Guidelines to Best Practices for Heavy Haul Railway Operations

656 Pages·48.588 MB·English

by  Cantrell D. (сост.)

GUIDELINES TO
BEST PRACTICES
FOR HEAVY HAUL
RAILWAY OPERATIONS
INFRASTRUCTURE CONSTRUCTION
AND
MAINTENANCE ISSUES
INTERNATIONAL HEAVY HAUL ASSOCIATION
VIRGINIA BEACH, VIRGINIA
These Guide lines have been prep ared by the Techn ic al Review Comm it tee
under the ausp ices of the Inter nat ional Heavy Haul Assoc ia t ion as an
input to the deci sion maki ng pro cesses of heavy haul rail ways. They rep-
res ent the best efforts of the Techn ic al Review Comm it tee authors and
reviewe rs. The Guide lines are neit her mand a tory direc tives nor intended
to sum mar ize and inter pret the exten sive heavy haul techn ic al lite ra t ure.
There are .spec ial com bi na tions of cir cums tances in which the best
pract ices may diff er from those dis cussed in the Guidel ines. Theref ore,
these guide lines are neit her mand a tory nor do they describe exclu sive
metho ds to achieve opti mum rail/wheel per for mance.
Copy right © 2009 Inter na tional Heavy Haul Asso cia tion
All rights reserved.
Repro duct ion or transl at ion of any part of this work with out the per mis-
sion of the copyr ight owner is unlawf ul. Requests for per miss ion or fur ther
inform at ion should be addressed to:
