Case Study
Long Rail Weld Depot
Project:
Serviceable Rail
Client: Network Rail
History: Network Rail had an existing long rail welding plant that flash butt welds new rails together, producing 216m lengths of rail for site installation on the national network. The plant, which covers a large area with two conveyor systems each approximately 450 meters long, operates semi-automatically with manual loading of the rails but fully automatic operation of the rail handling and welding systems.
To achieve cost savings, Network Rail aimed to modify the plant to reuse existing recovered rails from mainline service for lesser duties. This required the removed rail sections to be checked, straightened, and areas with damage or excess wear cut out, leaving only serviceable lengths. These sections were then welded together to form standard 216m lengths.
Solution
The project involved significant modifications to the existing handling and welding plant, including the integration of new equipment such as a straightening press and two multi-blade rail saws into the overall conveyor control system. Silchester Control Systems undertook the following tasks:
- Redesigned the complete control system to ensure that changes did not introduce new dangers or hazards to the existing operation.
- Ensured the new equipment was suitably designed from a safety/control perspective before integration.
- Redesigned the safety strategy to cover the separation of the second section of the in-feed conveyor system from the weld section.
- Improved the safety circuit design to increase reliability and functionality.
- Removed redundant sections from the safety system to prevent incorrect operation.
- Added new functionality to the existing plant’s operation to allow operators and maintenance staff to control dangers and hazards during transfer cart failures.
These changes were part of an overall project to extend the existing control system, improve operator visibility of plant operations, and enhance efficiency based on operational knowledge.
Results
The project was completed successfully, resulting in:
- Enhanced safety and reliability of the plant operations.
- Improved efficiency and operational flexibility.
- Better visibility and control for operators and maintenance staff.
- Successful integration of new equipment without introducing new hazards.
A full safety review was conducted with Network Rail safety staff to ensure all requirements were met and exceeded.
"Silchester's comprehensive redesign and integration of the control system were crucial in enhancing the safety, reliability, and efficiency of our rail welding plant operations."
- Client Representative
Silchester Control Systems
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