SIST-TP CLC/TR 50126-3:2006
(Main)Railway applications - The specification and demonstration of Reliability, Availability, Maintainability and Safety (RAMS) -- Part 3: Guide to the application of EN 50126-1 for rolling stock RAM
Railway applications - The specification and demonstration of Reliability, Availability, Maintainability and Safety (RAMS) -- Part 3: Guide to the application of EN 50126-1 for rolling stock RAM
This document provides guidance on applying the RAM requirements in EN 50126-1 to rolling stock and for dealing with RAM activities during the system life cycle phases from invitation to tender to demonstration in operation only. All references to EN 50126-1 concern the version of 1998. The guide is aimed at the customers/operators and main suppliers of rolling stock. The main purpose of the guide is to: enable a customer/operator of rolling stock: - to specify the RAM requirements addressing the type of operation in terms of the end customer needs, considering service availability and economic considerations; - to evaluate different tenders, in terms of RAM requirements, on a common basis with the aid of specific RAM documents; - to gain assurance, during design/development phase, that the rolling stock being offered is likely to satisfy the RAM contractual requirements by examining step by step detailed and specific RAM documents as an output of the RAM activities performed during the development phase; - to validate that the rolling stock, as delivered, satisfies the specified RAM requirements - to enable the main supplier of rolling stock - to understand the customers/operators RAM requirements - to provide substantive information/visibility in a tender to show that the product offered is likely to satisfy the RAM requirements by performing preliminary RAM analysis; - to provide substantive information during design/development phase to show that the product offered is likely to satisfy the RAM requirements by performing detailed RAM analysis; - to demonstrate that the product delivered satisfies the RAM requirements.
Applications ferroviaires - Spécification et démonstration de la fiabilité, de la disponibilité, de la maintenabilité et de la sécurité (FDMS) -- Partie 3: Guide pour l’application de l’EN 50126-1 à la fiabilité, la disponibilité, la maintenabilité et la sécurité du matériel roulant
Železniške naprave – Specifikacija in prikaz zanesljivosti, razpoložljivosti, vzdrževalnosti in varnosti (RAMS) – 3. del: Vodilo za uporabo EN 50126-1 za RAMS za vozna sredstva
General Information
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Standards Content (Sample)
SLOVENSKI SIST-TP CLC/TR 50126-3:2006
STANDARD
september 2006
Železniške naprave – Specifikacija in prikaz zanesljivosti, razpoložljivosti,
vzdrževalnosti in varnosti (RAMS) – 3. del: Vodilo za uporabo EN 50126-1 za
RAMS za vozna sredstva
Railway applications - The specification and demonstration of Reliability,
Availability, Maintainability and Safety (RAMS) - Part 3: Guide to the application of
EN 50126-1 for rolling stock RAMS
ICS 29.280; 45.020 Referenčna številka
SIST-TP CLC/TR 50126-3:2006(en)
© Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno
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TECHNICAL REPORT
CLC/TR 50126-3
RAPPORT TECHNIQUE
May 2006
TECHNISCHER BERICHT
ICS 29.280; 45.020
English version
Railway applications –
The specification and demonstration of
Reliability, Availability, Maintainability and Safety (RAMS)
Part 3: Guide to the application of EN 50126-1
for rolling stock RAMS
Applications ferroviaires –
Spécification et démonstration de la fiabilité,
de la disponibilité, de la maintenabilité
et de la sécurité (FDMS)
Partie 3: Guide pour l’application de l’EN 50126-1
à la fiabilité, la disponibilité, la maintenabilité
et la sécurité du matériel roulant
This Technical Report was approved by CENELEC on 2004-08-28.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, the Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: rue de Stassart 35, B - 1050 Brussels
© 2006 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. CLC/TR 50126-3:2006 E
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CLC/TR 50126-3:2006 - 2 -
Foreword
This Technical Report was prepared by Working Group B11 of SC 9XB, Electromechanical material on
board of rolling stock, of Technical Committee CENELEC TC 9X, Electrical and electronic applications for
railways.
The text of the draft was submitted to the formal vote and was approved by CENELEC as
CLC/TR 50126-3 on 2004-08-28.
This Technical Report forms an informative part of EN 50126 and contains guidelines for the application
of EN 50126-1 to Rolling Stock RAM.
