ApplGuide for EN50126 -May 02 for SC9XB

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CENELEC TC9-SC9XB Application Guide for EN 50126

WORKING GROUP B11 Draft May 2002

Application Guide for EN50126

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CONTENT

WORKING GROUP B11..........................................................................................................................1

APPLICATION GUIDE FOR EN50126.....................................................................................................1

CONTENT................................................................................................................................................2

CENELEC TC9-SC9XB............................................................................................................................1

APPLICATION GUIDE FOR EN 50126....................................................................................................1

DRAFT MAY 2002...................................................................................................................................1

TABLES.................................................................................................................................................90

TABLE 1: RAM FAILURE CATEGORIES 101......................................................................................90

TABLE 2: SIGNIFICANT FAILURE SPECIFICATION 102....................................................................90

TABLE 3: MAJOR FAILURE SPECIFICATION 103..............................................................................90

TABLE 4: MINOR FAILURE SPECIFICATION 103...............................................................................90

TABLE 5: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY SIGNIFICANT(IMMOBILISING FAILURE) 105....................................................................................................................90

TABLE 6: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MAJOR (SERVICE

FAILURE) 106................................................................................................................................................90

TABLE 7: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MINOR 107.........................90

TABLE 8: QUALITATIVE REQUIREMENTS FOR MAINTAINABILITY 108.........................................90

TABLE 9: PREVENTIVE/CORRECTIVE MAINTENANCE REQUIREMENTS 110...............................90

TABLE 10: LOGISTIC SUPPORT REQUIREMENTS 110....................................................................90

TABLE 11: MAINTENANCE COST REQUIREMENTS 111..................................................................90

TABLE 12: AVAILABILITY REQUIREMENTS 113...............................................................................90

FIGURES................................................................................................................................................90

FIG. 1 EXAMPLE OF RELIABILITY PREDICTION ANALYSIS SHEET 122.........................................90

FIG. 2 EXAMPLE OF PREVENTIVE MAINTENANCE ANALYSIS SHEET 127....................................90

FIG. 3 EXAMPLE OF PREVENTIVE MAINTENANCE SHEET FOR A SINGLE FREQUENCY 129.....90

FIG. 4 EXAMPLE OF CORRECTIVE MAINTENANCE ANALYSIS SHEET 132...................................90

FIG. 5 EXAMPLE OF FMECA SHEET 135............................................................................................90

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FIG. 6 RAM PROGRAMME AND LIFE CYCLE PHASES 136..............................................................90

FIG. 7 EXAMPLE OF STRUCTURE USING ORGANISATION CHART FOR AN ELECTRICALMULTIPLE UNIT COACH 150.......................................................................................................................90

FIG. 8 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) TRACTION VEHICLE 151.......................................................................90

FIG. 9 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) COACH 156.............................................................................................90

1 INTRODUCTION..................................................................................................................................91

EN50126 IS LIKELY TO ENHANCE THE GENERAL UNDERSTANDING OF THE ISSUES INVOLVEDIN ACHIEVING RAMS CHARACTERISTICS WITHIN THE RAILWAY FIELD. IT DEFINES ACOMPREHENSIVE SET OF TASKS FOR THE DIFFERENT PHASES OF A GENERIC LIFE CYCLE FORA TOTAL RAIL SYSTEM. ALTHOUGH SOME OF THE EXAMPLES GIVEN IN THE ANNEXES OF EN

50126 ARE FOR ROLLING STOCK, THE STANDARD IS ESSENTIALLY AIMED AS A TOP LEVELRAILWAY SYSTEM DOCUMENT..................................................................................................................91

RAMS CHARACTERISTICS FOR ROLLING STOCK (I.E. ITS LONG TERM OPERATINGBEHAVIOUR PERFORMANCE), AS FOR ANY OTHER SYSTEM, FORMS AN IMPORTANT PART OF ITSOVERALL PERFORMANCE CHARACTERISTICS. BUT THE CONSIDERATION OF RAMS, INCONTRACTUAL TERMS, BETWEEN A CUSTOMER / OPERATOR AND A SUPPLIER FOR THEPROCUREMENT OF ROLLING STOCK HAS BEEN PROBLEMATIC. ALSO, IN ROLLING STOCKCONTRACTS, THERE IS NOW A GREATER EMPHASIS ON THE IMPACT ON END CUSTOMERS OFSERVICE FAILURES AND ON THE ECONOMIC AND RISK CONSIDERATIONS OF RAMS (I.E. THEBUSINESS PERSPECTIVE)..........................................................................................................................91

ON THE OTHER SIDE, ALSO LIFE CYCLE COST IS BEING TAKEN INTO ACCOUNT TO SATISFY

THE CUSTOMER NEEDS AND TO HAVE A WIDE RANGE APPROACH...................................................91

LIFE CYCLE COST APPROACH REPRESENTS A HOLISTIC, TOTAL COST OF OWNERSHIPPHILOSOPHY FOR ADDRESSING THE ECONOMIC CONSIDERATIONS. THE CONTRIBUTION OFRAMS TO THE LCC OF ROLLING STOCK WOULD BE USED TO ALLOW THE ECONOMICCONSIDERATIONS TO BE ADDRESSED....................................................................................................91

THEREFORE THE APPLICATION GUIDE TO EN50126, FOCUSING ON THE PROCUREMENTISSUES AND PROVIDING A COMMON APPROACH FOR CAPTURING THE DIFFERENTPERFORMANCE REQUIREMENTS FROM AN OPERATOR/BUSINESS PERSPECTIVE, HAS BEENESTABLISHED..............................................................................................................................................91

EN50126 IS A STANDARD WHICH TREATS THE OVERALL ASPECTS OF RAMS IN RAILWAYBUSINESS. THE APPLICATION STANDARD SHALL PROVIDE GUIDANCE IN THE USAGE OF EN50126AND SHALL PROVIDE CLARIFICATION WHERE EN50126 COULD BE MIS-INTERPRETED. .......... .... .91

2 SCOPE.................................................................................................................................................92

THIS APPLICATION GUIDE PROVIDES A PRACTICAL BASIS AND APPROACH FOR:.................92

SPECIFYING RAM REQUIREMENTS FOR ROLLING STOCK ..........................................................92

ASSURING RAM PERFORMANCE FOR ROLLING STOCK, ..............................................................92

DEMONSTRATING RAM PERFORMANCES OF ROLLING STOCK ..................................................92

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THIS DOCUMENT IS ADDRESSED TO CUSTOMERS/OPERATORS AND SUPPLIERS OF ROLLINGSTOCK, FOR DEALING WITH RAM ACTIVITIES DURING DIFFERENT PHASES FROM TENDER TODEMONSTRATION IN OPERATION.............................................................................................................92

THE MAIN PURPOSE OF THE APPLICATION GUIDE IS:...................................................................92

1. TO ENABLE A CUSTOMER/OPERATOR OF ROLLING STOCK.....................................................92

TO SPECIFY THE RAM REQUIREMENTS ADDRESSING THE TYPE OF OPERATION IN TERMS OFTHE END CUSTOMER NEEDS, CONSIDERING SERVICE AVAILABILITY AND ECONOMICCONSIDERATIONS;......................................................................................................................................92

TO EVALUATE DIFFERENT TENDERS, IN TERMS OF RAM REQUIREMENTS, ON A COMMONBASIS WITH THE AID OF SPECIFIC RAM DOCUMENTS;.........................................................................92

TO GAIN ASSURANCE, DURING DESIGN/DEVELOPMENT PHASE, THAT THE ROLLING STOCKBEING OFFERED IS LIKELY TO SATISFY THE RAM CONTRACTUAL REQUIREMENTS BY EXAMINING

STEP BY STEP DETAILED AND SPECIFIC RAM DOCUMENTS AS AN OUTPUT OF THE RAMACTIVITIES PERFORMED DURING THE DEVELOPMENT PHASE;..........................................................92

TO VALIDATE THAT THE ROLLING STOCK, AS DELIVERED, SATISFIES THE SPECIFIED RAMREQUIREMENTS ..........................................................................................................................................92

2. TO ENABLE THE SUPPLIER OF ROLLING STOCK........................................................................92

TO UNDERSTAND THE CUSTOMERS/OPERATORS RAM REQUIREMENTS..................................92

TO PROVIDE SUBSTANTIVE INFORMATION/VISIBILITY IN A TENDER TO SHOW THAT THEPRODUCT OFFERED IS LIKELY TO SATISFY THE RAM REQUIREMENTS BY PERFORMINGPRELIMINARY RAM ANALYSIS;..................................................................................................................92

TO PROVIDE SUBSTANTIVE INFORMATION/VISIBILITY DURING DESIGN/DEVELOPMENTPHASE TO SHOW THAT THE PRODUCT OFFERED IS LIKELY TO SATISFY THE RAMREQUIREMENTS BY PERFORMING DETAILED RAM ANALYSIS;...........................................................92

TO DEMONSTRATE THAT THE PRODUCT DELIVERED SATISFIES THE RAM REQUIREMENTS;92

REGARDING SAFETY THIS APPLICATION GUIDE PROVIDES A REFERENCE LIST OF THE MOSTCOMMON HAZARDS ASSOCIATED WITH OPERATION............................................................................92

REGARDING LCC (LIFE CYCLE COST) THIS APPLICATION GUIDE ESTABLISHES RAM KEY

PARAMETERS NECESSARY TO BE INCORPORATED INTO AN LCC MODEL........................................92

THIS APPLICATION GUIDE DOESN’T ESTABLISH:...........................................................................92

RAM FIGURES CONNECTED TO THE DIFFERENT RAM REQUIREMENTS (HOWEVER THEAPPLICATION GUIDE CONTAINS A SIMPLE GUIDE LINE OF ACTIONS SUPPORTING THE DECISIONMAKING PROCESS FOR CHOOSING APPROPRIATE FIGURES, SEE ITEM 8.4)....................................92

SPECIFIC RAM DOCUMENTS AND ACTIVITIES TO BE PERFORMED (HOWEVER, THEAPPLICATION GUIDE WILL CONTAIN, AS AN EXAMPLE, TYPICAL FORM AND DATA OF SOME RAMDOCUMENT TO BE INTENDED AS AN OUTPUT OF THE PERFORMED ANALYSIS)..............................93

3 NORMATIVE REFERENCES...............................................................................................................93

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EN50126.................................................................................................................................................93

RAILWAY APPLICATIONS – THE SPECIFICATION AND DEMONSTRATION OF RELIABILITY,AVAILABILITY, MAINTAINABILITY AND SAFETY (RAMS)........................................................................93

PR ENV 50127-1....................................................................................................................................93

RAILWAY APPLICATIONS - GUIDE TO THE SPECIFICATION OF A GUIDED TRANSPORTSYSTEM. PART 1: GENERAL......................................................................................................................93

EN 60721-1............................................................................................................................................93

CLASSIFICATION OF ENVIRONMENTAL CONDITIONS. PART 1: ENVIRONMENTALPARAMETERS AND THEIR SEVERITY.......................................................................................................93

4 INFORMATIVE REFERENCES............................................................................................................93

UNIFE LCC GROUP..............................................................................................................................93

SERIES OF DOCUMENTS FROM VOLUME I TO IV............................................................................93

5 DEFINITIONS.......................................................................................................................................93

THIS DOCUMENT ADOPTS THE SAME DEFINITIONS OF THE EN 50126........................................93

ANY OTHER DEFINITION NECESSARY WILL BE EXPLAINED AND INTRODUCED IN THISSECTION WHEN IT WILL BE USED.............................................................................................................93

PART NUMBER: IT IS ALPHANUMERIC, GENERALLY ASSIGNED BY THE SUPPLIER, TOREPRESENT A FAMILY OF ITEMS WITH THE SAME CHARACTERISTICS OF FORM, FIT ANDFUNCTION. ...................................................................................................................................................93

6 APPROACH ADOPTED.......................................................................................................................93

THE APPROACH ADOPTED FOR EACH PHASE OF THE LIFE CYCLE TO SET UP ANDSUCCESSIVELY MEET THE REQUIREMENTS OF THE STANDARD IS TO RAISE THE FOLLOWINGQUESTIONS: ...............................................................................................................................................93

WHAT: WHAT ACTIVITIES / TASKS TO BE PERFORMED AND THE SUPPORTING DOCUMENTSTO BE PRODUCED .....................................................................................................................................93

WHO: WHO HAS THE RESPONSIBILITY FOR THESE ACTIVITIES / TASKS ................................93

HOW: WHICH TYPE OF METHOD OR TOOL TO BE USED .............................................................93

THIS PROCESS IS ADOPTED FOR THE DEVELOPMENT OF THE GUIDE AND WILL BE APPLIEDIN ACCORDANCE WITH THE STRUCTURE OF THE APPLICATION GUIDE............................................93

7 APPLICATION OF THIS GUIDE..........................................................................................................94

7.1 OBJECT OF THE APPLICATION.........................................................................................................................94

THIS DOCUMENT IS APPLICABLE TO ROLLING STOCK (TRAIN, COACH, LOCOMOTIVE, ETC…)AND TO ALL THE SUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TO THE ROLLING STOCKACCORDING TO THE BOUNDARY LIMITS.................................................................................................94

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REFERRING TO THE ITEM 1.2 OF EN 50126, THE GUIDE IS APPLICABLE TO:.............................94

NEW ROLLING STOCK.........................................................................................................................94

MODIFICATION/REFURBISHMENT OF EXISTING ROLLING STOCK...............................................94

FOR USE BY RAILWAY AUTHORITIES AND THE RAILWAY SUPPORT INDUSTRY.......................94

FOR THE USE OF THIS DOCUMENT ONLY, THE PREVIOUS TWO ITEM POINTS WILL BEINDICATED WITH THE GENERIC TERM “SYSTEM”, COMPRISING THE COMPLETE SEQUENCE“SYSTEM-SUB-SYSTEM-COMPONENT” OF THE BREAKDOWN STRUCTURE OF THE ROLLINGSTOCK...........................................................................................................................................................94

7.2 ENTITIES INVOLVED.....................................................................................................................................94

THE USE OF THIS DOCUMENT IS INDICATED BOTH FOR RAILWAY AUTHORITIES AND THERAILWAY SUPPORT INDUSTRY.................................................................................................................94

THE ENTITIES INVOLVED WITHIN THE LIFE CYCLE PHASES CAN BE REPRESENTED AS IN THEDIAGRAM BELOW:.......................................................................................................................................94

WITHIN THE FRAMEWORK OF A CONTRACTUAL RELATION CONSISTING IN SUPPLYING AROLLING STOCK (IN ACCORDANCE WITH THE INITIAL PURPOSE OF THE GUIDE), RELATIONS CANBE SIMPLIFIED AND ONLY 2 PARTNERS BE RETAINED: .......................................................................94

CUSTOMER (MUST TAKE INTO ACCOUNT PROBLEMS OF INTERFACE WITH NATIONALREGULATION AUTHORITY, MAINTAINER, OWNER AND INFRASTRUCTURE COMPANY), .................94

SUPPLIER (MANAGING SUB-SUPPLIER). .........................................................................................94

IN A TOTAL SYSTEM VISION, THE LEVEL OF RESPONSIBILITY, WHICH MUST BE KNOWNFROM THE FIRST STAGE OF THE PROJECT (PHASE 1 “CONCEPT”), IS AS FOLLOWS :...................94

................................................................................................................................................................95

THIS DIAGRAM MUST BE INTERPRETED IN THE FOLLOWING WAY: .........................................95

................................................................................................................................................................95

7.3 APPLICABILITY OF THE PHASES OF THE EN 50126............................................................................................96

WITHIN THE PREVIOUS CONCERN AND REFERRING TO THE ITEM 5.3 OF EN 50126, THEAPPLICATION OF THE STANDARD SHOULD BE FLEXIBLE AND EFFECTIVE BY CONSIDERING AND

ASSESSING A COST/BENEFIT RATIO, THE COMPLEXITY AND THE SIZE OF THE SYSTEM...............96

ACCORDINGLY TO THE ITEM 5.3.4 OF THE STANDARD, THE ASSESSMENT OF THEAPPLICATION OF THE EN 50126 SHALL:..................................................................................................96

1 SPECIFY PHASES APPLICABLE, AND FOR EACH ONE OF THESE:............................................96

JUSTIFY AND DEMONSTRATE THE COMPLIANCE WITH THE PRINCIPLES OF THEREQUIREMENTS OF THE STANDARD........................................................................................................96

SPECIFY THE MANDATORY ACTIVITIES/REQUIREMENTS INCLUDING, REFERRING TO THESYSTEM UNDER CONSIDERATION:...........................................................................................................96

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1 THE SCOPE OF EACH REQUIREMENT...........................................................................................96

2 THE METHODS, TOOLS AND TECHNIQUES REQUIRED AGAINST EACH REQUIREMENT ANDTHE SCOPE AND DEPTH OF THEIR APPLICATION..................................................................................96

3 THE VERIFICATION/VALIDATION ACTIVITIES REQUIRED AGAINST EACH REQUIREMENT ANDTHE SCOPE OF THEIR APPLICATION........................................................................................................96

4 INPUT/OUTPUT DOCUMENTATION.................................................................................................96

2 JUSTIFY ANY DEVIATION FROM THE ACTIVITIES AND REQUIREMENT OF THE STANDARD. 96

3 JUSTIFY THE ADEQUACY OF THE TASKS CHOSEN FOR THE SYSTEM UNDERCONSIDERATION..........................................................................................................................................96

7.4 MANDATORY REQUIREMENTS ........................................................................................................................96

THE CORRECT APPLICATION OF EN 50126 IS GUARANTEED THROUGH SEVERALREQUIREMENTS...........................................................................................................................................96

THE FOLLOWING REQUIREMENTS ARE MANDATORY (SEE ITEM 5.3.5 OF EN 50126):.......... ....96

DEFINE RESPONSIBILITY FOR CARRYING OUT ALL RAMS TASKS WITHIN EACH PHASECHOSEN........................................................................................................................................................96

MAKE SURE ABOUT THE COMPETENCE OF THE PERSONNEL INVOLVED WITHIN RAMSTASKS...........................................................................................................................................................96

ESTABLISH AND IMPLEMENT A RAM PROGRAMME AND A SAFETY PLAN, WHERE HAVE TOBE IDENTIFIED AND MANAGED:................................................................................................................96

CONFLICTS BETWEEN RAM AND SAFETY TASKS..........................................................................96

2 DETAILS OF ALL RAMS ANALYSIS, INCLUDING THE DEPTH OF ANALYSIS ACTIVITIES....... .96

MAKE SURE THAT THE REQUIREMENTS OF THIS STANDARD ARE IMPLEMENTED WITHINBUSINESS PROCESSES, SUPPORTED BY A QUALITY MANAGEMENT SYSTEM (QMS) COMPLIANTWITH THE REQUIREMENTS OF EN ISO 9000 SERIES..............................................................................96

ESTABLISH AND IMPLEMENT AN ADEQUATE AND EFFECTIVE CONFIGURATIONMANAGEMENT SYSTEM, AT LEAST INCLUDING:....................................................................................96

1 ALL SYSTEM DOCUMENTATION.....................................................................................................96

2 ALL OTHER SYSTEM DELIVERABLES ...........................................................................................96

8 SPECIFYING RAM REQUIREMENTS.................................................................................................97

THE PURPOSE OF THIS SECTION IS TO ESTABLISH THE PROCESS TO DEFINE RAMREQUIREMENTS FOR ROLLING STOCK AND FOR ALL THE SUBSYSTEMS, ASSEMBLIES ANDPARTS BELONGING TO THE ROLLING STOCK ACCORDING TO THE BOUNDARY LIMITS.................97

THE DEFINITION PROCESS IS CARRIED OUT THROUGH DIFFERENT ACTIVITIES WITH THESCOPE OF OBTAINING DATA AND ALL KIND OF AVAILABLE INFORMATION ABOUT THE ROLLINGSTOCK UNDER CONSIDERATION..............................................................................................................97

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THE FINAL GOAL IS THE DERIVATION OF RAM TARGETS THROUGH THE ANALYSIS OF ALLTHE INFORMATION COLLECTED AND ORGANISED IN A STRUCTURED WAY.....................................97

8.1 PRELIMINARY RAM ANALYSIS.......................................................................................................................97

8.1.1 Introduction....................................................................................................................................97

THE PRELIMINARY RAM ANALYSIS HAS THE PURPOSE OF IDENTIFYING THE APPLICATIONENVIRONMENT AND THE OPERATING CONDITIONS OF THE ROLLING STOCK, IN ORDER TORECOGNISE THE FUNDAMENTAL CONCEPTS WHICH THE OVERALL RAM REQUIREMENTS HAVETO BE BASED ON.........................................................................................................................................97

THE ANALYSIS IS DEVELOPED THROUGH DIFFERENT ACTIVITIES TO COVER THEFOLLOWING ASPECTS:...............................................................................................................................97

SIMILAR SYSTEM REVIEW:.................................................................................................................97

A LIST OF THE EXISTING ROLLING STOCK, APPLICABLE FOR PROVIDING SUITABLE RAM-

RELATED INFORMATION, IS MADE;..........................................................................................................97

PRELIMINARY SYSTEM ANALYSIS: ..................................................................................................97

THE ROLLING STOCK AVAILABLE DOCUMENTATION IS REVIEWED IN ORDER TO DEFINE, ATA PRELIMINARY LEVEL, THE OVERALL SYSTEM STRUCTURE AND ITS MISSION PROFILE AND TORECOGNISE THE SYSTEM FAILURE CONDITIONS..................................................................................97

THE DELIVERABLES OF THESE PRELIMINARY RAM-RELATED ACTIVITIES CONSTITUTE THEBACKGROUND NECESSARY FOR DEFINING THE OVERALL RAM REQUIREMENTS SPECIFICATIONIN TERMS OF:...............................................................................................................................................97

RAM REQUIREMENTS;........................................................................................................................97

DEMONSTRATION AND ACCEPTANCE CRITERIA;..........................................................................97

RAM PROGRAMME REQUIREMENTS.................................................................................................97

8.1.2 Preliminary RAM Analysis activities...............................................................................................97

THE PRELIMINARY RAM-RELATED ACTIVITIES CONSIST IN INVESTIGATING ALL THERELEVANT AVAILABLE DOCUMENTATION IN ORDER TO RECOGNISE ALL THE FUNCTIONALREQUIREMENTS WHICH MAY AFFECT THE RAM PERFORMANCES OF THE ROLLING STOCK........97

THE DELIVERABLES OF THE PRELIMINARY RAM-RELATED ACTIVITIES RESULT:....................97

SYSTEM IDENTIFICATION, WHERE THE ROLLING STOCK HAS TO BE IDENTIFIED IN TERMS OFBOUNDARY LIMITS, OPERATIONAL CONDITIONS, FUNCTIONS, INTERFACES, STRUCTURE,LOGISTICS AND MAINTENANCE CONDITIONS.........................................................................................97

FAILURE CONDITIONS, WHERE THE FAILURES OF THE ROLLING STOCK HAVE TO BEIDENTIFIED AND CATEGORISED IN ORDER TO DEFINE APPROPRIATE REQUIREMENTS.................97

8.1.3 System Identification ....................................................................................................................98

THIS SECTION PROVIDES FOR A GENERAL OVERVIEW OF THE MAIN FEATURES IDENTIFYINGA ROLLING STOCK (SEE ANNEX A, ITEM A2 OF EN 50126)....................................................................98

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THE IDENTIFICATION PROCESS FOR A ROLLING STOCK IS MADE IN ORDER TO GAINASSURANCE THAT THE PROCESS IS CORRECTLY ANALYSING ALL THE FACTORS INFLUENCINGTHE RAM PERFORMANCES........................................................................................................................98

THESE CHARACTERISTICS DEFINE THE CONDITIONS UNDER WHICH THE ROLLING STOCK ISREQUIRED TO ACCOMPLISH ITS MISSION AND CONSTITUTE THE REFERENCE CONDITIONS FOR:98

DEFINING THE ROLLING STOCK RAM REQUIREMENTS.................................................................98

DEMONSTRATING, BY ANALYSIS AND TESTS, THAT EACH SPECIFIC IMPLEMENTATIONFULFILS THE RAM REQUIREMENTS IN ALL THE LIFECYCLE PHASES.................................................98

THE MAIN CHARACTERISTICS AND FEATURES NECESSARY TO DESCRIBE A ROLLING STOCKARE THE MISSION PROFILE, OPERATING CONDITIONS, ENVIRONMENTAL CONDITIONS ANDMAINTENANCE CONDITIONS (INCLUDING LOGISTICS):.........................................................................98

1 MISSION PROFILE :...........................................................................................................................98

ROUTE OF REFERENCE......................................................................................................................98

COMMERCIAL SPEED (MISSION DURATION / MISSION LENGTH)..................................................98

MEAN LENGTH OF A RUN ..................................................................................................................98

MEAN DISTANCE BETWEEN TRAIN STOPS .....................................................................................98

NUMBER OF TUNNELS RELATED TO COMMERCIAL DISTANCE...................................................98

NUMBER OF VIADUCTS RELATED TO COMMERCIAL DISTANCE .................................................98

DISTANCE CUMULATED UNDER TUNNEL ........................................................................................98

DISTANCE CUMULATED ON TUNNELS.............................................................................................98

OPERATING TIME OR DISTANCE PER YEAR....................................................................................98

REVENUE OPERATING TIME OR DISTANCE PER YEAR..................................................................98

STAND-BY TIME PER DAY...................................................................................................................98

OFF-OPERATING TIME PER DAY........................................................................................................98

PLANNED TOTAL TIME OF USE (LIFE EXPECTANCY IN YEARS)...................................................98

SLOPES.................................................................................................................................................98

2 OPERATING CONDITIONS :..............................................................................................................98

EQUIVALENT SPEED RELATED TO THE TIME THE EQUIPMENT IS POWERED DURING A GIVENCALENDAR PERIOD (CUMULATED DISTANCE / TIME THE EQUIPMENT IS POWERED OVER THEPERIOD).........................................................................................................................................................98

TIME AN EQUIPMENT IS POWERED OVER A GIVEN CALENDAR PERIOD (THIS PARAMETERCOULD BE DEFINED FOR EACH EQUIPMENT, BUT IS GENERALLY DEFINED FOR CATEGORIES OF

EQUIPMENT).................................................................................................................................................98

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TIME DURING WHICH TRACTION IS ACTIVATED..............................................................................98

TIME DURING WHICH ELECTRIC BRAKING IS ACTIVATED.............................................................98

OPERATING TIME OF THE COMPRESSOR........................................................................................98

NUMBER OF COMPRESSOR STARTING UP......................................................................................99

TIME OF PRESENCE OF CATENARY POWER, FOR EACH VOLTAGE............................................99

TIME DURING WHICH TRAINSET IS AWAKEN...................................................................................99

OPERATING TIME FOR HEATING VENTILATION AIR CONDITIONING IN HEATING MODE ANDAIR CONDITIONING MODE..........................................................................................................................99

AVERAGE SPEED, MAXIMUM SPEED................................................................................................99

POTENTIAL USE IN MULTIPLE UNITS................................................................................................99

TIME OF COUPLING.............................................................................................................................99

INTERNAL TEMPERATURE RANGE OF THE ROLLING STOCK.......................................................99

MECHANICAL (SHOCK AND VIBRATION)..........................................................................................99

ELECTRICAL (POWER SUPPLIES).....................................................................................................99

ELECTROMAGNETIC COMPATIBILITY...............................................................................................99

ERGONOMICS.......................................................................................................................................99

3 ENVIRONMENTAL CONDITIONS :....................................................................................................99

RANGE OF OUTSIDE TEMPERATURES.............................................................................................99

MAXIMUM HEIGHT ABOVE THE SEA LEVEL.....................................................................................99

AMBIENT TEMPERATURE...................................................................................................................99

SOLAR RADIATION..............................................................................................................................99

HUMIDITY..............................................................................................................................................99

WIND AND PRESSURE PULSES.........................................................................................................99

ALTITUDE..............................................................................................................................................99

WATER AND PRECIPITATION.............................................................................................................99

POLLUTANTS AND CONTAMINANTS.................................................................................................99

ALSO, CRITERIA FOR DETERMINING NORMAL ENVIRONMENTAL CONDITIONS CAN BE FOUNDWITHIN PR ENV 50127-1 AND EN 60721-1..................................................................................................99

4 MAINTENANCE CONDITIONS :.........................................................................................................99

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INDICATIVE MAINTENANCE PLAN (I.E. MINIMUM PREVENTIVE MAINTENANCE INTERVAL,MAXIMUM CONTEMPORARY NUMBER OF PERSONNEL REQUIRED FOR MAINTENANCE INTERVALTASKS, MAXIMUM STANDSTILL TIME TO COMPLETE MAINTENANCE INTERVAL TASKS, ETC…).. .99

NUMBER, LOCATION AND DESCRIPTION OF THE SITES OF MAINTENANCE..............................99

DESCRIPTION OF THE STANDARD EQUIPMENT, TOOLS AND RESOURCES OF THE SITES OFMAINTENANCE.............................................................................................................................................99

8.1.4 Breakdown Structure and boundary limits ....................................................................................99

THE BREAKDOWN STRUCTURE OF THE ROLLING STOCK IS THE MOST IMPORTANTBASELINE OF THE IDENTIFICATION PROCESS. ESTABLISHING A STRUCTURE OF THE ROLLINGSTOCK, A CLEAR REFERENCE OUTLINE IS GIVEN TO ALL THE ACTIVITIES AND ANALYSESSUPPORTING RAM PROGRAMME ALONG THE LIFE CYCLE..................................................................99

GENERALLY, THE SCOPE OF THE STRUCTURE IS TO SET UP THE BORDERS OF A SYSTEM BYLISTING ALL THE ITEMS BELONGING TO THE STRUCTURE OF THAT SYSTEM AND USING AN

APPROPRIATE NUMBER OF DISCRETE LEVELS TO DISTINGUISH THE RELATIONSHIPS EXISTINGBETWEEN DIFFERENT AREAS OF THE ROLLING STOCK....................................................................100

8.1.4.1 Common rules to set up a structure.........................................................................................................100

SETTING UP A STRUCTURE, A DECOMPOSITION PROCESS IS CARRIED OUT STARTING FROMTHE FIRST LEVEL TO THE OTHER LEVELS IDENTIFIED AND BEING ABLE TO REPRESENT ALL THEITEMS AND ITS FUNCTIONAL RELATIONSHIPS.....................................................................................100

THE DECOMPOSITION PROCESS IS BASED ON A HIERARCHICAL BREAKDOWN IN A TOPDOWN PROCESS COMMENCING WITH THE ROLLING STOCK AS THE SYSTEM UNDERCONSIDERATION........................................................................................................................................100

AT EACH LEVEL IDENTIFIED IN THE HIERARCHY, EVERY SYSTEM IDENTIFIED BECOMES THENEXT SYSTEM UNDER CONSIDERATION AND CAN BE FURTHER DECOMPOSED INTO LOWERLEVEL ITEMS, AS NECESSARY................................................................................................................100

THERE ARE SEVERAL METHODS AND TOOLS TO SET UP A STRUCTURE, BUT HERE THEFOLLOWING ARE RECOMMENDATIONS TO BE FOLLOWED IN ORDER TO DEVELOP ANAPPROPRIATE AND SUITABLE STRUCTURE FOR RAM PURPOSES:.................................................100

AVOID THE USE OF "INFINITE LEVELS STRUCTURE" AND LIMIT THE LEVELS UP TO AREASONABLE NUMBER (3 OR 4 ARE SUGGESTED).............................................................................100

THE LAST ITEM IDENTIFIED ALONG A BRANCH MUST BE A LRU (LINE REPLACEABLE UNIT)100

FORCE TO USE THE SAME DEFINITIONS WHEN IDENTICAL ITEMS ARE DEFINED...................100

BE SURE THAT THE DEFINITION USED FOR EVERY ITEM IS THE SAME USED ALONG ALL THEDESIGN DOCUMENTS (DRAWINGS, OUTLINES, DIAGRAMS, SPECIFICATIONS, ETC…).............. ....100

AFTER THE FIRST ISSUE OF THE STRUCTURE AVOID CONTINUOUS MODIFICATIONS...........100

AVOID THE USE OF VAGUE OR UNCLEAR DEFINITIONS..............................................................100

THE DEFINITION USED FOR LRU (LINE REPLACEABLE UNIT) IS WELL EXPLAINED WITHIN8.5.4.3...........................................................................................................................................................100

8.1.4.2 Data to identify the Structure...................................................................................................................100

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EVERY STRUCTURE MUST BE PRESENTED TOGETHER WITH A SET OF DRAWINGS,DIAGRAMS, FUNCTIONAL OUTLINES IN ORDER TO MEET THE TARGET OF IDENTIFYING THEROLLING STOCK AND ALL THE SUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TOROLLING STOCK CLARIFYING AT LEAST:.............................................................................................100

ALL THE RELATIONSHIPS BETWEEN THE ITEMS OF THE STRUCTURE.....................................100

THE FUNCTIONAL BORDERS BETWEEN DIFFERENT SYSTEMS, SUBSYSTEMS, ASSEMBLIES100

A MINIMUM SET OF DATA IS USED TO REPRESENT AND TO MANAGE THE STRUCTURE... .. .100

THIS KIND OF DATA IS THE BASELINE OF THE DIFFERENT ANALYSES THAT WILL BECARRIED OUT DURING THE LIFE CYCLE................................................................................................100

EVERY STRUCTURE SHOULD BE REPRESENTED WITH A HEADER CONTAINING AT LEASTTHE FOLLOWING:......................................................................................................................................100

ROLLING STOCK................................................................................................................................101

ID CODE OR DEFINITION OF ROLLING STOCK...............................................................................101

DOC.N..................................................................................................................................................101

CODE OF DOCUMENT........................................................................................................................101

