Shaping the Future of RAIL IV

Shaping the Future of RAIL IV “RAIL” Project Reliability centred maintenance (RCM) Approach for Infrastructure and Logistics of railway operation Shaping the Future of RAIL IV 25 & 26 / 01 / 2001 A project supported by the European Commission under the Framework 5 Programme “Growth” Dr. Norberto Cotaina, a specialist in European projects at ADEPA speaking on behalf of RAIL consortium members The RAIL Consortium The partners : R&D performers Baas&Roost Shaping the Future of RAIL IV Railway companies IE IARNROD EIREANN (Irish Railways) (Netherlands R&D) 25 & 26 / 01 / 2001 EI ENTERPRISE IRELAND (Irish R&D) NS NEDERLANDSE SPOORWEGEN (Netherlands Railways) ADEPA Agence pour le DEveloppement de la Productique Appliquée (Co-ordinator & R&D ) DB DEUTSCHE BAHN NETZ AG (German Railways) UPM UNIVERSIDAD POLITECNICA DE MADRID (Spanish R&D) RENFE RED NACIONAL DE LOS FERROCARRILES ESPANOLES (Spanish Railways) FIR FORSCHUNGS INSITUT RATIONALISIERUNG (German R&D) RCM and RAIL approach Reliability centred maintenance (RCM) Approach for Shaping the Future of RAIL IV 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) 25 & 26 / 01 / 2001  The The RCM international standard: CEI 60 300-3-11  The MSG3 Airline /Manufacturer, September 1993 MAINTENANCE PROGRAM DEVELOPMENT DOCUMENT The RCM international standard: CEI 60 300-3-11 Tasks Information collection Outputs Technical data feedback Identification of systems Identification of system functions Master system index List of system functions Listing of ranked systems Shaping the Future of RAIL IV Selection of systems 25 & 26 / 01 / 2001 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 Listing of 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 The RAIL approach Sequential approach : Net Beakdown Shaping the Future of RAIL IV Lines-Corridors 25 & 26 / 01 / 2001 Criticality analysis Criticality analysis Criticality & State analysis Sections Components (SCRIC) (Safety Critical Railway Infrastructure Component) … Subassemblies Maintenance Items (like in standard FSI :Functional Significant Items) RAIL approach using a Cost Model the Life Cycle costs analysis and the related model were developed before operation during operation after operation Shaping the Future of RAIL IV Life Cycle Costs 25 & 26 / 01 / 2001 INVESTMENT COSTS OPERATING COSTS DISPOSAL COSTS  Equipment and Material Purchase Cost  Engineering Cost  Installation Cost  Initial Spares Cost  Initial Training Cost  ... Maintenance and Operating Cost Delay Cost Hazard Cost  Disposal Cost  Reinvestment Cost  ...  Corrective Maintenance Cost  Calendar based PM Cost  Condition based PM Cost  Operating Cost  Energy Consumption Cost  ...  Short Term Delay Cost  Long Term Delay Cost  ...  Human Safety Cost  Environmental Threat Cost  Cleaning Cost  Rebuilding Cost  ... Approach to limit and classify the elements of the Net RAIL Sequential approach Analysis of the section in a Line - Corridor of the Net Form 1 Information about the sections and criticality grid Component Information & Criticality grid State grid Sections List & classification Section Component Analysis Form 2 New comparison with RCM Standard SCRIC List & classification Shaping the Future of RAIL IV SCRIC functional decomposition Form 3 Template of SCRIC and Maintenance Item information Breakdown decomposition of SCRIC 25 & 26 / 01 / 2001 FMECA FMECA SCRIC analysis Form 4 RAIL criticality grid to evaluate the failures effects Very Similar to RCM Standard SCRIC failure modes & causes evaluated and classified Maintenance Programme Determination of maintenance task Form 5 Logical decision tree to maintenance task Maintenance task List and cost analysis Maintenance LCC evaluated by task Grouping and analysis of Maintenance Tasks Form6 Maintenance LCC evaluated by Working zone New compare with RCM Standard Maintenance Task List modified Feed Back Experience Form Examples RCM FORM 1 Reliability Centred Maintenance Line : Project : RAIL Date : 19/09/2000 Railway comp : Section designation