Inter na tional Heavy Haul Asso ci a tion
2808 For est Hills Court
Vir ginia Beach, Vir ginia 23454 USA
13 12 11 10 9 1 2 3 4 5
ISBN 978-1-930566-74-3
Library of Cong ress Cont rol No.: 2009926418
Printed in the United States of Ameri ca
Book design and lay out by D. & F. Scott Pub lish ing, Inc.,
North Richland Hills, Texas
Con tents
Fore word xiii
Acknowle dgm ents xvii
Metr ic and US Units Conv er sion Table xxi
Intro duc tion Intro-1
Chap ter 1: Track as a Key Enabler for Heavy Haul Succ ess 1-1
1.1 Introd uct ion (Michael Roney) 1-1
1.2 Intera c tion with Vehic les (Harry M. Tournay) 1-3
1.2.1 Action of a Wheelset on the Track 1-4
1.2.2 Vehi cle Susp ens ion Elem ents and Track Response 1-12
1.2.3 Conc lus ion 1-19
1.3 Track Geom e try (Michael T. Mischke) 1-19
1.3.1 Track Geome t ry Defi n it ions 1-20
1.3.2 Gage Track Geom e try 1-23
1.3.3 Sur face Track Geom e try 1-24
1.3.4 Horizontal Alignment 1-26
1.3.5 Roles and Feat ures of Track Geom e try 1-32
1.3.6 How Track Geom e try Intera cts 1-36
1.4 Track Cant (Superelevation) and Vehi cle Intera c tion
(Jude O. Igwemezie, Ph.D., P.Eng.) 1-38
1.4.1 Bala nced Superelevation for Short Trains 1-38
1.4.2 Curve Failu re Modes Under Tract ion and Braki ng 1-39
1.4.3 Train Forces 1-43
1.4.4 Anal yzi ng Your Track 1-46
1.4.5 Effect of Train Opera tional Parame ters on
Superelevation Require ments 1-47
1.4.6 Superelevation Require ments for Long Trains
Opera t ing on Heavy Grades (A Case Study) 1-55
1.4.7 Sum mary 1-56
1.5 Track Stiff ness (David M. Read) 1-58
1.5.1 The Role of Track Stiff ness 1-58
1.5.2 How Track Char ac ter ist ics Affect Track Stiff ness 1-65
1.5.3 Track Tran sit ions and their Import ance 1-66
1.5.4 Best Pract ices for Design ing Tran sit ions 1-67
A iii B
Contents
1.6 Track Lat eral Sta bili ty (Andrew Kish, Ph.D.) 1-71
1.6.1. Syn op sis of the Track Lat eral Sta bili ty Prob lem 1-73
1.6.2 Track Buck ling Mechani cs and Safety Conc erns 1-77
1.6.3 Key Param e ters Influe nci ng Track Buckl ing 1-79
1.6.4 Buck ling Anal y sis Tools 1-80
1.6.5 Param etr ic Influe nces 1-81
1.6.6 Advanced Conc epts in Buckl ing Safety Eval ua tions:
Probab ili st ic (Risk Based) Approaches 1-82
1.6.7 Best Pract ice Guide lines for Buck ling Prev en tion 1-84
Chapt er 2: Econ omi cs 2-1
2.1 Intro duct ion (Carl D. Martland) 2-1
2.1.1 Eco nomic Issues Related to Heavy Haul Rail road ing 2-1
2.1.2 Over view of the Chap ter 2-3
2.2 Life Cycle Costs (Step hen H. Mor rell and Michael N.
Armstrong) 2-3
2.2.1 Introd uct ion to Life Cycle Costi ng 2-3
2.2.2 Term in olo gy 2-4
2.2.3 Metho do lo gy 2-6
2.2.4 Heavy Haul LLC Examp les 2-8
2.3 Unit Costs (Carl D. Martland) 2-11
2.3.1 Introd uct ion 2-11
2.3.2 Prod uct ion Rates 2-12
2.3.3 Train Delay Costs 2-14
2.3.4 Estim ati ng the Cost/Ton-mile 2-15
2.3.5 Track Qual ity and Opera t ing Cons traints 2-16
2.3.6 Estim at ing Heavy Haul Bene fits: the AAR’s HAL
Econ omic Analy s is 2-17
2.4 Life Cycle Cost ing in Pract ice in Europe (Peter Veit and
Klaus Riessberger) 2-22
2.4.1 Basic Defi n it ions and Chara ct eri st ics of the
TUG-LCC Eval u a tion Model 2-23
2.4.2 Jus ti fy ing Pre mium Com po nents for Track