DATE....................................................................................................................................................101

DATE OF DOCUMENT........................................................................................................................101

PAGE N/N............................................................................................................................................101

CONSECUTIVE NUMBER OF PAGE/TOTAL NUMBER OF PAGES.................................................101

DRAWN UP BY....................................................................................................................................101

FIRST AND LAST NAME OF AUTHOR..............................................................................................101

FILENAME...........................................................................................................................................101

NAME OF FILE OF THE DOCUMENT.................................................................................................101

THE FOLLOWING ARE THE MINIMUM SET OF DATA TO REPRESENT A STRUCTURE:.............101

.............................................................................................................................................................101

CODE...................................................................................................................................................101

BREAKDOWN LEVEL CODE OF THE ITEM......................................................................................101

DESCRIPTION.....................................................................................................................................101

DESCRIPTION OF THE ITEM..............................................................................................................101

QTY......................................................................................................................................................101

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AMOUNT OF THE ITEM UNDER CONSIDERATION IN THE HIGHER LEVEL ITEM........................101

THE USE OF QUANTITY INFORMATION IS SUGGESTED FOR BREAKDOWN STRUCTUREWHERE THE PRODUCT IS DEFINED........................................................................................................101

AS APPROPRIATE, IT IS RECOMMENDED THE USE OF THE PART NUMBER FOR EVERY ITEMOF THE STRUCTURE.................................................................................................................................101

PART NO.............................................................................................................................................101

PART NO. OF THE ITEM.....................................................................................................................101

EXAMPLES OF BREAKDOWN STRUCTURE ARE GIVEN WITHIN ANNEX A - EXAMPLES OFBREAKDOWN STRUCTURE......................................................................................................................101

8.2 FAILURE CONDITIONS................................................................................................................................102

THE FOLLOWING GENERAL FAILURE CONDITIONS ARE DEFINED FOR THE ROLLING STOCKACCORDING TO THE GENERAL FAILURE CATEGORIES WHICH MAY BE EXPERIENCED BY AGENERIC RAILWAY TRANSPORT (SEE 4.5.2.2 IN EN 50126):..............................................................102

IMMOBILISING FAILURE....................................................................................................................102

SERVICE FAILURE.............................................................................................................................102

MINOR FAILURE.................................................................................................................................102

THE FOLLOWING TABLE SHOWS THE FAILURE CATEGORIES AS INDICATED IN EN 50126.. .102

TABLE 1: RAM FAILURE CATEGORIES...........................................................................................102

FAILURE CATEGORY.........................................................................................................................102

DEFINITION.........................................................................................................................................102

SIGNIFICANT.......................................................................................................................................102

(IMMOBILISING FAILURE)..................................................................................................................102

A FAILURE THAT:...............................................................................................................................102

- PREVENTS TRAIN MOVEMENT OR CAUSES A DELAY TO SERVICE GREATER THAN A

SPECIFIED TIME AND/OR .........................................................................................................................102

GENERATES A COST GREATER THAN A SPECIFIED LEVEL........................................................102

MAJOR.................................................................................................................................................102

(SERVICE FAILURE)...........................................................................................................................102

A FAILURE THAT:...............................................................................................................................102

- MUST BE RECTIFIED FOR THE SYSTEM TO ACHIEVE ITS SPECIFIED PERFORMANCE AND 102

- DOES NOT CAUSE A DELAY OR COST GREATER THAN THE MINIMUM THRESHOLD

SPECIFIED FOR A SIGNIFICANT FAILURE..............................................................................................102

Page 13 of 158





MINOR..................................................................................................................................................102

A FAILURE THAT:...............................................................................................................................102

- DOES NOT PREVENT A SYSTEM ACHIEVING ITS SPECIFIED PERFORMANCE AND ..............102

DOES NOT MEET CRITERIA FOR SIGNIFICANT OR MAJOR FAILURES.......................................102

IN ORDER TO BETTER DEFINE THE ABOVE MENTIONED FAILURE CATEGORIES THEFOLLOWING CONDITIONS ARE APPLICABLE TO ROLLING STOCK AND TO ALL THE SUBSYSTEMS,ASSEMBLIES AND PARTS BELONGING TO ROLLING STOCK :...........................................................102

SIGNIFICANT FAILURE (IMMOBILISING FAILURE): ANY FAILURE OCCURRING ON ROLLINGSTOCK AND LEADING, AT LEAST, TO ONE OF THE FOLLOWING CONDITIONS:...............................102

A DELAY GREATER THAN A SPECIFIED TIME................................................................................102

A STOP OF THE TRAIN ON THE TRACK..........................................................................................102

A WITHDRAWAL OF THE TRAIN FROM SERVICE ..........................................................................102

A COST GREATER THAN A SPECIFIED THRESHOLD....................................................................102

MAJOR FAILURE (SERVICE FAILURE): ANY FAILURE OCCURRING ON THE ROLLING STOCKAND LEADING, AT LEAST, TO ONE OF THE FOLLOWING CONDITIONS:............................................102

A DELAY LESS THAN A SPECIFIED TIME........................................................................................102

FAILING SPECIFIED PERFORMANCES............................................................................................102

A COST LESS THAN A SPECIFIED THRESHOLD............................................................................102

MINOR FAILURE.................................................................................................................................103

ANY FAILURE OCCURRING ON THE ROLLING STOCK AND LEADING TO A MAINTENANCETASK, EVEN IF THIS FAILURE HAS NO IMPACT ON SERVICE..............................................................103

ACCORDING THE ABOVE MENTIONED DEFINITIONS AND CONDITIONS OF FAILURES THECUSTOMER HAS TO ESTABLISH:............................................................................................................103

THE NUMBER OF MINUTES OF DELAY FOR SIGNIFICANT FAILURES AND MAJOR FAILURE. 103

THE THRESHOLD COST FOR SIGNIFICANT FAILURES AND MAJOR FAILURE..........................103

THE MODE OF COUNTING THE DELAY (I.E. AT THE END OF THE RUN ONLY, CUMULATEDDURING ALL THE STOPS, THE MAXIMUM BETWEEN TWO STOPS, ETC…).......................................103

SPECIAL SERVICE CONDITIONS UNDER WHICH THE CUSTOMER DECIDES FOR STOPPINGTHE TRAIN ON THE TRACK OR WITHDRAWING THE TRAIN FROM THE SERVICE IN CASE OFSIGNIFICANT FAILURE OR CONSIDER A MAJOR FAILURE FOR SPECIFIED PERFORMANCESFAILED (I.E. THE FAILURE OF THE PASSENGER AIR-CONDITIONING, THE FAILURE OF DRIVER’SCAB AIR-CONDITIONING, THE FAILURE OF DOOR SYSTEM PER SIDE, THE FAILURE OF ASPECIFIED NUMBER OF TOILET SYSTEM, THE FAILURE OF THE COACH LIGHTING SYSTEM,ETC…)..........................................................................................................................................................103

THE FOLLOWING TABLES SHOW THE SPECIFICATIONS OF EACH FAILURE CATEGORY. ....103

Page 14 of 158





TABLE 2: SIGNIFICANT FAILURE SPECIFICATION.........................................................................103


CONDITIONS.......................................................................................................................................103

THRESHOLD DIMENSION..................................................................................................................103

SPECIFICATION REQUESTED...........................................................................................................103

SIGNIFICANT.......................................................................................................................................103

(IMMOBILISING FAILURE)..................................................................................................................103

FCI........................................................................................................................................................103

DELAY GREATER THAN....................................................................................................................103

MINUTES.............................................................................................................................................103

SPECIFY MODE OF COUNTING DELAY...........................................................................................103

STOP OF THE TRAIN ON THE TRACK..............................................................................................103

ROLLING STOCK DOES NOT RUN ON ITS OWN.............................................................................103

WITHDRAWAL OF THE TRAIN ON THE SERVICE...........................................................................103

SPECIFY SPECIAL SERVICE CONDITIONS UNDER WHICH THE CUSTOMER DECIDES FORSTOPPING THE TRAIN ON THE TRACK OR WITHDRAWING THE TRAIN FROM THE SERVICE ........103

COST GREATER THAN......................................................................................................................103

MONEY................................................................................................................................................103

TABLE 3: MAJOR FAILURE SPECIFICATION...................................................................................104


CONDITIONS.......................................................................................................................................104



MAJOR.................................................................................................................................................104

(SERVICE FAILURE)...........................................................................................................................104

FCS......................................................................................................................................................104

DELAY LESS THAN............................................................................................................................104

MINUTES.............................................................................................................................................104

Page 15 of 158





SPECIFY MODE OF COUNTING DELAY...........................................................................................104

FAILING SPECIFIED PERFORMANCE..............................................................................................104

SPECIFY SERVICE CONDITIONS UNDER WHICH THE CUSTOMER CONSIDERS FAILED THEPERFORMANCE.........................................................................................................................................104

COST LESS THAN..............................................................................................................................104

MONEY................................................................................................................................................104

TABLE 4: MINOR FAILURE SPECIFICATION....................................................................................104


CONDITIONS.......................................................................................................................................104



MINOR..................................................................................................................................................104

FCM......................................................................................................................................................104

ANY FAILURE OCCURRING ON THE ROLLING STOCK.................................................................104

8.3 RAM REQUIREMENTS...............................................................................................................................105

8.3.1 Introduction..................................................................................................................................105

THE AIM OF THIS PARAGRAPH IS TO GIVE AN OVERVIEW OF THE MOST USED RAMREQUIREMENTS IN ORDER TO HELP CUSTOMER IN CHOOSING OF THE APPROPRIATEREQUIREMENTS FOR ROLLING STOCK..................................................................................................105

CHOOSING THE APPROPRIATE RAM REQUIREMENTS, THE CUSTOMER IS STRONGLY ASKEDTO CONSIDER:...........................................................................................................................................105

SYSTEM IDENTIFICATION CHARACTERISTICS (MISSION PROFILE, OPERATING CONDITION,FUNCTION REQUESTED, ETC…)..............................................................................................................105

ECONOMIC IMPLICATIONS ..............................................................................................................105

THE PRACTICAL POSSIBILITY TO MEASURE RAM REQUIREMENTS FROM THE FIELD INOPERATION ACCORDING TO ITS ORGANISATIONAL AND LOGISTICAL STRUCTURE AND SERVICEPROCEDURES............................................................................................................................................105

THE CUSTOMER SHOULD DOCUMENT THE CHOOSING PROCESS OF RAM REQUIREMENTSSPECIFYING THE CONSIDERATION ADOPTED TO ADDRESS EACH REQUIREMENT CHOSEN.......105

8.3.2 Reliability Targets........................................................................................................................105

THIS SECTION DESCRIBES THE RELIABILITY TARGETS REQUIRED FOR THE FAILURECATEGORIES SIGNIFICANT (IMMOBILISING), MAJOR (SERVICE) AND MINOR FAILURE. (I.E. MTBF INHOURS, FAILURE RATE PER MILLION OF HOURS/KILOMETRES).......................................................105

Page 16 of 158





THE RELIABILITY TARGETS ARE APPLICABLE TO THE TOTAL ROLLING STOCK AND TO ALLTHE SUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TO THE ROLLING STOCK ACCORDINGTO THE BOUNDARY LIMITS DEFINED.....................................................................................................105

USING THE ABOVE MENTIONED DEFINITIONS THE CUSTOMER INDICATES THE RELIABILITYTARGETS FOR EACH ONE OF THE FAILURE CATEGORIES IN TERMS OF:........................................105

MAXIMUM ACCEPTED FAILURE RATE (NUMBERS OF FAILURES PER MILLIONHOURS/KILOMETRES)...............................................................................................................................105

MINIMUM ACCEPTED MTBF/MTTF/MDBF (MEAN NUMBER OF HOURS/KILOMETRESBETWEEN/TO FAILURES)..........................................................................................................................105

THE TERMS HOURS/KILOMETRES ARE TO BE INTENDED AS HOURS/KILOMETRES OFSERVICE......................................................................................................................................................105

THE REQUIREMENT MTBF IS INTENDED FOR REPAIRABLE UNITS AND MTTF IS INTENDED

FOR NON-REPAIRABLE UNITS.................................................................................................................105

IF THE REAL OPERATING TIME OF SERVICE FOR THE ROLLING STOCK AND FOR THESUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TO THE ROLLING STOCK MAY NOT BEMEASURED, THE CUSTOMER CAN CHOOSE, AS APPROPRIATE, THE FOLLOWINGS:....................105

MAXIMUM ACCEPTED FAILURE RATE (NUMBERS OF FAILURES PER MILLION / KILOMETRES)105

MINIMUM ACCEPTED MDBF (NUMBER OF KILOMETRES)............................................................105

THE MDBF IS TO BE UNDERSTOOD IN THE FOLLOWING WAY:..................................................105

THE TOTAL DISTANCE TRAVELLED OVER A PERIOD OF TIME / THE TOTAL NUMBER OFFAILURES OCCURRING DURING THE SAME PERIOD...........................................................................105

IN ADDITION, RELIABILITY TARGETS COULD BE SPECIFIED BY THE CUSTOMER FORIMPORTANT SYSTEMS/SUBSYSTEMS. IN THIS CASE THE CUSTOMER COULD APPLY THEFOLLOWING DEFINITION FOR FAILURES AFFECTING IMPORTANT SYSTEMS/SUBSYSTEMS:.......106

ANY FAILURE OCCURRING ON THE SYSTEM/SUBSYSTEM AND LEADING TO FAIL SPECIFIEDPERFORMANCES.......................................................................................................................................106

ANY FAILURE OCCURRING ON THE SYSTEM/SUBSYSTEM AND LEADING TO A MAINTENANCETASK, EVEN IF THIS FAILURE HAS NO IMPACT ON SERVICE..............................................................106

THE CUSTOMER SHOULD SPECIFY THE FAILURE CONDITIONS IN WHICH THESYSTEM/SUBSYSTEM DOES NOT ACCOMPLISH ITS SPECIFIED PERFORMANCES. .......................106

THE FOLLOWING TABLE GROUP THE ABOVE MENTIONED RELIABILITY REQUIREMENTS:. .106

TABLE 5: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY SIGNIFICANT(IMMOBILISING FAILURE).........................................................................................................................106

APPLICABLE TO:................................................................................................................................106

REQUIREMENT...................................................................................................................................106

DIMENSION.........................................................................................................................................106

Page 17 of 158





SYMBOL..............................................................................................................................................106

ROLLING STOCK................................................................................................................................106

MAX N. OF FAILURES........................................................................................................................106

NUMBER / MILLION KM .....................................................................................................................106

OR........................................................................................................................................................106

NUMBER / MILLION HOURS..............................................................................................................106

FRI........................................................................................................................................................106

MTBF/MTTF/MDBF..............................................................................................................................106

HOURS OR KILOMETRES..................................................................................................................106

MTBFI/MTTFI/MDBFI...........................................................................................................................106

SYSTEM/..............................................................................................................................................106

SUBSYSTEM 1....................................................................................................................................106

MAX N. OF FAILURES........................................................................................................................106


OR........................................................................................................................................................106


FRI........................................................................................................................................................106

MTBF/MTTF/MDBF..............................................................................................................................106



SYSTEM/..............................................................................................................................................106

SUBSYSTEM 2....................................................................................................................................106

MAX N. OF FAILURES........................................................................................................................106


OR........................................................................................................................................................106


FRI........................................................................................................................................................106

MTBF/MTTF/MDBF..............................................................................................................................106

Page 18 of 158







SYSTEM/..............................................................................................................................................106

SUBSYSTEM …...................................................................................................................................106

MAX N. OF FAILURES........................................................................................................................106


OR........................................................................................................................................................106


FRI........................................................................................................................................................106

MTBF/MTTF/MDBF..............................................................................................................................106



SYSTEM/..............................................................................................................................................106

SUBSYSTEM N....................................................................................................................................106

MAX N. OF FAILURES........................................................................................................................106


OR........................................................................................................................................................106


FRI........................................................................................................................................................106

MTBF/MTTF/MDBF..............................................................................................................................106



TABLE 6: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MAJOR (SERVICEFAILURE).....................................................................................................................................................107

APPLICABLE TO:................................................................................................................................107

REQUIREMENT...................................................................................................................................107

DIMENSION.........................................................................................................................................107

SYMBOL..............................................................................................................................................107

Page 19 of 158





ROLLING STOCK................................................................................................................................107

MAX N. OF FAILURES........................................................................................................................107


OR........................................................................................................................................................107


FRS......................................................................................................................................................107

MTBF/MTTF/MDBF..............................................................................................................................107


MTBFS/MTTFS/MDBFS.......................................................................................................................107

SYSTEM/..............................................................................................................................................107

SUBSYSTEM 1....................................................................................................................................107

MAX N. OF FAILURES........................................................................................................................107


OR........................................................................................................................................................107


FRS......................................................................................................................................................107

MTBF/MTTF/MDBF..............................................................................................................................107



SYSTEM/..............................................................................................................................................107

SUBSYSTEM 2....................................................................................................................................107

MAX N. OF FAILURES........................................................................................................................107


OR........................................................................................................................................................107


FRS......................................................................................................................................................107

MTBF/MTTF/MDBF..............................................................................................................................107


Page 20 of 158






SYSTEM/..............................................................................................................................................107

SUBSYSTEM …...................................................................................................................................107

MAX N. OF FAILURES........................................................................................................................107


OR........................................................................................................................................................107


FRS......................................................................................................................................................107

MTBF/MTTF/MDBF..............................................................................................................................107



SYSTEM/..............................................................................................................................................107

SUBSYSTEM N....................................................................................................................................107

MAX N. OF FAILURES........................................................................................................................107


OR........................................................................................................................................................107


FRS......................................................................................................................................................107

MTBF/MTTF/MDBF..............................................................................................................................107



TABLE 7: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MINOR..............................108

APPLICABLE TO:................................................................................................................................108

REQUIREMENT...................................................................................................................................108

DIMENSION.........................................................................................................................................108

SYMBOL..............................................................................................................................................108

ROLLING STOCK................................................................................................................................108

MAX N. OF FAILURES........................................................................................................................108

Page 21 of 158






OR........................................................................................................................................................108


FRM......................................................................................................................................................108

MTBF/MTTF/MDBF..............................................................................................................................108


MTBFM/MTTFM/MDBFM.....................................................................................................................108

SYSTEM/..............................................................................................................................................108

SUBSYSTEM 1....................................................................................................................................108

MAX N. OF FAILURES........................................................................................................................108


OR........................................................................................................................................................108


FRM......................................................................................................................................................108

MTBF/MTTF/MDBF..............................................................................................................................108



SYSTEM/..............................................................................................................................................108

SUBSYSTEM 2....................................................................................................................................108

MAX N. OF FAILURES........................................................................................................................108


OR........................................................................................................................................................108


FRM......................................................................................................................................................108

MTBF/MTTF/MDBF..............................................................................................................................108



SYSTEM/..............................................................................................................................................108

Page 22 of 158





SUBSYSTEM …...................................................................................................................................108

MAX N. OF FAILURES........................................................................................................................108


OR........................................................................................................................................................108


FRM......................................................................................................................................................108

MTBF/MTTF/MDBF..............................................................................................................................108



SYSTEM/..............................................................................................................................................108

SUBSYSTEM N....................................................................................................................................108

MAX N. OF FAILURES........................................................................................................................108


OR........................................................................................................................................................108


FRM......................................................................................................................................................108

MTBF/MTTF/MDBF..............................................................................................................................108



THE CUSTOMER CAN ESTABLISH DIFFERENT TABLES FOR EACH ONE FAILURE CATEGORYSPECIFYING THE REQUIREMENTS APPLICABLE FOR EACH TABLE..................................................108

THE REQUIREMENTS APPLICABLE TO SYSTEMS/SUBSYSTEMS OF THE ROLLING STOCK

HAVE TO BE REFERRED TO THE BREAKDOWN STRUCTURE IN WHICH EACHSYSTEM/SUBSYSTEM IS CLEARLY IDENTIFIED.....................................................................................108

8.3.3 Maintainability Targets.................................................................................................................108

THIS SECTION DESCRIBES THE MAINTAINABILITY TARGETS REQUIRED FOR ROLLINGSTOCK AND FOR ALL THE SUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TO THEROLLING STOCK ACCORDING TO THE BOUNDARY LIMITS DEFINED................................................108

FOR A ROLLING STOCK AND FOR ALL THE SUBSYSTEMS, ASSEMBLIES AND PARTSBELONGING TO THE ROLLING STOCK ACCORDING TO THE BOUNDARY LIMITS DEFINED THEREARE DIFFERENT TYPES OF MAINTAINABILITY TARGETS: ..................................................................108

Page 23 of 158





GENERIC QUALITATIVE REQUIREMENTS (ACCESSIBILITY, DISMOUNTING, HANDINESS,STANDARDISATION, ETC…).....................................................................................................................108

PREVENTIVE MAINTENANCE REQUIREMENTS (QUALITATIVE/QUANTITATIVE) (I.E.

FREQUENCY, MAXIMUM NUMBER OF PERSONNEL RELATED TO EACH FREQUENCY, MAXIMUMNUMBER OF HOURS RELATED TO EACH FREQUENCY, ETC…)..........................................................108

CORRECTIVE MAINTENANCE REQUIREMENTS (QUALITATIVE/QUANTITATIVE) (I.E. MTTR,MAXIMUM TTR, ETC…)..............................................................................................................................108

LOGISTIC SUPPORT REQUIREMENTS (SUPPLY AND ADMINISTRATIVE DELAY, SPARE PARTSAVAILABILITY, ETC…)...............................................................................................................................109

MAINTENANCE COST REQUIREMENTS..........................................................................................109

8.3.3.1 Generic Qualitative Requirements for Maintainability..............................................................................109

THE QUALITATIVE REQUIREMENTS OF MAINTAINABILITY SHOULD CONSIDER AT LEAST THE

FOLLOWING, AS AN EXAMPLE:...............................................................................................................109

TABLE 8: QUALITATIVE REQUIREMENTS FOR MAINTAINABILITY..............................................109

ACCESSIBILITY:.................................................................................................................................109

THE LAYOUT OF EACH PIECE OF EQUIPMENT AND ITS POSITION ON THE ROLLING STOCKAND RELATIVE CONNECTIONS SHALL BE MADE IN SUCH A WAY AS TO MAKE IT POSSIBLE TOPERFORM INSPECTIONS, REPAIRS, REVISION, REPLACEMENT, TAKING INTO CONSIDERATIONTHE DIMENSIONS OF THE TOOLS THAT MAY BE NECESSARY TO PERFORM THESE OPERATIONS,THE WORKING AREA NECESSARY FOR THE MAINTENANCE PERSONNEL, THE SAFETYSTANDARDS AND POSSIBLE NEED FOR LOCALISED ILLUMINATION................................................109

ALL FASTENING POINTS OF THE EQUIPMENT AND INTERFACING POINTS BETWEEN IT ANDTHE INFRASTRUCTURES (VENTILATION CHANNELS, FANS, FILTERS, ETC.) SHALL, AS A RULE, BEACCESSIBLE WITHOUT THE NEED OF SPECIAL TOOLS......................................................................109

DISMOUNTING:...................................................................................................................................109

IT MUST BE POSSIBLE TO DISMANTLE ANY PIECE OF EQUIPMENT, OR ANY PART OF IT, INCASE OF NEED FOR FAILURE OR SCHEDULED MAINTENANCE, WITHOUT HAVING TO OPERATEON OTHER PIECES OF EQUIPMENT NOT DIRECTLY INVOLVED IN THE SPECIFIC MAINTENANCEACTION........................................................................................................................................................109

EVALUATION OF REMOVABILITY SHOULD ALSO TAKE INTO ACCOUNT THE POSSIBLE NEEDTO REMOVE PARTS OF THE STRUCTURE OF THE ROLLING STOCK (HATCHES, CASINGS, ETC.)AND THE EASE OF DISMANTLING OR OPENING AND HANDLING THEM............................................109

MODULARITY:.....................................................................................................................................109

IN DESIGNING EQUIPMENT EVERY OPPORTUNITY SHOULD BE APPLIED TO INCREASE THEMODULARITY OF THE OBJECT SO AS TO REDUCE INTERVENTION TIME, THE SPECIALISATION OFTHE PERSONNEL REQUIRED AND THE STOCKS TO BE KEPT ON HAND..........................................109

MODULARITY SHOULD MAKE IT POSSIBLE TO DIVIDE MAINTENANCE ACTIVITIES INTO TWOLEVELS: PRIMARY MAINTENANCE (RAPID REPLACEMENT OF THE UNIT), SECONDARYMAINTENANCE (REPAIR OF THE UNIT ON THE WORKBENCH)...........................................................109

HANDINESS:.......................................................................................................................................109

Page 24 of 158





EVERY PIECE OF EQUIPMENT, DEVICE AND ITEM OF FURNISHING SUBJECT TO DISMANTLINGFOR REPLACEMENT, REPAIR OR PROGRAMMED MAINTENANCE SHOULD NOT EXCEED A WEIGHTOF 25 KG AND SHOULD BE CAPABLE OF BEING HANDLED WITH MANUAL MEANS BY A SINGLEPERSON......................................................................................................................................................109

THIS MAXIMUM WEIGHT CAN BE DOUBLED WHEN THE CONDITIONS OF ACCESSIBILITYMAKE IT POSSIBLE FOR TWO PERSONS TO WORK TOGETHER. THE EXTERNAL FEATURES OFTHE SHAPE OF THE UNIT IN QUESTION SHOULD MAKE IT EASY TO HANDLE AND NOTHAZARDOUS OR CAPABLE OF INJURING THE PERSONNEL...............................................................109

IN THE CASE OF OBJECTS THAT HAVE TO BE MOVED USING MECHANICAL HOISTINGEQUIPMENT AND/OR TRANSPORTATION, THE LAYOUT AND CONSTRUCTION SHOULD PROVIDEFOR MAKING AVAILABLE THE NECESSARY PROVISIONS FOR HOOKING, FASTENING, HOISTINGWITH A FORKLIFT (EYEBOLTS, HOOKS, FEET, ETC.). IF THE HOOKING, HOISTING ORTRANSPORTATION EQUIPMENT IS NOT AVAILABLE ON THE MARKET, IT MUST BE DESIGNED,CONSTRUCTED AND SUPPLIED UNDER THE RESPONSIBILITY OF THE SUPPLIER.........................109

PAGE 158 OF 158....................................................................................................................................1

THE CONNECTIONS EXISTING BETWEEN THE UNIT AND THE STRUCTURE AND BETWEEN THEUNIT AND THE OTHER UNITS INTERFACED WITH IT SHALL BE REVERSIBLE, ACCESSIBLE, NOTSUBJECT TO CORROSION AND RUST IN RELATION TO THE ENVIRONMENT IN WHICH THEY ARELOCATED....................................................................................................................................................110

EASE OF CLEANING:.........................................................................................................................110

ALL ENVIRONMENTS, APPARATUS, FLOORING AND COVERINGS SHALL BE DESIGNED INSUCH A WAY AS TO FACILITATE ALL OPERATIONS OF CLEANING TO THE UTMOST. INPARTICULAR AS REGARDS PASSENGER VEHICLES AND ENVIRONMENTS, TEXTILE COVERINGSTHAT CAN BE CLEANED EFFICIENTLY OR HAVE STAINS REMOVED WITH DRY-CLEANING

SOLVENTS APPLIED WITH MECHANICAL MEANS BY SPRAYING AND VACUUMING WITH HIGHCAPACITY USING DETERGENT PRODUCTS SHOULD BE USED. CARPETING AND WALL-TO-WALLTEXTILE FLOORING SHALL BE DESIGNED FOR EASY REPLACEMENT FOR CLEANING OFF THEROLLING STOCK BY PROVIDING APPROPRIATE BREAKS ESPECIALLY IN THE ENVIRONMENTSSUBJECT TO HEAVY TRAFFIC (CORRIDORS, VESTIBULES, ETC.)......................................................110

THE SUPPLIER SHALL INDICATE THE CLEANSERS COMPATIBLE WITH THE MATERIALS ANDCOVERINGS USED.....................................................................................................................................110

AS A GENERAL RULE, IN THE VISIBLE ENVIRONMENTS, ALL EFFORTS SHOULD BE MADE TOAVOID SHARP CORNERS, INDENTATIONS, COMPLICATED RELIEF PATTERNS OR HOLLOWSWHERE DIRT COULD ACCUMULATE OR THAT COULD BE DIFFICULT TO CLEAN. THIS SHOULD BEVERIFIED ON THE MOCK-UP....................................................................................................................110

STANDARDISATION:..........................................................................................................................110

THE SOLUTIONS USED SHOULD, TO THE MAXIMUM EXTENT, MAKE IT POSSIBLE TOINTERCHANGE PARTS WITH OTHERS ALREADY IN USE BY THE CUSTOMER AND INSTALLED ONOTHER ROLLING STOCK. IN PARTICULAR, FOR ELEMENTARY OBJECTS, COMMERCIAL ORUNIFIED SOLUTIONS SHOULD BE USED, OR PARTS ALREADY IN USE BY THE CUSTOMER ASCLASSIFIED REPLACEMENT PARTS FOR WHICH THE CUSTOMER RESERVES TO ITSELF THERIGHT, IF NECESSARY, TO SUPPLY A LIST. THERE SHOULD ALSO BE A CLOSE MATCH BETWEENTHE DRAWINGS AND THE EFFECTIVE REALISATION OF THE PNEUMATIC AND ELECTRICCIRCUITS FOR ALL ROLLING STOCK OF THE SAME SUPPLY SAME EQUIPMENT ON ALL THEROLLING STOCK OF THE SAME SUPPLY...............................................................................................110

Page 25 of 158





INTERCHANGEABILITY.....................................................................................................................110

IT HAS TO BE POSSIBLE REMOVE AN ITEM AND INSTALL ANOTHER ONE IN ITS PLACEWITHOUT AFFECTING ANY EQUIPMENT CHARACTERISTICS..............................................................110

THE REPLACEMENT SHALL BE COMPATIBLE IN FORM, FIT AND FUNCTION...........................110

TESTABILITY.......................................................................................................................................110

THE OBJECTS HAVE TO BE DESIGNED IN SUCH A WAY AS TO MAKE IT POSSIBLE TOIDENTIFY THE CONDITIONS OF THE OBJECT CLEARLY AND RAPIDLY. THIS MEANS THAT ITSHOULD BE POSSIBLE TO PERFORM PREVENTIVE DIAGNOSTICS SO AS TO CHECK THECONDITION OF THE OBJECT BEFORE A FAILURE OCCURS AND TO BE ABLE TO PERFORMCORRECTIVE DIAGNOSTICS IN ORDER TO IDENTIFY CLEARLY WHICH ARE THE ITEMS THAT MAYBE MALFUNCTIONING OR DAMAGED.....................................................................................................110

8.3.3.2 Preventive/Corrective Maintenance Requirements .................................................................................111

THE PREVENTIVE/CORRECTIVE MAINTENANCE REQUIREMENTS CAN BE OF TWO TYPES:. 111

GENERAL (REFERRED TO ALL THE MAINTENANCE ACTIONS)...................................................111

SPECIFIC (REFERRED TO MAINTENANCE ACTIONS ON A SUB-SYSTEM).................................111

EXAMPLES OF GENERAL AND SPECIFIC REQUIREMENTS CAN BE THE FOLLOWINGS:........111

TABLE 9: PREVENTIVE/CORRECTIVE MAINTENANCE REQUIREMENTS....................................111

DEFINITION.........................................................................................................................................111

DIMENSION.........................................................................................................................................111

SYMBOL..............................................................................................................................................111

MINIMUM FREQUENCY FOR SCHEDULED MAINTENANCE ..........................................................111

HOURS, KILOMETRES.......................................................................................................................111

MINFREQSM........................................................................................................................................111

MAXIMUM STANDSTILL TIME TO COMPLETE MAINTENANCE ACTIONS....................................111

HOURS.................................................................................................................................................111

MAXSTCM...........................................................................................................................................111

MAXIMUM ALLOWED NUMBER OF PERSONNEL EMPLOYED FOR MAINTENANCE..................111

DIMENSIONLESS................................................................................................................................111

MAXANPM...........................................................................................................................................111

MAXIMUM ALLOWED TIME FOR DISMOUNTING/MOUNTING .......................................................111

HOURS.................................................................................................................................................111

MAXATD-M..........................................................................................................................................111

Page 26 of 158





MAXIMUM ALLOWED TIME FOR DETECT/ISOLATE/REPLACING FAULTY ITEMS......................111

HOURS.................................................................................................................................................111

MAXATD-I-R........................................................................................................................................111

FAULT COVERAGE............................................................................................................................111

DIMENSIONLESS................................................................................................................................111

FC.........................................................................................................................................................111

MEAN TIME TO RESTORE (CORRECTIVE MAINTENANCE)...........................................................111

HOURS.................................................................................................................................................111

MTTR....................................................................................................................................................111

MEAN TIME TO MAINTAIN (PREVENTIVE MAINTENANCE)............................................................111

HOURS.................................................................................................................................................111

MTTM...................................................................................................................................................111

MEAN TIME BETWEEN MAINTENANCE...........................................................................................111

TIME, DISTANCE, CYCLES................................................................................................................111

MTBM...................................................................................................................................................111

8.3.3.3 Logistic Support Requirements................................................................................................................111

TYPICAL LOGISTIC SUPPORT REQUIREMENTS CAN BE:.............................................................111

TABLE 10: LOGISTIC SUPPORT REQUIREMENTS .........................................................................111

DEFINITION.........................................................................................................................................111

DIMENSION.........................................................................................................................................111

SYMBOL..............................................................................................................................................111

MAXIMUM ALLOWED TIME TO REACH MAINTENANCE SITE .......................................................111

HOURS.................................................................................................................................................111

MAXATRM...........................................................................................................................................111