COUNTRY Spain Line Commuters C type Commuters A1 type High Speed C type Section Section name indentification 114-15 Chamartín-Pinar 23-24 114-17 Zafra-Huelva C5 Madrid-Valencia Madrid-Sevilla Tarragona-Salou Starting year ????? ????? ????? ????? ????? S 3 2 4 3 4 E A 4 3 4 3 4 1 4 1 2 1 Section state Section state Evaluation Q M 1 4 1 3 1 2 4 1 3 1 3 Classification CR 24 384 16 162 16 162 Class A C A B A B x x Criticality Evaluation S 1 Q 1 E 1 A 1 M 1 Classification CR1 1 0 0 Class1 Sum1 V x x 5 0 0 S 1 Remarks Sum 11 17 11 14 11 14 Shaping the Future of RAIL IV Spain Spain Spain Spain 25 & 26 / 01 / 2001 Spain RCM FORM 2 Reliability Centred Maintenance ????? 3 3 2 3 Line : Section : Date : 19/09/2000 SCRIC/Component classifica Project : RAIL Railway comp : State of the SCRIC Evaluation Q 1 R 1 E 3 M 1 CR2 3 0 0 Classification Class2 B x x Sum2 7 0 0 Card N° SCRIC/Component designation Working zone Chamartin SCRIC/ Component type SCRIC/ Component name SCRIC/ Under Starting Component reglemenyear number tation Restoration work Track circuit Hz Adtrans 50 2.1 YES RCM FORM 3 Reliability Centred Maintenance Line : Section : Date : 19/09/2000 List of Maintainable Items SUB Subsystem System Function Track circuit Component 50 Hz Adtrans F SCRIC/Component function and draft Component type Low frequency 50Hz 2.1 Train detection 2.1.1 Power supply 2.1.2 Sender 2.1.3 Track-sender adaptator 2.1.4 2.1.5 2.1.6 2.1.7 Inductive joints Isolating joints Track conections Receiver adaptator 2.1.8 Receiver 2.1.9 Return Current Conections 2.1.10 Signaling conections Form Examples RCM FORM 5 Reliability Centred Maintenance Line : Section : Date : 19/09/2000 Detection Way Maintainable Items Working zone : SCRIC/Component : Railway comp : Criticality CS CA1 CA2 CC FM FC 6 18 12 12 9 9 9 12 12 9 9 9 9 6 4 4 3 3 3 4 4 3 3 3 3 T T T T T T T T T T T T 1 2 2 2 2 2 2 2 2 2 2 2 1 2 3 4 4 5 6 7 8 8 9 4 4 4 3 3 3 4 4 3 3 3 3 Proposed Task Task intervals Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section Depends on the line section 1 1 1 1 1 1 1 1 1 1 1 1 Shaping the Future of RAIL IV Fuse Specific procedure MIN-PE-IS-001 Transformer Specific procedure MIN-PE-IS-001 Resistor Specific procedure MIN-PE-IS-001 Joints Specific procedure MIN-PE-IS-001 Joints Wires and Specific procedure MIN-PE-IS-001 conectors Specific procedure MIN-PE-IS-001 Condensator Specific procedure MIN-PE-IS-001 Relay Wires and Specific procedure MIN-PE-IS-001 conectors Wires and Specific procedure MIN-PE-IS-001 conectors Wires of the Specific procedure MIN-PE-IS-001 loop Specific procedure MIN-PE-IS-001 Joints Specific procedure MIN-PE-IS-001 25 & 26 / 01 / 2001 RAIL Approach RCM Reliability Centred Maintenance FORM 6 Corridor (Line) : Section : Date : 16/01/01 Working zone : SCRIC/Component : Railway comp : Maintainable Items Task groups Task intervals Planned stoppages Planned power supply stoppages On track security plan Staff category RAIL Planned activities for the next periods Shaping the Future of RAIL IV •Continue the RCM analysis of the main machines in the four railways (about 30 Safety Critical Railway Infrastructure components) 25 & 26 / 01 / 2001 •Develop a data-base : create the RAIL Database. develop a target of RCM analysis. •Discuss reliability problems with railway safety authorities. RAIL final result RCM Internet tool: Architecture Shaping the Future of RAIL IV Maint. Knowled ge S tate P redic tion Monitoring LCC Maint. Knowled ge Data Ac quisition 25 & 26 / 01 / 2001 R AIL R CM LightT ool Client Internet R AIL R CM LightT ool S erver R AIL Data Base Expected end of protect summer 2002 Data Ac quisition Monitoring Maint. Mgm nt. Maint. P lan LCC S tate P redic tion Monitoring Remarks and conclusions Shaping the Future of RAIL IV 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. 25 & 26 / 01 / 2001 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. The end Shaping the Future of RAIL IV Thank you for your attention 25 & 26 / 01 / 2001 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