shaping the future of rail iv
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Shaping the Future of RAIL IV. “RAIL” Project R eliability centred maintenance (RCM) A pproach for I nfrastructure and L ogistics of railway operation. A project supported by the European Commission under the Framework 5 Programme “Growth”. - PowerPoint PPT PresentationTRANSCRIPT
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Shaping the Future of RAIL IV
“RAIL” Project
Reliability centred maintenance (RCM)
Approach for Infrastructure and Logistics of railway operation
A project supported by the European Commission under the Framework 5 Programme “Growth”
Dr. Norberto Cotaina, a specialist in European projects at ADEPAspeaking on behalf ofRAIL consortium members
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The RAIL Consortium
Baas&Roost (Netherlands R&D)
NSNEDERLANDSE SPOORWEGEN
(Netherlands Railways)
UPMUNIVERSIDAD POLITECNICA DE MADRID (Spanish R&D) RENFE
RED NACIONAL DE LOSFERROCARRILES ESPANOLES
(Spanish Railways)
DB DEUTSCHE BAHN NETZ AG
(German Railways)
FIRFORSCHUNGS INSITUT
RATIONALISIERUNG(German R&D)
IEIARNROD EIREANN
(Irish Railways)
EIENTERPRISE IRELAND
(Irish R&D)
ADEPA Agence pour le DEveloppement
de la Productique Appliquée (Co-ordinator & R&D )
The partners :
R&D performers Railway companies
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The RAIL Objective
The application of the RCM to total railway infrastructure gives the project a total innovative approach to respect the safety and to structured technique dealing up with maintenance strategies based on awareness of the nature and causes of malfunctions. The RCM analysis will be developed, implemented and evaluated on :
• all various types of track circuitry• axle counters• point machines• the whole signalling equipment • interlocking devices such as: position of points, signals to clear etc.
The set of the above mentioned equipment is called in this proposal Safety Critical Railway Infrastructure components (SCRI components).
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DATASHEETS COMPONENT
LISTS (SCRIC)
RCM METHODOLOGY
GUDES
RAILWAYINFRASTRUCTURE
VALIDATION
STUDIES
MaintenanceProgrammes
EXPLOITATION
EuropeanRailways
InfrastructureComponent
ManufacturersRailway
InspectingOfficers
LCC
database
...
The RAIL Project Approach
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VRCM and
RAIL approach
Reliability centred maintenance (RCM) Approach for
Infrastructure and Logistics of railway operation
The RAIL approach is based on the :
The Standard prEN 50126 : Specifications and demonstration of reliability,
availability, maintainability and safety (RAMS)
The RCM international standard: CEI 60 300-3-11
The MSG3 Airline /Manufacturer, September 1993 MAINTENANCE
PROGRAM DEVELOPMENT DOCUMENT
standards regarding LCC :
CEI IEC 360-3-3
NORSOK
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VThe RCM The RCM international standard: international standard: CEI 60 300-3-11CEI 60 300-3-11
Tasks OutputsInformation collection Technical data feedback
Identification of systems
Identification of system functions
Selection of systems
Identification of a system functional failures and its
criticality ranking
Identification and analysis of functional significant items
(FSIs)
Selection of maintenance tasks
Initial maintenance programme
On-going programme
Operational experience
Master system index
List of system functions
Listing of ranked systems
Listingof system functional failures and ranking
Listing of FSIs
List of maintenance tasks
Initial maintenance procedures
Tasks in the development of RCM based preventive maintenance programme
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The RAIL approach
Sequential approach :
Net Beakdown
Lines-Corridors
Sections
Components (SCRIC)(Safety Critical Railway Infrastructure Component)
… Subassemblies
Maintenance Items(like in standard FSI :Functional Significant Items)
Criticality analysis
Criticality & State analysis
Criticality analysis
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RAIL approach using a Cost Model
the Life Cycle costs analysis and the related model were developed
Life Cycle Costs
INVESTMENTCOSTS
Maintenance andOperating Cost
Delay Cost Hazard Cost
Equipment andMaterial PurchaseCost
Engineering Cost
Installation Cost
Initial Spares Cost
Initial Training Cost
...
Corrective Main-tenance Cost
Calendar based PMCost
Condition based PMCost
Operating Cost
Energy ConsumptionCost
...