MAXIMUM ALLOWED TIME TO PLAN MAINTENANCE ACTIONS (TIME FOR TAKING SPAREPARTS FROM STORAGE DEPOT, TIME FOR TAKING TOOLS AND DIAGNOSIS EQUIPMENT)..........111

HOURS.................................................................................................................................................111

MAXATPM...........................................................................................................................................111

PROBABILITY OF SPARE PARTS ON STOCK WHEN NEEDED ....................................................111

Page 27 of 158





DIMENSIONLESS................................................................................................................................111

PS.........................................................................................................................................................111

NOTE: IF IT IS NOT POSSIBLE TO MEASURE TIME TO REACH MAINTENANCE SITE OR TOPLAN MAINTENANCE ACTIONS, CONTRACTUAL FIXED TIMES CAN BE USED.................................111

8.3.3.4 Maintenance Cost Requirements.............................................................................................................112

THE MAINTENANCE COST CONSTRAINTS CAN BE EXPRESSED IN DIFFERENT WAYS...........112

A WAY TO CONSIDER THE MAINTENANCE COST IS TO EXPRESS IT AS A MAXIMUM ALLOWEDPERCENTAGE OF THE WHOLE LIFE CYCLE COST................................................................................112

IN THIS CASE THE CUSTOMER HAS TO SPECIFY WHICH ITEMS ARE COUNTED ASMAINTENANCE COST................................................................................................................................112

EXAMPLES OF ITEMS FOR MAINTENANCE COST ARE THE FOLLOWING:.................................112

TABLE 11: MAINTENANCE COST REQUIREMENTS.......................................................................112

DEFINITION.........................................................................................................................................112

DIMENSION.........................................................................................................................................112

SYMBOL..............................................................................................................................................112

TRAINING OF THE MAINTENANCE PERSONNEL ...........................................................................112

MONEY................................................................................................................................................112

TMP......................................................................................................................................................112

TRAVEL COSTS SUSTAINED FOR REACHING THE MAINTENANCE SITES.................................112

MONEY................................................................................................................................................112

TCM......................................................................................................................................................112

SPARE PARTS ACQUISITION, PROVISION AND STORAGE...........................................................112

MONEY................................................................................................................................................112

SPA-P-S...............................................................................................................................................112

PREVENTIVE (SCHEDULED) MAINTENANCE ACTIONS (INCLUDING COST FOR SPARE PARTSAND COST FOR PERSONNEL EMPLOYED).............................................................................................112

MONEY................................................................................................................................................112

PMC......................................................................................................................................................112

CORRECTIVE MAINTENANCE ACTIONS (INCLUDING COST FOR SPARE PARTS AND COST FORPERSONNEL EMPLOYED).........................................................................................................................112

MONEY................................................................................................................................................112

Page 28 of 158





CMC.....................................................................................................................................................112

THE PERCENTAGE HAS TO BE EXPRESSED PER YEAR AND CONSIDERING THE PERIOD OFDURATION OF THE LIFE CYCLE...............................................................................................................112

OTHER MAINTENANCE COST REQUIREMENTS CAN BE THE COST OF PREVENTIVE ORCORRECTIVE (OR THE SUM OF THE TWO) MAINTENANCE WHERE THE CUSTOMER CAN USE THECOST PER KILOMETRE OR PER 1000 KILOMETRES OR OTHER SIGNIFICANT BASIS (I.E. PER YEAR,PER VEHICLE-TRAIN, PER SEAT).............................................................................................................112

ALSO IN THIS CASE CUSTOMER IS ASKED TO SPECIFY WHAT THIS COST INCLUDESDETAILING THE ITEMS COUNTED............................................................................................................112

AS APPROPRIATE, THE CUSTOMER CAN SPECIFY SPECIFIC TARGETS FOR IMPORTANT SUB-SYSTEMS OF THE ROLLING STOCK (BOGIE, SUPPLY POWER MODULE, DOORS, AIRCONDITIONING SYSTEM, TOILETTE, ETC…)..........................................................................................112

8.3.4 Availability Targets......................................................................................................................112

THIS SECTION DESCRIBES THE AVAILABILITY TARGETS REQUIRED FOR ROLLING STOCKAND FOR ALL THE SUBSYSTEMS, ASSEMBLIES AND PARTS BELONGING TO THE ROLLINGSTOCK ACCORDING TO THE BOUNDARY LIMITS DEFINED.................................................................112

FOLLOWING THE ANNEX A AND C OF THE EN 50126 THE AVAILABILITY A OF A ROLLINGSTOCK IS SPECIFIED AS THE TIME IN WHICH A ROLLING STOCK IS IN A STATE TO PERFORM ITSMISSION......................................................................................................................................................112

THE AVAILABILITY FORMULA IS GENERALLY INDICATED BY THE FOLLOWING:....................112

; WITH 0 ≤ A ≤ 1..............................................................................................................................113

WHERE,...............................................................................................................................................113

MUT = MEAN UP TIME;.......................................................................................................................113

MDT = MEAN DOWN TIME;................................................................................................................113

THEN THE CALCULATION OF THE AVAILABILITY CAN BE DONE STATING, OVER APREDEFINED TIME INTERVAL T, THE FOLLOWING ITEMS:..................................................................113

MUT (IN HOURS, KILOMETRES OR CYCLES)..................................................................................113

MDT (IN HOURS, KILOMETRES OR CYCLES)..................................................................................113

THE RESULTING DOWN TIME D (T) WITHIN A TIME INTERVAL T (E.G., 1 YEAR) IS:..................113

D (T) = (1 - A) ∗ T.................................................................................................................................113

THE AVAILABILITY NUMBER IS DIMENSIONLESS AND IS USUALLY INDICATED AS APERCENTAGE.............................................................................................................................................113

DEPENDING ON THE DEFINITION OF MUT AND MDT IT IS POSSIBLE TO HAVE DIFFERENTTYPES OF AVAILABILITY USING THE SAME FORMULA:......................................................................113

INHERENT AVAILABILITY, AI............................................................................................................113

Page 29 of 158





ACHIEVED (TECHNICAL) AVAILABILITY, AA..................................................................................113

OPERATIONAL (LOGISTIC) AVAILABILITY, AO..............................................................................113

FOR INHERENT AVAILABILITY, AI, THE DEFINITIONS USED FOR MUT AND MDT ARE:............113

MUT=MTBF=MEAN TIME BETWEEN FAILURES (HOURS)..............................................................113

MDT=MTTR=MEAN TIME TO RESTORE (HOURS)...........................................................................113

THEN THE FORMULA IS:...................................................................................................................113

..............................................................................................................................................................113

FOR ACHIEVED (TECHNICAL) AVAILABILITY, AA, THE DEFINITIONS FOR MUT AND MDT ARE:113

MUT=MTBM=MEAN TIME BETWEEN MAINTENANCE (HOURS)....................................................113

MDT=MTTM=MEAN TIME TO MAINTAIN (HOURS)...........................................................................113

IN THIS CASE THE MTTM TAKES INTO ACCOUNT THE MEAN TIME REQUIRED TO MAINTAINROLLING STOCK BOTH FOR PREVENTIVE AND CORRECTIVE MAINTENANCE AND THEN THEFORMULA IS:..............................................................................................................................................113

..............................................................................................................................................................113

FOR OPERATIONAL (LOGISTIC) AVAILABILITY, AO, THE DEFINITIONS FOR MUT AND MDTARE:.............................................................................................................................................................113

MUT=MTBM=MEAN TIME BETWEEN MAINTENANCE (HOURS)....................................................113

MDT=MTTM=MEAN TIME TO MAINTAIN (HOURS)...........................................................................113

IN THIS CASE THE MTTM TAKES INTO ACCOUNT THE MEAN TIME REQUIRED TO MAINTAINROLLING STOCK BOTH FOR PREVENTIVE AND CORRECTIVE MAINTENANCE INCLUDINGLOGISTICAL AND ADMINISTRATIVE DELAYS AND THEN THE FORMULA IS:....................................113

..............................................................................................................................................................114

ANOTHER MEASURE FOR AVAILABILITY CAN BE CONSIDERED CALCULATING THE RATIO OFTHE NUMBER OF ROLLING STOCK AVAILABLE FOR SERVICE TO THE WHOLE FLEET..................114

THIS IS INDICATED AS FLEET AVAILABILITY, AF, AND THE NUMBER OF ROLLING STOCKAVAILABLE FOR SERVICE IS DETERMINED BY THE DIFFERENCE BETWEEN THE NUMBER OFROLLING STOCK OF THE WHOLE FLEET AND THE NUMBER OF ROLLING STOCK NOT AVAILABLEFOR SERVICE DUE TO MAINTENANCE ACTIONS (PREVENTIVE OR CORRECTIVE MAINTENANCE)

114

IN THIS CASE THE FORMULA IS:.....................................................................................................114

..............................................................................................................................................................114

WHERE:...............................................................................................................................................114

FOP= NUMBER OF ROLLING STOCK AVAILABLE FOR SERVICE................................................114

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FM= NUMBER OF ROLLING STOCK NOT AVAILABLE FOR SERVICE DUE TO CORRECTIVE ANDPREVENTIVE MAINTENANCE...................................................................................................................114

FTOT= TOTAL NUMBER OF THE FLEET OF ROLLING STOCK .....................................................114

ALSO ANOTHER TYPE OF AVAILABILITY IS THE SCHEDULE ADHERENCE (RESPECT OF THESCHEDULE) MEASURED AS RATIO OF THE NUMBER OF JOURNEYS RUNNING ACCORDING TOSCHEDULE AND THE TOTAL NUMBER OF SCHEDULED JOURNEYS..................................................114

THE NUMBER OF JOURNEYS RUNNING TO SCHEDULE CAN BE DETERMINED BY THEDIFFERENCE BETWEEN THE TOTAL NUMBER OF SCHEDULED JOURNEYS AND THE NUMBER OFJOURNEYS NOT RUNNING TO SCHEDULE DUE TO CAUSES CONCERNING ROLLING STOCK.......114

IN THIS CASE THE FORMULA IS:.....................................................................................................114

..............................................................................................................................................................114

WHERE:...............................................................................................................................................114

FS= NUMBER OF JOURNEYS RUNNING TO SCHEDULE...............................................................114

FNS= NUMBER OF JOURNEYS NOT RUNNING TO SCHEDULE DUE TO CAUSES CONCERNINGROLLING STOCK........................................................................................................................................114

FTOT_S= TOTAL NUMBER OF SCHEDULED JOURNEYS..............................................................114

THE FOLLOWING TABLE GROUP THE ABOVE MENTIONED AVAILABILITY REQUIREMENTS:114

TABLE 12: AVAILABILITY REQUIREMENTS....................................................................................114

FORMULA............................................................................................................................................114

DEFINITION.........................................................................................................................................114

DIMENSION.........................................................................................................................................114

..............................................................................................................................................................114

INHERENT AVAILABILITY..................................................................................................................114

DIMENSIONLESS................................................................................................................................114

..............................................................................................................................................................115

ACHIEVED (TECHNICAL) AVAILABILITY.........................................................................................115

DIMENSIONLESS................................................................................................................................115

..............................................................................................................................................................115

OPERATIONAL (LOGISTIC) AVAILABILITY......................................................................................115

DIMENSIONLESS................................................................................................................................115

..............................................................................................................................................................115

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FLEET AVAILABILITY.........................................................................................................................115

DIMENSIONLESS................................................................................................................................115

..............................................................................................................................................................115

SCHEDULE ADHERENCE..................................................................................................................115

DIMENSIONLESS................................................................................................................................115

CHOOSING THE ABOVE REPORTED AVAILABILITY REQUIREMENTS THE CUSTOMER ISASKED TO:..................................................................................................................................................115

DETAIL THE FACTORS OF THE FORMULA CHOSEN.....................................................................115

TAKE INTO ACCOUNT THE RESPONSIBILITY OF EACH FACTOR ...............................................115

CONSIDER THE IMPLICATIONS OF THE NOTES GIVEN IN 8.3.1...................................................115

STATE THE TIME INTERVAL OF THE MONITORED PERIOD..........................................................115

8.4 RAM FIGURES CHOOSING PROCESS..............................................................................................................116

THE AIM OF THIS PARAGRAPH IS TO DEFINE A SIMPLE GUIDE LINE TO HELP CUSTOMER INCHOOSING APPROPRIATE FIGURES FOR RAM REQUIREMENTS.......................................................116

CONSIDERING THE DELIVERABLES OF THE PREVIOUS SECTIONS OF THE GUIDE THECUSTOMER IS ASKED TO: .......................................................................................................................116

ANALYSE ROLLING STOCK SYSTEM IDENTIFICATION AND ITS BREAKDOWN STRUCTURE. 116

CONSIDER FUNCTIONAL REQUIREMENTS INVOLVED AND ITS SUB-SYSTEMS RELATED .....116

CONSIDER RAM REQUIREMENTS AFFECTED BY FUNCTIONAL REQUIREMENTS ANALYSINGTHROUGH FAILURE CONDITIONS............................................................................................................116

CONSIDER RAM REQUIREMENTS OF SIMILAR ROLLING STOCK................................................116

REVIEW PAST ACHIEVED RAM PERFORMANCES.........................................................................116

CONSIDER TECHNICAL EVOLUTION OF THE ROLLING STOCK UNDER CONSIDERATION......116

EVALUATE THE IMPACT OF NEW FUNCTIONALITIES REQUESTED............................................116

CONSIDER A REALISTIC IMPROVEMENT OF RAM REQUIREMENTS ..........................................116

CONSIDER OTHER SPECIFIC AND DOCUMENTED NEEDS...........................................................116

THE PREVIOUS ACTION POINTS SHOULD ENABLE THE CUSTOMER TO MAKE THE BETTERCHOICE WITH SUBSTANTIAL SUPPORTING DOCUMENTATION..........................................................116

THE CUSTOMER SHOULD DOCUMENT THE CHOOSING PROCESS OF RAM FIGURESSPECIFYING THE CONSIDERATION ADOPTED TO ADDRESS EACH FIGURE CHOSEN....................116

8.5 RAM PROGRAMME..................................................................................................................................117

8.5.1 Introduction..................................................................................................................................117

Page 32 of 158





THE RAM PROGRAMME IS A SET OF ACTIVITIES TO BE PERFORMED ALONG THE SYSTEMLIFE CYCLE FOR ENSURING THAT THE RAM REQUIREMENTS STATED FOR THE ROLLING STOCKARE FULFILLED AT EACH DEVELOPMENT PHASE...............................................................................117

AN EFFICIENT RAM PROGRAMME SHALL BE ESTABLISHED AND MAINTAINED BY THESUPPLIER WITH THE PURPOSE OF ENSURING THAT THE RAM REQUIREMENTS ARE PROPERLYACHIEVED BY PROVIDING SUBSTANTIVE INFORMATION/VISIBILITY THROUGH APPROPRIATE RAMANALYSIS...................................................................................................................................................117

THE RAM PROGRAMME TASKS SHALL BE MANAGED WITH DIRECT RELATIONSHIPS WITHGENERAL FUNCTIONAL AND TECHNICAL TASKS OF THE LIFE CYCLE THROUGH PERIODICALREVIEWS.....................................................................................................................................................117

THE RAM PROGRAMME SHALL BE COHERENT WITH 7.3 AND 7.4..............................................117

8.5.2 Configuration Management System............................................................................................117

A SUITABLE CONFIGURATION MANAGEMENT SYSTEM SHALL BE ESTABLISHED AND

MAINTAINED BY THE SUPPLIER FOR IDENTIFYING AND DOCUMENTING MODIFICATIONS TOSPECIFIC CHARACTERISTICS OF A FUNCTIONAL OR PHYSICAL ITEM OF THE ROLLING STOCK,RECORDING AND REPORTING MODIFICATIONS PROCESSING AND IMPLEMENTATION STATUSAND VERIFYING COMPLIANCE WITH STATED RAM REQUIREMENTS................................................117

THE SUPPLIER IS RESPONSIBLE TO PROVIDE VISIBILITY OF THE CONFIGURATIONMANAGEMENT PROCESS THROUGH DOCUMENTED ACTIVITIES AND PERIODICAL REVIEWS......117

DURING THE PERIODICAL REVIEWS THE SUPPLIER IS ASKED TO PROVIDE REPORTSSPECIFYING, AS MINIMUM, THE FOLLOWINGS;....................................................................................117

DOCUMENTS DELIVERED, INDICATING THE RELEVANT REVISIONS.........................................117

STATUS OF THE CURRENT ACTIVITIES WITH OBJECTIVE EVIDENCE OF ACTIVITIES ANDDOCUMENTATION:.....................................................................................................................................117

ALREADY CARRIED OUT..................................................................................................................117

IN PROGRESS.....................................................................................................................................117

TO BE CARRIED OUT.........................................................................................................................117

NOTIFICATION OF PROBLEMS AFFECTING RAM REQUIREMENTS.............................................117

PROPOSAL FOR CORRECTIVE ACTIONS TO SOLVE PROBLEMS...............................................117

8.5.3 RAM Programme Outline ...........................................................................................................118

AN EXAMPLE OF TYPICAL OUTLINE OF RAM PROGRAMME IS SHOWED BELOW ALONG WITHA LIST OF CONTENTS:..............................................................................................................................118

1. INTRODUCTION..............................................................................................................................118

1.1. PURPOSE.....................................................................................................................................118

1.2. SCOPE..........................................................................................................................................118

1.3. REFERENCE DOCUMENTS.........................................................................................................118

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1.4. DEFINITIONS AND ACRONYMS.................................................................................................118

2. DESCRIPTION OF THE SYSTEM...................................................................................................118

2.1. GENERAL DESCRIPTION:...........................................................................................................118

2.2. SYSTEM BREAKDOWN:..............................................................................................................118

3. RAM CONTRACTUAL REQUIREMENTS:......................................................................................118

3.1. QUALITATIVE REQUIREMENTS.................................................................................................118

RELIABILITY REQUIREMENTS..........................................................................................................118

MAINTAINABILITY REQUIREMENTS................................................................................................118

AVAILABILITY REQUIREMENTS.......................................................................................................118

3.2. QUANTITATIVE REQUIREMENTS..............................................................................................118

RELIABILITY REQUIREMENTS..........................................................................................................118

MAINTAINABILITY REQUIREMENTS................................................................................................118

AVAILABILITY REQUIREMENTS.......................................................................................................118

4. RAM MANAGEMENT:.....................................................................................................................118

4.1. IMPLEMENTATION OF RAM.......................................................................................................118

4.2. MANAGEMENT OF THE INTERACTIONS BETWEEN RAM ANALYSES AND QUALITY PLAN118

4.3. CONFIGURATION MANAGEMENT PROCESS...........................................................................118

4.4. ORGANISATION AND RESPONSIBILITIES................................................................................118

4.5. RAM MAIN ACTIVITIES:...............................................................................................................118

SYSTEM LIFE CYCLE PHASES.........................................................................................................118

RAM ACTIVITIES DURING LIFE CYCLE............................................................................................118

RAM DOCUMENTATION.....................................................................................................................118

5. RAM PROGRAMME PLAN:.............................................................................................................118

ASSUMPTIONS AND SCOPE OF ANALYSES...................................................................................119

METHODS AND TOOLS USED...........................................................................................................119

RAM DETAILED ACTIVITIES, ANALYSES AND DOCUMENTS........................................................119

PERIODICAL RAM PROGRAMME REVIEWS....................................................................................119

Page 34 of 158





SYSTEM CONDITION AND MISSION PROFILE.................................................................................119

RELIABILITY MODELING, PREDICTION AND APPORTIONMENT..................................................119

FMECA ANALYSIS AND RELIABILITY BLOCK DIAGRAM..............................................................119

FAULT TREE ANALYSIS....................................................................................................................119

SOFTWARE RELIABILITY ANALYSIS...............................................................................................119

CORRECTIVE MAINTENANCE ANALYSIS........................................................................................119

PREVENTIVE MAINTENANCE ANALYSIS........................................................................................119

FAULT ISOLATION AND TROUBLE SHOOTING ACTIONS PLAN...................................................119

RELIABILITY DEVELOPMENT/GROWTH TESTING PROGRAMME.................................................119

MAINTAINABILITY PRELIMINARY TESTS........................................................................................119

RELIABILITY DEMONSTRATION TESTS..........................................................................................119

MAINTAINABILITY DEMONSTRATION TESTS.................................................................................119

FAILURE DATA COLLECTION FROM FIELD....................................................................................119

FOLLOW UP OF RAM CRITICAL ITEMS...........................................................................................119

6. RAM DELIVERABLE DOCUMENTS AND SCHEDULE..................................................................119

6.1 LIST OF RAM DELIVERABLES....................................................................................................119

6.2 SCHEDULE FOR RAM ANALYSES..............................................................................................119

6.3 PERIODICAL RAM ACTIVITIES REPORT....................................................................................119

THE RAM PROGRAMME PLAN ESTABLISHES ALL THE PROGRAMME MANAGEMENT TASKS,IN TERMS OF TIMING AND IMPLEMENTATION DETAILS OF THE PROGRAMME ACTIVITIES ANDDOCUMENTATION TO ACCOMPLISH THE RAM PROGRAMME REQUIREMENTS...............................119

IN THE RAM PROGRAMME PLAN THE SUPPLIER SHALL DECLARE THE PROCEDURES, THETOOLS AND THE TIMING FORESEEN FOR IMPLEMENTING THE RAM PROGRAMME.......................119

IT SHOULD BE NOTED THAT THE SUPPLIER IS RESPONSIBLE TO ESTABLISH THE CONTENTOF THE RAM PROGRAMME AND OF THE RAM PROGRAMME PLAN AND TO SUBMIT THESEDOCUMENTS TO THE CUSTOMER FOR ACCEPTANCE WITHIN A TIME AGREED BY THE PARTS INACCORDANCE WITH SYSTEM QUALITY PLAN.......................................................................................119

8.5.4 Example of RAM Analyses Document Forms and Data..............................................................119

THE AIM OF THIS PARAGRAPH IS TO PROVIDE AN OVERVIEW OF RAM ANALYSESDOCUMENT FORMS AND DATA IN ORDER TO GIVE TO THE READER THE ABILITY TO HANDLEWITH MORE PRACTICE ALL THE ISSUES RELATED TO RAM PROGRAMME.....................................119

THE FOLLOWINGS ARE EXAMPLE OF FORMS OF THE MOST COMMON RAMDOCUMENTATIONS AND ANALYSES TO BE PROVIDED BY THE SUPPLIER IN ORDER TO GIVE

Page 35 of 158





SUBSTANTIVE INFORMATION/VISIBILITY OF THE RAM ACTIVITIES CARRIED OUT AND TO SHOWTHAT THE ROLLING STOCK IS LIKELY TO SATISFY THE RAM REQUIREMENTS IN EACH PHASE OFTHE LIFE CYCLE FROM THE TENDER TO THE OPERATION PHASE....................................................119

A LIST OF TOOLS SUITABLE FOR USE TO PERFORM THE DIFFERENT ANALYSES AND TOMANAGE ALL RAM ACTIVITIES IS GIVEN WITHIN EN 50126 - ANNEX B - ITEM B5............................119

8.5.4.1 Common Data for the analyses...............................................................................................................119

A SET OF DATA ARE REFERRED TO THE IDENTIFICATION OF OBJECT OF ANALYSIS. THISTYPE OF DATA ARE COMMON THROUGH THE DIFFERENT ANALYSES AND ARE REFERRED TOTHE BREAKDOWN STRUCTURE..............................................................................................................119

THEY REPRESENT THE HEADER OF THE ANALYSIS....................................................................120

IN ORDER TO SIMPLIFY THE COMMON UNDERSTANDING, WITHIN THIS EXAMPLES A THREELEVEL BREAKDOWN STRUCTURE HAS BEEN CONSIDERED WHERE THE THIRD LEVEL IS THE LRULEVEL..........................................................................................................................................................120

GENERALLY THESE KIND OF DATA ARE AT LEAST THE FOLLOWING:.....................................120

ROLLING STOCK................................................................................................................................120

ID CODE OF ROLLING STOCK..........................................................................................................120

L1 CODE..............................................................................................................................................120

BREAKDOWN CODE OF THE LEVEL 1 ASSEMBLY........................................................................120

L1 ASSEMBLY.....................................................................................................................................120

DESCRIPTION OF THE LEVEL 1 ASSEMBLY ..................................................................................120

L2 CODE..............................................................................................................................................120

BREAKDOWN CODE OF THE HIGHER ASSEMBLY/SUBASSEMBLY............................................120

L2 ASSEMBLY.....................................................................................................................................120

DESCRIPTION OF THE LEVEL 2 ASSEMBLY ..................................................................................120

DRWG. OR DIAG. REF. ......................................................................................................................120

IDENTIFICATION NUMBER OF DRAWING OR DIAGRAM CONTAINING THE IDENTIFICATIONREFERENCES OF THE LRUS (CODE AND DESCRIPTION) UNDER CONSIDERATION .......................120

DOC.N..................................................................................................................................................120

CODE OF DOCUMENT........................................................................................................................120

DATE....................................................................................................................................................120

DATE OF DOCUMENT........................................................................................................................120

PAGE N/N............................................................................................................................................120

CONSECUTIVE NUMBER OF PAGE/TOTAL NUMBER OF PAGES.................................................120

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DRAWN UP BY....................................................................................................................................120

FIRST AND LAST NAME OF AUTHOR..............................................................................................120

FILENAME...........................................................................................................................................120

NAME OF FILE OF THE DOCUMENT.................................................................................................120

8.5.4.2 Reliability Prediction Analysis Form and Data Sheets.............................................................................121

THE RELIABILITY PREDICTION SHEETS SHOULD CONTAIN THE FOLLOWING INFORMATION:121

CODE...................................................................................................................................................121

BREAKDOWN CODE OF LRU............................................................................................................121

DESCRIPTION.....................................................................................................................................121

DESCRIPTION OF LRU.......................................................................................................................121

PART NO.............................................................................................................................................121

PART NO. OF LRU..............................................................................................................................121

FAILURE RATE (IN FAILURES/ MH)..................................................................................................121

FAILURE RATE OF LRU EXPRESSED IN NUMBER OF FAILURES PER MILLION HOURS..... ... ..121

MTBF (H)..............................................................................................................................................121

MTBF OF LRU IN HOURS...................................................................................................................121

QTY......................................................................................................................................................121

AMOUNT OF LRU IN L2 ASSEMBLY.................................................................................................121

TOTAL FAILURE RATE (IN FAILURES/MH)......................................................................................121

TOTAL FAILURE RATE, OBTAINED AS THE PRODUCT BETWEEN THE FAILURE RATE OF THELRU AND THE QTY OF THE LRUS IN THE L2 ASSEMBLY.....................................................................121

TOTAL MTBF (H).................................................................................................................................121

TOTAL MTBF REFERRED TO THE TOTAL FAILURE RATE............................................................121

TOTAL FAILURES RATE (IN FAILURES/MKM).................................................................................121

AVERAGE FAILURES PER MILLION KM OF THE LRU ...................................................................121

TOTAL QTY.........................................................................................................................................121

TOTAL NO. OF LRUS IN THE WHOLE ROLLING STOCK ...............................................................121

SOURCE OF FAILURE RATE.............................................................................................................121

ORIGIN OF THE FAILURE RATE INDICATED (ALSO CODES OF DATA SOURCES USED)..........121

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NOTES.................................................................................................................................................121

ANY POSSIBLE CLARIFICATIONS ON THE ORIGIN OF THE FAILURE RATE AND CORRECTIONFACTORS INTRODUCED...........................................................................................................................121

WORKING GROUP B11......................................................................................................................122

DRAFT MAY 2002...............................................................................................................................122

FIG. 1 EXAMPLE OF RELIABILITY PREDICTION ANALYSIS SHEET.............................................122

PAGE 158 OF 158................................................................................................................................122

CENELEC TC9-SC9XB........................................................................................................................122

APPLICATION GUIDE FOR EN 50126................................................................................................122

8.5.4.3 Maintenance Attributes (Maintenance Levels, Skill Level and LRU definition)........................................124

WITHIN RAILWAY FIELD THERE ARE SEVERAL DEFINITIONS AND ATTRIBUTES OFMAINTENANCE...........................................................................................................................................124

THE PURPOSE OF THIS PARAGRAPH IS TO ADDRESS TO EVERY PRACTICAL MAINTENANCEACTIONS IN ORDER TO CLEAR THE ISSUES AFFECTING RAM REQUIREMENTS AND THEN, WITHINTHE PREVIOUS SHORT LIST, ONLY THE SUITABLE DEFINITIONS WILL BE CONSIDERED. ............124

AS A COMMON SITUATION WITHIN RAILWAY FIELD, HERE IT IS CONSIDERED THE EXISTENCEOF A DEPOT FOR THE ROLLING STOCK WITH TRAINED PERSONNEL, RESOURCES, A MINIMUMSET OF SPARE PARTS, TOOLS AND EQUIPMENT TO CARRY OUT MAINTENANCE WHERE THETARGET IS TO MINIMISE THE STANDSTILL TIME OF THE ROLLING STOCK IN ORDER TO RELEASETHE MAINTAINED ROLLING STOCK READY FOR SERVICE WITHIN THE LOWEST POSSIBLE TIME.