and Turno ut 2-25
2.4.3 Eval u at ing Inno va tions 2-28
2.4.4 Evalu a ti ng Innov at ive Comp on ents 2-30
2.4.5 Eval u at ing Inno va tive Main te nance 2-33
2.4.6 Con clu sions 2-34
2.5 Summ ary (Carl D. Martland) 2-35
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Contents
Chap ter 3: Track Com po nents 3-1
3.1 Introd uct ion (David Staplin) 3-1
3.1.1 Chap ter Scope 3-1
3.1.2 Heavy Haul Track and For ma tion Develo p ment 3-1
3.2 Rails (Dan Stone, Joe LoPresti, Ste phen Marich, Sergie
Zahkarov, and Anatoly Naumov) 3-2
3.2.1 Introd uct ion 3-2
3.2.2 Rail Deter io r at ion 3-2
3.2.3 Microstructural and Chemi c al Chara ct eri st ics of
Rail Steels 3-14
3.2.4 Rail Mater ial Requirem ents and Prope r ties 3-19
3.2.5 Conc ludi ng Remarks 3-28
3.3 Rail Welds (Peter Mut ton, Charles Battisti, Mark Swartz,
and Dan Gutscher) 3-28
3.3.1 Introd uct ion 3-28
3.3.2 Defini ng Weld Per for mance 3-29
3.3.3 Theo r eti c al Backg round 3-31
3.3.4 Deter io r at ion and Failu re Modes 3-35
3.3.5 Best Weld ing Pract ices 3-38
3.3.6 Other Rail Weld ing Proc esses 3-45
3.3.7 Future of Weldi ng 3-45
3.4 Rail Joints (Dave Davis) 3-46
3.4.1 Introd uct ion 3-46
3.4.2 Insul ated Joints 3-46
3.4.3 Non-Insul ated Joints 3-49
3.5 Turn outs and Rail way Cross ing (Dave Davis) 3-50
3.5.1 Introd uct ion 3-50
3.5.2 Turn outs 3-50
3.5.4 Crossi ng Frog Designs 3-61
3.5.5 Flange Beari ng Spe cial Track Work 3-64
3.6 Crossties, Fast eni ng Syst ems, and Rail Anchors
(Dave Davis) 3-67
3.6.1 Introd uct ion 3-67
3.6.2 Crosstie/ Fast ener Types 3-67
3.6.3 Wood 3-68
3.6.4 Plast ic/Comp osi te Crossties 3-71
3.6.5 Steel with Elas tic Fast ene rs 3-71
3.6.6 Con crete 3-72
3.6.7 Spe cial Trackwork and Other Unique Envir onm ents 3-74
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Contents
3.7 Ball ast and Subballast (Steve Chrismer) 3-74
3.7.1 Intro duc tion 3-74
3.7.2 Ball ast 3-75
3.7.3 Subballast 3-78
3.8 Subgrade (Jim Hyslip and Ding Quig Li) 3-80
3.8.1 Intro duc tion 3-80
3.8.2 Geotechnical Requirem ents 3-80
3.8.3 Subgrade Prob lems 3-82
3.8.4 Subgrade Treat ments 3-86
3.8.5 Soil Improve ment 3-86
3.8.6 Geosynthetics 3-87
3.8.7 Hot Mix Asphalt (HMA) 3-88
3.9 Track Tran sit ions (Dave Davis) 3-90
3.9.1 Intro duc tion 3-90
3.9.2 Sig nif i cant Changes at Tran si tion 3-90
3.9.3 Attempts to Match Prop er ties 3-92
3.9.4 Best Pract ice 3-93
3.10 Track for Elec trif ied Lines (Sergie Zahkarov
and Anatoly Naumov) 3-95
3.10.1 Spe cific Fea tures of Track for Elec trif ied Lines 3-95
3.10.2 Crit e ria of Return Trac tion Rail Net Design for
Heavy Haul Opera tion 3-97
3.10.3 Requirem ents for the Rail Assemb ly and
Insu lated Joints 3-100
3.10.4 Strat egy for Com pat ib ili ty of Return Trac tion
Net with Railw ay Auto mat ics, Telemechanics and
Com mu ni ca tions 3-101
3.10.5 Mea sures to Strengthen the Return Trac tion
Rail Net when Opera t ing Heavy Trains 3-102
3.10.6 Other Con side r ations of Elec trif ied Rail Lines 3-103
A vi B
Contents
Chap ter 4: Track Inspect ion 4-1
4.1 Introd uct ion (Rob ert W. Blank) 4-1
4.2 Overv iew of Track Inspec tion in a Heavy Haul
Envir on ment (David W. Ferryman) 4-2