Short TermDelay Cost
Long TermDelay Cost
...
Human SafetyCost
EnvironmentalThreat Cost
Cleaning Cost
RebuildingCost
...
OPERATINGCOSTS
DISPOSALCOSTS
Disposal Cost
ReinvestmentCost
...
before operation during operation after operation
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VAnalysis of the section
in a Line - Corridor of the Net
Section ComponentAnalysis
Form 1 Information about thesections and criticality grid
Sections List & classification
Form 2
Component Information & Criticality grid
SCRIC List & classificationState grid
SCRIC functional decomposition Form 3
Template of SCRIC andMaintenance Item information
Breakdown decomposition of SCRIC
FMECA SCRICanalysis Form 4
SCRIC failure modes & causes evaluated and classified
Determinationof maintenance task Form 5
RAIL criticality gridto evaluate the failures effects
Maintenance task List and cost analysis
Logical decision treeto maintenance task
Grouping and analysis of Maintenance Tasks Form6
Maintenance Task List modified
Feed Back Experience
Maintenance LCCevaluated by task
FM
EC
A
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Pro
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RAIL Sequential approach
New comparison with RCM Standard
Very Similar to RCM Standard
Maintenance LCCevaluated by Working zone
New compare with RCM Standard
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Form ExamplesRCM
RAIL
Evaluation
COUNTRY LineSection
indentificationSection name
Starting year
S E A Q M CR Class Sum
Spain Commuters 114-15 Chamartín-Pinar ????? 3 4 1 1 2 24 A 11
Spain C type 23-24 Zafra-Huelva ????? 2 3 4 4 4 384 C 17
Spain Commuters 114-17 C5 ????? 4 4 1 1 1 16 A 11
Spain A1 type Madrid-Valencia ????? 3 3 2 3 3 162 B 14
Spain High Speed Madrid-Sevilla ????? 4 4 1 1 1 16 A 11
Spain C type Tarragona-Salou ????? 3 3 2 3 3 162 B 14
x
x
RemarksClassification
Section stateSection designation
Date :Project :
Reliability Centred Maintenance Section state FORM 1 Line :
Railway comp :19/09/2000
RCM FORM 2
Section : RAILDate :
Evaluation Classification Evaluation
Working zoneSCRIC/
Component type
SCRIC/ Component
name
SCRIC/ Component
number
Under reglemen-
tation
Starting year
S Q E A M CR1 Class1 Sum1 S Q R E M CR2 Class2 Sum2Card N°
Chamartin Track circuit50 Hz Adtrans 2.1 YES 1 1 1 1 1 1 V 5 1 1 1 3 1 3 B 7
0 x 0 0 x 0
0 x 0 0 x 0
SCRIC/Component classificationReliability Centred Maintenance Line :
SCRIC/Component designation Restoration worksClassification
Criticality State of the SCRIC
Railway comp :Project :
19/09/2000
RCM Reliability Centred Maintenance
Section :Date : 19/09/2000
System Function
Component FSCRIC/Component function and draft
Component type SUB Subsystem
Track circuit 50 Hz Adtrans 2.1 Train detection Low frequency 50Hz 2.1.1 Power supply
2.1.2 Sender
2.1.3 Track-sender adaptator
2.1.4 Inductive joints
2.1.5 Isolating joints
2.1.6 Track conections
2.1.7 Receiver adaptator
2.1.8 Receiver
2.1.9 Return Current Conections
2.1.10 Signaling conections
FORM 3 Line :List of Maintainable Items
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Form Examples
Reliability Centred MaintenanceLine : Working zone :
Section : SCRIC/Component :Date : 19/09/2000 Railway comp :
CS CA1 CA2 CC FM FC6 18 6 T 1 1 1 Fuse Specific procedure MIN-PE-IS-001 Depends on the line section
4 12 4 T 2 2 1 Transformer Specific procedure MIN-PE-IS-001 Depends on the line section
4 12 4 T 2 3 1 Resistor Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 4 1 Joints Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 4 1 Joints Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 5 1Wires and conectors Specific procedure MIN-PE-IS-001 Depends on the line section
4 12 4 T 2 6 1 Condensator Specific procedure MIN-PE-IS-001 Depends on the line section
4 12 4 T 2 7 1 Relay Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 8 1Wires and conectors Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 8 1Wires and conectors Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 9 1Wires of the
loop Specific procedure MIN-PE-IS-001 Depends on the line section
3 9 3 T 2 4 1 Joints Specific procedure MIN-PE-IS-001 Depends on the line section
RCM FORM 5
DetectionWay
Criticality Proposed TaskMaintainableItems Task intervals
RAIL Approach RCM Reliability Centred Maintenance
FORM 6 Corridor (Line) : Working zone :Section : SCRIC/Component :
Date : 16/01/01 Railway comp :
Staff category
Maintainable ItemsTask
intervalsPlanned power
supply stoppagesOn track
security planTask groupsPlanned
stoppages
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RAIL Planned activities for the next periods
•Continue the RCM analysis of the main machines in the four railways (about 30 Safety Critical Railway Infrastructure components)
•Develop a data-base :
create the RAIL Database.