124

WHERE THE COMPLEXITY OF THE MAINTENANCE ACTIONS, RELATED TO THE TRAINEDPERSONNEL, RESOURCES, A MINIMUM SET OF SPARE PARTS, TOOLS AND EQUIPMENTAVAILABLE WITHIN THE DEPOT, DOES NOT MEET THIS TARGET, THE MAINTENANCE ACTIONSWILL BE CARRIED OUT WITH THE ROLLING STOCK OUT OF SERVICE WITHIN A SPECIALISEDWORKSHOP................................................................................................................................................124

THE FIRST SITUATION IT IS COMMONLY CALLED AS "FIRST LEVEL MAINTENANCE" AND THESECOND ONE IT IS COMMONLY CALLED AS "SECOND LEVEL MAINTENANCE"..............................124

CONSIDERING THE PREVIOUS CONCERN AND AS THE MAIN PURPOSE OF THE ANALYSES ISTO MEET RAM REQUIREMENTS, THERE ARE 2 POSSIBILITIES TO CARRY OUT THE PREVENTIVEMAINTENANCE:..........................................................................................................................................124

1 FIRST LEVEL MAINTENANCE: IN THIS CASE TWO CHOICES CAN BE CONSIDEREDADDRESSING THE TARGET OF THE FIRST LEVEL MAINTENANCE:...................................................124

ALL THE MAINTENANCE SCHEDULED ACTIONS ARE CARRIED OUT WITHIN THE DEPOT.. .. .124

ONLY DISASSEMBLING/ASSEMBLING OF ITEMS (REPLACING ITEMS WITH SPARE PARTS),AND THE OTHER MAINTENANCE ACTIONS ARE CARRIED OUT ON THE DISMANTLED ITEMSWITHIN THE DEPOT/WORKSHOP.............................................................................................................124

2 SECOND LEVEL MAINTENANCE: IN THIS CASE ONLY ONE CHOICE CAN BE CONSIDERED:

124

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ALL THE MAINTENANCE SCHEDULED ACTIONS ARE CARRIED OUT WITHIN A WORKSHOP.124

WITHIN THIS CONCERN FOR THE PREVENTIVE MAINTENANCE ANALYSIS FORM AND DATASHEETS CAN BE USED THIS TWO CODES AS "MAINTENANCE LEVEL CODES":.............................124

FLPM (FIRST LEVEL PREVENTIVE MAINTENANCE).......................................................................124

SLPM (SECOND LEVEL PREVENTIVE MAINTENANCE).................................................................124

A SIMILAR SITUATION OCCURS WHEN CORRECTIVE MAINTENANCE IS CONSIDERED, BUT INTHIS CASE BESIDES THE RESOURCES OF THE DEPOT (PERSONNEL, TOOLS, EQUIPMENT, ANDSO ON) ALSO THE FAILURE MODE MUST BE TAKEN INTO ACCOUNT AS AN ATTRIBUTEAFFECTING THE RAM REQUIREMENTS:.................................................................................................124

1 FIRST LEVEL MAINTENANCE: IN THIS CASE TWO CHOICES CAN BE CONSIDEREDADDRESSING THE TARGET OF THE FIRST LEVEL MAINTENANCE:...................................................124

REPAIRABLE FAILURE MODE: ALL THE REPAIR MAINTENANCE ACTIONS ARE CARRIED OUTWITHIN THE DEPOT...................................................................................................................................124

NOT REPAIRABLE FAILURE MODE: ONLY DISASSEMBLING/ASSEMBLING OF ITEMS(REPLACING ITEMS WITH SPARE PARTS)..............................................................................................124

2 SECOND LEVEL MAINTENANCE: IN THIS CASE ONLY ONE CHOICE CAN BE CONSIDERED:124

REPAIRABLE FAILURE MODE: ONLY DISASSEMBLING/ASSEMBLING OF ITEMS (REPLACINGITEMS WITH SPARE PARTS), AND THE OTHER REPAIR MAINTENANCE ACTIONS ARE CARRIEDOUT ON THE DISMANTLED ITEMS WITHIN THE DEPOT/WORKSHOP..................................................125

WITHIN THIS CONCERN FOR THE CORRECTIVE MAINTENANCE ANALYSIS FORM AND DATASHEETS CAN BE USED THIS THREE CODES AS "MAINTENANCE LEVEL CODES":..........................125

FLCM - REP (FIRST LEVEL CORRECTIVE MAINTENANCE WITH REPAIRABLE FAILURE MODE)125

FLCM - NOT REP (FIRST LEVEL CORRECTIVE MAINTENANCE WITH NOT REPAIRABLEFAILURE MODE).........................................................................................................................................125

SLCM (SECOND LEVEL CORRECTIVE MAINTENANCE)................................................................125

DEPENDING ON THE DEFINITION OF FIRST LEVEL MAINTENANCE, ALSO THE DEFINITION OF

LRU (LINE REPLACEABLE UNIT) CAN BE CLARIFIED:..........................................................................125

LRU = IT IS THE ITEM ON WHICH FIRST LEVEL MAINTENANCE ACTIONS ARE CARRIED OUT.125

THIS DEFINITION CAN BE USED WHERE THE DEPTH OF THE BREAKDOWN STRUCTURE MUSTBE DEFINED. (SEE 8.1.3)...........................................................................................................................125

AS AN AID TO ESTABLISH "SKILL LEVEL CODES", THE FOLLOWING ARE SUGGESTED AS ANEXAMPLE:...................................................................................................................................................125

LOW SKILL LEVEL (CODE "L"): PERSONNEL WITH BASIC KNOWLEDGE OF THESYSTEMS/SUBSYSTEMS AND ABLE TO CARRY OUT SIMPLE AND EASY ACTIONS SUCH AS:......125

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ACTIONS IN WHICH THE ITEM IS DIRECTLY VISIBLE (EASILY ACCESSIBLE WITHOUTCOMPLEX DISASSEMBLING ACTIONS) AND THAT CAN BE PERFORMED USING STANDARD TOOLS(SCREWDRIVER, WRENCH, …).................................................................................................................125

INTERMEDIATE SKILL LEVEL (CODE "I"): PERSONNEL WITH SPECIFIC KNOWLEDGE OF THESYSTEMS/SUBSYSTEMS AND ABLE TO CARRY OUT DETAILED ACTIONS SUCH AS: ....................125

SEARCHING FOR THE ITEM NEEDING MAINTENANCE, ALSO USING NOT STANDARDTOOLS/EQUIPMENT (MULTIMETER, GAUGE, TESTER,…) AND WITH DISASSEMBLING ACTIONSEVEN USING DIAGRAMS AND MAINTENANCE MANUAL......................................................................125

HIGH SKILL LEVEL (CODE "H"): PERSONNEL WITH COMPLETE AND SPECIALISEDKNOWLEDGE OF THE SYSTEMS/SUBSYSTEMS AND ABLE TO CARRY OUT DETAILED ACTIONSSUCH AS: ...................................................................................................................................................125

SEARCHING FOR THE ITEM NEEDING MAINTENANCE, ALSO USING SOPHISTICATED TOOLSFOR TECHNICAL MEASURES (OSCILLOSCOPE, LOGIC STATE ANALYSER, …) AND FOR FINE

TUNING AND WITH DISASSEMBLING ACTIONS EVEN USING DRAWINGS, DIAGRAMS ANDMAINTENANCE MANUAL...........................................................................................................................125

8.5.4.4 Preventive Maintenance Analysis Form and Data Sheets.......................................................................125

THE PREVENTIVE MAINTENANCE ANALYSIS SHEETS SHOULD CONTAIN THE FOLLOWINGINFORMATION:...........................................................................................................................................125

CODE...................................................................................................................................................125


DESCRIPTION.....................................................................................................................................125


PART NO.............................................................................................................................................125

PART NO. OF LRU..............................................................................................................................125

QTY......................................................................................................................................................125


PAGE 158 OF 158................................................................................................................................124

STEP NO..............................................................................................................................................126

CENELEC TC9-SC9XB........................................................................................................................124


WORKING GROUP B11......................................................................................................................124

DRAFT MAY 2002...............................................................................................................................124

CONSECUTIVE NUMBER USED TO IDENTIFY EACH MAINTENANCE TASK ...............................126

MAINTENANCE TASK........................................................................................................................126

Page 40 of 158





DESCRIPTION OF THE PREVENTIVE MAINTENANCE TASK.........................................................126

SPARE PARTS AND SPECIAL TOOLS..............................................................................................126

DESCRIPTION OF THE SPECIAL EQUIPMENT (NOT PROVIDED BY THE DEPOT OR WORKSHOPAND IN ANY CASE NOT EASILY AVAILABLE ON THE MARKET) AND MATERIALS NECESSARY(CONSUMABLES AND SPARES)...............................................................................................................126

FREQUENCY.......................................................................................................................................126

FREQUENCY OF THE MAINTENANCE TASK (TIME OR KM)..........................................................126

MAINTENANCE LEVEL.......................................................................................................................126

CODES OF THE MAINTENANCE LEVELS USED BY THE MAINTAINER .......................................126

PERSONNEL.......................................................................................................................................126

NUMBER OF PERSONS NECESSARY AT THE SAME TIME FOR THE MAINTENANCE TASKDESCRIBED ...............................................................................................................................................126

SKILL LEVEL.......................................................................................................................................126

CODE OF THE SKILL LEVEL REQUESTED FOR THE PERSONNEL TO CARRY OUT THEMAINTENANCE TASK................................................................................................................................126

SPARE PARTS COST.........................................................................................................................126

UNIT COST OF MATERIALS EXPRESSED IN EURO........................................................................126

MAN HOURS........................................................................................................................................126

TIME REQUIRED FOR THE MAINTENANCE TASK MULTIPLIED BY THE NUMBER OF PERSONSNECESSARY...............................................................................................................................................126

STANDSTILL TIME..............................................................................................................................126

STANDSTILL TIME FOR THE ROLLING STOCK DURING THE MAINTENANCE TASK.............. ...126

TOTAL QTY.........................................................................................................................................126


NOTES.................................................................................................................................................126

ANY NOTES, COMMENTS OR REMARKS ON THE LOGISTICS OR OTHER (E.G. REFERENCESTO THE MAINTENANCE MANUAL)...........................................................................................................126

AS AN AID TO ESTABLISH THE MAINTENANCE PLAN THE FOLLOWING SHEET CONTAINSREARRANGED DATA FOR THE SAME FREQUENCY. THIS SHEET ALSO CONTAINS AN INDICATIONFOR LOGISTIC ORGANISATION OF THE MAINTAINER WITH THE "FREQUENCY TOTAL DATA",WHERE THE SUPPLIER IS ASKED TO INDICATE THE FOLLOWING DATA FOR THE FREQUENCYANALYSED:.................................................................................................................................................126

MAN-HOUR REQUESTED TO COMPLETE ALL THE MAINTENANCE TASKS OF THE FREQUENCY

126

Page 41 of 158





STANDSTILL TIME FOR THE ROLLING STOCK TO COMPLETE ALL THE MAINTENANCE TASKSOF THE FREQUENCY.................................................................................................................................126

MAXIMUM NUMBER OF PERSONS SIMULTANEOUSLY INVOLVED TO COMPLETE ALL THE

MAINTENANCE TASKS OF THE FREQUENCY .......................................................................................126

CENELEC TC9-SC9XB........................................................................................................................127


FIG. 2 EXAMPLE OF PREVENTIVE MAINTENANCE ANALYSIS SHEET........................................127

PAGE 158 OF 158................................................................................................................................127

FIG. 3 EXAMPLE OF PREVENTIVE MAINTENANCE SHEET FOR A SINGLE FREQUENCY..........129

WORKING GROUP B11......................................................................................................................127

DRAFT MAY 2002...............................................................................................................................127

8.5.4.5 Corrective Maintenance Analysis Form and Data Sheets.......................................................................130

CENELEC TC9-SC9XB........................................................................................................................130


WORKING GROUP B11......................................................................................................................130

DRAFT MAY 2002...............................................................................................................................130

THE CORRECTIVE MAINTENANCE ANALYSIS SHEETS SHOULD CONTAIN THE FOLLOWINGINFORMATION:...........................................................................................................................................130

CODE...................................................................................................................................................130


DESCRIPTION.....................................................................................................................................130


PART NO.............................................................................................................................................130

PART NO. OF LRU..............................................................................................................................130

QTY......................................................................................................................................................130


FAILURE MODE..................................................................................................................................130

FAILURE MODE ANALYSED FOR THE LRU REFERRING THE FMECA ANALYSIS SHEET.........130

MAINTENANCE TASK........................................................................................................................130

DESCRIPTION OF THE CORRECTIVE MAINTENANCE TASK.........................................................130

Page 42 of 158





SPARE PARTS AND SPECIAL TOOLS..............................................................................................130

DESCRIPTION OF THE SPECIAL EQUIPMENT (NOT PROVIDED BY THE DEPOT OR WORKSHOPAND IN ANY CASE NOT EASILY AVAILABLE ON THE MARKET) AND MATERIALS NECESSARY

(CONSUMABLES AND SPARES)...............................................................................................................130


FAILURE RATE OF THE FAILURE MODE OF THE LRU EXPRESSED IN NUMBER OF FAILURESPER MILLION HOURS.................................................................................................................................130

MAINTENANCE LEVEL ......................................................................................................................130

CODES OF THE MAINTENANCE LEVELS USED BY THE MAINTAINER .......................................130

PERSONNEL.......................................................................................................................................130

NUMBER OF PERSONS NECESSARY AT THE SAME TIME FOR THE MAINTENANCE TASKDESCRIBED ...............................................................................................................................................130

SKILL LEVEL.......................................................................................................................................130

CODE OF THE SKILL LEVEL REQUESTED FOR THE PERSONNEL TO CARRY OUT THEMAINTENANCE TASK................................................................................................................................130

SPARE PARTS COST.........................................................................................................................130

UNIT COST OF MATERIALS EXPRESSED IN EURO........................................................................130

MAN HOURS........................................................................................................................................130

TIME REQUIRED FOR THE MAINTENANCE TASK MULTIPLIED BY THE NUMBER OF PERSONSNECESSARY...............................................................................................................................................130

STANDSTILL TIME..............................................................................................................................130

STANDSTILL TIME FOR THE ROLLING STOCK DURING THE MAINTENANCE TASK.............. ...130

TOTAL QTY.........................................................................................................................................130


NOTES.................................................................................................................................................130

ANY NOTES, COMMENTS OR REMARKS ON THE LOGISTICS OR OTHER (E.G. REFERENCESTO THE MAINTENANCE MANUAL)...........................................................................................................130

PAGE 158 OF 158................................................................................................................................130

FIG. 4 EXAMPLE OF CORRECTIVE MAINTENANCE ANALYSIS SHEET........................................132

CENELEC TC9-SC9XB........................................................................................................................131


WORKING GROUP B11......................................................................................................................131

Page 43 of 158





DRAFT MAY 2002...............................................................................................................................131

PAGE 158 OF 158................................................................................................................................131

8.5.4.6 Failure Mode Effects and Criticality Analysis Form and Data Sheets......................................................133

WORKING GROUP B11......................................................................................................................133

DRAFT MAY 2002...............................................................................................................................133

THE FMECA CAN BE CARRIED OUT ADDRESSING ANALYSIS TO EXAMINE FUNCTIONS ORITEMS; THE FOLLOWING SHOWED EXAMPLE IS ADDRESSED TO ITEMS ANALYSIS.................. ....133

THE FMECA SHEETS SHOULD CONTAIN THE FOLLOWING INFORMATION:..............................133

CODE...................................................................................................................................................133


DESCRIPTION.....................................................................................................................................133


PART NO.............................................................................................................................................133

PART NO. OF LRU..............................................................................................................................133

QTY......................................................................................................................................................133


FUNCTION...........................................................................................................................................133

SHORT DESCRIPTION OF THE FUNCTION PERFORMED BY THE LRU .......................................133

FAILURE MODE..................................................................................................................................133

THE PREDICTED OR OBSERVED RESULTS OF A FAILURE CAUSE ON THE LRU IN RELATIONTO THE OPERATING CONDITIONS AT THE TIME OF THE FAILURE.....................................................133

FAILURE CAUSE.................................................................................................................................133

THE CIRCUMSTANCES WHICH HAVE LED TO A FAILURE............................................................133


FAILURE RATE OF THE FAILURE MODE OF THE LRU EXPRESSED IN NUMBER OF FAILURESPER MILLION HOURS.................................................................................................................................133

LOCAL EFFECTS................................................................................................................................133

WORST EFFECTS OF THE FAILURE MODE ON THE LRU..............................................................133

EFFECT ON HIGHER ASSY................................................................................................................133

WORST EFFECTS OF THE FAILURE MODE ON THE L1/L2 ASSEMBLY.......................................133

Page 44 of 158





EFFECTS ON ROLLING STOCK........................................................................................................133

WORST EFFECTS OF THE FAILURE MODE ON THE ROLLING STOCK, ALSO CONSIDERING ITSPOSSIBLE EFFECTS ON OTHER ASSEMBLIES OR SUBASSEMBLIES................................................133

CRITICALITY.......................................................................................................................................133

CODE OF THE CATEGORY OF CRITICALITY OF THE FAILURE MODE ACCORDING TO ASTATED TABLE OF REFERENCE CONSIDERING ON THE BASIS OF EFFECTS AFFECTING SAFETYAND/OR SERVICE.......................................................................................................................................133

FAILURE CATEGORY DESCRIPTION...............................................................................................133

CODES AND DESCRIPTION OF THE FAILURE CATEGORY ACCORDING THE FAILURECATEGORIES ESTABLISHED ...................................................................................................................133

DIAGNOSIS..........................................................................................................................................133

DESCRIPTION OF THE METHOD OF DETECTING AND DIAGNOSTICS USED TO DETECT ANDIDENTIFY THE FAILURE MODE.................................................................................................................133

CORRECTIVE ACTIONS.....................................................................................................................133

DESCRIPTION OF THE MEASURES OR COMPENSATORY MEANS SUGGESTED TO PREVENTTHE FAILURE MODE, MINIMISE ITS CRITICALITY OR REDUCE/ELIMINATE ITS EFFECTS................133

NOTES.................................................................................................................................................133

ANY NOTES, COMMENTS OR REMARKS USEFUL FOR THE ANALYSIS......................................133

NOTE THAT THE CORRECTIVE ACTIONS MUST BE ADDRESSED TO:........................................133

THE DESIGNER WHEN THE FMECA IS CARRIED OUT DURING THE DESIGN PHASE IN ORDERTO IMPROVE THE DESIGN OF THE ROLLING STOCK............................................................................133

ON BOARD AND MAINTENANCE PERSONNEL AND THEN INCLUDED WITHIN MAINTENANCEAND USER MANUAL IN ORDER TO IMPROVE THE SERVICE OF THE ROLLING STOCK, .................134

CENELEC TC9-SC9XB........................................................................................................................133


PAGE 158 OF 158................................................................................................................................133

CENELEC TC9-SC9XB........................................................................................................................135


WORKING GROUP B11......................................................................................................................135

DRAFT MAY 2002...............................................................................................................................135

FIG. 5 EXAMPLE OF FMECA SHEET.................................................................................................135

PAGE 158 OF 158................................................................................................................................135

Page 45 of 158





9 RAM ASSURANCE DURING LIFE CYCLE.......................................................................................136

9.1 RAM PROGRAMME AND PHASES OF THE LIFE CYCLE......................................................................................136

THIS SECTION PROVIDES INFORMATION SUPPORTING OVERALL AND PRELIMINARY RAMREQUIREMENTS.........................................................................................................................................136

ALSO IT GIVES INFORMATION ABOUT ACTIVITIES AND DOCUMENTATION DURING THE LIFECYCLE PHASES SUPPORTING DETAILED SPECIFICATIONS AND REQUIREMENTS FOR THEROLLING STOCK INCLUDING ITS SYSTEMS AND SUB-SYSTEMS.......................................................136

ALSO, THIS SECTION AIMS TO DEFINE WHAT PHASES OF THE SYSTEM LIFE CYCLE THE RAMPROGRAMME DEALS WITH AND TO PROVIDE MORE INFORMATION ABOUT:..................................136

ACTIVITIES TO BE MANAGED...........................................................................................................136

ANALYSIS AND TOOLS TO BE IMPLEMENTED ..............................................................................136

DOCUMENTATION TO BE PROVIDED .............................................................................................136

DURING THE RAM PROGRAMME PROCESS. .................................................................................136

ACCORDING TO THE DEFINITIONS ABOVE, WE CAN DEFINE THE RAM PROGRAMME ASSHOWN IN THE FOLLOWING DIAGRAM..................................................................................................136

FIG. 6 RAM PROGRAMME AND LIFE CYCLE PHASES...................................................................136

THE ENTITIES INVOLVED IN THE LIFE CYCLE ARE EXPLAINED IN 7.2. .....................................136

THE FOLLOWING EXAMPLE SHOWS THE INTEGRATION PROCESS AND THE PROGRAMME

IMPLEMENTATION WHEN:........................................................................................................................136

THE CUSTOMER IS ALSO THE OPERATOR AND THE MAINTAINER;...........................................137

THE MAIN SUPPLIER IS ALONE AND HAS TO NEGOTIATE SUB-CONTRACTS WITH SUPPLIERS.137

..............................................................................................................................................................137

9.1.1 Tender phase:.............................................................................................................................138

THE TENDER PHASE IS PREPARED BY THE CUSTOMER DURING THE PREVIOUS PHASES(SEE FIG. 6 PHASES 1 TO 5) AND IT RESULTS IN THE CALL FOR TENDER DOCUMENT SENT TO ALL

THE POTENTIAL SUPPLIERS....................................................................................................................138

THE CALL FOR TENDER CONTAINS DATA ABOUT CONCEPT, DEFINITION AND SPECIFICATIONOF ROLLING STOCK AND RAM REQUIREMENT TO BE FULFILLED ACCORDING 8..........................138

THE CUSTOMER SHOULD ASK THE POTENTIAL SUPPLIERS FOR DATA AND ANALYSISDURING TENDER PHASE. THIS DOCUMENTATION IS USEFUL TO BETTER MATCH DIFFERENTOFFERS ON THE SAME BASIS.................................................................................................................138

EXAMPLES OF DOCUMENTATION TO BE REQUIRED DURING TENDER PHASE CAN BE TAKENFROM DESIGN PHASE DOCUMENTATION. (SEE 8.5.4)..........................................................................138

Page 46 of 158





BEFORE ANSWERING TO THE CALL FOR TENDER, THE SUPPLIER HAS TO PERFORMRELEVANT TASKS TO INSURE THAT ALL RISKS RELATED TO THE COMPLIANCE WITH EACHREQUIREMENTS ARE TAKEN INTO CONSIDERATION:.........................................................................138

FEASIBILITY ANALYSIS: THIS ANALYSIS ALLOWS TO DETERMINATE THE BEST REASONABLEPERFORMANCES WHICH CAN BE ACHIEVED TAKING INTO ACCOUNT CURRENT EXPERIENCERESULTING FROM THE NEW MISSION PROFILE AND TAKING INTO ACCOUNT VARIATIONS ON THEDEFINITION OF THE SYSTEM. THIS TASK IS PERFORMED AT ROLLING STOCK LEVEL, USINGCURRENT EXPERIENCE ON SIMILAR APPLICATIONS AND CALCULATION MODELS LIKE FAULTTREE ANALYSIS OR RELIABILITY BLOCK DIAGRAMS.........................................................................138

RISK ANALYSIS: REFERRING TO THE BEST REASONABLE PERFORMANCES CALCULATEDTHROUGH FEASIBILITY ANALYSIS, THIS TASK ALLOWS TO DETERMINE THE PROBABILITY TOPAY PENALTIES TAKING INTO ACCOUNT THE GAP BETWEEN REQUIRED AND ACHIEVABLEPERFORMANCES.......................................................................................................................................138

ANSWER TO THE TENDER: WRITE THE DIFFERENT SECTIONS OF THE OFFER RELATED TO

RAM ACTIVITY PROVIDING THE RAM DOCUMENTS REQUESTED BY THE CUSTOMER...................138

NEGOTIATION: ANSWER TO THE QUESTIONS ASKED BY THE CUSTOMER AND/OR SUPPORTTHE NEGOTIATION TEAM DURING THE NEGOTIATION PHASE...........................................................138

AFTER RECEIVING OFFERS THE CUSTOMER EVALUATES THE DOCUMENTS AND CHOOSESFOR THE BEST OFFER..............................................................................................................................138

USUALLY A SHORT PHASE OF NEGOTIATION BETWEEN THE CUSTOMER AND THEPOTENTIAL SUPPLIER IS PLANNED, WHERE CONTRACTUAL AGREEMENTS ARE TAKEN............138

THE TENDER PHASE IS CONCLUDED BY THE CONTRACT AWARD OR THE NOTICE TOPROCEED....................................................................................................................................................138

9.1.2 Design Phase..............................................................................................................................139

CENELEC TC9-SC9XB........................................................................................................................136


THE FOLLOWING FLOW CHART SHOWS THE DIFFERENT TASKS INCLUDED IN THE RAMPROGRAMME TO BE IMPLEMENTED AFTER CONTRACT AWARD OR NOTICE TO PROCEED.........139

THE INPUT DOCUMENTATION OF THIS PHASE IS THE TENDER DOCUMENTATION PRESENTEDBY THE SUPPLIER AND THE CONTRACTUAL AGREEMENTS FULFILLED DURING NEGOTIATION.139

..............................................................................................................................................................140

THE FOLLOWING IS THE DESCRIPTION OF A POSSIBLE DEFINITION OF THE TASKS:............140

DESIGNATION.....................................................................................................................................140

DESCRIPTION OF THE TASK............................................................................................................140

RAM SPECIFICATION.........................................................................................................................140

THIS FIRST STEP, AFTER CONTRACT AWARD, ALLOWS THE ROLLING STOCK MAINCONTRACTOR TO SPECIFY TO SUB CONTRACTORS, PARTNERS OR EQUIPMENT SUPPLIERS THECONTRACTUAL REQUIREMENTS RELATED TO SUBSYSTEMS, FUNCTIONS OR EQUIPMENTS IN

THEIR SCOPE OF SUPPLY........................................................................................................................140

Page 47 of 158





WORKING GROUP B11......................................................................................................................136

DRAFT MAY 2002...............................................................................................................................136

ALSO, IT GENERALLY INCLUDES THE DELIVERY FOR APPROVAL OF THE RAM PROGRAMME.141

PRELIMINARY ANALYSES.................................................................................................................141

THE INPUTS OF THIS TASK ARE THE TENDER DOCUMENTS AND THE CONTRACTUALAGREEMENTS............................................................................................................................................141

IMPLEMENTED AT FUNCTIONAL LEVEL, THIS TASK AIMS TO HIGHLIGHT THE RAM CRITICALFUNCTIONS ON WHICH FURTHER DETAILED ANALYSES WILL FOCUS.............................................141

DURING THIS PHASE, THE CLASSIFICATION OF FUNCTIONS WILL BE MADE USING THEFAILURE CATEGORIES DEFINED BY THE SUPPLIER AND ADAPTED TO THE SPECIFIC

REQUIREMENTS OF THE CONTRACT......................................................................................................141

THIS TASK IS PERFORMED USING FUNCTIONAL FMECAS TO IDENTIFY RAM CRITICALFUNCTIONS AND RELIABILITY BLOCK DIAGRAMS...............................................................................141

THE DELIVERABLE OF THIS TASK IS A SET OF PRELIMINARY ANALYSIS TO COVER ALL THERAM REQUIREMENTS................................................................................................................................141

GENERALLY, THE LEVEL OF DEPTH OF THE ANALYSES IS NOT LOW, BUT THE LEVEL ISESTABLISHED ACCORDING THE BREAKDOWN STRUCTURE OF THE ROLLING STOCK ANDACCORDING THE LEVEL OF DEFINITION AND SPECIFICATION OF THE TECHNICAL ANDFUNCTIONAL DESIGN................................................................................................................................141

PRELIMINARY DESIGN REVIEW.......................................................................................................141

THIS MILESTONE IS STATED TO CHECK THE DESIGN PROCESS AND TO REVIEW ALL THERAM DOCUMENTATION WITH THE PURPOSE OF ENSURING THAT THE RAM REQUIREMENTS AREPROPERLY ACHIEVED AND TO EXAMINE PROBLEMS ARISING.........................................................141

DETAILED ANALYSES.......................................................................................................................141

THIS TASK AIMS TO PERFORM DETAILED ANALYSES HIGHLIGHTED DURING THEPRELIMINARY ANALYSES........................................................................................................................141

DURING THIS TASK THE SUPPLIER HAS ALREADY REACH A GOOD LEVEL OF DEPTH FOR

THE DESIGN AND THEN THE CORRESPONDING BREAKDOWN STRUCTURE OF THE ROLLINGSTOCK WILL BE AT LRU LEVEL...............................................................................................................141

AS A CONSEQUENCE, THE SET OF THE ANALYSES OF THE PREVIOUS PHASE WILL BEUPDATED AND DETAILED CONSIDERATIONS ACCORDING THE RAM REQUIREMENT ARE MADE.

141

THE FINAL SCOPE OF SUCH ANALYSES IS TO MAKE SURE OF THE FULFILLMENT OF THERAM REQUIREMENT OF THE DESIGNED ROLLING STOCK..................................................................141

SOLVE LAST PROBLEMS, WHEN ARISEN.......................................................................................141

VERIFY THE COMPLETENESS OF THE SET OF DOCUMENTS......................................................141

Page 48 of 158





PREPARE ACTIVITIES FOR TESTS AND COLLECTION OF DATA FROM FIELD..........................141

DURING THIS PHASE THE SUPPLIER COLLECTS DETAILED ANALYSES CARRIED OUT BYSUB CONTRACTORS IN ORDER TO:........................................................................................................141

INSURE A GOOD CONSISTENCY BETWEEN THEM;.......................................................................141

INTEGRATE THE PREVISIONS PROVIDED BY THEM, AT EQUIPMENT LEVEL IN THE MODEL, INORDER TO GET PREVISIONS AT ROLLING STOCK LEVEL;................................................................141

INTEGRATE INTERFACES MALFUNCTIONS IN THE MODEL FOR PREVISION............................141

FINAL DESIGN REVIEW.....................................................................................................................141

THIS MILESTONE IS STATED TO CHECK THE DESIGN PROCESS AND TO REVIEW ALL THERAM DOCUMENTATION WITH THE PURPOSE OF ENSURING THAT THE RAM REQUIREMENTS AREPROPERLY ACHIEVED AND TO EXAMINE PROBLEMS ARISING.........................................................141

THE FINAL SCOPE OF THIS REVIEW IS TO:....................................................................................141

CHECK THE FULFILLMENT OF THE RAM REQUIREMENTS..........................................................141

SOLVE LAST PROBLEMS, WHEN ARISEN.......................................................................................142

VERIFY THE COMPLETENESS OF THE SET OF DOCUMENTS......................................................142

PREPARE ACTIVITIES FOR TESTS AND COLLECTION OF DATA FROM FIELD..........................142

RAM GROWTH MONITORING............................................................................................................142

THIS TASK AIMS TO MONITOR RAM GROWTH (ESSENTIALLY RELIABILITY GROWTH) SO THATTHE TIME TO GET STEADY STATE LEVEL IS THE SHORTEST POSSIBLE..........................................142

THIS TASK CONSISTS IN THE IMPLEMENTATION OF A PROBLEM SOLVING PROCESSINVOLVING ALL THE SUBCONTRACTORS AND THE CONTRACTOR IN ORDER TO:.........................142

IDENTIFY THE PROBLEMS OCCURRING DURING THE EARLIEST OPERATION PHASE;..........142

HIGHLIGHT THE MOST CONTRIBUTIVE PROBLEMS AFFECTING CONTRACTUAL SERVICEPERFORMANCES;......................................................................................................................................142

ELABORATE AN ACTION PLAN ALLOWING TO ERADICATE THE PROBLEMS OR MITIGATE

THEIR EFFECTS;........................................................................................................................................142

FOLLOW UP THE IMPACT OF SUCH ACTION PLAN TO DECIDE ABOUT CARRYING ON THEITERATIVE PROCESS OR STOP IT...........................................................................................................142

FOLLOW UP OF CRITICAL ITEMS.....................................................................................................142

THIS TASK IS A SPECIFIC MANAGEMENT TASK IMPLEMENTED ALL ALONG THE DESIGNPROCESS FROM PRELIMINARY ANALYSIS TO SERVICE OPERATION...............................................142

IT CONSISTS IN:.................................................................................................................................142

Page 49 of 158





IDENTIFYING, AS ISSUES OF THE RAM ANALYSIS PROCESS (PRELIMINARY AND DETAILEDANALYSIS) THE CRITICAL SCENARIOS (FAILURES ASSOCIATED TO THEIR EFFECTS ON SERVICEOR ON SAFETY) ;.......................................................................................................................................142

CLASSIFYING THESE SCENARIOS ACCORDING TO COMBINATION OF THEIR ESTIMATEDFREQUENCY AND THEIR EFFECTS ON SAFETY OR SERVICE;............................................................142

PROPOSING OR ASK THE DESIGNERS TO PROPOSE ACTIONS OR PROVISIONS TOELIMINATE THE SCENARIOS OR MITIGATE THEIR EFFECTS;.............................................................142

ESTIMATING THE IMPACT OF THE ACTION PLAN; .......................................................................142

FOLLOWING UP APPLICATION OF THESE ACTIONS DURING THE LATEST DESIGN PHASES ORDURING MANUFACTURING;.....................................................................................................................142

THIS TASK IS PERFORMED USING PROBLEM SOLVING TECHNIQUES......................................142

9.1.3 Demonstration Phase..................................................................................................................142

9.1.3.1 Introduction..............................................................................................................................................142

THIS PARAGRAPH DEALS WITH THE OPERATION PERIOD IN WHICH CUSTOMER IS ASKED TOCHECK THE FULFILMENT OF RAM CONTRACTUAL TARGETS FOR THE ROLLING STOCK UNDERCONSIDERATION BY RAM DEMONSTRATION TESTS AND COLLECTION OF DATA FROM FIELD...142

FROM THE POINT OF VIEW OF THE CUSTOMER, THE COLLECTION OF DATA FROM FIELD HASTHE TARGET OF ADDRESSING:...............................................................................................................142

A BASIS FOR ROLLING STOCK ACCEPTANCE .............................................................................142

A KNOWLEDGE ABOUT THE ROLLING STOCK PERFORMANCE.................................................142

A REFERENCE DATA BASE FOR NEW ROLLING STOCKS/SYSTEMS/SUBSYSTEMS TENDERING142

ALSO, FROM THE POINT OF VIEW OF THE SUPPLIER, THE COLLECTION OF DATA FROMFIELD HAS THE TARGET OF:....................................................................................................................142

MONITORING/VERIFYING DESIGN, MANUFACTURE AND INSTALLATION PHASE....................142

MONITORING ROLLING STOCK OPERATION TO ADDRESS CORRECTIVE ACTIONS................142

GATHERING DATA AND KNOWLEDGE FOR FURTHER DEVELOPMENT ....................................143

ALSO, IN THE LONG TERM OPERATION, THE TARGET IS TO FIND OUT WEAK POINTS IN THEMANAGEMENT PROCESS (OPERATION AND MAINTENANCE PHASES) IN ORDER TO FORM ABASIS FOR PERFORMANCE IMPROVEMENT AND COST REDUCTION TO OPTIMISE MAINTENANCEAND OPERATION........................................................................................................................................143

THE DEFINITION OF TEST PROCEDURES HAVE TO BE COHERENT WITH THE SYSTEMIDENTIFICATION PROCESS AND DEFINITION GIVEN IN 8. ...................................................................143

ALL THE RAM DOCUMENTS PROVIDED DURING DESIGN PERIOD ACCORDING THE RAMPROGRAMME ARE INTENDED TO BE PROOF OF COMPLIANCE WITH RAM REQUIREMENTS OF THEDESIGNED ROLLING STOCK....................................................................................................................143

9.1.3.2 RAM Acceptance Criteria.........................................................................................................................143

Page 50 of 158





ON THE BASIS OF THE RAM REQUIREMENTS CHOSEN, THE CUSTOMER IS ASKED TO DEFINETHE RAM ACCEPTANCE CRITERIA ON THE FIELD................................................................................143

THE DEFINITION OF RELIABILITY ACCEPTANCE CRITERIA HAS TO BE ADDRESSED TO

SPECIFY THE CONDITIONS IN WHICH A FAILURE IS CLASSIFIED AS "CHARGEABLE" OR DUE TORESPONSIBILITY OF THE SUPPLIER, OR ALTERNATIVELY IS CLASSIFIED AS "UNCHARGEABLE".143

THE FOLLOWING GENERAL CONDITIONS OF FAILURE ARE TO BE CONSIDERED AS"UNCHARGEABLE" WHEN VERIFIED:.....................................................................................................143

FAILURES OCCURRED DURING THE SERVICE OUT OF THE STATED CONDITIONS OFOPERATION................................................................................................................................................143

FAILURES DUE TO CUSTOMER PERSONNEL.................................................................................143

FAILURES DUE TO ACCIDENTAL EVENTS......................................................................................143

IN THE SAME WAY THE CUSTOMER IS ASKED TO DEFINE FOR EACH RAM REQUIREMENTDETAILED ACCEPTANCE CRITERIA IN ORDER TO ESTABLISH, BEFORE THE BEGINNING OF THECHECKING PERIOD, CLEAR RULES TO BE FOLLOWED.......................................................................143

9.1.3.3 In service checking Period.......................................................................................................................143

THE CUSTOMER IS RESPONSIBLE IN DEFINING AN APPROPRIATE DURATION OF THECHECKING PERIOD....................................................................................................................................143

DEFINING THE CHECKING PERIOD, THE CUSTOMER SHOULD CONSIDER THAT USUALLY THERAM TARGETS ARE NOT ACHIEVED IN THE FIRST PERIOD OF OPERATION, BUT AFTER A BURN-INPERIOD WHERE A RELIABILITY GROWTH MONITORING PROCESS HAS TO BE IMPLEMENTED....143

GENERALLY THE STEADY STATE LEVEL IS ACHIEVED AT LEAST AFTER 2 YEARS OFREVENUE SERVICE....................................................................................................................................143