__________
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Contents
Page
Introduction.5
1 Scope.6
1.1 Limitation of scope .6
2 Definitions .6
3 Approach adopted for the Guide.7
4 Application of this Guide .7
4.1 Object of the application.7
4.2 Application of EN 50126-1 .7
4.2.1 Assessment of the application of EN 50126-1.7
4.2.2 Mandatory requirements for the application of EN 50126-1.8
5 Specifying RAM requirements.8
5.1 Preliminary RAM analysis.8
5.1.1 Introduction.8
5.1.2 Preliminary RAM Analysis activities .9
5.1.3 System Identification.9
5.1.4 Breakdown structure and boundary limits .11
5.2 Failure conditions .12
5.3 RAM requirements.15
5.3.1 Introduction.15
5.3.2 Reliability Targets .15
5.3.3 Maintainability Targets.16
5.3.4 Availability Targets.20
5.4 Process for choosing RAM figures.23
5.5 RAM Programme.23
5.5.1 Introduction.23
5.5.2 Configuration Management System .23
5.5.3 RAM Programme Outline.24
5.5.4 Example of RAM Analyses Document Template and Data.25
6 RAM Assurance during Life Cycle.38
6.1 RAM Programme and Phases of the Life Cycle .38
6.1.1 Tender Phase.39
6.1.2 Design Phase.40
6.1.3 Demonstration Phase.43
7 Specific Hazards related to rolling stock .46
7.1 Introduction.46
7.2 Hazard Identification Process .46
7.3 List of the common hazards related to rolling stock.46
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8 RAM Parameters to be incorporated into LCC Model.48
8.1 Introduction.48
8.2 Overview of LCC Modelling.48
8.3 RAM parameters for LCC.49
Annex A (informative) – Examples of breakdown structure.51
Bibliography.62
Table 1 Possible sharing of responsibility .5
Table 2 Example of header for a form representing a breakdown structure.12
Table 3 Example of minimum set of data representing a breakdown structure .12
Table 4 RAM Failure Categories .13
Table 5 Significant Failure Specification .14
Table 6 Major Failure Specification .14
Table 7 Minor Failure Specification .14
Table 8 Reliability Requirements for Failure Categories.16
Table 9 Quantitive Requirements for Maintainability.17
Table 10 Preventive/Corrective Maintenance Requirements.19
Table 11 Logistic Support Requirements .19
Table 12 Maintenance Cost Requirements.20
Table 13 Availability Requirements .22
Table 14 Example of header for RAM analyses Template.26
Table 15 Example of minimum set of data for Reliability Prediction sheets.26
Table 16 Example of minimum set of data for Preventive Maintenance sheets .29
Table 17 Example of minimum set of data for Corrective Maintenance sheets.33
Table 18 Example of minimum set of data for items FMECA sheets.35
Table 19 Description of the main tasks of Design Phase.41
Figure 1 Example of Reliability Prediction Analysis Sheet .27
Figure 2 Example of Preventive Maintenance Analysis Sheet.30
Figure 3 Example of Preventive Maintenance Sheet for a single frequency.32
Figure 4 Example of Corrective Maintenance Analysis Sheet .34
Figure 5 Example of items FMECA Sheet.36
Figure 6 Example of functions FMECA Sheet .37
Figure 7 RAM Programme and Life Cycle Phases.38
Figure 8 Possible relationships between Customer, Main Supplier, Sub-Supplier during
some phases of Life Cycle for rolling stock.39
Figure 9 Flow diagramme representing activities/documentations of Design Phase.41
Figure A.1 Example of structure using organisation chart for an Electrical Multiple Unit Coach.52
Figure A.2 Example of structure using the tree breakdown chart for an EMU
(Electrical Multiple Unit) Traction Vehicle.53
Figure A.1 Example of structure using the tree breakdown chart for an EMU
(Electrical Multiple Unit) Coach .59
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Introduction
EN 50126-1 is likely to enhance the general understanding of the issues involved in achieving RAMS
characteristics within the railway field. It defines a comprehensive set of tasks for the different phases of a
generic life cycle for a total rail system. Although some of the examples given in the annexes of
EN 50126-1 are for rolling stock, the standard is essentially aimed as a top level railway system
document.
