a major issue
• Hopper doors a major issue
• Wheelset & bearing life high cost

   6 x Supersites
SUPERSITE - Inspect, measure, assess and report:

•   Wheel dimensions
•   Wheel condition
•   Back to Back
•   Axle bearings
•   Bogie equipment
•   Brake pad/shoe size
•   Brake shoe carrier
•   Pantograph
•   Axle load imbalance
•   Missing fasteners
•   Missing equipment
•   Brake disc size and condition
•   Coupler / headstock alignment
                                    Machine Vision Algorithms
•   Hopper doors & equipment
AURIZON SUPERSITE – MVA images
AURIZON SUPERSITE - Headstock / coupler deformation
AURIZON SUPERSITE – Wagon hopper door mechanisms
AURIZON SUPERSITE - Missing critical fasteners underframe
AURIZON SUPERSITE - RESULTS

• Each train pass generates data file of 5Tb
• Data reviewed locally – exception report
• 16 major detections per month

  •   Critical safety events - 87%
  •   Brake blocks – 40%
  •   Wheel consumption – 47%
  •   Inspection interval doubled to 84 days
  •   HM interval doubled to 24 months
  •   Unscheduled maintenance - 50%
  •   Shunting – 50%
  •   Availability - +3% ( = 1 x train)
VR Finland (Helsinki)

• Entire fleet covered
• 7 years in service
• Works well in the snow!
SNCF Paris

• Depot site inspects 60 x TGV sets per day
Consider the future – Diesel is not Dead!

• Rail development strategies published
• Move towards sustainable mobility –
  progressive move to electrification for
  2040
• IE company strategy adopted in 2016 -
  no more diesel only trains

        Future trains will be:
        • Electric only or
        • Diesel Bi mode or
        • Diesel Battery hybrid
Consider the future
• Electrification to Maynooth, Drogheda and
  Hazelhatch
• Bi mode trains allow DART expansion earlier
  than Electrification
• 10 yr framework order for 300-400 vehicles

                                                Removable mini
                                                 generator car
Battery Hybrids

• Diesel Battery
  “Prius” gives +30%
  energy saving

• Battery Electric
  allows 50km running
  “off wire”
Conclusion and Summary

•   Technology now available to optimise and transform maintenance
•   Key objectives for Technology met
•   Safer through more frequent measured inspections
•   Reduced costs through optimised output
•   New fleets will be specified with “Supersite” & Diagnostics
•   Need to channel the “Big Data” to a central point of use
Iarnród Éireann
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