THE RELIABILITY GROWTH PROCESS IS A CONTINUOUS MONITORING OF THE TARGETS ONFIELD AND SUCCESSIVE ANALYSIS OF THE RESULTS AND MATCHING AGAINST THECONTRACTUAL REQUIREMENTS............................................................................................................143

WHERE RESULTS FROM FIELD DO NOT MEET CONTRACTUAL REQUIREMENTS, CORRECTIVEACTIONS ARE REQUESTED TO THE SUPPLIER.....................................................................................143

CHOOSING THE CHECKING PERIOD, IT IS IMPORTANT TO HIGHLIGHT THAT:.........................143

WITHIN THE RELIABILITY GROWTH PROCESS, THE CORRECTIVE ACTIONS MUST BEMANAGED AS DESCRIBED IN 8.5.2, WITH A CORRECTIVE ACTION PLAN, AS APPROPRIATE... ....143

AT THE BEGINNING OF THE RAM CHECKING PERIOD, THE RELIABILITY GROWTH PROCESSHAS TO BE CONCLUDED..........................................................................................................................143

IN ORDER TO MANAGE A COHERENT FIELD DATA COLLECTION THE CONFIGURATION OFTHE ROLLING STOCK HAS TO BE FROZEN............................................................................................143

THE DURATION OF THE CHECKING PERIOD HAS TO BE CHOSEN EVALUATING:....................144

THE NUMBER OF ROLLING STOCK OF THE FLEET AND THE CUMULATIVE ANNUALKILOMETRES OF SERVICE.......................................................................................................................144

Page 51 of 158





THE MAINTENANCE PLAN OF THE ROLLING STOCK....................................................................144

THE RAM REQUIREMENTS CHOSEN BY THE CUSTOMER............................................................144

THE DURATION OF THE CONTRACTUAL RELATIONSHIPS BETWEEN CUSTOMER ANDSUPPLIER (I.E. DURATION OF WARRANTY PERIOD) ............................................................................144

ALSO, THE CUSTOMER MUST CONSIDER, AS APPROPRIATE, IF THE CHECKING PERIOD ANDTHE FIELD DATA COLLECTION IS ADDRESSED TO COVER:...............................................................144

THE ENTIRE ROLLING STOCK FLEET.............................................................................................144

A SELECTED NUMBER OF ROLLING STOCK OF THE FLEET.......................................................144

OTHER SYSTEMS/SUBSYSTEMS OF INTEREST.............................................................................144

9.1.3.4 Data Report from field and organisation..................................................................................................144

THE FIELD DATA COLLECTION, WITHIN THE CHECKING PERIOD, COMPRISES THE WHOLEPROCESS OF GATHERING DATA ON FIGURES AND EVENTS OCCURRING SUCH AS:....................144

FAILURES DURING OPERATION AND MAINTENANCE..................................................................144

CLASSIFICATION OF THE FAILURES (SIGNIFICANT, MAJOR, MINOR)........................................144

STRUCTURE CODE OF THE ITEM SOURCE OF THE FAILURE......................................................144

DESCRIPTION OF THE FAULT DETECTED......................................................................................144

WORK DURING MAINTENANCE........................................................................................................144

AMOUNT OF MAN-HOURS.................................................................................................................144

MATERIAL CONSUMPTION...............................................................................................................144

KILOMETRES/HOURS OF SERVICE..................................................................................................144

DOWNTIMES AND STANDSTILL TIMES (ALSO LOGISTIC AND ADMINISTRATIONAL DELAYS)144

ALSO REPORTS ABOUT REPAIR AND CAUSE OF FAILURE ARE NECESSARY TO ADDRESSCORRECT CORRECTIVE ACTIONS..........................................................................................................144

OBVIOUSLY, IDENTIFICATION DATA HAS TO BE COLLECTED TO GAIN TRACEABILITY FOR

FURTHER INVESTIGATIONS SUCH AS:...................................................................................................144

IDENTIFICATION NUMBER OF THE REPORT CONTAINING DATA................................................144

DATE OF THE EVENT OCCURRED...................................................................................................144

DESCRIPTION OF THE OPERATION STATUS..................................................................................144

IDENTIFICATION NUMBER OF THE ROLLING STOCK (OR VEHICLE) WITHIN THE FLEET...... ..144

ALSO A PREVENTIVE INFORMATION ON RESPONSIBILITY COULD BE GIVEN TO ADDRESSACCEPTANCE CRITERIA...........................................................................................................................144

Page 52 of 158





USUALLY THE CUSTOMER AND THE SUPPLIER AGREE FOR A RAM DEMONSTRATION PLANCONTAINING, AT LEAST, SPECIFICATION OF:.......................................................................................144

RULES AND METHODS......................................................................................................................144

RESOURCE AND TOOLS...................................................................................................................145

ORGANISATION AND RESPONSIBILITY..........................................................................................145

FIELD DATA COLLECTION SITES (DEPOTS, WORKSHOPS).........................................................145

REFERENCE DOCUMENTS (I.E. RAM ANALYSES AND BREAKDOWN STRUCTURE)................145

RAM CONTRACTUAL TARGETS.......................................................................................................145

ACCEPTANCE CRITERIA...................................................................................................................145

PROCEDURE TO COLLECT DATA....................................................................................................145

DETECTION OF ALL SOURCE OF DATA AND ANY DISTURBANCES...........................................145

SCHEDULE OF PERIODICAL FIELD DATA COLLECTION REVIEWS.............................................145

PROCEDURE TO SOLVE PROBLEMS AND TO ADDRESS CORRECTIVE ACTIONS....................145

PROCEDURE FOR IMPLEMENTING CORRECTIVE ACTION PLAN................................................145

IT IS IMPORTANT TO NOTE THAT THE CORRECTIVE ACTION PLAN HAS TO CONTAIN ALSOTHE ASSESSMENT OF THE IMPACT OF THE CORRECTIVE ACTIONS ON THE CONFIGURATIONMANAGEMENT PROCESS AS EXPLAINED IN 8.5.2................................................................................145

10 SPECIFIC HAZARDS RELATED TO ROLLING STOCK................................................................146

10.1 INTRODUCTION.......................................................................................................................................146

THE AIM OF THIS PARAGRAPH IS TO GIVE A REFERENCE LIST OF THE MOST COMMONHAZARDS ASSOCIATED WITH ROLLING STOCK...................................................................................146

THE READER IS ASKED TO CONSIDER THIS LIST AS AN AID TO DEVELOP MORE SUITABLEAND COHERENT LIST OF HAZARDS RELATED TO THE ROLLING STOCK UNDER CONSIDERATION.

146

10.2 HAZARD

IDENTIFICATION

PROCESS

..............................................................................................................146THE DEFINITION OF A LIST OF HAZARDS IS A COMPLEX AND DELICATE PROCESS

REQUIRING A DEEP KNOWLEDGE OF THE RAILWAY SCENARIOS....................................................146

THE PROCESS OF DERIVING DETAILED HAZARDS FOR ROLLING STOCK SHALL BEADDRESSED TO COVER ALL THE POSSIBLE AND REASONABLE FACTORS INFLUENCING SAFETYBY CONSIDERING AT LEAST THE FOLLOWING:....................................................................................146

TYPE OF OPERATION........................................................................................................................146

PROCEDURES OF SIGNALLING.......................................................................................................146

MODE OF OPERATION.......................................................................................................................146

Page 53 of 158





RULES AND LAWS CONSTRAINTS..................................................................................................146

STANDARDS APPLICABLE...............................................................................................................146

TECHNICAL AND FUNCTIONAL SPECIFICATION...........................................................................146

MAINTENANCE AND LOGISTIC SUPPORT ISSUES........................................................................146

HUMAN FACTORS..............................................................................................................................146

ENVIRONMENT AND FUNCTIONAL INTERFACE ISSUES...............................................................146

AND SO ON.........................................................................................................................................146

ALL THE CONSIDERATION SHALL BE ADDRESSED TO IDENTIFY ALL THE POSSIBLESITUATIONS OR ASSOCIATED EVENTS LIKELY TO HAVE AN EFFECT ON THE SAFETY, IN TERMSOF INJURY OR DEATH OF HUMANS, FOR PASSENGERS AND/OR SERVICE PERSONNEL WHEN

THEY ARE:..................................................................................................................................................146

ON THE ROLLING STOCK..................................................................................................................146

ENTERING/ALIGHTING VEHICLES....................................................................................................146

ON OR NEAR THE LINE.....................................................................................................................146

ON THE STATION...............................................................................................................................146

PERFORMING MAINTENANCE..........................................................................................................146

THE USE OF DATA OF PREVIOUS ACCIDENTS AND INCIDENTS, GENERIC LISTS AND EACHOTHER DOCUMENT DEALING WITH SAFETY HAZARDS IS RECOMMENDED.....................................146

PAGE 158 OF 158................................................................................................................................136

10.3 LIST OF THE MOST COMMON HAZARDS RELATED TO ROLLING STOCK.....................................................................147

ON THE ABOVE MENTIONED BASIS AND CONSIDERATION THE BELOW REPORTED LISTCONTAINS THE MOST COMMON HAZARDS RELATED TO ROLLING STOCK GROUPED INTOGENERAL CATEGORIES...........................................................................................................................147

ELECTRICAL.......................................................................................................................................147

TENSIONED SURFACES/POINTS......................................................................................................147

OVERHEATING...................................................................................................................................147

IGNITION OF COMBUSTIBLES..........................................................................................................147

INDUCED VOLTAGE (CAPACITIVE COUPLING)..............................................................................147

ELECTROSTATIC DISCHARGE.........................................................................................................147

INADVERTENT ACTIVATION.............................................................................................................147

ELECTRICAL ARC..............................................................................................................................147

Page 54 of 158





MECHANICAL......................................................................................................................................147

SHARP EDGES/POINTS.....................................................................................................................147

LIFTING WEIGHTS..............................................................................................................................147

VIBRATION..........................................................................................................................................147

ROTATING EQUIPMENT.....................................................................................................................147

STABILITY/TOPPLING POTENTIAL...................................................................................................147

RECIPROCATING EQUIPMENT.........................................................................................................147

EJECTED/THROWN PARTS/FRAGMENTS.......................................................................................147

PINCH POINTS....................................................................................................................................147

CRUSHING SURFACES .....................................................................................................................147

ALTERED STRUCTURAL PROPERTIES...........................................................................................147

PNEUMATIC/HYDRAULIC PRESSURE..............................................................................................147

OVERPRESSURIZATION....................................................................................................................147

BLOWN OBJECTS..............................................................................................................................147

PIPE/VESSEL/DUCT RUPTURE.........................................................................................................147

CROSSFLOW......................................................................................................................................147

PIPE/HOSE WHIP................................................................................................................................147

IMPLOSION..........................................................................................................................................147

BACKFLOW/SIPHON EFFECT...........................................................................................................147

BLAST..................................................................................................................................................147

ACCELERATION/DECELERATION/GRAVITY...................................................................................147

EXCESSIVE ACCELERATION............................................................................................................147

EXCESSIVE DECELERATION............................................................................................................147

INADVERTENT MOTION.....................................................................................................................147

LOOSE OBJECT TRANSLATION.......................................................................................................147

DERAILMENT......................................................................................................................................147

COLLISION..........................................................................................................................................147

SLIP/TRIP............................................................................................................................................147

Page 55 of 158





FALLING OBJECTS............................................................................................................................147

FALLS..................................................................................................................................................147

TEMPERATURE EXTREMES..............................................................................................................147

HOT/COLD SURFACE.........................................................................................................................147

FREEZING...........................................................................................................................................147

CONFINED GAS/LIQUID.....................................................................................................................147

REDUCED RELIABILITY.....................................................................................................................147

PRESSURE ELEVATION....................................................................................................................147

HUMIDITY/MOISTURE........................................................................................................................147

ELEVATED FLAMMABILITY...............................................................................................................147

ELEVATED VOLATILITY.....................................................................................................................147

FIRE/FLAMMABILITY/NOISE..............................................................................................................147

PRESENCE OF:...................................................................................................................................147

– NOISE ..............................................................................................................................................147

– FUEL.................................................................................................................................................147

– IGNITION SOURCE..........................................................................................................................147

– OXIDIZER..........................................................................................................................................148

– RADIATION.......................................................................................................................................148

– EXPLOSIVE PROPELLANT ............................................................................................................148

– EXPLOSIVE GAS .............................................................................................................................148

– EXPLOSIVE LIQUID ........................................................................................................................148

– EXPLOSIVE VAPOR ........................................................................................................................148

– EXPLOSIVE DUST ...........................................................................................................................148

– COMPRESSED AIR/GAS.................................................................................................................148

– LUBRICATION..................................................................................................................................148

LEAKS/SPILLS....................................................................................................................................148

MATERIALS: .......................................................................................................................................148

– LIQUIDS/CRYOGENS.......................................................................................................................148

Page 56 of 158





– GASES/VAPORS .............................................................................................................................148

– DUSTS .............................................................................................................................................148

– TOXIC................................................................................................................................................148

– IRRITANTS .......................................................................................................................................148

– CORROSIVE ....................................................................................................................................148

– ASPHYXIANTS ................................................................................................................................148

– ALLERGENS ....................................................................................................................................148

HUMAN FACTORS (ALSO SEE ERGONOMIC).................................................................................148

OPERATOR ERROR ..........................................................................................................................148

OPERATION OUT OF SEQUENCE.....................................................................................................148

INADVERTENT OPERATION .............................................................................................................148

RIGHT OPERATION/WRONG CONTROL..........................................................................................148

FAILURE TO OPERATE .....................................................................................................................148

OPERATE TOO LONG........................................................................................................................148

OPERATION EARLY/LATE ................................................................................................................148

OPERATE TOO BRIEFLY...................................................................................................................148

ERGONOMIC (ALSO SEE HUMAN FACTORS).................................................................................148

FATIGUE..............................................................................................................................................148

INACCESSIBILITY...............................................................................................................................148

INADEQUATE CONTROL/ READOUT DIFFERENTIATION...............................................................148

INAPPROPRIATE CONTROL/ READOUT LOCATION......................................................................148

FAULTY/ INADEQUATE CONTROL/ READOUT LABELLING..........................................................148

INADEQUATE/ IMPROPER ILLUMINATION......................................................................................148

GLARE.................................................................................................................................................148

NON EXISTING/ INADEQUATE "KILL" SWITCHES..........................................................................148

FAULTY WORKSTATION DESIGN.....................................................................................................148

CONTROL SYSTEMS..........................................................................................................................148

POWER OUTAGE ...............................................................................................................................148

Page 57 of 158





SNEAK SOFTWARE............................................................................................................................148

INTERFERENCE (EMI/ESI) ................................................................................................................148

LIGHTNING STRIKE............................................................................................................................148

MOISTURE ..........................................................................................................................................148

GROUNDING FAILURE.......................................................................................................................148

SNEAK CIRCUIT .................................................................................................................................148

INADVERTENT ACTIVATION.............................................................................................................148

THE ABOVE REPORTED HAZARDS ARE GENERAL OR HIGH LEVEL CATEGORIES OFHAZARDS APPLICABLE TO ROLLING STOCK........................................................................................148

THE LIST IS INTENTIONALLY REDUNDANT IN ANY CATEGORY, WHERE THE REPEATEDHAZARD ARE LISTED TO HIGHLIGHT AND CAPTURE THE ATTENTION ON IT...................................148

11 RAM PARAMETERS TO BE INCORPORATED INTO LCC MODEL..............................................148

TO BE DEFINED..................................................................................................................................148

12 ANNEX A - EXAMPLES OF BREAKDOWN STRUCTURE.............................................................149

HERE BELOW THERE ARE HIGHLIGHTED TWO POSSIBLE WAYS TO REPRESENT ASTRUCTURE:..............................................................................................................................................149

THE ORGANISATION CHART............................................................................................................149

THE TREE BREAKDOWN CHART.....................................................................................................149

THE FOLLOWING IS AN EXAMPLE USING THE ORGANISATION CHART FOR THE ROLLINGSTOCK "EMU (ELECTRICAL MULTIPLE UNIT) COACH", WHERE ONLY FOR VISUAL PURPOSES TWOBRANCH HAVE BEEN DEVELOPED.........................................................................................................149

..............................................................................................................................................................150

FIG. 7 EXAMPLE OF STRUCTURE USING ORGANISATION CHART FOR AN ELECTRICALMULTIPLE UNIT COACH............................................................................................................................150

THE FOLLOWING IS AN EXAMPLE OF REPRESENTATION OF THE BREAKDOWN STRUCTUREUSING A TREE DIAGRAM FOR A EMU TRACTION VEHICLE.................................................................151

FIG. 8 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) TRACTION VEHICLE............................................................................151

TREE BREAKDOWN STRUCTURE....................................................................................................151

ROLLING STOCK: EMU TRACTION VEHICLE..................................................................................151

DOC. N.................................................................................................................................................151

DATE....................................................................................................................................................151

Page 58 of 158





DRAWN UP BY....................................................................................................................................151

PAGE N/N............................................................................................................................................151

FILE NAME..........................................................................................................................................151

CODE...................................................................................................................................................151

L1 - SYSTEM........................................................................................................................................151

QTY......................................................................................................................................................151

CODE...................................................................................................................................................151

L2 - SUB-SYSTEM OR LRU................................................................................................................151

QTY......................................................................................................................................................151

CODE...................................................................................................................................................151

L3 - LRU...............................................................................................................................................151

QTY......................................................................................................................................................151

1............................................................................................................................................................151

CARBODY...........................................................................................................................................151

1............................................................................................................................................................151

1.1.........................................................................................................................................................151

HEAT INSULATION.............................................................................................................................151

1............................................................................................................................................................151

1.2.........................................................................................................................................................151

FRONT PANEL....................................................................................................................................151

1............................................................................................................................................................151

1.3.........................................................................................................................................................151

SIDE WINDOW, PASSENGER ROOM................................................................................................151

14..........................................................................................................................................................151

1.4.........................................................................................................................................................151

SIDE WINDOW, DRIVER'S CAB.........................................................................................................151

2............................................................................................................................................................151

1.5.........................................................................................................................................................151

Page 59 of 158





FLOOR.................................................................................................................................................151

1............................................................................................................................................................151

1.6.........................................................................................................................................................151

SIDE WALL, PANELLING...................................................................................................................151

2............................................................................................................................................................151

1.7.........................................................................................................................................................151

ROOF...................................................................................................................................................151

1............................................................................................................................................................151

1.8.........................................................................................................................................................151

NOSE COVER......................................................................................................................................151

1............................................................................................................................................................151

1.9.........................................................................................................................................................151

OBSTACLE DEFLECTOR...................................................................................................................151

1............................................................................................................................................................151

1.10.......................................................................................................................................................151

ENERGY ABSORBTION ELEMENTS.................................................................................................151

2............................................................................................................................................................151

1.11.......................................................................................................................................................151

AERODYNAMIC FRONT NOSE STRUCTURE...................................................................................151

1............................................................................................................................................................151

1.12.......................................................................................................................................................151

UNDERFRAME....................................................................................................................................151

1............................................................................................................................................................151

2............................................................................................................................................................151

MOTOR BOGIE....................................................................................................................................151

1............................................................................................................................................................151

2.1.........................................................................................................................................................151

BOGIE FRAME....................................................................................................................................151

Page 60 of 158





1............................................................................................................................................................151

2.2.........................................................................................................................................................151

CARRIER.............................................................................................................................................151

1............................................................................................................................................................151

2.2.1......................................................................................................................................................151

STEERING ROD..................................................................................................................................151

1............................................................................................................................................................151

2.3.........................................................................................................................................................151

PRIMARY SUSPENSION.....................................................................................................................151

4............................................................................................................................................................151

2.3.1......................................................................................................................................................151

DAMPER..............................................................................................................................................151

1............................................................................................................................................................151

2.3.2......................................................................................................................................................151

HELICAL SPRING...............................................................................................................................151

1............................................................................................................................................................151

2.4.........................................................................................................................................................151

SECONDARY SUSPENSION..............................................................................................................151

1............................................................................................................................................................151

2.4.1......................................................................................................................................................151

AIR SPRING.........................................................................................................................................151

2............................................................................................................................................................151

2.4.2......................................................................................................................................................151

PNEUMATIC COMPONENTS FOR SECONDARY SUSPENSION (SET)...........................................151

1............................................................................................................................................................151

2.4.3......................................................................................................................................................151

VERTICAL DAMPER...........................................................................................................................151

2............................................................................................................................................................151

Page 61 of 158





2.4.4......................................................................................................................................................151

HORIZONTAL DAMPER......................................................................................................................151

2............................................................................................................................................................151

2.5.........................................................................................................................................................151

BEARING ASSEMBLY........................................................................................................................151

4............................................................................................................................................................151

2.5.1......................................................................................................................................................151

BEARING BOX....................................................................................................................................151

1............................................................................................................................................................151

2.5.2......................................................................................................................................................151

BEARING.............................................................................................................................................151

1............................................................................................................................................................151

2.6.........................................................................................................................................................151

WHEEL SET.........................................................................................................................................151

2............................................................................................................................................................151

2.6.1......................................................................................................................................................151

AXLE....................................................................................................................................................151

1............................................................................................................................................................151

PAGE 158 OF 158..............................................................................................................................158

2.6.2......................................................................................................................................................152

WHEEL DISK.......................................................................................................................................152

2............................................................................................................................................................152

2.6.3......................................................................................................................................................152

BRAKE DISK.......................................................................................................................................152

2............................................................................................................................................................152

2.7.........................................................................................................................................................152

AXLE GEARBOX.................................................................................................................................152

2............................................................................................................................................................152

Page 62 of 158





2.8.........................................................................................................................................................152

AXLE BOX TEMPERATURE DEVICE.................................................................................................152

2............................................................................................................................................................152

2.9.........................................................................................................................................................152

INDUSI-MAGNET.................................................................................................................................152

1............................................................................................................................................................152

2.10.......................................................................................................................................................152

MECHANICAL INTERFACE WITH BODYSHELL (SET).....................................................................152

1............................................................................................................................................................152

2.11.......................................................................................................................................................152

PNEUMATIC EQUIPMENT ON BOGIE (SET).....................................................................................152

1............................................................................................................................................................152

2.12.......................................................................................................................................................152

SPEED SENSOR.................................................................................................................................152

2............................................................................................................................................................152

2.13.......................................................................................................................................................152

BRAKE EQUIPMENT ON THE BOGIE (SET).....................................................................................152

1............................................................................................................................................................152

2.14.......................................................................................................................................................152

EARTHING CONTACTS......................................................................................................................152

2............................................................................................................................................................152

3............................................................................................................................................................152

TRAILER BOGIE..................................................................................................................................152

1............................................................................................................................................................152

3.1.........................................................................................................................................................152

BOGIE FRAME....................................................................................................................................152

1............................................................................................................................................................152

3.2.........................................................................................................................................................152

Page 63 of 158





CARRIER.............................................................................................................................................152

1............................................................................................................................................................152

3.2.1......................................................................................................................................................152

STEERING ROD..................................................................................................................................152

1............................................................................................................................................................152

3.3.........................................................................................................................................................152

PRIMARY SUSPENSION.....................................................................................................................152

4............................................................................................................................................................152

3.3.1......................................................................................................................................................152

DAMPER..............................................................................................................................................152

1............................................................................................................................................................152

3.3.2......................................................................................................................................................152

HELICAL SPRING...............................................................................................................................152

1............................................................................................................................................................152

3.4.........................................................................................................................................................152

SECONDARY SUSPENSION..............................................................................................................152

1............................................................................................................................................................152

3.4.1......................................................................................................................................................152

AIR SPRING.........................................................................................................................................152

4............................................................................................................................................................152

3.4.2......................................................................................................................................................152

PNEUMATIC COMPONENTS FOR SECONDARY SUSPENSION (SET)...........................................152

1............................................................................................................................................................152

3.4.3......................................................................................................................................................152

VERTICAL DAMPER...........................................................................................................................152

4............................................................................................................................................................152

3.4.4......................................................................................................................................................152

HORIZONTAL DAMPER......................................................................................................................152

Page 64 of 158





1............................................................................................................................................................152

3.5.........................................................................................................................................................152

BEARING ASSEMBLY........................................................................................................................152

4............................................................................................................................................................152

3.5.1......................................................................................................................................................152

BEARING BOX....................................................................................................................................152

1............................................................................................................................................................152

3.5.2......................................................................................................................................................152

BEARING.............................................................................................................................................152

1............................................................................................................................................................152

3.6.........................................................................................................................................................152

WHEEL SET.........................................................................................................................................152

2............................................................................................................................................................152

3.6.1......................................................................................................................................................152

AXLE....................................................................................................................................................152

1............................................................................................................................................................152

3.6.2......................................................................................................................................................152

WHEEL DISK.......................................................................................................................................152

2............................................................................................................................................................152

3.6.3......................................................................................................................................................152

BRAKE DISK.......................................................................................................................................152

2............................................................................................................................................................152

3.7.........................................................................................................................................................152

AXLE BOX TEMPERATURE DEVICE.................................................................................................152

2............................................................................................................................................................152

3.8.........................................................................................................................................................152

MECHANICAL INTERFACE WITH BODYSHELL (SET).....................................................................152

1............................................................................................................................................................152

Page 65 of 158





3.9.........................................................................................................................................................152

PNEUMATIC EQUIPMENT ON BOGIE (SET).....................................................................................152

1............................................................................................................................................................152

3.10.......................................................................................................................................................152

SPEED SENSOR.................................................................................................................................152

2............................................................................................................................................................152

3.11.......................................................................................................................................................152

BRAKE EQUIPMENT ON THE BOGIE (SET).....................................................................................152

1............................................................................................................................................................152

3.12.......................................................................................................................................................152

EARTHING CONTACTS......................................................................................................................152

2............................................................................................................................................................152

4............................................................................................................................................................152

AUXILIARY ELEMENTS ON THE BOGIE...........................................................................................152

1............................................................................................................................................................152

4.1.........................................................................................................................................................152

SANDING DEVICE...............................................................................................................................152

2............................................................................................................................................................152

4.1.1......................................................................................................................................................152

SANDING TRAP..................................................................................................................................152

1............................................................................................................................................................152

4.1.2......................................................................................................................................................152

SANDING PIPE AND NOZZLES..........................................................................................................152

1............................................................................................................................................................152

4.2.........................................................................................................................................................152

WHEEL FLANGE LUBRICATION.......................................................................................................152

2............................................................................................................................................................152

4.2.1......................................................................................................................................................152

Page 66 of 158





TANK....................................................................................................................................................152

1............................................................................................................................................................152

4.2.2......................................................................................................................................................152

PUMP...................................................................................................................................................152

1............................................................................................................................................................152

4.2.3......................................................................................................................................................152

MAGNETIC VALVE..............................................................................................................................152

1............................................................................................................................................................152

4.2.4......................................................................................................................................................152

TURBOLUB DISTRIBUTER.................................................................................................................152

1............................................................................................................................................................152

4.2.5......................................................................................................................................................152

NOZZLE...............................................................................................................................................152

2............................................................................................................................................................152

4.2.6......................................................................................................................................................153

CONTROL UNIT...................................................................................................................................153

1............................................................................................................................................................153

5............................................................................................................................................................153

DOOR...................................................................................................................................................153

1............................................................................................................................................................153

5.1.........................................................................................................................................................153

PASSENGER DOOR...........................................................................................................................153

2............................................................................................................................................................153

5.1.1......................................................................................................................................................153

DRIVE/MOTOR UNIT...........................................................................................................................153

1............................................................................................................................................................153

5.1.2......................................................................................................................................................153

ROLLER SWING ARM, RIGHT............................................................................................................153

Page 67 of 158





1............................................................................................................................................................153

5.1.3......................................................................................................................................................153

ROLLER SWING ARM, LEFT..............................................................................................................153

1............................................................................................................................................................153

5.1.4......................................................................................................................................................153

EMERGENCY EGRESS DEVICE (INSIDE).........................................................................................153

1............................................................................................................................................................153

5.1.5......................................................................................................................................................153

BOWDEN CABLE, EMERGENCY EGRESS DEVICE (INSIDE)..........................................................153

1............................................................................................................................................................153

5.1.6......................................................................................................................................................153

EMERGENCY EGRESS DEVICE (OUTSIDE).....................................................................................153

1............................................................................................................................................................153

5.1.7......................................................................................................................................................153

BOWDEN CABLE, EMERGENCY EGRESS DEVICE (OUTSIDE)......................................................153

1............................................................................................................................................................153

5.1.8......................................................................................................................................................153

DOORLEAF, RIGHT............................................................................................................................153

1............................................................................................................................................................153

5.1.9......................................................................................................................................................153

DOORLEAF, LEFT...............................................................................................................................153

1............................................................................................................................................................153

5.1.10....................................................................................................................................................153

LOCK BOX...........................................................................................................................................153

1............................................................................................................................................................153

5.1.11....................................................................................................................................................153

LIGHT BARRIER..................................................................................................................................153

1............................................................................................................................................................153

Page 68 of 158





5.1.12....................................................................................................................................................153

CONTROL UNIT...................................................................................................................................153

1............................................................................................................................................................153

5.2.........................................................................................................................................................153

INTERNAL DOOR................................................................................................................................153

1............................................................................................................................................................153

5.3.........................................................................................................................................................153

EXTERNAL CAB DOOR......................................................................................................................153

2............................................................................................................................................................153

5.4.........................................................................................................................................................153

SLIDING DOOR DRIVER'S CAB.........................................................................................................153

1............................................................................................................................................................153

6............................................................................................................................................................153

DRAW AND BUFFER GEAR...............................................................................................................153

1............................................................................................................................................................153

6.1.........................................................................................................................................................153

AUTOMATIC COUPLER......................................................................................................................153

1............................................................................................................................................................153

6.1.1......................................................................................................................................................153

COUPLER HEAD.................................................................................................................................153

1............................................................................................................................................................153

6.1.2......................................................................................................................................................153

UNCOUPLE DEVICE...........................................................................................................................153

1............................................................................................................................................................153

6.1.3......................................................................................................................................................153

AIR COUPLER FOR MAIN AIR PIPE COUPLER................................................................................153

1............................................................................................................................................................153

6.1.4......................................................................................................................................................153

Page 69 of 158





AIR COUPLER FOR UNCOUPLE DEVICE PIPE................................................................................153

1............................................................................................................................................................153

6.1.5......................................................................................................................................................153

ELECTRICAL COUPLER OPERATION DEVICE................................................................................153

1............................................................................................................................................................153

6.1.6......................................................................................................................................................153

COUPLING ROD..................................................................................................................................153

1............................................................................................................................................................153

6.1.7......................................................................................................................................................153

BEARING BLOCK...............................................................................................................................153

1............................................................................................................................................................153

6.1.8......................................................................................................................................................153

ELECTRICAL COUPLER....................................................................................................................153

1............................................................................................................................................................153

6.1.9......................................................................................................................................................153

COVERING..........................................................................................................................................153

1............................................................................................................................................................153

6.1.10....................................................................................................................................................153

CENTER POSITION.............................................................................................................................153

1............................................................................................................................................................153

6.1.11....................................................................................................................................................153

SUPPLIES............................................................................................................................................153

1............................................................................................................................................................153

6.1.12....................................................................................................................................................153

EARTHING...........................................................................................................................................153

1............................................................................................................................................................153

6.1.13....................................................................................................................................................153

COUPLER HEAD, ELECTRICAL PART..............................................................................................153

Page 70 of 158





1............................................................................................................................................................153

6.2.........................................................................................................................................................153

COUPLING LINK.................................................................................................................................153

1............................................................................................................................................................153

6.2.1......................................................................................................................................................153

SPECIAL BEARING FOR ARTICULATION........................................................................................153

1............................................................................................................................................................153

6.2.2......................................................................................................................................................153

COUPLING FORK................................................................................................................................153

1............................................................................................................................................................153

6.2.3......................................................................................................................................................153

GUIDE ROD SUPPORT.......................................................................................................................153

1............................................................................................................................................................153

7............................................................................................................................................................153

ARTICULATION...................................................................................................................................153

1............................................................................................................................................................153

7.1.........................................................................................................................................................153

ARTICULATED DAMPER, ROLLING..................................................................................................153

1............................................................................................................................................................153

7.2.........................................................................................................................................................153

ARTICULATED DAMPER, PITCHING.................................................................................................153

1............................................................................................................................................................153

7.3.........................................................................................................................................................153

ARTICULATED DAMPER, YAWING...................................................................................................153

1............................................................................................................................................................153

7.4.........................................................................................................................................................153

INTERCOMMUNICATING GANGWAY................................................................................................153

1............................................................................................................................................................153

Page 71 of 158





7.4.1......................................................................................................................................................153

BELLOWS............................................................................................................................................153

1............................................................................................................................................................153

7.4.2......................................................................................................................................................153

BELLOWS FRAME..............................................................................................................................153

2............................................................................................................................................................153

7.4.2......................................................................................................................................................153

STEP BOARD......................................................................................................................................153

1............................................................................................................................................................153

8............................................................................................................................................................154

ELECTRICAL EQUIPMENT.................................................................................................................154

1............................................................................................................................................................154

8.1.........................................................................................................................................................154

TRACTION...........................................................................................................................................154

1............................................................................................................................................................154

8.1.1......................................................................................................................................................154

PROPULSION INVERTER BOXES.....................................................................................................154

1............................................................................................................................................................154

8.1.2......................................................................................................................................................154

ELECTRIC TRACTION MOTOR..........................................................................................................154

2............................................................................................................................................................154

8.1.3......................................................................................................................................................154

SPEED SENSOR FOR TRACTION CONTROL...................................................................................154

4............................................................................................................................................................154

8.1.4......................................................................................................................................................154

TRACTION CONTROL UNIT..............................................................................................................154

1............................................................................................................................................................154

8.1.5......................................................................................................................................................154

Page 72 of 158





RHEOSTATIC BREAKING RESISTORS.............................................................................................154