RAMS characteristics for rolling stock (i.e. its long term operating behaviour performance), as for any
other system, forms an important part of its overall performance characteristics. But the consideration of
RAMS, in contractual terms, between a customer / operator and a Main Supplier for the procurement of
rolling stock has been problematic. Also, in rolling stock contracts, there is now a greater emphasis on the
impact on end customers of service failures and on the economic and risk considerations of RAMS
(i.e. the business perspective).
Consequently, Life Cycle Cost is being used as a measure of satisfying customer needs and providing a
wider perspective of RAM’s importance in terms of the business economics.
Life Cycle Cost approach represents a holistic, total cost of ownership philosophy for addressing the
economic considerations. The contribution of RAMS to the LCC of rolling stock could be used to allow the
economic considerations to be addressed.
This application guide focuses mainly on the procurement issues, from the tender to the operation phase,
and is intended to help in establishing a common approach for capturing the different, time dependant,
performance requirements of rolling stock from an operator/business perspective.
EN 50126-1 is a standard, which treats the overall aspects of RAMS in Railway Applications. This guide
deals with the application of RAM part of EN 50126-1 to rolling stock only, as stated in the Scope and
clarifies areas where EN 50126-1 could be misinterpreted.
Entities Involved In the Life Cycle Phases of Rolling Stock:
Depending on the organisational and management structure of the railway system concerned, a number
of entities, performing different functions, may be involved within the life cycle phases of rolling stock. For
the purpose of guidance on contractual relations, the entities are divided into 2 main categories, i.e.
customer and supplier.
It is therefore advisable, to identify all the entities that can be a part of this relationship and to examine
how the responsibilities of dealing with these entities are shared between the customer and supplier
relationship. Table 1 gives some typical examples only:
Table 1 – Possible sharing of responsibility
Supplier Customer
Entity
responsibility responsibility
Main supplier of the rolling stock X
Sub supplier of the rolling stock X
Operator of the rolling stock X
Owner of the rolling stock X
Maintainer of the rolling stock X X
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1 Scope
This document provides guidance on applying the RAM requirements in EN 50126-1 to rolling stock and
for dealing with RAM activities during the system life cycle phases from invitation to tender to
demonstration in operation only. All references to EN 50126-1 concern the version of 1998.
The guide is aimed at the customers/operators and main suppliers of rolling stock. The main purpose of
the guide is to:
• enable a customer/operator of rolling stock:
− to specify the RAM requirements addressing the type of operation in terms of the end customer
needs, considering service availability and economic considerations;
− to evaluate different tenders, in terms of RAM requirements, on a common basis with the aid of
specific RAM documents;
− to gain assurance, during design/development phase, that the rolling stock being offered is likely to
satisfy the RAM contractual requirements by examining step by step detailed and specific RAM
documents as an output of the RAM activities performed during the development phase;
− to validate that the rolling stock, as delivered, satisfies the specified RAM requirements
• to enable the main supplier of rolling stock
− to understand the customers/operators RAM requirements
− to provide substantive information/visibility in a tender to show that the product offered is likely to
satisfy the RAM requirements by performing preliminary RAM analysis;
− to provide substantive information during design/development phase to show that the product
offered is likely to satisfy the RAM requirements by performing detailed RAM analysis;
− to demonstrate that the product delivered satisfies the RAM requirements;
1.1 Limitation of scope
Regarding Safety, this application guide is restricted to providing, for reference purposes only, a list of the
most common rolling stock Hazards associated with an operation.
Regarding LCC (Life Cycle Cost), this application guide is restricted to providing only the key RAM
parameters necessary to be incorporated into an LCC Model.
This application guide excludes:
• RAM values connected to the different RAM requirements (however, it contains a simple guide line of
actions for supporting the decision making process and choosing appropriate values, see 5.4)
• specific RAM documents to be produced and activities to be performed. However, it provides, only as
an example, typical data and document templates for recording the output of a RAM analysis).
2 Definitions
For this guide, the in EN 50126-1 and the following apply:
2.1
Part Number
the alphanumeric code, generally assigned by the Main Supplier, to represent a family of items with the
same characteristics of Form, Fit and Function.
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3 Approach adopted for the Guide
The approach adopted is to raise the following questions, for each phase of the Life Cycle, in order to
successively set up the requirements of EN 50126-1 and the basis for satisfying them:
• WHAT: what activities / tasks are to be performed and the supporting documents to be produced?