develop a target to made RCM analysis.
•Discuss reliability problems with railway safety authorities.
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VRAIL final resultRAIL final result
RCM Internet tool: RCM Internet tool: Architecture
RAIL Da ta Ba se
RAIL RC MLig htTo o l
C lie nt
RAIL RC MLig htTo o l
Se rve r
M a int. Kno wle d g eSta te Pre d ic tio n
M o nito ringLC C
M a int. Kno wle d g eDa ta Ac q u isitio n
Sta te Pre d ic tio nM o nito ring
M a int. M g m nt.M a int. Pla n
LC C
Da ta Ac q u isitio nM o nito ring
Inte rne t
Expected end ofproject summer 2002
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Remarks and conclusions
At this state of the project concerning the RCM methodology we adapt the forms and the criteria to evaluate the criticalities of the failure causes. At this state we modify the RCM standards to introduce the specificities of Infrastructure and Logistics of railway operation.
The LCC aspects introduced must be tested to appreciate the feasibility and usefulness for the railways companies.
At this state we have not enough experience to validate the RCM approach proposed and the LCC models to be implemented in the data base. This work will be done in the next months.
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VTemplate : example
Level crossingObject type Component Function Failure mode Failure cause Component
Condition of the failure
Automatic half barriers Post To attach the safety installation
Position of positioner, bells, St Andrew 's cross or lights is not right Post inclined Post Collision
Post footing SubsidencePost bended Post CorrosionAttachment loosened Post footing Corrosion
No signal or pow er Defect cables Cables AgeingCables Work
Seal defect Junction box AgeingConnections corroded Junction box Corrosion
PositionerTo control the position of the barrier
Barrier closed too soon, too late or not in right position
Mechanical resistance positioner Positioner Corrosion
Positioner Wear / play
Bearing w orn / stuck Bearing barrierWear, insufficient lubrication
Bearing w orn / stuckBearing barrier cycle path
Wear, insufficient lubrication
Seal housing defect Housing AgeingSw itch cams moved Sw itch cams Post inclined
Sw itch camsSocket screw loosened
Defect microsw itches Microsw itch Ageing / fatigueMovement counter defect CounterWiring loosened / damaged Wiring AgeingCarbon brushes w orn Motor WearCollector w orn Motor Wear, sparking
Bearings motor w orn / stuck MotorWear, insufficient lubrication
Bearings gear w heels w orn / stuck Gear w heels
Wear, insufficient lubrication
Gear w heels w orn Gear w heelsWear, insufficient lubrication
Gear w heels moved Gear w heels Fastening loose
Defect break resistanceBrake resistance Ageing
Defect diode Diode AgeingDefect magnet MagnetDefect friction clutch Friction clutch Adjustment w anderedDefect motor relay Relay Fatigue, contaminationCounter w eight moved Counterw eight Fastening loose
Barrier doesn't close by pow er failure Resistance in positioner PositionerTo arrange a physical separation betw een road- and rail traff ic Insufficient separation of road- and rail traff ic Barrier or barrier tip broken Barrier Collision
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The end
Thank you for your attention
If you are willing to participate in the RAIL Industrial Interested Group Please fill a membership form
As a RAIL IIG member you will be informed of the progress and results of the project