1............................................................................................................................................................154

8.2.........................................................................................................................................................154

AUXILIARY ELECTRICAL ENERGY...................................................................................................154

1............................................................................................................................................................154

8.2.1......................................................................................................................................................154

LV AND MV CONTACTORS, RELAY CONTACTORS, FUSES, AUTOMATIC CIRCUIT BREAKER154

1............................................................................................................................................................154

8.2.2......................................................................................................................................................154

BATTERY.............................................................................................................................................154

1............................................................................................................................................................154

8.2.3......................................................................................................................................................154

AUXILIARY STATIC CONVERTER WITH BATTERY CHARGER......................................................154

1............................................................................................................................................................154

9............................................................................................................................................................154

PNEUMATIC AND BRAKING SYSTEM..............................................................................................154

1............................................................................................................................................................154

9.1.........................................................................................................................................................154

BRAKE CONTROL DEVICE................................................................................................................154

1............................................................................................................................................................154

9.2.........................................................................................................................................................154

DIRECT BRAKE CONTROL DEVICE..................................................................................................154

1............................................................................................................................................................154

9.3.........................................................................................................................................................154

ELECTRONIC CONTROL UNIT..........................................................................................................154

1............................................................................................................................................................154

9.4.........................................................................................................................................................154

SIGNALLING REPETITION PLATE....................................................................................................154

Page 73 of 158





1............................................................................................................................................................154

9.5.........................................................................................................................................................154

ANTISKID REDOUNDED (1 PER AXE)...............................................................................................154

1............................................................................................................................................................154

9.6.........................................................................................................................................................154

PNEUMATIC GROUP..........................................................................................................................154

1............................................................................................................................................................154

9.7.........................................................................................................................................................154

BRAKE DEVICES GROUP..................................................................................................................154

1............................................................................................................................................................154

9.8.........................................................................................................................................................154

MOTOR BOGIE SECONDARY SUSPENSION RESERVOIR..............................................................154

1............................................................................................................................................................154

9.9.........................................................................................................................................................154

TRAILER BOGIE SECONDARY SUSPENSION RESERVOIR...........................................................154

1............................................................................................................................................................154

9.10.......................................................................................................................................................154

PASSENGER ALARM BRAKE............................................................................................................154

1............................................................................................................................................................154

10..........................................................................................................................................................154

LIGHTING SYSTEM.............................................................................................................................154

1............................................................................................................................................................154

10.1.......................................................................................................................................................154

COMPARTMENT LIGHTS...................................................................................................................154

1............................................................................................................................................................154

10.2.......................................................................................................................................................154

DRIVING CAB LIGHTS........................................................................................................................154

1............................................................................................................................................................154

Page 74 of 158





10.3.......................................................................................................................................................154

EXTERNAL LIGHTS............................................................................................................................154

1............................................................................................................................................................154

10.3.1....................................................................................................................................................154

WHITE LIGHTS....................................................................................................................................154

2............................................................................................................................................................154

10.3.2....................................................................................................................................................154

RED LIGHTS........................................................................................................................................154

2............................................................................................................................................................154

10.3.3....................................................................................................................................................154

GREEN LIGHTS...................................................................................................................................154

1............................................................................................................................................................154

10.3.4....................................................................................................................................................154

CENTRAL LIGHTS..............................................................................................................................154

2............................................................................................................................................................154

11..........................................................................................................................................................154

FITTINGS.............................................................................................................................................154

1............................................................................................................................................................154

11.1.......................................................................................................................................................154

COMPARTMENT FITTINGS................................................................................................................154

1............................................................................................................................................................154

11.1.1....................................................................................................................................................154

PASSENGER SEAT.............................................................................................................................154

61..........................................................................................................................................................154

11.1.2....................................................................................................................................................154

FOLDABLE SEAT................................................................................................................................154

2............................................................................................................................................................154

11.1.3....................................................................................................................................................154

Page 75 of 158





MANUAL CURTAIN.............................................................................................................................154

18..........................................................................................................................................................154

11.1.4....................................................................................................................................................154

DRESSHANGER (SET).......................................................................................................................154

1............................................................................................................................................................154

11.1.5....................................................................................................................................................154

LUGGAGE RACK................................................................................................................................154

1............................................................................................................................................................154

11.1.6....................................................................................................................................................154

HAND RAILS (SET).............................................................................................................................154

1............................................................................................................................................................154

11.1.7....................................................................................................................................................154

LITTER BOX........................................................................................................................................154

1............................................................................................................................................................154

11.1.8....................................................................................................................................................154

TICKET VENDING MACHINE..............................................................................................................154

1............................................................................................................................................................154

11.1.9....................................................................................................................................................154

FIRE EXTINGUISHER..........................................................................................................................154

1............................................................................................................................................................154

11.2.......................................................................................................................................................154

DRIVING CAB FITTINGS.....................................................................................................................154

1............................................................................................................................................................154

11.2.1....................................................................................................................................................154

DRIVER SEAT (ADJUSTABLE)..........................................................................................................154

1............................................................................................................................................................154

11.2.2....................................................................................................................................................154

SUNSHAD CURTAIN...........................................................................................................................154

Page 76 of 158





3............................................................................................................................................................154

12..........................................................................................................................................................155

AUTOMATIC FIRE EXTINGUISHING..................................................................................................155

1............................................................................................................................................................155

13..........................................................................................................................................................155

DRIVING CAB AIR CONDITIONING...................................................................................................155

1............................................................................................................................................................155

13.1.......................................................................................................................................................155

VENTILATION......................................................................................................................................155

1............................................................................................................................................................155

13.2.......................................................................................................................................................155

COOLING.............................................................................................................................................155

1............................................................................................................................................................155

13.3.......................................................................................................................................................155

HEATING.............................................................................................................................................155

1............................................................................................................................................................155

14..........................................................................................................................................................155

COMPART AIR CONDITIONING.........................................................................................................155

1............................................................................................................................................................155

14.1.......................................................................................................................................................155

VENTILATION......................................................................................................................................155

1............................................................................................................................................................155

14.2.......................................................................................................................................................155

COOLING.............................................................................................................................................155

1............................................................................................................................................................155

14.3.......................................................................................................................................................155

HEATING.............................................................................................................................................155

1............................................................................................................................................................155

Page 77 of 158





14.4.......................................................................................................................................................155

HEATERS............................................................................................................................................155

45..........................................................................................................................................................155

15..........................................................................................................................................................155

TACHOGRAPH DEVICE......................................................................................................................155

1............................................................................................................................................................155

16..........................................................................................................................................................155

DEAD MAN DEVICE............................................................................................................................155

1............................................................................................................................................................155

17..........................................................................................................................................................155

DRIVER'S DESK .................................................................................................................................155

1............................................................................................................................................................155

17.1.......................................................................................................................................................155

LIGHT RACK........................................................................................................................................155

1............................................................................................................................................................155

17.2.......................................................................................................................................................155

INSTRUMENTS RACK........................................................................................................................155

1............................................................................................................................................................155

17.3.......................................................................................................................................................155

VIDEO SURVEILLANCE MONITOR....................................................................................................155

1............................................................................................................................................................155

17.4.......................................................................................................................................................155

CONSOLE............................................................................................................................................155

1............................................................................................................................................................155

17.5.......................................................................................................................................................155

RADIO EQUIPMENT ...........................................................................................................................155

1............................................................................................................................................................155

17.6.......................................................................................................................................................155

Page 78 of 158





ATP EQUIPMENT................................................................................................................................155

1............................................................................................................................................................155

18..........................................................................................................................................................155

SERVICE FUNCTIONS........................................................................................................................155

1............................................................................................................................................................155

18.1.......................................................................................................................................................155

PASSENGER INFORMATION SYSTEM.............................................................................................155

1............................................................................................................................................................155

18.1.1....................................................................................................................................................155

LOUDSPEAKER..................................................................................................................................155

8............................................................................................................................................................155

18.1.2....................................................................................................................................................155

CONTROLLER.....................................................................................................................................155

1............................................................................................................................................................155

18.1.3....................................................................................................................................................155

CAB CONTROL UNIT..........................................................................................................................155

1............................................................................................................................................................155

18.1.4....................................................................................................................................................155

EMERGENCY SPEECH UNIT..............................................................................................................155

4............................................................................................................................................................155

18.1.5....................................................................................................................................................155

INTERNAL INFORMATION DISPLAY.................................................................................................155

2............................................................................................................................................................155

18.1.6....................................................................................................................................................155

EXTERNAL SIDE DISPLAY.................................................................................................................155

2............................................................................................................................................................155

18.1.7....................................................................................................................................................155

HANDSET............................................................................................................................................155

Page 79 of 158





1............................................................................................................................................................155

18.2.......................................................................................................................................................155

VIDEO SURVEILLANCE SYSTEM......................................................................................................155

1............................................................................................................................................................155

18.2.1....................................................................................................................................................155

EXTERNAL CAM.................................................................................................................................155

2............................................................................................................................................................155

18.2.2....................................................................................................................................................155

INTERNAL CAM..................................................................................................................................155

3............................................................................................................................................................155

18.2.3....................................................................................................................................................155

VIDEO MONITOR.................................................................................................................................155

1............................................................................................................................................................155

19..........................................................................................................................................................155

WASHING AND WIPER SYSTEM.......................................................................................................155

1............................................................................................................................................................155

20..........................................................................................................................................................155

COMMAND & CONTROL/DIAGNOSTIC SYSTEM.............................................................................155

1............................................................................................................................................................155

20.1.......................................................................................................................................................155

COMMAND & CONTROL/DIAGNOSTIC ............................................................................................155

1............................................................................................................................................................155

20.2.......................................................................................................................................................155

INPUT/OUTPUT REMOTED DEVICE..................................................................................................155

1............................................................................................................................................................155

20.3.......................................................................................................................................................155

DIAGNOSTIC MONITOR.....................................................................................................................155

1............................................................................................................................................................155

Page 80 of 158





20.4.......................................................................................................................................................155

INSTRUMENTS MONITOR..................................................................................................................155

1............................................................................................................................................................155

20.5.......................................................................................................................................................155

TCN KNOT...........................................................................................................................................155

1............................................................................................................................................................155

THE FOLLOWING IS AN EXAMPLE OF REPRESENTATION OF THE BREAKDOWN STRUCTUREUSING A TREE DIAGRAM FOR A EMU (ELECTRICAL MULTIPLE UNIT) COACH.................................156

FIG. 9 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) COACH..................................................................................................156

TREE BREAKDOWN STRUCTURE....................................................................................................156

ROLLING STOCK: EMU COACH........................................................................................................156

DOC. N.................................................................................................................................................156

DATE....................................................................................................................................................156

DRAWN UP BY....................................................................................................................................156

PAGE N/N............................................................................................................................................156

FILE NAME..........................................................................................................................................156

CODE...................................................................................................................................................156

L1 - SYSTEM........................................................................................................................................156

QTY......................................................................................................................................................156

CODE...................................................................................................................................................156

L2 - SUB-SYSTEM OR LRU................................................................................................................156

QTY......................................................................................................................................................156

CODE...................................................................................................................................................156

L3 - LRU...............................................................................................................................................156

QTY......................................................................................................................................................156

1............................................................................................................................................................156

CARBODY...........................................................................................................................................156

1............................................................................................................................................................156

Page 81 of 158





1.1.........................................................................................................................................................156

HEAT INSULATION.............................................................................................................................156

1............................................................................................................................................................156

1.2.........................................................................................................................................................156

SIDE WINDOW, PASSENGER ROOM................................................................................................156

10..........................................................................................................................................................156

1.3.........................................................................................................................................................156

FLOOR.................................................................................................................................................156

1............................................................................................................................................................156

1.4.........................................................................................................................................................156

SIDE WALL, PANELLING...................................................................................................................156

2............................................................................................................................................................156

1.5.........................................................................................................................................................156

ROOF...................................................................................................................................................156

1............................................................................................................................................................156

1.6.........................................................................................................................................................156

UNDERFRAME....................................................................................................................................156

1............................................................................................................................................................156

2............................................................................................................................................................156

DOOR...................................................................................................................................................156

1............................................................................................................................................................156

2.1.........................................................................................................................................................156

PASSENGER DOOR...........................................................................................................................156

2............................................................................................................................................................156

2.1.1......................................................................................................................................................156

DRIVE/MOTOR UNIT...........................................................................................................................156

1............................................................................................................................................................156

2.1.2......................................................................................................................................................156

Page 82 of 158





ROLLER SWING ARM, RIGHT............................................................................................................156

1............................................................................................................................................................156

2.1.3......................................................................................................................................................156

ROLLER SWING ARM, LEFT..............................................................................................................156

1............................................................................................................................................................156

2.1.4......................................................................................................................................................156

EMERGENCY EGRESS DEVICE (INSIDE).........................................................................................156

1............................................................................................................................................................156

2.1.5......................................................................................................................................................156

BOWDEN CABLE, EMERGENCY EGRESS DEVICE (INSIDE)..........................................................156

1............................................................................................................................................................156

2.1.6......................................................................................................................................................156

EMERGENCY EGRESS DEVICE (OUTSIDE).....................................................................................156

1............................................................................................................................................................156

2.1.7......................................................................................................................................................156

BOWDEN CABLE, EMERGENCY EGRESS DEVICE (OUTSIDE)......................................................156

1............................................................................................................................................................156

2.1.8......................................................................................................................................................156

DOORLEAF, RIGHT............................................................................................................................156

1............................................................................................................................................................156

2.1.9......................................................................................................................................................156

DOORLEAF, LEFT...............................................................................................................................156

1............................................................................................................................................................156

2.1.10....................................................................................................................................................156

LOCK BOX...........................................................................................................................................156

1............................................................................................................................................................156

2.1.11....................................................................................................................................................156

LIGHT BARRIER..................................................................................................................................156

Page 83 of 158





1............................................................................................................................................................156

2.1.12....................................................................................................................................................156

CONTROL UNIT...................................................................................................................................156

1............................................................................................................................................................156

2.2.........................................................................................................................................................156

RAMP...................................................................................................................................................156

2............................................................................................................................................................156

3............................................................................................................................................................156

PNEUMATIC AND BRAKING SYSTEM..............................................................................................156

1............................................................................................................................................................156

3.1.........................................................................................................................................................156

PRODUCTION/TREATMENT AIR GROUP.........................................................................................156

1............................................................................................................................................................156

3.2.........................................................................................................................................................156

BRAKE DEVICES GROUP..................................................................................................................156

1............................................................................................................................................................156

3.3.........................................................................................................................................................156

PASSENGER ALARM BRAKE............................................................................................................156

1............................................................................................................................................................156

3.4.........................................................................................................................................................156

MAIN RESERVOIR..............................................................................................................................156

1............................................................................................................................................................156

4............................................................................................................................................................156

LIGHTING SYSTEM.............................................................................................................................156

1............................................................................................................................................................156

4.1.........................................................................................................................................................156

COMPARTMENT LIGHTS...................................................................................................................156

1............................................................................................................................................................156

Page 84 of 158





5............................................................................................................................................................156

FITTINGS.............................................................................................................................................156

1............................................................................................................................................................156

5.1.........................................................................................................................................................156

COMPARTMENT FITTINGS................................................................................................................156

1............................................................................................................................................................156

5.1.1......................................................................................................................................................157

PASSENGER SEAT.............................................................................................................................157

37..........................................................................................................................................................157

5.1.2......................................................................................................................................................157

FOLDABLE SEAT................................................................................................................................157

12..........................................................................................................................................................157

5.1.3......................................................................................................................................................157

MANUAL CURTAIN.............................................................................................................................157

12..........................................................................................................................................................157

5.1.4......................................................................................................................................................157

DRESSHANGER (SET).......................................................................................................................157

1............................................................................................................................................................157

5.1.5......................................................................................................................................................157

LUGGAGE RACK (SET)......................................................................................................................157

1............................................................................................................................................................157

5.1.6......................................................................................................................................................157

HAND RAILS (SET).............................................................................................................................157

1............................................................................................................................................................157

5.1.7......................................................................................................................................................157

LITTER BOX........................................................................................................................................157

1............................................................................................................................................................157

5.1.8......................................................................................................................................................157

Page 85 of 158





FIRE EXTINGUISHER..........................................................................................................................157

1............................................................................................................................................................157

6............................................................................................................................................................157

AUTOMATIC FIRE EXTINGUISHING..................................................................................................157

1............................................................................................................................................................157

7............................................................................................................................................................157

COMPART AIR CONDITIONING.........................................................................................................157

1............................................................................................................................................................157

7.1.........................................................................................................................................................157

VENTILATION......................................................................................................................................157

1............................................................................................................................................................157

7.2.........................................................................................................................................................157

COOLING.............................................................................................................................................157

1............................................................................................................................................................157

7.3.........................................................................................................................................................157

HEATING.............................................................................................................................................157

1............................................................................................................................................................157

7.4.........................................................................................................................................................157

HEATERS............................................................................................................................................157

45..........................................................................................................................................................157

8............................................................................................................................................................157

SERVICE FUNCTIONS........................................................................................................................157

1............................................................................................................................................................157

8.1.........................................................................................................................................................157

PASSENGER INFORMATION SYSTEM.............................................................................................157

1............................................................................................................................................................157

8.1.1......................................................................................................................................................157

LOUDSPEAKER..................................................................................................................................157

Page 86 of 158





10..........................................................................................................................................................157

8.1.2......................................................................................................................................................157

EMERGENCY SPEECH UNIT..............................................................................................................157

5............................................................................................................................................................157

8.1.3......................................................................................................................................................157

INTERNAL INFORMATION DISPLAY.................................................................................................157

2............................................................................................................................................................157

8.1.4......................................................................................................................................................157

EXTERNAL SIDE DISPLAY.................................................................................................................157

2............................................................................................................................................................157

8.2.........................................................................................................................................................157

VIDEO SURVEILLANCE SYSTEM......................................................................................................157

1............................................................................................................................................................157

8.2.1......................................................................................................................................................157

EXTERNAL CAM.................................................................................................................................157

2............................................................................................................................................................157

8.2.2......................................................................................................................................................157

INTERNAL CAM..................................................................................................................................157

3............................................................................................................................................................157

9............................................................................................................................................................157

TOILET.................................................................................................................................................157

1............................................................................................................................................................157

9.1.........................................................................................................................................................157

VACUUM FLUSH TOILET SYSTEM....................................................................................................157

1............................................................................................................................................................157

9.2.........................................................................................................................................................157

WATER LEVEL SENSOR (MAX AND MIN)........................................................................................157

2............................................................................................................................................................157

Page 87 of 158





9.3.........................................................................................................................................................157

COMMAND BUTTON...........................................................................................................................157

1............................................................................................................................................................157

9.4.........................................................................................................................................................157

PHOTOELECTRIC SENSOR...............................................................................................................157

2............................................................................................................................................................157

9.5.........................................................................................................................................................157

DOUBLE CONTACT LIGHTING BUTTON..........................................................................................157

2............................................................................................................................................................157

9.6.........................................................................................................................................................157

PIEZORESISTIVE SENSOR................................................................................................................157

1............................................................................................................................................................157

9.7.........................................................................................................................................................157

CONTACT PROBE FOR LIQUID LEVEL CONTOURING...................................................................157

1............................................................................................................................................................157

9.8.........................................................................................................................................................157

ELECTROPNEUMATIC VALVE FOR WATER....................................................................................157

1............................................................................................................................................................157

9.9.........................................................................................................................................................157

BOILER ...............................................................................................................................................157

1............................................................................................................................................................157

9.10.......................................................................................................................................................157

HK TOILET DOOR ELECTRONIC CONTROL UNIT...........................................................................157

1............................................................................................................................................................157

9.11.......................................................................................................................................................157

WHITE AND BLACK WATER TANK...................................................................................................157

1............................................................................................................................................................157

9.12.......................................................................................................................................................157

Page 88 of 158





HK WASH-BASIN ELECTRONIC CONTROL UNIT............................................................................157

1............................................................................................................................................................157

9.13.......................................................................................................................................................157

INTERFACE BUS TRAIN ELECTRONIC CONTROL UNIT................................................................157

1............................................................................................................................................................157

9.14.......................................................................................................................................................157

HK INTERIORS....................................................................................................................................157

1............................................................................................................................................................157

9.15.......................................................................................................................................................157

COMPLETE DOOR LOCK...................................................................................................................157

1............................................................................................................................................................157

9.16.......................................................................................................................................................157

HK AUTOMATIC DOOR......................................................................................................................157

1............................................................................................................................................................157

9.17.......................................................................................................................................................157

ELECTRIC TOWEL..............................................................................................................................157

1............................................................................................................................................................157

9.18.......................................................................................................................................................157

WC AUTOCLEANING SYSTEM..........................................................................................................157

1............................................................................................................................................................157

10..........................................................................................................................................................157

ELECTRICAL EQUIPMENT.................................................................................................................157

1............................................................................................................................................................157

10.1.......................................................................................................................................................157

AUXILIARY ELECTRICAL ENERGY...................................................................................................157

1............................................................................................................................................................157

10.1.1....................................................................................................................................................157

LV AND MV CONTACTORS, RELAY CONTACTORS, FUSES, AUTOMATIC CIRCUIT BREAKER157

Page 89 of 158





1............................................................................................................................................................157

TABLES

TABLE 1: RAM FAILURE CATEGORIES...................................................................................................102

TABLE 2: SIGNIFICANT FAILURE SPECIFICATION.................................................................................103

TABLE 3: MAJOR FAILURE SPECIFICATION..........................................................................................104

TABLE 4: MINOR FAILURE SPECIFICATION...........................................................................................104

TABLE 5: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY SIGNIFICANT (IMMOBILISINGFAILURE).....................................................................................................................................................106

TABLE 6: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MAJOR (SERVICE FAILURE).107

TABLE 7: RELIABILITY REQUIREMENTS FOR FAILURE CATEGORY MINOR......................................108

TABLE 8: QUALITATIVE REQUIREMENTS FOR MAINTAINABILITY......................................................109

TABLE 9: PREVENTIVE/CORRECTIVE MAINTENANCE REQUIREMENTS............................................111

TABLE 10: LOGISTIC SUPPORT REQUIREMENTS .................................................................................111

TABLE 11: MAINTENANCE COST REQUIREMENTS...............................................................................112

TABLE 12: AVAILABILITY REQUIREMENTS............................................................................................114

FIGURES

FIG. 1 EXAMPLE OF RELIABILITY PREDICTION ANALYSIS SHEET.....................................................122

FIG. 2 EXAMPLE OF PREVENTIVE MAINTENANCE ANALYSIS SHEET................................................127

FIG. 3 EXAMPLE OF PREVENTIVE MAINTENANCE SHEET FOR A SINGLE FREQUENCY..................129

FIG. 4 EXAMPLE OF CORRECTIVE MAINTENANCE ANALYSIS SHEET................................................132

FIG. 5 EXAMPLE OF FMECA SHEET.........................................................................................................135

FIG. 6 RAM PROGRAMME AND LIFE CYCLE PHASES...........................................................................136

FIG. 7 EXAMPLE OF STRUCTURE USING ORGANISATION CHART FOR AN ELECTRICAL MULTIPLEUNIT COACH...............................................................................................................................................150

FIG. 8 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) TRACTION VEHICLE............................................................................151

FIG. 9 EXAMPLE OF STRUCTURE USING THE TREE BREAKDOWN CHART FOR AN EMU(ELECTRICAL MULTIPLE UNIT) COACH..................................................................................................156

Page 90 of 158





1 INTRODUCTION

EN50126 is likely to enhance the general understanding of the issues involved inachieving RAMS characteristics within the railway field. It defines a comprehensive setof tasks for the different phases of a generic life cycle for a total rail system. Althoughsome of the examples given in the annexes of EN 50126 are for rolling stock, thestandard 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 overallperformance characteristics. But the consideration of RAMS, in contractual terms,between a customer / operator and a supplier for the procurement of rolling stock hasbeen problematic. Also, in rolling stock contracts, there is now a greater emphasis on theimpact on end customers of service failures and on the economic and riskconsiderations of RAMS (i.e. the business perspective).

On the other side, also Life Cycle Cost is being taken into account to satisfy thecustomer needs and to have a wide range approach.

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 rollingstock would be used to allow the economic considerations to be addressed.

Therefore the application guide to EN50126, focusing on the procurement issues andproviding a common approach for capturing the different performance requirements froman operator/business perspective, has been established.

EN50126 is a standard which treats the overall aspects of RAMS in Railway business.The Application Standard shall provide guidance in the usage of EN50126 and shallprovide clarification where EN50126 could be mis-interpreted.

Page 91 of 158





2 SCOPE

This Application Guide provides a practical basis and approach for:

specifying RAM requirements for rolling stock

assuring RAM performance for rolling stock,

demonstrating RAM performances of rolling stock

This document is addressed to customers/operators and suppliers of rolling stock, for dealing with RAM activities during different phases from tender to demonstration inoperation.

The main purpose of the application guide is:

1. 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 economicconsiderations;

to evaluate different tenders, in terms of RAM requirements, on a commonbasis with the aid of specific RAM documents;

to gain assurance, during design/development phase, that the rolling stockbeing offered is likely to satisfy the RAM contractual requirements byexamining 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 RAMrequirements

2. to enable the supplier of rolling stock

to understand the customers/operators RAM requirements

to provide substantive information/visibility in a tender to show that theproduct offered is likely to satisfy the RAM requirements by performingpreliminary RAM analysis;

to provide substantive information/visibility during design/development phaseto show that the product offered is likely to satisfy the RAM requirements byperforming detailed RAM analysis;

to demonstrate that the product delivered satisfies the RAM requirements;

Regarding Safety this Application Guide provides a reference list of the most commonHazards associated with operation.

Regarding LCC (Life Cycle Cost) this Application Guide establishes RAM keyparameters necessary to be incorporated into an LCC Model.

This Application Guide doesn’t establish:

RAM figures connected to the different RAM requirements (however theApplication Guide contains a simple guide line of actions supporting thedecision making process for choosing appropriate figures, see item 8.4)

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specific RAM documents and activities to be performed (however, theApplication Guide will contain, as an example, typical form and data of someRAM document to be intended as an output of the performed analysis).

3 NORMATIVE REFERENCES

EN50126Railway applications – The specification anddemonstration of Reliability, Availability,Maintainability and Safety (RAMS)

Pr ENV 50127-1 Railway applications - Guide to the specification of aguided transport system. Part 1: General

EN 60721-1 Classification of environmental conditions. Part 1:Environmental parameters and their severity.

4 INFORMATIVE REFERENCES

UNIFE LCC GROUP Series of documents from Volume I to IV

5 DEFINITIONS

This document adopts the same definitions of the EN 50126.

Any other definition necessary will be explained and introduced in this section when itwill be used.

Part Number: It is alphanumeric, generally assigned by the Supplier, to represent a

family of items with the same characteristics of Form, Fit and Function.

6 APPROACH ADOPTED

The approach adopted for each phase of the Life Cycle to set up and successively meetthe requirements of the standard is to raise the following questions:

WHAT: what activities / tasks to be performed and the supporting documentsto be produced

WHO: who has the responsibility for these activities / tasks

HOW: which type of method or tool to be used

This process is adopted for the development of the guide and will be applied inaccordance with the structure of the application guide.

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7 APPLICATION OF THIS GUIDE

7.1 O BJECT OF THE APPLICATION

This document is applicable to rolling stock (train, coach, locomotive, etc…) and to allthe subsystems, assemblies and parts belonging to the rolling stock according to theboundary limits.

Referring to the item 1.2 of EN 50126, the Guide is applicable to:

new rolling stock

modification/refurbishment of existing rolling stock

for use by Railway Authorities and the railway support industry.

For the use of this document only, the previous two item points will be indicated with thegeneric term “system”, comprising the complete sequence “system-sub-system-

component” of the breakdown structure of the rolling stock.

7.2 E NTITIES INVOLVED

The use of this document is indicated both for Railway Authorities and the railwaysupport industry.

The entities involved within the Life Cycle phases can be represented as in the diagrambelow:

Within the framework of a contractual relation consisting in supplying a rolling stock (inaccordance with the initial purpose of the guide), relations can be simplified and only 2partners be retained:

Customer (must take into account problems of interface with NationalRegulation Authority, Maintainer, Owner and Infrastructure company),

Supplier (managing sub-supplier).

In a total system vision, the level of responsibility, which must be known from the firststage of the project (phase 1 “concept”), is as follows :

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S U P P





T r a i n O p e r a t i n

C o m p a n y

I n f r a s t r u c t u r e

C o n t r o l l e r

M a i n S u p p l i e

S u b S u p p l i e r

R e s p on si b i l i t y

This diagram must be interpreted in the following way:

E n t i t y 2

E n t i t y 1

L i s tr e q u i r e m e n t s

P r o n o u n c ea p p r o v a l

G i v ep r o o f

W a i tf o r t h e a u t h o r i

t o " g o a h e

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7.3 APPLICABILITY OF THE PHASES OF THE EN 50126

Within the previous concern and referring to the item 5.3 of EN 50126, the application of the standard should be flexible and effective by considering and assessing a cost/benefitratio, the complexity and the size of the system.

Accordingly to the item 5.3.4 of the standard, the assessment of the application of theEN 50126 shall:

1 Specify phases applicable, and for each one of these:

Justify and demonstrate the compliance with the principles of therequirements of the standard.

Specify the mandatory activities/requirements including, referring to thesystem under consideration:

1 The scope of each requirement

2 The methods, tools and techniques required against each requirement and thescope and depth of their application

3 The verification/validation activities required against each requirement and thescope of their application

4 Input/Output documentation

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

7.4 M ANDATORY R EQUIREMENTS

The correct application of EN 50126 is guaranteed through several requirements.

The following requirements are mandatory (see item 5.3.5 of EN 50126):

define responsibility for carrying out all RAMS tasks within each phasechosen

make sure about the competence of the personnel involved within RAMStasks

establish and implement a RAM Programme and a Safety Plan, where haveto be identified and managed:

conflicts between RAM and Safety tasks

2details of all RAMS analysis, including the depth of analysis activities

make sure that the requirements of this standard are implemented withinbusiness processes, supported by a Quality Management System (QMS)compliant with the requirements of EN ISO 9000 series

establish and implement an adequate and effective configurationmanagement system, at least including:

1all system documentation

2all other system deliverables

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8 SPECIFYING RAM REQUIREMENTS

The purpose of this section is to establish the process to define RAM Requirements for rolling stock and for all the subsystems, assemblies and parts belonging to the rollingstock according to the boundary limits.

The definition process is carried out through different activities with the scope of obtaining data and all kind of available information about the rolling stock under consideration.

The final goal is the derivation of RAM targets through the analysis of all the informationcollected and organised in a structured way.

8.1 P RELIMINARY RAM ANALYSIS

8.1.1 Introduction

The preliminary RAM Analysis has the purpose of identifying the application environmentand the operating conditions of the rolling stock, in order to recognise the fundamentalconcepts which the overall RAM requirements have to be based on.

The analysis is developed through different activities to cover the following aspects:

similar system review:

a list of the existing rolling stock, applicable for providing suitable RAM-relatedinformation, is made;

preliminary system analysis:

the rolling stock available documentation is reviewed in order to define, at a

preliminary level, the overall system structure and its mission profile and torecognise the system failure conditions.

The deliverables of these preliminary RAM-related activities constitute the backgroundnecessary for defining the Overall RAM Requirements Specification in terms of:

RAM requirements;

Demonstration and acceptance criteria;

RAM programme requirements.

8.1.2 Preliminary RAM Analysis activities

The preliminary RAM-related activities consist in investigating all the relevant availabledocumentation in order to recognise all the functional requirements which may affect theRAM performances of the rolling stock.

The deliverables of the preliminary RAM-related activities result:

System identification, where the rolling stock has to be identified in terms of boundary limits, operational conditions, functions, interfaces, structure,logistics and maintenance conditions.

Failure conditions, where the failures of the rolling stock have to be identifiedand categorised in order to define appropriate requirements.

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8.1.3 System Identification

This section provides for a general overview of the main features identifying a rollingstock (see Annex A, item A2 of EN 50126).

The identification process for a rolling stock is made in order to gain assurance that theprocess is correctly analysing all the factors influencing the RAM performances.

These characteristics define the conditions under which the rolling stock is required toaccomplish its mission and constitute the reference conditions for:

defining the rolling stock RAM requirements

demonstrating, by analysis and tests, that each specific implementation fulfilsthe RAM requirements in all the Lifecycle phases.

The main characteristics and features necessary to describe a rolling stock are theMission Profile, Operating Conditions, Environmental Conditions and MaintenanceConditions (including logistics):

1 Mission Profile :

Route of reference

commercial speed (mission duration / mission length)

Mean length of a run

Mean distance between train stops

Number of tunnels related to commercial distance

Number of viaducts related to commercial distance

Distance cumulated under tunnel Distance cumulated on tunnels

Operating time or distance per year

Revenue operating time or distance per year

Stand-by time per day

Off-operating time per day

planned total time of use (life expectancy in years)

slopes

2 Operating Conditions : Equivalent speed related to the time the equipment is powered during a

given calendar period (cumulated distance / Time the equipment is poweredover 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 categoriesof equipment)

Time during which traction is activated

Time during which electric braking is activated

Operating time of the compressor

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Number of compressor starting up

Time of presence of catenary power, for each voltage

Time during which trainset is awaken

Operating time for Heating Ventilation Air Conditioning in heating mode andair conditioning mode.

Average speed, maximum speed

Potential use in multiple units

Time of coupling

internal temperature range of the rolling stock

Mechanical (shock and vibration)

Electrical (power supplies)

Electromagnetic compatibility

Ergonomics

3 Environmental Conditions :

Range of outside temperatures

Maximum height above the sea level

Ambient temperature

Solar radiation

Humidity

Wind and pressure pulses

Altitude

Water and precipitation

Pollutants and contaminants

Also, criteria for determining normal environmental conditions can be found within pr ENV 50127-1 and EN 60721-1.