• WHO: who has the responsibility for these activities / tasks?
• HOW: which type of method or tool should be used?
This process is adopted for the development of the guide and should be applied in accordance with the
structure of the application guide.
4 Application of this Guide
4.1 Object of the application
This document is applicable to rolling stock (train, coach, locomotive, etc…) and to all the subsystems,
assemblies and parts belonging to the rolling stock, according to their boundary limits.
Referring to 1.2 of EN 50126-1, the Guide is for use by Railway Authorities and the railway support
industry and is applicable to:
• new rolling stock
• modification/refurbishment of existing rolling stock
For use in this document only, the above two bullet point items should be referred to by the generic term
“system”, comprising the complete sequence “system, sub-system, component” of a rolling stock or the
whole rolling stock itself breakdown structure.
4.2 Application of EN 50126-1
4.2.1 Assessment of the application of EN 50126-1
Referring to 5.3 of EN 50126-1 and taking into account the responsibilities of the different entities involved
in the life cycle phases, the following section gives a synthesis of the main actions required to meet the
requirements.
According to 5.3.2 of EN 50126-1, the assessment of the application of the requirements of EN 50126-1
to rolling stock (system under consideration) shall be defined by the Railway Authority and according to
5.3.4 of EN 50126-1, the assessment shall:
1 Specify phases applicable, and for each one of these:
• Justify and demonstrate the compliance with the principles of the requirements of the standard.
• Specify the mandatory activities/requirements, with respect to rolling stock (system under
consideration), including :
I. The scope of each requirement
II. The methods, tools and techniques required against each requirement and the scope
and depth of their application
III. The verification/validation activities required against each requirement and the scope
of their application
IV. Input/Output documentation
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2 Justify any deviation from the activities and requirement of the standard
3 Justify the adequacy of the tasks chosen for the system under consideration
Both the Customer and the Main Supplier should provide documented evidence for the above
specifications and justifications that are within their responsibility.
Where Main Supplier introduces limitations, they should be discussed and agreed with the Customer.
These documents are considered as part of the RAM Programme.
4.2.2 Mandatory requirements for the application of EN 50126-1
The correct application of EN 50126-1 is effected through several requirements.
The following is a synthesis of the mandatory requirements in 5.3.5 of EN 50126-1:
• define and agree the responsibilities for carrying out all RAMS tasks within each phase chosen
• ensure the competence of the personnel involved within RAMS tasks
• establish and implement a RAM Programme and a Safety Plan, where the following should be
identified and managed:
− conflicts between RAM and Safety tasks
− details of all RAMS analysis, including the depth of analysis activities
• ensure that the requirements of EN 50126-1 are implemented within business processes, supported
by a Quality Management System (QMS) compliant with the requirements of EN ISO 9000 series
• establish and implement an adequate and effective configuration management system including, at
least:
− all system documentation
− all other system deliverables
Both the Customer and the Main Supplier should provide evidence by documents about the fulfilment of
these mandatory requirements, within their responsibility.
These documents are considered as part of the RAM Programme.
5 Specifying RAM requirements
The purpose of this clause is to establish the process to define RAM Requirements for rolling stock and
for all the subsystems, assemblies and parts belonging to the rolling stock according to its boundary
limits.
This clause gives detailed information on phases 1, 2, 4 and 5 of system life cycle requirements
described in 6.1, 6.2, 6.4 and 6.5 of EN 50126-1.
To start with, as part of the system definition process, all available data and relevant information about
the rolling stock under consideration should be collected.
The final goal is the derivation of RAM targets through the appropriate analysis of all the information
collected and organised in a structured way.
5.1 Preliminary RAM analysis
This section complements 6.1.3.4, 6.2.3.1, 6.2.3.2, 6.4.3.1 and A2 of EN 50126-1 and gives further
details.
5.1.1 Introduction
Purpose of the preliminary RAM Analysis is to identify the application environment and the operating
conditions of the rolling stock, in order to recognise the fundamental concepts for basing the overall RAM
requirements.