4.2.1 Types of Inspec tion 4-2
4.2.2 Data Mana gem ent and Analy s is 4-4
4.3. Track Integ rity Inspect ion 4-5
4.3.1 Rail Defect Detect ion and Tech nolo gies (Carlo M.
Patr ick, R. Mark Havira, Greg ory A. Gar cia) 4-5
4.3.2 Prac tic al Use of Gage Restraint Meas urem ent
Syst ems (GRMS) and Data (Rob ert N. Madderom,
Har old T. Ruggles) 4-16
4.3.3 Rail Stress Meas urem ent Techn olo g ies
(David M. Read) 4-21
4.4 Track Geom e try and New Tech nolo gies 4-27
4.4.1 Track Geom e try Inspect ion Syst ems
(Kevin J. Kesler) 4-27
4.4.2 Perf orm ance-Based Track Geome t ry Meas urem ents
(Dingqing Li) 4-34
4.5 Track Comp on ent/Subs truct ure Cond it ion Inspect ion 4-38
4.5.1 Rail Joint Inspect ion (Gary A. Carr) 4-38
4.5.2 Track Sub struct ure Inspect ion (Dingqing Li) 4-40
4.6 Coeff ic ient of Frict ion Meas urem ent
(Haro ld D. Harr is on) 4-41
4.6.1 Hand Meas urem ents 4-42
4.6.2 Mobile (High Speed) Mea surem ents 4-43
4.6.3 Data Sum ma ries and Form ats 4-45
4.6.4 Future Develo p ments 4-46
4.7 Intell ig ent Infra struct ure (David D. Davis) 4-48
4.7.1 Introd uct ion and Techn olo gy Needs 4-48
4.7.2. Spe cial Trackwork/Switch Point Wear 4-48
4.7.3 Rock Fall and Geotechnical Haz ards 4-51
4.8 Cleara nce Meas urem ents (Dwight W. Clark) 4-53
4.8.1 HH Cleara nce Cons ide ra tions 4-53
4.8.2 Hori z ont al and Vert ic al Cleara nces 4-55
4.8.3 Track Cen ters 4-54
4.8.4 Meas uri ng Cleara nces 4-54
4.8.5 Cleara nce Pro cess 4-55
4.8.6 Gene ral Dimens ion and Weight Lim it a tions 4-55
4.8.7 Main tain ing Min i mum Clear ances 4-56
A vii B
Contents
Chap ter 5: Upgrad ing Track for Heavy Haul Serv ice 5-1
5.1 Introd uct ion (Don Holfeld) 5-1
5.2 Eval ua t ing the Pro jected Serv ice (Heavy) Load Den sity
(David Connell) 5-1
5.3 Reinf orc ing the Track Struc ture (David Connell) 5-2
5.4 Track Com po nents (David Connell) 5-2
5.4.1 Ties 5-2
5.4.2 Rail 5-3
5.4.3 Rail Joints 5-4
5.4.4 Fast ene rs 5-5
5.4.5 Tie Pads 5-6
5.5 Long it ud in al restraint (David Connell) 5-6
5.5.1 Spec ial Trackwork Cons ide ra tions 5-6
5.6 Struc tures (David Connell) 5-8
5.6.1 Cond it ion Assessm ent 5-8
5.6.2 Tran si tion Issues 5-9
5.6.3 Replace ment 5-10
5.7 Track Design and Cons truct ion (Rob ert J. Boileau) 5-10
5.7.1 Introd uct ion 5-10
5.7.2 Review of Track Design Param e ters 5-11
5.7.3 Plan ning 5-14
5.7.4 Civil Con struc tion 5-16
5.7.6 Track Con struct ion Metho ds 5-19
5.7.7 Turn out Con struc tion 5-20
Chap ter 6: Track Main te nance 6-1
6.1 Intro duc tion (Don Bagley) 6-1
6.2 Draina ge Heavy Haul Track Struc tures (Darrell
D. Cantrell and Dex McCulloch) 6-2
6.2.1 Introd uct ion 6-2
6.2.2 Ditch and Shoul der Maint e nance 6-2
6.2.3 Reco mm ended Corr ect ion of Infer ior Draina ge
out side the Track Sec tion 6-4
6.2.4 Sur face Draina ge 6-5
6.2.5 Drain age of Bal last and Subballast 6-6
6.2.6 Fouled Ball ast 6-7
6.2.7 Bal last Main te nance Activ i ties to Increase
Bal last Drain age 6-8
6.2.8 Sub struc ture Drain age 6-9
6.2.9 Track Subsurface Draina ge 6-10
A viii B
Contents
6.2.10 Non-Track Groundw at er Interc ept ion
and Draina ge 6-11
6.2.11 Trench Drains 6-12
