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“RAIL” Project

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					                                                                     The RAIL project presentation

“RAIL” Project

Reliability centred maintenance (RCM) Approach for Infrastructure and Logistics of railway operation (RAIL)




A project supported by the European Commission under the Framework 5 Programme “Growth”

“Ensuring rail safety by improving the reliability of railway infrastructure”

EC Project Number:         2000-RD.10810

Project acronym:           RAIL

Project full title:        Reliability centred maintenance (RCM) Approach for the Infrastructure and
                           Logistics of railway operation



1.        Objectives of the RAIL project
A structured technique dealing up with maintenance strategies based on awareness of the nature and
causes of malfunctions is called Reliability Centred Maintenance (RCM). This technique was
developed for aircraft and nuclear industry maintenance. The underlying technique in the total
methodology is known as Failure Mode, Effects and Criticality Analysis (FMECA).
This concept identifies :
         why a failure can occur
         how it occurs and
         the consequences of the failure
The application of the RCM to total railway infrastructure gives the project a total innovative approach.
The RCM analysis will be developed, implemented and evaluated on :
        1. all various types of track circuitry
        2. axle counters
        3. point machines
        4. the whole signalling equipment
        5. 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).
This sector of chosen railway infrastructure gives the greatest potential for improving safety and train delays.
However the techniques to be developed can be applied to the other aspects of the railway infrastructure.
Trials and evaluations will take place in each participating railway ( RENFE, DB Netz AG, NS RIB, Irish Railways)




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Shaping The future Of Rail IV                              page 1               Paris, 25 + 26 January 2001
                                                                      The RAIL project presentation

2.       The consortium
The RAIL consortium consists of by two types of partners :
  1. R&D performer
        ADEPA – F
        Consultancy & Engineering service network in France specialised in Industrial Maintenance and RCM
        approach. Define the requirements for maintenance policies in signal railway. Start and transfer the RCM
        approach to analysis of the machines in signal railway in Spain. Participate in the validation of an integrated
        RCM approach
        FIR - D
        Research organisation specialised on operations management (e.g. maintenance management). Define
        the requirements for maintenance policies in signal railway. Start and transfer the RCM approach to
        analysis of the machines in signal railway in the Germany. Participate in the validation of an integrated
        RCM approach
        EI - IRL
        Consultancy & Engineering service network in Ireland specialised in Industrial Maintenance and RCM
        approach. Define the requirements for maintenance policies in signal railway. Start and transfer the RCM
        approach to analysis of the machines in signal railway in Ireland. Participate in the validation of an
        integrated RCM approach
        UPM - E
        Research organisation specialised in industrial engineering. Develop the database (first version) to support
        the results of the RCM analysis
        BAAS & ROOST (subcontractor of NS RIB) - NL
        Consultancy & Engineering service network in Netherlands. Define the requirements for maintenance
        policies in signal railway. Start and transfer the RCM approach to analysis of the machines in signal railway
        in the Netherlands. Participate in the validation of an integrated RCM approach
 2. Railway companies
      DB Netz AG – D - National Railway in Germany
      Specify Railways requirements concerning the maintenance of equipment in railways signal. Participate in
      the definition of the common approach and the performance regime for the railway infrastructure. Develop
      the maintenance plans for this equipment. Implement, test and validate the results of RAIL project
      IE – IRL - National Railway in Ireland
      Specify Railways requirements concerning the maintenance of equipment in railways signal. Participate in
      the definition of the common approach and the performance regime for the railway infrastructure. Develop
      the maintenance plans for this equipment. Implement, test and validate the results of RAIL project
      NS RIB – NL - Railway in Netherlands
      Specify Railways requirements concerning the maintenance of equipment in railways signal. Participate in
      the definition of the common approach and the performance regime for the railway infrastructure. Develop
      the maintenance plans for this equipment. Implement, test and validate the results of RAIL project
      RENFE – E - Railway in Spain
Specify Railways requirements concerning the maintenance of equipment in railways signal. Participate in the
definition of the common approach and the performance regime for the railway infrastructure. Develop the
maintenance plans for this equipment. Implement, test and validate the results of RAIL project.