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The analysis involves undertaking the following activities :
• similar system review:
− a list of similar existing rolling stock is created, suitable for extracting relevant RAM-related
information;
• preliminary system analysis:
− all available and relevant rolling stock documentation is reviewed in order to define, at a preliminary
level, the overall system structure and its mission profile and to recognise the system failure
conditions.
Deliverables of the preliminary RAM-related activities constitute the necessary background for defining
the overall RAM Requirements Specification in terms of:
• RAM requirements;
• Demonstration and acceptance criteria;
• RAM programme requirements.
5.1.2 Preliminary RAM Analysis activities
Preliminary RAM-related activities consist of investigating all the relevant available documentation in
order to recognise all the functional requirements, which may affect the RAM performance of the rolling
stock.
The resultant deliverables of the preliminary RAM-related activities are:
• System identification: where the rolling stock has to be identified in terms of its boundary limits,
operational conditions, functions, interfaces, system breakdown structure, logistics and maintenance
conditions.
• Failure conditions: where the failures of the rolling stock have to be identified and categorised in order
to define appropriate requirements.
5.1.3 System Identification
This section provides a general overview of the main features identifying a rolling stock (see EN 50126-1,
Clause A.2).
The identification process is carried out to gain assurance that the rolling stock is correctly analysed and
all the factors influencing its RAM performance have been identified.
These characteristics define the conditions under which the rolling stock is required to accomplish its
mission and constitute the reference conditions for:
• defining the rolling stock RAM requirements
• demonstrating, by analysis and tests, that each specific implementation fulfils the RAM requirements
in all relevant Lifecycle phases.
The main characteristics and features necessary to describe a rolling stock are its Mission Profile, Route
Profile, Operating Conditions, Environmental Conditions and Maintenance Conditions (including logistics).
Items contained in each of these are listed below:
1 Mission Profile:
• Reference route,
• Commercial speed (mission duration / mission length),
• Mean length of a run,
• Mean distance between train stops,
• Operating time or distance per year,
• Revenue operating time or distance per year,
• Stand-by time per day,
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• Idle time per day (i.e. time when the rolling stock is neither in operation nor stand-by)
• Planned total time of use (life expectancy in years).
2 Route Profile:
• Number of tunnels related to reference route
• Number of viaducts related to reference route
• Cumulative distance in tunnels,
• Cumulative distance on surface, including viaducts,
• Gradients and Curves on the route with their lengths.
3 Operating Conditions:
• Equivalent speed related to the time the equipment is powered during a given calendar period
(cumulated distance / Time the equipment is powered over the period),
• Time an equipment is powered over a given calendar period (this parameter could be defined for
each equipment, but is generally defined for categories of equipment),
• Time during which traction is activated,
• Time or percentage of time during which electric braking is activated,
• Operating time of the compressor,
• Number of compressor startups,
• Time of presence of catenary power, for each voltage,
• Time during which a trainset is awake (i.e. in operation or standby),
• Operating time for Heating Ventilation and Air Conditioning, in heating mode and in air conditioning
mode,
• Average speed and maximum speed,
• Potential use in multiple units,
• Total time of coupled operation,
• Frequency of coupling and de-coupling,
• Internal temperature range of the rolling stock,
• Mechanical (shock and vibration),
• Electrical (power supplies),
• Electromagnetic compatibility (e.g. EMC – train to train or system to system),
• Signalling Interfaces (e.g. on-board and way-side),
• Ergonomics.
4 Environmental Conditions:
• Outside Air Temperatures (OAT),
• Maximum height above the sea level,
• Solar radiation,
• Humidity,
• Wind and pressure pulses,
• Water and precipitation,
• Pollutants and contaminants.
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5 Maintenance Conditions:
• Indicative maintenance plan (i.e. minimum preventive maintenance interval, maximum
contemporary number of personnel required for maintenance interval tasks, maximum standstill
time to complete maintenance interval tasks, etc…),
• Number, location and description of the sites for maintenance,
• Description of the standard equipment, tools and resources at the maintenance sites.
5.1.4 Breakdown structure and boundary limits
Breakdown structure of the rolling stock is the most important baseline of the identification process.
Establishing a breakdown structure of the rolling stock, gives a clear reference outline for all the activities
and analyses for supporting RAM Programme through the Life Cycle.
Generally, the scope of the breakdown structure is to set up the borders of a system by listing all the
items belonging to that system and, by using an appropriate number of discrete b
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