6.2.12 Advan tages of Trench Drains 6-13
6.2.13 Trench Drain Install at ion 6-14
6.2.14 Sum mary 6-18
6.3 Rail Grindi ng (Peter S. Sroba) 6-18
6.3.1 Introd uct ion 6-18
6.3.2 Rea sons for Rail Grindi ng 6-19
6.3.3 Rail Grind ing Def i ni tions 6-19
6.3.4 Rail Grindi ng The ory 6-20
6.3.5 What is Best Prac tice Rail Grindi ng? 6-22
6.3.6 Fac tors that Influe nce Prev en tive Rail Grindi ng 6-26
6.3.7 Pre ven tive Grindi ng Metal Removal Rates 6-29
6.3.8 Grindi ng Cycles for Pre ven tive Grindi ng 6-31
6.3.9 Rail Grindi ng Sur face Fini sh 6-32
6.3.10 Grind ing of Turn outs 6-32
6.3.11 Plan ning and Qual ity Cont rol of Rail Grind ing 6-34
6.3.12 Case Studi es 6-37
6.4 Rail Lubric at ion and Frict ion Modi f ic at ion
(Michael Roney) 6-42
6.4.1 Fric tion as a Pro tec tion for Wear 6-43
6.4.2 The Effect of Fric tion on Lat eral Forces 6-44
6.4.3 Tar get Fric tion Lev els 6-45
6.4.4 Rail Gauge Face Lubric a tion Applic a tion Metho ds 6-46
6.4.5 Char ac ter ist ics of Rail Gauge Face Lubri cants 6-48
6.4.6 Best Pract ices for Gauge Face Lubri ca tion 6-48
6.4.7 Top of Rail Frict ion Cont rol 6-53
6.4.8 100% Effec tive Fric tion Cont rol 6-57
6.5 Destressing/Restress ing for Improved CWR Neu tral
Temp era t ure Mana gem ent (Andrew Kish) 6-58
6.5.1 Introd uct ion 6-58
6.5.2 Fund a ment als of Rail Break Mechani cs 6-61
6.5.3 New Meth od ol ogy for RNT Read justm ent 6-64
6.5.4 Guidel ines For Pract ic al Applic at ions 6-69
6.5.5 “Smart Techn olo gy” Applic at ions to
RNT Man age ment 6-72
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Contents
6.6 Ball ast Main te nance (Rainer Wenty) 6-73
6.6.1 Intro duc tion 6-73
6.6.2 Bal last Clean ing 6-76
6.6.3 Shoul der Ball ast Cleani ng 6-85
6.6.4 Spec ial ball ast maint en ance metho ds 6-87
6.6.5 Best Pract ice Examp les of Heavy Haul Railw ays 6-88
6.6.6 Track Surf aci ng, Lini ng, and Stab il iz at ion 6-89
6.6.7 Conc lus ion 6-107
6.7 Maint en ance Mana gem ent Analy s is Tools
(Allan Zarembski) 6-107
6.7.1 Introd uct ion to Maint en ance Mana gem ent
Anal y sis Tools 6-107
6.7.2 Rail Life Fore casti ng and Maint e nance Plann ing 6-110
6.7.3 Tie (Sleeper) Life Fore casti ng and Maint e nance
Plan ning 6-112
6.7.4 Surf aci ng Forec asti ng and Maint en ance Plann ing 6-114
6.7.5 Risk Mana ge ment Mode ls 6-115
6.7.6 Pro duc tion Mon i tor ing Tools 6-116
Chap ter 7: Over view of Bridges and Struct ures for Heavy Haul
Opera t ions 7-1
7.1 Types of Rail way Bridges 7-2
7.1.1 Bridge Lay out and Conf ig ur a tion (W.G. Byers) 7-2
7.1.2 Mater ia ls of Bridge Cons truct ion (J.F. Unsworth) 7-4
7.1.3 Railw ay Bridge Decks (J.F. Unsworth) 7-5
7.1.4 Railw ay Bridge Supers truct ures (J.F. Unsworth) 7-7
7.1.5 Subs truct ures and Foun dat ions (W.G. Byers) 7-11
7.2 Assess ment of Railw ay Bridges for Heavy
Haul Opera t ions 7-15
7.2.1 Inspect ion of Rail way Bridges for HAL Oper a tion
(R.A.P. Sween ey) 7-15
7.2.2 Strength of Rail way Bridges (Rati ng) (W.G. Byers) 7-20
7.2.3 Fatigue Strength of Rail way Bridges
(R.A.P. Sween ey) 7-22
7.2.4 Eco nomi cs of Heavy Haul Oper a tion on Bridges
(D.E. Otter) 7-28
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