3.       Summary of the current developments
The RAIL project has started on April 4, 2000. The objectives of this first period are the following
        Analyse the state of the art in RCM approaches and the current state of the maintenance levels
           (strategies, statistical data on failures,...) in the four countries participating in the RAIL project.
        Develop the methodology of benchmarking railway infrastructure maintenance
        Define the procedures of information gathering necessary for RCM analysis
        Form an interested group, in order to guarantee effective dissemination and exploitation of the results


The work done in concerned by this first period is the following :

2.1 Total liaison with project interest groups

The objectives of this Work are :
        To ensure that the views of an interested group as wide as possible are taken into account in the
           development of the maintenance systems.
        To ensure an implementation of the results as wide as possible.
        To guarantee effective dissemination and exploitation of the results




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Shaping The future Of Rail IV                               page 2                   Paris, 25 + 26 January 2001
                                                                The RAIL project presentation

2.2 Determination of the state of the art in safety, regulations, risk analysis and statistical choice of the
tools and methods to use

The objectives of Work are the following :

       Update the state of the art of RCM methods used in the other industrial sectors
       Update the international state of research and implementation activities in the maintenance of railway
          infrastructures (European projects, best practise from USA and Japan, literature, etc.)
       Analysis of existing methods for measuring maintenance costs
       Analysis of existing approaches and methods in safety and regulation in 4 European railway companies.
       Update different historical data about safety and reliability
       Synthesis of the state of the art
       Identify the various types of machines operated in the signal railways sector
       Synthesis of the state of the art in SCRI equipment and their dependability level
      
The approach in this Work is the study on the state of the art in RCM methodology and its applications,
the definition of questionnaires and then on site audits in order to validate and fill in these
questionnaires. The different questionnaires which were established in this Work are :

       Study of existing methods to classify and assess the current condition of technical equipment
          in SCRI
       Historical Data in Safety and Reliability



2.3 Development of a methodology to study the priorities and the Life Cycle Cost reduction methodology

The objectives of this Work are the identification of needs and requirements concerning safety,
reliability and maintainability of the infrastructure and the best approach to study the priorities. Taking
into account the Life Cycle Cost and safety point of view should help reach these objectives. Defining
of the objectives to be reached by a strong (safe and reliable) and cost-effective (Life Cycle Costs)
maintenance programme for the SCRI Components on the basis of the RCM approach. The various
activities developed in this Work are the following :




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Shaping The future Of Rail IV                          page 3                 Paris, 25 + 26 January 2001
                                                                The RAIL project presentation


RCM-RAIL methodology

       1. LCC-RAIL methodology
       2. Test + proposal RCM / LCC-RAIL methodology

The two first activities progress in parallel.

The RCM Methodology
     The work so far done is the definition of a RCM methodology adapted to railway infrastructure
     equipment. The basis of this RCM approach is the international standard IEC 60300-3-11.

This methodology was developed according to :
       - RCM International Standard IEC 60300-3-11
       - RAMS (Reliability ; Availability ; Maintainability ; Security) Standard for Railway
           Infrastructure.
       - MSG-3 Revision 2.
       - Rail consortium approach.

The RCM developed is divided in Four steps. Each level corresponds to a form to fill in




                               Figure 1 : RCM international Standard

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Shaping The future Of Rail IV                          page 4                 Paris, 25 + 26 January 2001
                                                                  The RAIL project presentation

The RAIL RCM approach is divided into four steps.

Step 1

This step consists in defining the rail sections and Safety Critical Railway Infrastructure (SCRI)
components to study :

         - A list of existing documents concerning lists of sections, maps and description must be
             drawn up.
         - A mark must be given to the various sections by the way of a form to be filled in
         - A classification of all sections through the calculated criticality is carried out.
         - For each section a double SCRI component classification is obtained through two
             complementary
         - analyses which are:
         - A SCRI component classification according to its criticality by using
         - A SCRI component classification according to its present state including:
         - A selection made between all the SCRI components and for each of them Step 2 must be
             applied.

Step 2

This step will be carried out for each SCRI component selected from Step 1 application ; it includes :

         - A functional analysis (of each SCRI component) named : Functional schema
         - A functional failure modes analysis

Then all functional failure modes are classified and studied
        - A failure cause analysis by using :
        - A listing of Functional Significant Items (FSI)
        - A Failure Mode Effects and Criticality Analysis (FMECA) of each selected FSI

Step 3

This step will be carried out for each classified FSI (Step 2) ; it will include :

         - A grid in which all tasks will be reported.
         - An application which will allow to define an appropriate task to each FSI. This application is
             named : Task selection
         - A grid which will summarise the task planning.