4 Maintenance Conditions :

Indicative maintenance plan (i.e. minimum preventive maintenance interval,maximum contemporary number of personnel required for maintenanceinterval tasks, maximum standstill time to complete maintenance intervaltasks, etc…)

Number, location and description of the sites of maintenance

Description of the standard equipment, tools and resources of the sites of maintenance

8.1.4 Breakdown Structure and boundary limits

The breakdown structure of the rolling stock is the most important baseline of theidentification process. Establishing a structure of the rolling stock, a clear reference

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outline is given to all the activities and analyses supporting RAM Programme along theLife Cycle.

Generally, the scope of the structure is to set up the borders of a system by listing all the

items belonging to the structure of that system and using an appropriate number of discrete levels to distinguish the relationships existing between different areas of therolling stock.

8.1.4.1 Common rules to set up a structure

Setting up a structure, a decomposition process is carried out starting from the first levelto the other levels identified and being able to represent all the items and its functionalrelationships.

The decomposition process is based on a hierarchical breakdown in a top down processcommencing with the Rolling Stock as the system under consideration.

At each level identified in the hierarchy, every system identified becomes the nextsystem under consideration and can be further decomposed into lower level items, asnecessary.

There are several methods and tools to set up a structure, but here the following arerecommendations to be followed in order to develop an appropriate and suitablestructure for RAM purposes:

avoid the use of "infinite levels structure" and limit the levels up to areasonable number (3 or 4 are suggested)

the last item identified along a branch must be a LRU (Line ReplaceableUnit)

force to use the same definitions when identical items are defined be sure that the definition used for every item is the same used along all the

design documents (drawings, outlines, diagrams, specifications, etc…)

after the first issue of the structure avoid continuous modifications

avoid the use of vague or unclear definitions

The definition used for LRU (Line Replaceable Unit) is well explained within 8.5.4.3.

8.1.4.2 Data to identify the Structure

Every structure must be presented together with a set of drawings, diagrams, functionaloutlines in order to meet the target of identifying the Rolling Stock and all thesubsystems, assemblies and parts belonging to rolling stock clarifying at least:

all the relationships between the items of the structure

the functional borders between different systems, subsystems, assemblies

A minimum set of data is used to represent and to manage the structure.

This kind of data is the baseline of the different analyses that will be carried out duringthe Life Cycle.

Every structure should be represented with a header containing at least the following:

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Rolling stock ID code or definition of rolling stock

Doc.N. Code of document

Date Date of documentPage n/N Consecutive number of page/total number of pages

Drawn up by First and last name of author

Filename Name of file of the document

The following are the minimum set of data to represent a structure:

Code Breakdown level code of the item

Description Description of the item

Qty Amount of the item under consideration in the higher level item

The use of quantity information is suggested for breakdown structure where the productis defined.

As appropriate, it is recommended the use of the Part Number for every item of thestructure.

Part No. Part No. of the item

Examples of Breakdown Structure are given within Annex A - Examples of breakdownstructure.

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8.2 F AILURE C ONDITIONS

The following general failure conditions are defined for the rolling stock according to thegeneral failure categories which may be experienced by a generic railway transport (see4.5.2.2 in EN 50126):

Immobilising failure

Service failure

Minor failure

The following table shows the Failure Categories as indicated in EN 50126.

Table 1: RAM Failure Categories

Failure Category Definition

Significant(Immobilising Failure)

A failure that:- prevents train movement or causes a delay to service

greater than a specified time and/or generates a cost greater than a specified level

Major (Service Failure)

A failure that:- must be rectified for the system to achieve its specified

performance anddoes not cause a delay or cost greater than the minimum

threshold specified for a significant failure

Minor

A failure that:- does not prevent a system achieving its specified

performance anddoes not meet criteria for Significant or Major failures

In order to better define the above mentioned Failure Categories the following conditionsare applicable to Rolling Stock and to all the subsystems, assemblies and partsbelonging to rolling stock :

Significant Failure (Immobilising Failure): Any failure occurring on Rollingstock and leading, at least, to one of the following conditions:

A delay greater than a specified time

A stop of the train on the track

A withdrawal of the train from service

A cost greater than a specified threshold

Major Failure (Service Failure): Any failure occurring on the Rolling Stockand leading, at least, to one of the following conditions:

A delay less than a specified time

Failing specified performances

A cost less than a specified threshold

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Minor Failure

Any failure occurring on the Rolling Stock and leading to a maintenance task,even if this failure has no impact on service.

According the above mentioned definitions and conditions of Failures the Customer hasto establish:

the number of minutes of delay for Significant Failures and Major Failure

the threshold cost for Significant Failures and Major Failure

the mode of counting the delay (i.e. at the end of the run only, cumulatedduring all the stops, the maximum between two stops, etc…)

special service conditions under which the Customer decides for stoppingthe train on the track or withdrawing the train from the service in case of Significant Failure or consider a Major Failure for specified performancesfailed (i.e. the failure of the passenger air-conditioning, the failure of driver’s

cab air-conditioning, the failure of door system per side, the failure of aspecified number of toilet system, the failure of the coach lighting system,etc…)

The following tables show the specifications of each Failure Category.

Table 2: Significant Failure Specification

FailureCategory

ConditionsThresholddimension

Specification Requested

SIGNIFICANT(ImmobilisingFailure)FCI

Delay greater than MinutesSpecify mode of counting

delay

Stop of the train on thetrack

Rolling Stock does not runon its own

Withdrawal of the trainon the service

Specify special serviceconditions under which theCustomer decides for stopping the train on thetrack or withdrawing thetrain from the service

Cost greater than Money

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Table 3: Major Failure Specification

FailureCategory



MAJOR(Service Failure)FCS

Delay less than MinutesSpecify mode of countingdelay

Failing specifiedperformance

Specify service conditionsunder which the Customer considers failed theperformance

Cost less than Money

Table 4: Minor Failure Specification

FailureCategory



MINORFCM

Any failure occurring onthe rolling stock

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8.3 RAM R EQUIREMENTS

8.3.1 Introduction

The aim of this paragraph is to give an overview of the most used RAM Requirements inorder to help Customer in choosing of the appropriate requirements for rolling stock.

Choosing the appropriate RAM Requirements, the Customer is strongly asked toconsider:

system identification characteristics (mission profile, operating condition,function requested, etc…)

economic implications

the practical possibility to measure RAM Requirements from the field inoperation according to its organisational and logistical structure and service

procedures.The Customer should document the choosing process of RAM Requirements specifyingthe consideration adopted to address each requirement chosen.

8.3.2 Reliability Targets

This section describes the Reliability Targets required for the Failure CategoriesSignificant (Immobilising), Major (Service) and Minor Failure. (i.e. MTBF in Hours, failurerate per million of hours/kilometres).

The Reliability Targets are applicable to the total rolling stock and to all the subsystems,assemblies and parts belonging to the rolling stock according to the boundary limits

defined.Using the above mentioned definitions the Customer indicates the Reliability Targets for each one of the Failure Categories in terms of:

maximum accepted Failure Rate (numbers of failures per millionhours/Kilometres)

minimum accepted MTBF/MTTF/MDBF (mean number of hours/Kilometresbetween/to failures)

The terms hours/Kilometres are to be intended as hours/Kilometres of service.

The requirement MTBF is intended for repairable units and MTTF is intended for non-repairable units.

If the real operating time of service for the rolling stock and for the subsystems,assemblies and parts belonging to the rolling stock may not be measured, the Customer can choose, as appropriate, the followings:

maximum accepted Failure Rate (numbers of failures per million /Kilometres)

minimum accepted MDBF (number of Kilometres)

The MDBF is to be understood in the following way:

the total distance travelled over a period of time / the total number of failuresoccurring during the same period.

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In addition, Reliability Targets could be specified by the Customer for importantsystems/subsystems. In this case the Customer could apply the following definition for Failures affecting important systems/subsystems:

Any failure occurring on the System/Subsystem and leading to fail specifiedperformances

Any failure occurring on the System/Subsystem and leading to amaintenance task, even if this failure has no impact on service.

The Customer should specify the Failure conditions in which the System/Subsystemdoes not accomplish its specified performances.

The following table group the above mentioned Reliability Requirements:

Table 5: Reliability Requirements for Failure Category Significant (ImmobilisingFailure)

Applicable to: Requirement Dimension Symbol

Rolling StockMax N. of Failures

Number / Million KmOr Number / Million hours

FRI

MTBF/MTTF/MDBF Hours or Kilometres MTBFI/MTTFI/MDBFI

System/Subsystem 1

Max N. of FailuresNumber / Million KmOr Number / Million hours

FRI


System/Subsystem 2


FRI


System/Subsystem …


FRI


System/Subsystem n

Max N. of Failures

Number / Million Km

Or Number / Million hours

FRI


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Table 6: Reliability Requirements for Failure Category Major (Service Failure)




FRS

MTBF/MTTF/MDBF Hours or Kilometres MTBFS/MTTFS/MDBFS

System/Subsystem 1


FRS


System/Subsystem 2

Max N. of FailuresNumber / Million KmOr

Number / Million hours

FRS




FRS


System/Subsystem n


FRS


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Table 7: Reliability Requirements for Failure Category Minor




FRM

MTBF/MTTF/MDBF Hours or Kilometres MTBFM/MTTFM/MDBFM

System/Subsystem 1


FRM


System/

Subsystem 2

Max N. of FailuresNumber / Million KmOr

Number / Million hours

FRM




FRM


System/Subsystem n


FRM


The Customer can establish different tables for each one Failure Category specifying theRequirements applicable for each table

The Requirements applicable to Systems/Subsystems of the rolling stock have to bereferred to the Breakdown Structure in which each System/Subsystem is clearlyidentified.

8.3.3 Maintainability Targets

This section describes the Maintainability Targets required for rolling stock and for all thesubsystems, assemblies and parts belonging to the rolling stock according to theboundary limits defined.

For a rolling stock and for all the subsystems, assemblies and parts belonging to therolling stock according to the boundary limits defined there are different types of Maintainability Targets:

Generic Qualitative Requirements (accessibility, dismounting, handiness,standardisation, etc…)

Preventive Maintenance Requirements (qualitative/quantitative) (i.e.frequency, maximum number of personnel related to each frequency,maximum number of hours related to each frequency, etc…)

Corrective Maintenance Requirements (qualitative/quantitative) (i.e. MTTR,Maximum TTR, etc…)

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Logistic Support Requirements (supply and administrative delay, spare partsavailability, etc…)

Maintenance Cost Requirements

8.3.3.1 Generic Qualitative Requirements for Maintainability

The qualitative requirements of maintainability should consider at least the following, asan example:

Table 8: Qualitative Requirements for Maintainability

Accessibility: the layout of each piece of equipment and its position on the rollingstock and relative connections shall be made in such a way as tomake it possible to perform inspections, repairs, revision,replacement, taking into consideration the dimensions of the toolsthat may be necessary to perform these operations, the workingarea necessary for the maintenance personnel, the safety standardsand possible need for localised illumination.

All fastening points of the equipment and interfacing points betweenit and the infrastructures (ventilation channels, fans, filters, etc.)shall, as a rule, be accessible without the need of special tools.

Dismounting: it must be possible to dismantle any piece of equipment, or any partof it, in case of need for failure or scheduled maintenance, withouthaving to operate on other pieces of equipment not directly involvedin the specific maintenance action.

Evaluation of removability should also take into account the possibleneed to remove parts of the structure of the rolling stock (hatches,casings, etc.) and the ease of dismantling or opening and handlingthem.

Modularity: in designing equipment every opportunity should be applied toincrease the modularity of the object so as to reduce interventiontime, the specialisation of the personnel required and the stocks tobe kept on hand.

Modularity should make it possible to divide maintenance activitiesinto two levels: primary maintenance (rapid replacement of the unit),secondary maintenance (repair of the unit on the workbench).

Handiness: every piece of equipment, device and item of furnishing subject todismantling for replacement, repair or programmed maintenanceshould not exceed a weight of 25 kg and should be capable of beinghandled with manual means by a single person.

This maximum weight can be doubled when the conditions of accessibility make it possible for two persons to work together. Theexternal features of the shape of the unit in question should make iteasy to handle and not hazardous or capable of injuring thepersonnel.

In the case of objects that have to be moved using mechanical

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hoisting equipment and/or transportation, the layout andconstruction should provide for making available the necessaryprovisions for hooking, fastening, hoisting with a forklift (eyebolts,

hooks, feet, etc.). If the hooking, hoisting or transportationequipment is not available on the market, it must be designed,constructed and supplied under the responsibility of the supplier.

The connections existing between the unit and the structure andbetween the unit and the other units interfaced with it shall bereversible, accessible, not subject to corrosion and rust in relation tothe environment in which they are located.

Ease of cleaning: all environments, apparatus, flooring and coverings shall bedesigned in such a way as to facilitate all operations of cleaning tothe utmost. In particular as regards passenger vehicles andenvironments, textile coverings that can be cleaned efficiently or

have stains removed with dry-cleaning solvents applied withmechanical means by spraying and vacuuming with high capacityusing detergent products should be used. Carpeting and wall-to-walltextile flooring shall be designed for easy replacement for cleaningoff the rolling stock by providing appropriate breaks especially in theenvironments subject to heavy traffic (corridors, vestibules, etc.).

The supplier shall indicate the cleansers compatible with thematerials and coverings used.

As a general rule, in the visible environments, all efforts should bemade to avoid sharp corners, indentations, complicated relief patterns or hollows where dirt could accumulate or that could be

difficult to clean. This should be verified on the mock-up.

Standardisation: the solutions used should, to the maximum extent, make it possibleto interchange parts with others already in use by the customer andinstalled on other rolling stock. In particular, for elementary objects,commercial or unified solutions should be used, or parts already inuse by the customer as classified replacement parts for which thecustomer reserves to itself the right, if necessary, to supply a list.There should also be a close match between the drawings and theeffective realisation of the pneumatic and electric circuits for allrolling stock of the same supply same equipment on all the rollingstock of the same supply..

Interchangeability It has to be possible remove an item and install another one in itsplace without affecting any equipment characteristics.

The replacement shall be compatible in form, fit and function

Testability the objects have to be designed in such a way as to make it possibleto identify the conditions of the object clearly and rapidly. Thismeans that it should be possible to perform preventive diagnosticsso as to check the condition of the object before a failure occurs andto be able to perform corrective diagnostics in order to identifyclearly which are the items that may be malfunctioning or damaged.

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8.3.3.2 Preventive/Corrective Maintenance Requirements

The Preventive/Corrective Maintenance Requirements can be of two types:

general (referred to all the maintenance actions)

specific (referred to maintenance actions on a sub-system)

Examples of general and specific requirements can be the followings:

Table 9: Preventive/Corrective Maintenance Requirements

Definition Dimension Symbol

Minimum Frequency for ScheduledMaintenance

hours, kilometres MinFreqsm

Maximum Standstill Time to complete

maintenance actions

hours MaxSTcm

Maximum Allowed Number of Personnelemployed for maintenance

dimensionless MaxANPm

Maximum Allowed Time for dismounting/mounting

hoursMaxATd-m

Maximum Allowed Time for detect/isolate/replacing faulty items

hours MaxATd-i-r

Fault Coverage Dimensionless Fc

Mean Time To Restore (correctivemaintenance)

hours MTTR

Mean Time To Maintain (preventive

maintenance)

hours MTTM

Mean Time Between MaintenanceTime, distance,cycles

MTBM

8.3.3.3 Logistic Support Requirements

Typical Logistic Support Requirements can be:

Table 10: Logistic Support Requirements


Maximum Allowed time to reachmaintenance site

hours MaxATrm

Maximum Allowed Time to plan maintenanceactions (time for taking spare parts fromstorage depot, time for taking tools anddiagnosis equipment)

hours MaxATpm

probability of spare parts on stock whenneeded

dimensionless Ps

Note: If it is not possible to measure time to reach maintenance site or to planmaintenance actions, contractual fixed times can be used.

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8.3.3.4 Maintenance Cost Requirements

The maintenance cost constraints can be expressed in different ways.A way to consider the maintenance cost is to express it as a maximum allowedpercentage of the whole Life Cycle Cost.

In this case the Customer has to specify which items are counted as maintenance cost.

Examples of items for maintenance cost are the following:

Table 11: Maintenance Cost Requirements


training of the maintenance personnel Money Tmp

travel costs sustained for reaching themaintenance sites

Money Tcm

spare parts acquisition, provision andstorage

Money SPa-p-s

Preventive (scheduled) maintenanceactions (including cost for spare partsand cost for personnel employed)

Money PMc

Corrective maintenance actions(including cost for spare parts and costfor personnel employed)

Money CMc

The percentage has to be expressed per year and considering the period of duration of the Life Cycle.

Other Maintenance Cost Requirements can be the cost of Preventive or Corrective (or the sum of the two) Maintenance where the Customer can use the cost per Kilometre or per 1000 Kilometres or other significant basis (i.e. per year, per vehicle-train, per seat).

Also in this case Customer is asked to specify what this cost includes detailing the itemscounted.

As appropriate, the Customer can specify specific targets for important sub-systems of

the rolling stock (bogie, supply power module, doors, air conditioning system, toilette,etc…)

8.3.4 Availability Targets

This section describes the Availability Targets required for rolling stock and for all thesubsystems, assemblies and parts belonging to the rolling stock according to theboundary limits defined.

Following the Annex A and C of the EN 50126 the availability A of a rolling stock isspecified as the time in which a rolling stock is in a state to perform its mission.

The availability formula is generally indicated by the following:

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MDT MUT

MUT A

+

= ; with 0 ≤ A ≤ 1

where,

MUT = Mean Up Time;

MDT = Mean Down Time;

Then the calculation of the availability can be done stating, over a predefined timeinterval T, the following items:

MUT (in hours, kilometres or cycles)

MDT (in hours, kilometres or cycles)

The resulting down time d (T) within a time interval T (e.g., 1 year) is:

d (T) = (1 - A) ∗ T

The availability number is dimensionless and is usually indicated as a percentage.

Depending on the definition of MUT and MDT it is possible to have different types of availability using the same formula:

Inherent Availability, Ai

Achieved (technical) Availability, Aa

Operational (logistic) Availability, Ao

For Inherent Availability, Ai, the definitions used for MUT and MDT are:

MUT=MTBF=Mean Time Between Failures (hours)

MDT=MTTR=Mean Time To Restore (hours)then the formula is:

MTTRMTBF

MTBF A

i

+

=

For Achieved (technical) Availability, Aa, the definitions for MUT and MDT are:

MUT=MTBM=Mean Time Between Maintenance (hours)

MDT=MTTM=Mean Time To Maintain (hours)

In this case the MTTM takes into account the mean time required to maintain rollingstock both for preventive and corrective maintenance and then the formula is:

MTTM MTBM

MTBM A

a

+

=

For Operational (logistic) Availability, Ao, the definitions for MUT and MDT are:

MUT=MTBM=Mean Time Between Maintenance (hours)

MDT=MTTM=Mean Time To Maintain (hours)

In this case the MTTM takes into account the mean time required to maintain rollingstock both for preventive and corrective maintenance including logistical andadministrative delays and then the formula is:

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MTTM MTBM

MTBM A

o

+

=

Another measure for availability can be considered calculating the ratio of the number of

rolling stock available for service to the whole fleet.This is indicated as Fleet Availability, Af, and the number of rolling stock available for service is determined by the difference between the number of rolling stock of the wholefleet and the number of rolling stock not available for service due to maintenance actions(preventive or corrective maintenance)

In this case the formula is:

tot

mtot

tot

op

f F

F F

F

F A

−==

where:

Fop= number of rolling stock available for service

Fm= number of rolling stock not available for service due to corrective andpreventive maintenance

Ftot= total number of the fleet of rolling stock

Also another type of availability is the schedule adherence (respect of the schedule)measured as ratio of the number of journeys running according to schedule and the totalnumber of scheduled journeys.

The number of journeys running to schedule can be determined by the differencebetween the total number of scheduled journeys and the number of journeys not runningto schedule due to causes concerning rolling stock.

In this case the formula is:

stot

ns stot

stot

s

s

F

F F

F

F A

_

_

_

−

==

where:

Fs= number of journeys running to schedule

Fns= number of journeys not running to schedule due to causes concerning rollingstock

Ftot_s= total number of scheduled journeys

The following table group the above mentioned Availability Requirements:

Table 12: Availability Requirements

Formula Definition Dimension

MTTRMTBF

MTBF A

i

+

= Inherent Availability Dimensionless

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MTTM MTBM

MTBM A

a

+

= Achieved (technical) Availability Dimensionless

MTTM MTBM

MTBM Ao

+

= Operational (logistic) Availability Dimensionless

tot

mtot

tot

op

f F

F F

F

F A

−== Fleet Availability Dimensionless

stot

ns stot

stot

s

s

F

F F

F

F A

_

_

_

−

== Schedule Adherence Dimensionless

Choosing the above reported availability requirements the Customer is asked to:

detail the factors of the formula chosen

take into account the responsibility of each factor

consider the implications of the notes given in 8.3.1.

state the time interval of the monitored period

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8.4 RAM FIGURES CHOOSING PROCESS

The aim of this paragraph is to define a simple guide line to help Customer in choosingappropriate figures for RAM requirements.

Considering the deliverables of the previous sections of the Guide the Customer isasked to:

Analyse Rolling Stock System Identification and its Breakdown Structure

Consider Functional Requirements involved and its sub-systems related

Consider RAM Requirements affected by Functional Requirements analysingthrough Failure Conditions

Consider RAM requirements of similar rolling stock

Review past achieved RAM performances

Consider Technical evolution of the rolling stock under consideration

Evaluate the impact of new functionalities requested

Consider a realistic improvement of RAM requirements

Consider other specific and documented needs

The previous action points should enable the Customer to make the better choice withsubstantial supporting documentation.

The Customer should document the choosing process of RAM Figures specifying theconsideration adopted to address each figure chosen.

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8.5 RAM P ROGRAMME

8.5.1 Introduction

The RAM Programme is a set of activities to be performed along the system Life Cyclefor ensuring that the RAM Requirements stated for the rolling stock are fulfilled at eachdevelopment phase.

An efficient RAM Programme shall be established and maintained by the Supplier withthe purpose of ensuring that the RAM Requirements are properly achieved by providingsubstantive information/visibility through appropriate RAM analysis.

The RAM Programme tasks shall be managed with direct relationships with generalfunctional and technical tasks of the Life Cycle through periodical reviews.

The RAM Programme shall be coherent with 7.3 and 7.4.

8.5.2 Configuration Management System

A suitable Configuration Management System shall be established and maintained bythe Supplier for identifying and documenting modifications to specific characteristics of afunctional or physical item of the rolling stock, recording and reporting modificationsprocessing and implementation status and verifying compliance with stated RAMRequirements.

The Supplier is responsible to provide visibility of the configuration management processthrough documented activities and periodical reviews.

During the periodical reviews the Supplier is asked to provide reports specifying, asminimum, the followings;

documents delivered, indicating the relevant revisions

status of the current activities with objective evidence of activities anddocumentation:

already carried out

in progress

to be carried out

notification of problems affecting RAM Requirements

proposal for corrective actions to solve problems

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8.5.3 RAM Programme Outline

An example of typical outline of RAM Programme is showed below along with a list of

contents:

1. INTRODUCTION

1.1. PURPOSE

1.2. SCOPE

1.3. REFERENCE DOCUMENTS

1.4. DEFINITIONS AND ACRONYMS

2. DESCRIPTION OF THE SYSTEM

2.1. GENERAL DESCRIPTION:

2.2. SYSTEM BREAKDOWN:

3. RAM CONTRACTUAL REQUIREMENTS:

3.1. QUALITATIVE REQUIREMENTS

• Reliability requirements

• Maintainability requirements

• Availability requirements

3.2. QUANTITATIVE REQUIREMENTS

• Reliability requirements

• Maintainability requirements

• Availability requirements

4. RAM MANAGEMENT:

4.1. IMPLEMENTATION OF RAM

4.2. MANAGEMENT OF THE INTERACTIONS BETWEEN RAM ANALYSES AND QUALITY

PLAN4.3. CONFIGURATION MANAGEMENT PROCESS

4.4. ORGANISATION AND RESPONSIBILITIES

4.5. RAM MAIN ACTIVITIES:

• System Life Cycle Phases

• RAM activities during life cycle

• RAM documentation

5. RAM PROGRAMME PLAN:

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• Assumptions and scope of analyses

• Methods and tools used

• RAM detailed activities, analyses and documents

Periodical RAM Programme reviews

System Condition and Mission ProfileReliability Modeling, prediction and apportionment

FMECA analysis and Reliability Block Diagram

Fault Tree Analysis

Software Reliability analysis

Corrective Maintenance Analysis

Preventive Maintenance Analysis

Fault isolation and trouble shooting actions Plan

Reliability development/growth testing programme

Maintainability preliminary tests

Reliability demonstration tests

Maintainability demonstration tests

Failure data collection from field

• Follow up of RAM critical items

6. RAM DELIVERABLE DOCUMENTS AND SCHEDULE

6.1 LIST OF RAM DELIVERABLES

6.2 SCHEDULE FOR RAM ANALYSES

6.3 PERIODICAL RAM ACTIVITIES REPORT

The RAM Programme Plan establishes all the programme management tasks, in termsof timing and implementation details of the programme activities and documentation toaccomplish the RAM Programme Requirements.

In the RAM Programme Plan the Supplier shall declare the procedures, the tools and the

timing foreseen for implementing the RAM Programme.

It should be noted that the Supplier is responsible to establish the content of the RAMProgramme and of the RAM Programme Plan and to submit these documents to theCustomer for acceptance within a time agreed by the parts in accordance with SystemQuality Plan.

8.5.4 Example of RAM Analyses Document Forms and Data

The aim of this paragraph is to provide an overview of RAM Analyses Document Formsand Data in order to give to the reader the ability to handle with more practice all theissues related to RAM Programme.

The followings are example of forms of the most common RAM documentations andanalyses to be provided by the Supplier in order to give substantive information/visibilityof the RAM activities carried out and to show that the rolling stock is likely to satisfy theRAM Requirements in each phase of the Life Cycle from the tender to the operationphase.

A list of tools suitable for use to perform the different analyses and to manage all RAMactivities is given within EN 50126 - Annex B - item B5.

8.5.4.1 Common Data for the analyses

A set of data are referred to the identification of object of analysis. This type of data arecommon through the different analyses and are referred to the Breakdown Structure.

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They represent the header of the analysis.

In order to simplify the common understanding, within this examples a three levelbreakdown structure has been considered where the third level is the LRU level.

Generally these kind of data are at least the following:

Rolling stock ID code of rolling stock

L1 Code Breakdown code of the level 1 assembly

L1 assembly Description of the Level 1 assembly

L2 Code Breakdown code of the higher assembly/subassembly

L2 assembly Description of the Level 2 assembly

Drwg. or Diag. ref. Identification number of drawing or diagram containing

the identification references of the LRUs (code anddescription) under consideration

Doc.N. Code of document

Date Date of document

Page n/N Consecutive number of page/total number of pages

Drawn up by First and last name of author

Filename Name of file of the document

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8.5.4.2 Reliability Prediction Analysis Form and Data Sheets

The reliability prediction sheets should contain the following information:

Code Breakdown code of LRU

Description Description of LRU

Part No. Part No. of LRU

Failure rate (infailures/ Mh)

Failure rate of LRU expressed in number of failures per million hours

MTBF (h) MTBF of LRU in hours

Qty Amount of LRU in L2 assembly

Total failure rate (infailures/Mh)

Total failure rate, obtained as the product between thefailure rate of the LRU and the qty of the LRUs in the L2assembly

Total MTBF (h) Total MTBF referred to the total failure rate

Total Failures Rate(in failures/MKm)

Average failures per million km of the LRU

Total Qty Total no. of LRUs in the whole rolling stock

Source of failure rate Origin of the failure rate indicated (also codes of datasources used)

Notes Any possible clarifications on the origin of the failure rateand correction factors introduced

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Fig. 1 Example of Reliability Prediction Analysis Sheet

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Reliability Prediction Sheets

Doc. N.

Rolling Stock Code L2 Date

Code L1 L2 Assy Drawn up by

L1 Assy Drwg or Diagr Ref Page n/N

File name

L2 Assy total Data

Code Qty

LRU

LRU DescriptionFailure Rate

(f/10^6 h)MTBF (h)

Total F. Rate

(g/10^6 h)

Total MTBF

(h)

Part

Number Notes

Total Failure

Rate

(f/Mkm )

Total MKBF

(km)

Total

Qty

Failure Rate

Source





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8.5.4.3 Maintenance Attributes (Maintenance Levels, Skill Level and LRU definition)

Within railway field there are several definitions and attributes of maintenance.

The purpose of this paragraph is to address to every practical maintenance actions inorder to clear the issues affecting RAM Requirements and then, within the previous shortlist, only the suitable definitions will be considered.

As a common situation within railway field, here it is considered the existence of a depotfor the Rolling Stock with trained personnel, resources, a minimum set of spare parts,tools and equipment to carry out maintenance where the target is to minimise thestandstill time of the Rolling Stock in order to release the maintained Rolling Stock readyfor service within the lowest possible time.

Where the complexity of the maintenance actions, related to the trained personnel,resources, a minimum set of spare parts, tools and equipment available within the depot,does not meet this target, the maintenance actions will be carried out with the RollingStock out of service within a specialised workshop.

The first situation it is commonly called as "First Level Maintenance" and the second oneit is commonly called as "Second Level Maintenance".

Considering the previous concern and as the main purpose of the analyses is to meetRAM Requirements, there are 2 possibilities to carry out the Preventive Maintenance:.

1 First Level Maintenance: In this case two choices can be considered addressing thetarget of the first level maintenance:

All the maintenance scheduled actions are carried out within the depot

Only disassembling/assembling of items (replacing items with spare parts),

and the other maintenance actions are carried out on the dismantled itemswithin the depot/workshop

2 Second Level Maintenance: In this case only one choice can be considered:

All the maintenance scheduled actions are carried out within a workshop

Within this concern for the Preventive Maintenance Analysis Form and Data Sheets canbe used this two codes as "Maintenance Level Codes":

FLPM (First Level Preventive Maintenance)

SLPM (Second Level Preventive Maintenance)

A similar situation occurs when Corrective Maintenance is considered, but in this case

besides the resources of the depot (personnel, tools, equipment, and so on) also thefailure mode must be taken into account as an attribute affecting the RAMRequirements:

1 First Level Maintenance: In this case two choices can be considered addressing thetarget of the first level maintenance:

Repairable Failure Mode: All the repair maintenance actions are carried outwithin the depot

Not Repairable Failure Mode: Only disassembling/assembling of items(replacing items with spare parts)

2 Second Level Maintenance: In this case only one choice can be considered:

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Repairable Failure Mode: Only disassembling/assembling of items (replacingitems with spare parts), and the other repair maintenance actions are carriedout on the dismantled items within the depot/workshop

Within this concern for the Corrective Maintenance Analysis Form and Data Sheets canbe used this three codes as "Maintenance Level Codes":

FLCM - Rep (First Level Corrective Maintenance with Repairable FailureMode)

FLCM - Not Rep (First Level Corrective Maintenance with Not RepairableFailure Mode)

SLCM (Second Level Corrective Maintenance)

Depending on the definition of First Level Maintenance, also the definition of LRU (LineReplaceable Unit) can be clarified:

LRU = It is the item on which first level maintenance actions are carried out.

This definition can be used where the depth of the Breakdown Structure must bedefined. (see 8.1.3)

As an aid to establish "Skill Level Codes", the following are suggested as an example:

Low Skill Level (Code "L"): Personnel with basic knowledge of thesystems/subsystems and able to carry out simple and easy actions such as:

actions in which the item is directly visible (easily accessible without complexdisassembling actions) and that can be performed using standard tools(screwdriver, wrench, …)

Intermediate Skill Level (Code "I"): Personnel with specific knowledge of the

systems/subsystems and able to carry out detailed actions such as:

searching for the item needing maintenance, also using not standardtools/equipment (multimeter, gauge, tester,…) and with disassembling actionseven using diagrams and maintenance manual

High Skill Level (Code "H"): Personnel with complete and specialisedknowledge of the systems/subsystems and able to carry out detailed actionssuch as:

searching for the item needing maintenance, also using sophisticated tools for technical measures (oscilloscope, logic state analyser, …) and for fine tuningand with disassembling actions even using drawings, diagrams and

maintenance manual

8.5.4.4 Preventive Maintenance Analysis Form and Data Sheets

The preventive maintenance analysis sheets should contain the following information:





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Step no. Consecutive number used to identify eachmaintenance task

Maintenance Task Description of the preventive maintenance task

Spare Parts and specialtools

description of the special equipment (not providedby the depot or workshop and in any case not easilyavailable on the market) and materials necessary(consumables and spares)

Frequency Frequency of the maintenance task (time or Km)

Maintenance level Codes of the maintenance levels used by themaintainer

Personnel number of persons necessary at the same time for the maintenance task described

Skill Level Code of the Skill level requested for the personnel tocarry out the maintenance task

Spare Parts Cost Unit cost of materials expressed in EURO

Man hours time required for the maintenance task multiplied bythe number of persons necessary

Standstill time Standstill time for the rolling stock during themaintenance task


Notes any notes, comments or remarks on the logistics or

other (e.g. references to the maintenance manual)As an aid to establish the Maintenance Plan the following sheet contains rearrangeddata for the same frequency. This sheet also contains an indication for logisticorganisation of the maintainer with the "Frequency total data", where the Supplier isasked to indicate the following data for the frequency analysed:

man-hour requested to complete all the maintenance tasks of the frequency

Standstill time for the rolling stock to complete all the maintenance tasks of the frequency

Maximum number of persons simultaneously involved to complete all themaintenance tasks of the frequency

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Fig. 2 Example of Preventive Maintenance Analysis Sheet

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Preventive Maintenance Sheets

Doc. N.




