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Biodegradable Lubricants for Railway Applications

Biodegradable Lubricants for Railway Applications. Content: Wheel Flange Lubrication. 1 Introduction 2 Wheel/Rail contact 3 Requirements 4 Solutions. 5 Application 6 Results 7 Future Aspects 8 Summary. Lubricant consumption. World‘s lubricant consumption: 37.000.000 tons

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Biodegradable Lubricants for Railway Applications

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  1. Biodegradable Lubricants for Railway Applications 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  2. 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  3. Content: Wheel Flange Lubrication 1 Introduction 2 Wheel/Rail contact 3 Requirements 4 Solutions 5 Application 6 Results 7 Future Aspects 8 Summary 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  4. Lubricant consumption World‘s lubricant consumption: 37.000.000 tons Consumption in Germany: 1.200.000 tons Total loss lubricants: 40.000 tons Railway Systems: 3.000 tons • Total loss lubricants: • Concrete release agents • Two-stroke engine oils • Chain saw oils • Chain- and Wire rope lubricants • ... • Switch lubricants • Wheel flange lubricants • Rail lubricants 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  5. Wheel / Rail contact • Wheel/Rail contact area fulfills several demands: • transmission of traction and braking forces between rail head and wheel surface • absorption of steering forces between wheel flange and rail flange • transmission of electric signals 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  6. Wear area Loss of Material when reprofiling Lubricated Not Lubricated Wheel / Rail contact Influence of Lubrication on Wheel flange wear 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  7. Wear Effects on Rails and Wheel Flanges 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  8. Wear Effects on Rails 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  9. Requirements Generally: • Environmentally harmless • Low water pollution • High biodegradability • No toxic components • Should be solvent-free • etc. • These requirements are not yet homogeneously regulated. Regarding biodegradability, the test method according to CEC L-33-A-93 standard is commonly used. Additionally different OECD-guidelines are used. 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  10. Requirements • Wheel flange lubrication: • primary: • Reduction of friction between wheel and rail flange to reduce the risk of derailment and to minimise rolling noises generated in these contact zones. • Reduction of wear of wheel and rail to minimise maintenance work and life cycle costs and to increase the availability of the rolling stock. • secondary: • High adhesion (gets more and more important for high speed trains) • Lubricity and sprayability should be independent from temperature • Independence from the lubricating system used • Good resistance against ageing • Long storage time 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  11. Solution • Basics of lubricant formulation: • In these applications normally soft free-flowing greases are used, which can contain special solid lubricants. • It is important, that all single components are checked with regard to their environmental potential, even though the base oil is by far the biggest portion of the lubricant. • Base oils: • Regarding biodegradability we can choose • from the following fluids: • Native esters • Synthetic esters • Low-viscous Polyglycols • Low-viscous synthetic hydrocarbons 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  12. Solution • Beside the biodegradability the following properties have to be considered with the base oils: • Lubricity • Flow behaviour at low temperatures • Thermal resistance • Solubility / Miscibility of additives • Compatibility with materials • Following the thickeners, which can be used in biodegradable lubricants: • Lithium soap • Calcium soap • Li-/Ca-Mix soap • Inorganic thickeners, e.g. Bentonite 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  13. Boundary Frict. Solution Additives and Solid lubricants: EP additives play an important role, because wheel flange lubrication, as well as switch lubrication is working under boundary or extreme mixed friction conditions. Static friction Boundary friction Mixed friction Fluid friction(hydrodynamic friction) Coefficient of friction µ Mixed Friction Hydrodyn. Frict. Speed (n) 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  14. Solution Additives and Solid lubricants: Selection of additives must be done also with regard to the strong requirements of environmental aspects and must fulfil all the tribological demands as well. Long-term experience in practical applications has shown, that special solid lubricants can be extremely helpful in these applications. Mostly special graphite types as well as combinations of the so-called white solid lubricants are used. 