Network Rail reports cost savings resulting from trials of a new lubrication system

Network Rail has reported significant cost and time savings from a lubrication trial conducted at London Waterloo station

The trial involved the installation of innovative lubrication equipment on switch and crossing components in the approach area to the station.

The high traffic volume at the turnouts has led to increased rolling contact fatigue and a higher turnover of switch and crossing components, resulting in elevated maintenance and renewal costs. In early 2022, Network Rail discovered that the existing automated lubrication devices required extensive maintenance interventions, prompting them to seek a solution to reduce the maintenance burden, reported by Railway Supply magazine, citing LB Foster.

Rail friction management specialist LB Foster was approached to assess potential solutions, and they proposed a trial of a novel hydraulic lubricator with a vertical lubricant reservoir that could be installed trackside in the limited space of the Waterloo track layout.

For the trial, LB Foster adapted its PW Series hydraulic lubricator to distribute grease to the rail in the confined and heavily loaded location. The lubricator, available in capacities of 12.5 kg and 37.5 kg, was partially buried trackside during the initial test period to allow trains to pass without obstruction. As the train wheels passed over the lubricator, a plunger was activated, pushing grease onto the applicator bars on the rail. The train wheels picked up the grease, which was spread over a pre-defined distance on the railhead.

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A set of points covering platforms 1, 2, 3, and 4 was selected for the trial, resulting in the removal of both automatic lubrication systems from set of points 1564B, with satisfactory grease application rates recorded.

An analysis of track defect rates during the trial period demonstrated the effectiveness of the lubrication method. The lubricant, combined with a proactive switch and crossing grinding program to extend the lifespan of the trackwork, contributed to a reduction in P8 and 053 defects.

Based on the trial’s success, Network Rail estimated a cost saving of £18,546.48 over five years by installing a single 12.5 kg capacity PW lubricator on two sets of switch and crossing units, compared to the equivalent installation of three legacy automatic lubrication systems.

Network Rail now plans to install another PW Series unit on another set of points in the Waterloo area, with the intention of removing additional automatic lubrication systems.

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Neil Cassidy, NR Project Manager, expressed confidence in the long-term cost savings, noting that the installation of eight LB Foster units on a 42-day frequency, compared to the 24 automatic lubrication systems on a 28-day replacement frequency, would provide an exceptional return on investment while reducing the need for trackside maintenance.

Jonathan Paragreen, General Manager at LB Foster Friction Management, explained that the defects in switches and crossings primarily resulted from track curvature on the entry/exit to the platforms, leading to increased lateral forces on the rail. The collaboration between Network Rail and LB Foster aimed to reduce the maintenance teams’ trackside work and extend the lifespan of the switches and crossings, yielding outstanding results in terms of cost savings and improved operative safety through reduced time spent trackside.

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