IÉ Safety Approval of FFU material

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Allison Atkins
5 years ago
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1 Process followed IM-SMS-014 Safety Approval of Changes in Plant, Equipment, Infrastructure and Operations (PEIO). New PEIO shall be subject to: robust process of risk assessment and safety approval prior to implementing new systems or changes to existing systems.

2 Process 3b of IM-SMS-014 applies to Non-Significant Changes affecting only one department. The rationale for applying process 3b is that it is not a change which is significant in nature for the following reasons: The change is a simple material change. Timber waybeams exchanged for FFU as part of routine maintenance. No change to track fastening arrangements. Existing baseplates are re-used. The only department affected by the change is the CCE Department. The changes will have no impact on Train Operator and rail services. There are no signalling track circuits at UBE16.

4 Documentation in Appendices Business Case document with appraisal of engineering options Sekisui FFU working guidelines Sekisui description of FFU product development and industry usage Report on fire classification in compliance with DIN EN :2010 DEKRA Rail (Netherlands) Certification report of Sekisui FFU sleepers FFU test report 2466 Technical University Munich 2008 FFU test report 3017 (slim ties) Technical University Munich 2013 Certificate of compliance for FFU with EU rail system interoperability TSI 1299/2014 and 1303/2014 for tunnel safety Network Rail (UK) certificate of acceptance of FFU Railcert (Netherlands) certificate of acceptance of FFU

5 FFU can be machined or worked using the same methods and tools as for timber sleepers Hazards identified - Safety precautions required for working with the FFU material: To protect from dust and fine particles, staff drilling or cutting FFU material must wear protective clothing (overalls, gloves, breathing masks, safety goggles, etc.). Clothing is disposed of after each shift. All other persons must be a safe distance away or wear protective gear. To prevent glass fibres in the FFU material from melting and tools becoming stuck, the RPM speed of drilling equipment must be reduced.

6 Training Event - special requirements for working with the FFU synthetic material - sample sleeper was sourced and a training & familiarisation exercise took place in Mullingar on 27 January Using electric saw

7 Using chisel and hammer Using electric sander

8 Using chainsaw Using chisel and hammer

9 Representatives from the IÉ CCE Dept. visited a Network Rail installation in the UK over the weekend of 25/26 March 2017 Site near Ashford, Kent.

10 FFU sleepers are drilled for fixing to longitudinal FFU waybeam. Note industrial vacuum cleaner used to remove debris/dust.

11 Baseplates fitted and ready to receive rails.

12 Network Rail worksite near Ashford, Kent. Adjacent track was fitted with FFU in Note shims under baseplate and anti-slip surface to FFU sleeper.

13 FFU installation at UBE16 Long Welded Rail removed Short jointed rails to be fitted Rail length to suit waybeams

14 FFU installation at UBE16 Bridge Gang made hanging work platform

15 FFU installation at UBE16 The FFU took 6 weeks shipping time from Japan. Installation started on 19 Sept Completed on 15 Dec 2017 (13 weeks).

16 FFU installation at UBE16 In-house IÉ Bridge Gang and IÉ Permanent Way staff supplemented by contract plant operators. Working in nightly possessions: Tuesday Friday/Saturday 22:00 to 05:30 46 No. FFU Waybeams installed

17 FFU installation at UBE16 Video clip

Using industrial vacuum cleaner to remove

18 FFU installation at UBE16 Inserting foam strips to prevent debris from dropping into watercourse below. Using industrial vacuum cleaner to remove debris/dust while drilling. Drill bits become blunt more quickly.

19 FFU installation at UBE16

20 FFU installation at UBE16 Thank-you for Listening

- 4 - Fig. 3b. Fig. 1b. Fig. 2. Fig. 2b MT 300

- 4 - Fig. 3b. Fig. 1b. Fig. 2. Fig. 2b MT 300 MP 00 Manual 1 7 6 9 8 5 1 1 10 11 1 Fig. 1a Fig. 1b MT 00 Breite Buche Erle Pappel Balsa 0 0,5 0,8 0,8 0,8 max. Zustellung mm 0 0, 0,6 0,8 0,8 60 0, 0, 0, 0,8 80 0,1 0,1 0, 0,6 n Messerwelle = 6.000/min