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  15. Solution Synergetic combination of the mentioned components to ready formulations: *AC = Anti-corrosion, AW = Anti-wear, AO = Anti-oxydant, EP = Extreme Pressure **FSS = solid lubricants 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  16. Application • to make sure that you have the right quantity of lubricant right in time at the right place • Application to the wheel flange with On-Board-Systems • Application to the rail flanks with Track-Side-Systems 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  17. Application • with automatic lubricators, which spray extremely small quantities of lubricant onto the wheel flanges • normally only the first wheel set is lubricated, all the following axles are lubricated indirectly 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  18. Rail and Wheel Flange Lubrication Systems On-Board-Systems Airless Air-operated sep. compressor On-board comp. Vogel SP 8 Vogel SP 9 DeLimon RE DeLimon Railjet ÖBB Sepuls Secheron Woerner Beka Fluilub Rebs Saxonia SSL-3 Rebs Beka Fluilub Mannesmann Rexroth Vogel-Brush Rebs 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  19. Controlling of Lubricating Systems On-Board-Systems • path-controlled • time-controlled • curve-controlled • GPS-controlled • combined Track-Side-Systems • mechanically • time-controlled • vibration-controlled • noise-controlled 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  20. Application Wheel flange lubrication, example: Type Vogel SP 9 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  21. Application Wheel flange lubrication, example: Type DeLimon RE 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  22. Wheel flange lubricating systems, nozzles mainly used nozzles at DB AG 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  23. Wheel Flange Lubrication, Fitting Position of Spray Nozzles Best position: L with brake shoe: L2 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  24. Application Wheel flange lubrication, calculation example: Width of the spray jet on the wheel flange: 20 mm Wheel diameter: 900 mm Lubricant quantity per spray cycle: 30 mg Thickness of lube film on the first wheel set: ca. 0,5 µm Spray pattern from test rig trial 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  25. Application Wheel flange lubrication, calculation example: Lubricant quantity per cycle: 30 mg Travelling distance per cycle: 500 m Total distance: 1000 km Lubricant consumption at each side: 60 g Spray pattern from test rig trial 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  26. Wear Effects on Rails 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  27. Results: Field test Result: Remarkably lower wear rates with the biodegradable lubricant 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  28. Results: Field test 1991: Changing over from a conventional, mineral oil based grease to a high performance, biodegradable lubricant. Causes for Wheel Flange Wear on Locomotive Wheels (source: Austrian Railway) Flange wear Flange/surface wear Surface wear Flat surfaces Others Cracks 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  29. Rail and Wheel Flange Lubrication Until 1991: conventional lubricant based on mineral oil Since 1993: TRAMLUB F 234 MOD 1 Wear Rate on Wheel Flanges (source: Austrian Railway) 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  30. Summary • Biodegradable lubricants for wheel flange lubrication • have overrun their conventional ancestors and completely removed in many applications • perform much better and at the same time help our environment by: • Reduction of driving power (up to 15%) • Reduction of wear, noise and friction • Increase of the maintenance intervals • Reduction of maintenance works • Reduction of lubricant consumption • Reduction of the risk of derailment • Increase of Reliability, Availability, Maintainability, Safety (RAMS) • Decrease of Life Cycle Costs (LCC) • ... 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  31. Rail and Wheel Flange Lubrication Systems Track-Side-Systems Hi-Rail Portec PL SRS Clicomatic Schreck-Mieves/Moklansa Schörling Portec etc. Portec PL on duty 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  32. Rail flank lubrication Portec lubricator 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  33. Rail flank lubrication Delimon track-side lubricator 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  34. Rail flank lubrication Schreck-Mieves track-side lubricator Delimon track-side lubricator 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  35. Hi-rail systems Schoerling 2-way vehicle for cleaning and lubricating of rails and switches 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  36. 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

  37. Thank you very much for your kind attention. www.fuchs-lubritech.de 06.06.2014 / HW / Biodegradable Lubricants for Railway Systems

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