Step 4

This step includes :

         - Life-Cycle-Cost analysis.
         - Feedback data analysis.
         - Optimisation of Maintenance Tasks.

This approach and the related criteria used are validated by the different railway companies involved in
the project. A final version of this RCM tool is underway.




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Shaping The future Of Rail IV                            page 5                 Paris, 25 + 26 January 2001
                                                                            The RAIL project presentation

In parallel the Life Cycle costs analysis and the related model were developed.

     before operation                               during operation                             after operation



                                             Life Cycle Costs




       INVESTMENT                                     OPERATING                                     DISPOSAL
          COSTS                                         COSTS                                        COSTS



    Equipment and                                                                                Disposal Cost
     Material Purchase         Maintenance and                                                    Reinvestment
                                                           Delay Cost        Hazard Cost
     Cost                       Operating Cost                                                     Cost
    Engineering Cost                                                                             ...
    Installation Cost
    Initial Spares Cost      Corrective Main-           Short Term        Human Safety
    Initial Training Cost     tenance Cost                Delay Cost         Cost
    ...                      Calendar based PM          Long Term         Environmental
                               Cost                        Delay Cost         Threat Cost
                              Condition based PM         ...               Cleaning Cost
                               Cost                                          Rebuilding
                              Operating Cost                                 Cost
                              Energy Consumption                            ...
                               Cost
                              ...


                                                      Figure 2 : Life Cycle Costs Model

This model has been proposed to all the railway companies of the consortium and is under evaluation.
The final version will be developed from the feed-back data from the railway companies.


2.4 RCM analysis of the main machines in the four railways

The aims of this WP are to analyse SCRI components to identify the failures and establish a generic database of
SCRI equipment. This analysis will be based on historical data and the derived knowledge regarding risks, costs,
maintainability and reliability as well as on the experiences in maintenance management for the SCRI. This
analysis will provide the basis to develop the preventive tasks proposed to reduce the probability of occurrence of
the main cause of failure during the data-base development.
As a first step of this WP the developed RCM Methodology for SCRI components were tested by the four railway
companies. A very first draft evaluation of the methodology is underway. Its objective is to validate the various
criteria which are used in the railway companies. The various data available to make the RCM analysis is also
identified in railway companies. The first full study of RCM is underway in each railway company.

2.5 Discuss reliability problems with railway safety authorities

The objectives of this Work are :
                Development of a “Rail study group” with local authorities in charge of the safety of railway
                 infrastructure in order to discuss the standardisation of the methodology or parts of the methodology
                 (e.g. standardisation of performance indicators regarding safety, quality level etc. or standards of
                 comparison of costs with results of preventive maintenance issues).
                Development of an approach to implement an efficient preventive maintenance programme in the
                 railway infrastructure in Europe on the basis of RCM.
                Specification of system safety requirements and targets

This Work has just started. Information on safety authorities in each country are gathered. The key
actors are identified. Contacts and further actions will be done in the coming period.




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Shaping The future Of Rail IV                                      page 6                     Paris, 25 + 26 January 2001
                                                                   The RAIL project presentation



5. Planned activities for the next periods
Continue the RCM analysis of the main machines in the four railways. The aims of this Work are to analyse
the SCRI Components to identify the failures and establish a generic database of SCRI equipment. This
analysis will be based on historical data and the derived knowledge regarding risks, costs, maintainability and
reliability as well as on the experiences in SCRI maintenance management. This analysis will provide the
basis to develop the preventive tasks proposed to reduce the probability of occurrence of the main causes of
failure in the future data-base

Develop a data-base . The objective of this Work during the next period is to define the functional
specification of the RAIL RCM database. As a first step a conceptual model of the data structure will be
developed taking into account the analysis improved in the RCM analysis of the main machines. Then a
physical model will be developed in order to create the RAIL Database. The RCM analysis made during
the work done before will be dealt with again in this Work in order to develop a target of RCM analysis.

Discuss reliability problems with railway safety authorities. This Work will continue. Its objective during the
next period is to consolidate a workgroup of safety authorities in Europe in order to discuss and define the
constraints and problems met in railway operations. This WP will define the guidelines and safety
specifications to be taken into account in the database of the RAIL project.

5. 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 standard 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 during the next months.




                                                                                           th    th
Shaping The future Of Rail IV                             page 7                  Paris, 25 + 26 January 2001

				
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