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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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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 The RCM international standard: CEI 60 300-3-11

The MSG3 Airline /Manufacturer, September 1993 MAINTENANCE

PROGRAM DEVELOPMENT DOCUMENT

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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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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 of 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 ofprotect 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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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