File name

Spare Parts

Cost

(€/1000km)

Man-hour

Cost

(€/1000km)

Total Cost

(€/1000km)

L2 Assy total Data

Code QtyStep

N°

Maintenance

Task

Spare

Parts and

Special

Tools

FrequencyMaintenanc

e LevelPersonnel Skill

Spare Parts

Cost

Man-

hour

Standstill

TimeTotal Qty Notes

LRU N. Level

Part

Number

LRU

Description





Page 128 of 158

Preventive Maintenance Sheets for Frequency

Doc. N.




File name

Spare Parts

Cost (€)

Man-hour

(h)

Standstill Time

(h)

Max number of

persons

contemporary

involved

Frequency total Data

Code QtyStep

N°

Maintenance

Task

Spare

Parts and

Special

Tools

Maintenance

LevelPersonnel Skill

Spare

Parts

Cost

Man-hour Standst

ill TimeTot al Qty Note s

LRU N. Level

Part

Number

LRU

Description





Fig. 3 Example of Preventive Maintenance Sheet for a single frequency

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8.5.4.5 Corrective Maintenance Analysis Form and Data Sheets

The corrective maintenance analysis sheets should contain the following information:





Failure Mode. Failure Mode analysed for the LRU referring theFMECA analysis sheet

Maintenance Task Description of the corrective maintenance task

Spare Parts and specialtools

description of the special equipment (not providedby the depot or workshop and in any case not easilyavailable on the market) and materials necessary(consumables and spares)

Failure rate (in failures/Mh)

Failure rate of the failure mode of the LRUexpressed in number of failures per million hours

Maintenance Level Codes of the maintenance levels used by themaintainer

Personnel number of persons necessary at the same time for the maintenance task described

Skill Level Code of the Skill level requested for the personnel tocarry out the maintenance task

Spare Parts Cost Unit cost of materials expressed in EURO

Man hours Time required for the maintenance task multiplied bythe number of persons necessary

Standstill time Standstill time for the rolling stock during themaintenance task


Notes any notes, comments or remarks on the logistics or other (e.g. references to the maintenance manual)

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Page 131 of 158

Corrective Maintenance Sheets

Doc. N.




File name

Spare Parts

Cost

(€/1000km)

Man-hour

Cost

(€/1000km)

Total Cost

(€/1000km)

L2 Assy total Data

Code QtyMaintenance

Task

Spare

Parts and

Special

Tools

Maintenance

LevelPersonnel Skill

Spare Parts

Cost

Man-

hour

Standstill

TimeTotal Qty

LRU N. Level

Failure Rate

(f/10^6 h)

Part

Number

LRU

Description

Failure

Mode

Notes





Fig. 4 Example of Corrective Maintenance Analysis Sheet

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8.5.4.6 Failure Mode Effects and Criticality Analysis Form and Data Sheets

The FMECA can be carried out addressing analysis to examine functions or items; the

following showed example is addressed to items analysis.The FMECA sheets should contain the following information:





Function Short description of the function performed by the

LRUFailure Mode. The predicted or observed results of a failure cause

on the LRU in relation to the operating conditions atthe time of the failure

Failure Cause. The circumstances which have led to a failure

Failure rate (in failures/Mh)

Failure rate of the failure mode of the LRUexpressed in number of failures per million hours

Local effects worst effects of the failure mode on the LRU

Effect on higher assy. worst effects of the failure mode on the L1/L2assembly

Effects on rolling stock worst effects of the failure mode on the rolling stock,also considering its possible effects on other assemblies or subassemblies

Criticality Code of the category of criticality of the failure modeaccording to a stated table of reference consideringon the basis of effects affecting safety and/or service

Failure CategoryDescription

Codes and description of the failure categoryaccording the Failure Categories established

Diagnosis description of the method of detecting anddiagnostics used to detect and identify the failuremode

Corrective Actions description of the measures or compensatorymeans suggested to prevent the failure mode,minimise its criticality or reduce/eliminate its effects.

Notes any notes, comments or remarks useful for theanalysis

Note that the Corrective Actions must be addressed to:

the designer when the FMECA is carried out during the design phase in

order to improve the design of the Rolling Stock

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on board and maintenance personnel and then included within Maintenanceand User Manual in order to improve the service of the Rolling Stock,

Page 134 of 158





Fig. 5 Example of FMECA Sheet

Page 135 of 158

FMECA Sheets

Doc. N.




File name

Code QtyFuncti

on

Failure

Mode

Failure

Cause

Failure

RateCriticality

Failure

CategoryDiagnosis

Corrective

ActionsNotes

LRU (F/Mh) Local AssyRolling

Stock

Part

Number

LRU

Description

Effects





9 RAM ASSURANCE DURING LIFE CYCLE

9.1 RAM P ROGRAMME AND P HASES OF THE LIFE C YCLE

This section provides information supporting overall and preliminary RAM requirements.

Also it gives information about activities and documentation during the life cycle phasessupporting detailed specifications and requirements for the rolling stock including itssystems and sub-systems.

Also, this section aims to define what phases of the system Life Cycle the RAMProgramme deals with and to provide more information about:

activities to be managed

analysis and tools to be implemented

documentation to be provided

during the RAM Programme process.

According to the definitions above, we can define the RAM Programme as shown in thefollowing diagram.

Fig. 6 RAM Programme and Life Cycle Phases

The entities involved in the Life Cycle are explained in 7.2.

The following example shows the integration process and the programmeimplementation when:

Page 136 of 158

Concept1

System definition and application conditions2

Risk Analysis3

System Requirements4

Apportionment of system requirement5

Design and implementation6

Manufacture7

Installation8

System validation9

System acceptance10

Operation and maintenance11

Performance monitoring12

Modification and retrofit13

Decommissioning and disposal14





The Customer is also the Operator and the Maintainer;

The Main Supplier is alone and has to negotiate sub-contracts with suppliers.

TENDER PHASE

• Feasability analysis• Risk analysis

• Answer to the tender

• Negociation

• Concept

• System definition and application

conditions

• Risk analysis

• System requirements

• Apportionment of system

requirements

Concept,definition andspecification of Rolling stock

Customer

• Concept

• Generic Rolling Stock definition

and application conditions

• Risk analysis

• Rolling Stock performances


requirements

Concept,definition andspecificationof rollingstock

Rolling Stock Supplier

• Concept

• Equipment definition and

application conditions

• Risk analysis

• System performances


requirements

Concept,definition andspecificationof equipments

Equipment Supplier

• Call for tender

• Negociation

• Decision

• Feasability analysis• Risk analysis

• Answer to the tender

• Negociation

PROGRAMME IMPLEMENTATION

• Mission profile

• Operating rules

• Apportionment of RS performances

• Definition of mission profile

RAM Programme Plan

• RAM Preliminary analyses

• RAM Detailed analyses

• Consolidation of RAM analyses

• Performance growth monitoring• RAM Demonstration

RAM Synthesis Report

• Apportionment or equipment

• Definition of mission profile

•

• Detailed analyses

RAM synthesis reports

• Implementation of action plans

Preliminary Design Review

Final Design Review

Final acceptance

Customer Main Contractor Sub Contractors

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9.1.1 Tender phase:

The tender phase is prepared by the Customer during the previous phases (see Fig. 6

phases 1 to 5) and it results in the call for tender document sent to all the potentialSuppliers.

The call for tender contains data about concept, definition and specification of rollingstock and RAM Requirement to be fulfilled according 8.

The Customer should ask the potential Suppliers for data and analysis during tender phase. This documentation is useful to better match different offers on the same basis.

Examples of documentation to be required during tender phase can be taken fromdesign phase documentation. (see 8.5.4)

Before answering to the call for tender, the Supplier has to perform relevant tasks toinsure that all risks related to the compliance with each requirements are taken into

consideration:

Feasibility analysis: This analysis allows to determinate the best reasonableperformances which can be achieved taking into account current experienceresulting from the new mission profile and taking into account variations onthe definition of the system. This task is performed at rolling stock level,using current experience on similar applications and calculation models likeFault Tree Analysis or Reliability Block Diagrams

Risk analysis: Referring to the best reasonable performances calculatedthrough feasibility analysis, this task allows to determine the probability topay penalties taking into account the gap between required and achievableperformances.

Answer to the tender: Write the different sections of the offer related to RAMactivity providing the RAM documents requested by the Customer

Negotiation: Answer to the questions asked by the Customer and/or supportthe negotiation team during the negotiation phase.

After receiving offers the Customer evaluates the documents and chooses for the bestoffer.

Usually a short phase of negotiation between the Customer and the potential Supplier isplanned, where Contractual Agreements are taken.

The tender phase is concluded by the Contract Award or the Notice to proceed.

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9.1.2 Design Phase

The following flow chart shows the different tasks included in the RAM Programme to be

implemented after Contract Award or Notice To Proceed.The input documentation of this phase is the tender documentation presented by theSupplier and the contractual agreements fulfilled during negotiation.

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RAM

specification

Preliminary

analyses

Detailed

analyses

Allocations

ACCEPT

ANCE

&

RAM Growth

monitoring

Satisfactory

Final

synthesis report

Contractual

requirements

Mission

profileProduct

definition

Functionalspecifications

Action

Plan

FOLLOW UP

OF

CRITICAL

ITEMS

Recommendations

RAMProgramme

Contractual

agreements

Tender

documentation

Critical

Points

Identification

PreliminaryDesignReview

FinalDesignReview

Final

Acceptance

Data from testand field

COMMISS

IONING

The following is the description of a possible definition of the tasks:

Designation Description of the task

RAM specification This first step, after Contract Award, allows the Rolling Stock main

Page 140 of 158





Contractor to specify to Sub Contractors, Partners or Equipment

Suppliers the Contractual requirements related to subsystems,

functions or equipments in their scope of supply.

Also, it generally includes the delivery for approval of the RAM

Programme.

Preliminary

analyses

The inputs of this task are the tender documents and the contractual

agreements.

Implemented at functional level, this task aims to highlight the RAM

critical functions on which further detailed analyses will focus.

During this phase, the classification of functions will be made using the

Failure Categories defined by the Supplier and adapted to the specific

requirements of the Contract.

This task is performed using functional FMECAs to identify RAM critical

functions and Reliability Block Diagrams

The deliverable of this task is a set of Preliminary Analysis to cover all

the RAM Requirements.

Generally, the level of depth of the analyses is not low, but the level is

established according the Breakdown Structure of the Rolling Stock

and according the level of definition and specification of the technical

and functional design.

Preliminary Design

Review

This milestone is stated to check the design process and to review all

the RAM documentation with the purpose of ensuring that the RAM

Requirements are properly achieved and to examine problems arising.

Detailed analyses This task aims to perform detailed analyses highlighted during the

preliminary analyses.

During this task the Supplier has already reach a good level of depth

for the design and then the corresponding Breakdown Structure of theRolling Stock will be at LRU Level.

As a consequence, the set of the analyses of the previous phase will be

updated and detailed considerations according the RAM Requirement

are made.

The final scope of such analyses is to make sure of the fulfillment of

the RAM Requirement of the designed rolling stock.

solve last problems, when arisen

verify the completeness of the set of documents

prepare activities for tests and collection of data from field

During this phase the Supplier collects detailed analyses carried out

by sub contractors in order to:

• Insure a good consistency between them;

• Integrate the previsions provided by them, at equipment

level in the model, in order to get previsions at rolling

stock level;

• Integrate interfaces malfunctions in the model for prevision

Final Design Review This milestone is stated to check the design process and to review all

the RAM documentation with the purpose of ensuring that the RAM

Requirements are properly achieved and to examine problems arising.

The final scope of this review is to:

check the fulfillment of the RAM Requirements

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solve last problems, when arisen

verify the completeness of the set of documents

prepare activities for tests and collection of data from field

RAM Growthmonitoring

This task aims to monitor RAM growth (essentially reliability growth) sothat the time to get steady state level is the shortest possible.

This task consists in the implementation of a problem solving process

involving all the subcontractors and the contractor in order to:

• Identify the problems occurring during the earliest operation

phase;

• Highlight the most contributive problems affecting contractual

service performances;

• Elaborate an action plan allowing to eradicate the problems or

mitigate their effects;

• Follow up the impact of such action plan to decide about carrying

on the iterative process or stop it.

Follow up of criticalitems

This task is a specific management task implemented all along thedesign process from preliminary analysis to service operation.

It consists in:

Identifying, as issues of the RAM analysis process (preliminary and

detailed analysis) the critical scenarios (failures associated to their

effects on service or on safety) ;

Classifying these scenarios according to combination of their

estimated frequency and their effects on safety or service;

Proposing or ask the designers to propose actions or provisions to

eliminate the scenarios or mitigate their effects;

Estimating the impact of the action plan;

Following up application of these actions during the latest design

phases or during manufacturing;

This task is performed using problem solving techniques.

9.1.3 Demonstration Phase

9.1.3.1 Introduction

This paragraph deals with the operation period in which Customer is asked to check thefulfilment of RAM Contractual Targets for the rolling stock under consideration by RAMDemonstration tests and collection of data from field.

From the point of view of the Customer, the collection of data from field has the target of addressing:

a basis for rolling stock acceptance

a knowledge about the rolling stock performance

a reference data base for new rolling stocks/systems/subsystems tendering

Also, from the point of view of the Supplier, the collection of data from field has the targetof:

monitoring/verifying design, manufacture and installation phase

monitoring rolling stock operation to address corrective actions

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gathering data and knowledge for further development

Also, in the long term operation, the target is to find out weak points in the managementprocess (operation and maintenance phases) in order to form a basis for performance

improvement and cost reduction to optimise maintenance and operation.The definition of test procedures have to be coherent with the system identificationprocess and definition given in 8.

All the RAM documents provided during design period according the RAM Programmeare intended to be proof of compliance with RAM Requirements of the designed rollingstock.

9.1.3.2 RAM Acceptance Criteria

On the basis of the RAM Requirements chosen, the Customer is asked to define theRAM Acceptance Criteria on the field.

The definition of reliability acceptance criteria has to be addressed to specify theconditions in which a failure is classified as "chargeable" or due to responsibility of theSupplier, or alternatively is classified as "unchargeable".

The following general conditions of failure are to be considered as "unchargeable" whenverified:

failures occurred during the service out of the stated conditions of operation

failures due to Customer personnel

failures due to accidental events

In the same way the Customer is asked to define for each RAM Requirement detailed

acceptance criteria in order to establish, before the beginning of the checking period,clear rules to be followed.

9.1.3.3 In service checking Period

The Customer is responsible in defining an appropriate duration of the checking period.

Defining the checking period, the Customer should consider that usually the RAMtargets are not achieved in the first period of operation, but after a burn-in period wherea reliability growth monitoring process has to be implemented.

Generally the steady state level is achieved at least after 2 years of revenue service.

The reliability growth process is a continuous monitoring of the targets on field and

successive analysis of the results and matching against the contractual requirements.

Where results from field do not meet contractual requirements, corrective actions arerequested to the Supplier.

Choosing the checking period, it is important to highlight that:

within the Reliability Growth Process, the corrective actions must bemanaged as described in 8.5.2, with a corrective action plan, as appropriate

at the beginning of the RAM Checking Period, the Reliability Growth Processhas to be concluded

in order to manage a coherent field data collection the configuration of the

rolling stock has to be frozen

Page 143 of 158





the duration of the checking period has to be chosen evaluating:

the number of rolling stock of the fleet and the cumulative annual kilometres of service

the maintenance plan of the rolling stock

the RAM Requirements chosen by the Customer

the duration of the contractual relationships between Customer and Supplier (i.e. duration of warranty period)

Also, the Customer must consider, as appropriate, if the checking period and the fielddata collection is addressed to cover:

the entire rolling stock fleet

a selected number of rolling stock of the fleet

other systems/subsystems of interest

9.1.3.4 Data Report from field and organisation

The field data collection, within the checking period, comprises the whole process of gathering data on figures and events occurring such as:

failures during operation and maintenance

classification of the failures (Significant, Major, Minor)

structure code of the item source of the failure

description of the fault detected

work during maintenance amount of man-hours

material consumption

kilometres/hours of service

downtimes and standstill times (also logistic and administrational delays)

Also reports about repair and cause of failure are necessary to address correctcorrective actions.

Obviously, identification data has to be collected to gain traceability for further investigations such as:

identification number of the report containing data

date of the event occurred

description of the operation status

identification number of the rolling stock (or vehicle) within the fleet

Also a preventive information on responsibility could be given to address acceptancecriteria.

Usually the Customer and the Supplier agree for a RAM Demonstration Plan containing,at least, specification of:

rules and methods

Page 144 of 158





resource and tools

organisation and responsibility

field data collection sites (depots, workshops)

reference documents (i.e. RAM analyses and Breakdown structure)

RAM contractual targets

acceptance criteria

procedure to collect data

detection of all source of data and any disturbances

schedule of periodical field data collection reviews

procedure to solve problems and to address corrective actions

procedure for implementing corrective action plan

It is important to note that the corrective action plan has to contain also the assessmentof the impact of the corrective actions on the configuration management process asexplained in 8.5.2.

Page 145 of 158





10 SPECIFIC HAZARDS RELATED TO ROLLING STOCK

10.1 I NTRODUCTION

The aim of this paragraph is to give a reference list of the most common hazardsassociated with rolling stock.

The reader is asked to consider this list as an aid to develop more suitable and coherentlist of hazards related to the rolling stock under consideration.

10.2 H AZARD I DENTIFICATION P ROCESS

The definition of a list of hazards is a complex and delicate process requiring a deepknowledge of the railway scenarios.

The process of deriving detailed hazards for rolling stock shall be addressed to cover allthe possible and reasonable factors influencing safety by considering at least the

following:

type of operation

procedures of signalling

mode of operation

rules and laws constraints

standards applicable

technical and functional specification

maintenance and logistic support issues

human factors

environment and functional interface issues

and so on.

All the consideration shall be addressed to identify all the possible situations or associated events likely to have an effect on the safety, in terms of injury or death of humans, for passengers and/or service personnel when they are:

on the rolling stock

entering/alighting vehicles

on or near the line

on the station

performing maintenance

The use of data of previous accidents and incidents, generic lists and each other document dealing with safety hazards is recommended.

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10.3 LIST OF THE MOST COMMON HAZARDS RELATED TO ROLLING STOCK

On the above mentioned basis and consideration the below reported list contains themost common hazards related to rolling stock grouped into general categories.

Electrical

Tensioned surfaces/points

Overheating

Ignition of Combustibles

Induced Voltage (CapacitiveCoupling)

Electrostatic Discharge

Inadvertent Activation

Electrical Arc

Mechanical

Sharp Edges/Points

Lifting Weights

Vibration

Rotating Equipment

Stability/Toppling Potential

Reciprocating Equipment

Ejected/Thrown Parts/Fragments

Pinch Points

Crushing Surfaces

Altered Structural Properties

Pneumatic/Hydraulic Pressure

Overpressurization

Blown Objects

Pipe/Vessel/Duct Rupture

Crossflow

Pipe/Hose Whip

Implosion

Backflow/Siphon Effect

Blast

Acceleration/Deceleration/Gravity

Excessive acceleration

Excessive deceleration

Inadvertent Motion

Loose Object Translation

Derailment

Collision

Slip/Trip

Falling Objects

Falls

Temperature Extremes

Hot/Cold Surface

Freezing

Confined Gas/Liquid

Reduced Reliability

Pressure Elevation

Humidity/Moisture

Elevated Flammability

Elevated Volatility

Fire/Flammability/Noise

Presence of:

– Noise

– Fuel

– Ignition Source

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– Oxidizer

– Radiation

– Explosive Propellant

– Explosive Gas

– Explosive Liquid

– Explosive Vapor

– Explosive Dust

– Compressed Air/Gas

– Lubrication

Leaks/Spills

Materials:

– Liquids/Cryogens

– Gases/Vapors

– Dusts

– Toxic

– Irritants

– Corrosive

– Asphyxiants

– Allergens

Human Factors (Also see Ergonomic)

Operator Error

Operation Out of Sequence

Inadvertent Operation

Right Operation/Wrong Control

Failure to Operate

Operate Too Long

Operation Early/Late

Operate Too Briefly

Ergonomic (Also see Human Factors)

Fatigue

Inaccessibility

Inadequate Control/ ReadoutDifferentiation

Inappropriate Control/ ReadoutLocation

Faulty/ Inadequate Control/Readout Labelling

Inadequate/ Improper Illumination

Glare

Non existing/ Inadequate "Kill"Switches

Faulty Workstation Design

Control Systems

Power Outage

Sneak Software

Interference (EMI/ESI)Lightning Strike

Moisture

Grounding Failure

Sneak Circuit

Inadvertent Activation

The above reported hazards are general or high level categories of hazards applicableto rolling stock.

The list is intentionally redundant in any category, where the repeated hazard are listedto highlight and capture the attention on it.

11 RAM PARAMETERS TO BE INCORPORATED INTO LCC MODEL

To Be Defined

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12 ANNEX A - EXAMPLES OF BREAKDOWN STRUCTURE

Here below there are highlighted two possible ways to represent a structure:

the organisation chart

the tree breakdown chart

The following is an example using the organisation chart for the rolling stock "EMU(Electrical Multiple Unit) COACH", where only for visual purposes two branch have beendeveloped.

Page 149 of 158



C o d e : .

D e f :H e a t

I n s u l i

Q t :

C o d e : .

D e f :S i d e i

p a s s e

Q t :

C o d e : .

D e f :F l o o r

Q t :

C o d e : .

D e f :S i d e l l

p a n e l l i

Q t :

C o d e : .

D e f :R o o f

Q t :

C o d e : .

D e f :U n d e

Q t :

C o d e :

D e f :C a r b

Q t :

C o d e :

D e f :D o o r

Q t :

C o d e :

D e f :P n e

b r a k i nQ t :

C o d e :

D e f :L i g h t i

s y s tQ t :

C o d e :

D e f :F i t t i n

Q t :

C o d e :

D e f :A u t o i

e x t i n g i iQ t :

C o d e :

D e f :C o m i

c o n d i i iQ t :

C o d e : . .

D e f :L o u d

Q t :

C o d e : . .

D e f :E m e

s p e e i

Q t :

C o d e : . .

D e f :I n t e r l i

d i s p l

Q t :

C o d e : . .

D e f :E x t e l

s i d e i l

Q t :

C o d e : .

D e f :P a s s

i n f . s

Q t :

C o d e : . .

D e f :E x t e l

c a m

Q t :

C o d e : .

D e f :I n t e r l

c a m

Q t :

C o d e : .

D e f :V i d e i

I n s u l i

Q t :

C o d e :

D e f :S e r v i

f u n c iQ t :

C o d e :

D e f :T o i l e

Q :

C o d e :

D e f :E l e c t i

e q u i pQ t :

E MC o

Fig. 7 Example of structure using organisation chart for an Electrical Multiple Unit Coach



The following is an example of representation of the Breakdown Structure using atree diagram for a EMU Traction Vehicle.

Fig. 8 Example of structure using the tree breakdown chart for an EMU

(Electrical Multiple Unit) Traction Vehicle

TREE BREAKDOWN STRUCTURE

ROLLING STOCK: EMU TRACTION VEHICLE Doc. N.

Date

Drawn up by

Page n/N

File name

Code L1 - System Qty Code L2 - Sub-system or LRU Qty Code L3 - LRU Qty

1 Carbody 1

1.1 Heat insulation 1

1.2 Front panel 1

1.3 Side window, passenger room 14

1.4 Side window, driver's cab 2

1.5 Floor 1

1.6 Side wall, panelling 2

1.7 Roof 1

1.8 Nose cover 1

1.9 Obstacle deflector 1

1.10 Energy absorbtion elements 2

1.11 Aerodynamic front nose structure 1

1.12 Underframe 1

2 Motor bogie 1

2.1 Bogie frame 1

2.2 Carrier 1

2.2.1 Steering rod 1

2.3 Primary suspension 4

2.3.1 Damper 1

2.3.2 Helical spring 1

2.4 Secondary suspension 1

2.4.1 Air spring 2

2.4.2 Pneumatic components for secondarysuspension (set)

1

2.4.3 Vertical damper 2

2.4.4 Horizontal damper 2

2.5 Bearing assembly 4

2.5.1 Bearing box 1

2.5.2 Bearing 1

2.6 Wheel set 2

2.6.1 Axle 1

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2.6.2 Wheel disk 2

2.6.3 Brake disk 2

2.7 Axle gearbox 2

2.8 Axle box temperature device 2

2.9 INDUSI-magnet 1

2.10 Mechanical interface with bodyshell (set) 1

2.11 Pneumatic equipment on bogie (set) 1

2.12 Speed sensor 2

2.13 Brake equipment on the bogie (set) 1

2.14 Earthing contacts 2

3 Trailer bogie 1

3.1 Bogie frame 1

3.2 Carrier 1

3.2.1 Steering rod 1

3.3 Primary suspension 4

3.3.1 Damper 1

3.3.2 Helical spring 1

3.4 Secondary suspension 1

3.4.1 Air spring 4

3.4.2 Pneumatic components for secondarysuspension (set)

1

3.4.3 Vertical damper 4

3.4.4 Horizontal damper 1

3.5 Bearing assembly 4

3.5.1 Bearing box 1

3.5.2 Bearing 1

3.6 Wheel set 2

3.6.1 Axle 1

3.6.2 Wheel disk 2

3.6.3 Brake disk 2

3.7 Axle box temperature device 2

3.8 Mechanical inte rface with bodyshe ll (set) 1

3.9 Pneumatic equipment on bogie (set) 1

3.10 Speed sensor 2

3.11 Brake equipment on the bogie (set) 1

3.12 Earthing contacts 2

4 Auxiliary elements on the bogie 1

4.1 Sanding device 2

4.1.1 Sanding trap 1

4.1.2 Sanding pipe and nozzles 1

4.2 Wheel flange lubrication 2

4.2.1 Tank 1

4.2.2 Pump 1

4.2.3 Magnetic valve 1

4.2.4 Turbolub distributer 1

4.2.5 Nozzle 2

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4.2.6 Control unit 1

5 Door 1

5.1 Passenger door 2

5.1.1 Drive/motor unit 1

5.1.2 Roller swing arm, right 1

5.1.3 Roller swing arm, left 1

5.1.4 Emergency egress device (inside) 1

5.1.5 Bowden cable, emergency egress device(inside)

1

5.1.6 Emergency egress device (outside) 1

5.1.7 Bowden cable, emergency egress device(outside)

1

5.1.8 Doorleaf, right 1

5.1.9 Doorleaf, left 1

5.1.10 Lock box 1

5.1.11 Light barrier 1


5.2 Internal door 1

5.3 External cab door 2

5.4 Sliding door driver's cab 1

6 Draw and buffer gear 1

6.1 Automatic coupler 1

6.1.1 Coupler head 1

6.1.2 Uncouple device 1

6.1.3 Air coupler for main air pipe coupler 1

6.1.4 Air coupler for uncouple device pipe 1

6.1.5 Electrical coupler operation device 1

6.1.6 Coupling rod 1

6.1.7 Bearing block 1

6.1.8 Electrical coupler 1

6.1.9 Covering 1

6.1.10 Center position 1

6.1.11 Supplies 1

6.1.12 Earthing 1

6.1.13 Coupler head, electrical part 1

6.2 Coupling link 1

6.2.1 Special bearing for articulation 1

6.2.2 Coupling fork 1

6.2.3 Guide rod support 1

7 Articulation 1

7.1 Articulated damper, rolling 1

7.2 Articulated damper, pitching 1

7.3 Articulated damper, yawing 1

7.4 Intercommunicating gangway 1

7.4.1 Bellows 1

7.4.2 Bellows frame 2

7.4.2 Step board 1

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8 Electrical equipment 1

8.1 Traction 1

8.1.1 Propulsion inverter boxes 1

8.1.2 Electric traction motor 2

8.1.3 Speed sensor for traction control 4

8.1.4 Traction control unit 1

8.1.5 Rheostatic breaking resistors 1

8.2 Auxiliary electrical energy 1

8.2.1 LV and MV contactors, relay contactors,fuses, automatic circuit breaker

1

8.2.2 Battery 1

8.2.3 Auxil iary static converter with batterycharger

1

9 Pneumatic and braking system 1

9.1 Brake control device 1

9.2 Direct brake control device 1

9.3 Electronic control unit 1

9.4 Signalling repetition plate 1

9.5 Antiskid redounded (1 per axe) 1

9.6 Pneumatic group 1

9.7 Brake devices group 1

9.8 Motor bogie secondary suspensionreservoir

1

9.9 Trailer bogie secondary suspensionreservoir

1

9.10 Passenger alarm brake 1

10 Lighting system 1

10.1 Compartment lights 1

10.2 Driving cab lights 1

10.3 External lights 1

10.3.1 White lights 2

10.3.2 Red lights 2

10.3.3 Green lights 1

10.3.4 Central lights 2

11 Fittings 1

11.1 Compartment fittings 1

11.1.1 Passenger seat 61

11.1.2 Foldable seat 2

11.1.3 Manual curtain 18

11.1.4 Dresshanger (set) 1

11.1.5 Luggage rack 1

11.1.6 Hand rails (set) 1

11.1.7 Litter box 1

11.1.8 Ticket vending machine 1

11.1.9 Fire extinguisher 1

11.2 Driving cab fittings 1

11.2.1 Driver seat (adjustable) 1

11.2.2 Sunshad curtain 3

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12 Automatic fire extinguishing 1

13 Driving cab air conditioning 1

13.1 Ventilation 1

13.2 Cooling 1

13.3 Heating 1

14 Compart air conditioning 1

14.1 Ventilation 1

14.2 Cooling 1

14.3 Heating 1

14.4 Heaters 45

15 Tachograph device 1

16 Dead man device 1

17 Driver's desk 1

17.1 Light rack 1

17.2 Instruments rack 1

17.3 Video surveillance monitor 1

17.4 Console 1

17.5 Radio equipment 1

17.6 ATP equipment 1

18 Service functions 1

18.1 Passenger information system 1

18.1.1 Loudspeaker 8

18.1.2 Controller 1

18.1.3 Cab Control Unit 1

18.1.4 Emergency speech unit 4

18.1.5 Internal information display 2

18.1.6 External side display 2

18.1.7 Handset 1

18.2 Video surveillance system 1

18.2.1 External cam 2

18.2.2 Internal cam 3

18.2.3 Video monitor 1

19 Washing and wiper system 1

20 Command & control/diagnosticsystem

1

20.1 Command & control/diagnostic 1

20.2 Input/output remoted device 1

20.3 Diagnostic monitor 1

20.4 Instruments monitor 1

20.5 TCN knot 1

Page 155 of 158



The following is an example of representation of the Breakdown Structure using atree diagram for a EMU (Electrical Multiple Unit) Coach.

Fig. 9 Example of structure using the tree breakdown chart for an EMU

(Electrical Multiple Unit) Coach

TREE BREAKDOWN STRUCTURE

ROLLING STOCK: EMU COACH Doc. N.

Date

Drawn up by

Page n/N

File name

Code L1 - System Qty Code L2 - Sub-system or LRU Qty Code L3 - LRU Qty

1 Carbody 1

1.1 Heat insulation 1

1.2 Side window, passenger room 10

1.3 Floor 1

1.4 Side wall, panelling 2

1.5 Roof 1

1.6 Underframe 1

2 Door 1

2.1 Passenger Door 2

2.1.1 Drive/motor unit 1

2.1.2 Roller swing arm, right 1

2.1.3 Roller swing arm, left 1

2.1.4 Emergency egress device (inside) 1

2.1.5 Bowden cable, emergency egress device (inside) 1

2.1.6 Emergency egress device (outside) 1

2.1.7 Bowden cable, emergency egress device (outside) 1

2.1.8 Doorleaf, right 1

2.1.9 Doorleaf, left 1

2.1.10 Lock box 1

2.1.11 Light barrier 1


2.2 Ramp 2

3 Pneumatic and braking system 1

3.1 Production/treatment air group 1

3.2 Brake devices group 1

3.3 Passenger alarm brake 1

3.4 Main reservoir 1

4 Lighting system 1

4.1 Compartment lights 1

5 Fittings 1

5.1 Compartment fittings 1

Page 156 of 158



5.1.1 Passenger seat 37

5.1.2 Foldable seat 12

5.1.3 Manual curtain 12

5.1.4 Dresshanger (set) 1

5.1.5 Luggage rack (set) 1

5.1.6 Hand rails (set) 1

5.1.7 Litter box 1

5.1.8 Fire extinguisher 1

6 Automatic fire extinguishing 1

7 Compart air conditioning 1

7.1 Ventilation 1

7.2 Cooling 1

7.3 Heating 1

7.4 Heaters 45

8 Service functions 1

8.1 Passenger information system 1

8.1.1 Loudspeaker 10

8.1.2 Emergency speech unit 5

8.1.3 Internal information display 2

8.1.4 External side display 2

8.2 Video surveillance system 1

8.2.1 External cam 2

8.2.2 Internal cam 3

9 Toilet 1

9.1 Vacuum flush toilet system 1

9.2 Water level sensor (Max and Min) 2

9.3 Command button 1

9.4 Photoelectric sensor 2

9.5 Double contact lighting button 2

9.6 Piezoresistive sensor 1

9.7 Contact probe for liquid level contouring 1

9.8 Electropneumatic valve for water 1

9.9 Boiler 1

9.10 HK toilet door electronic control unit 1

9.11 White and black water tank 1

9.12 HK wash-basin electronic control unit 1

9.13 Interface bus train electronic control unit 1

9.14 HK interiors 1

9.15 Complete door lock 1

9.16 HK automatic door 1

9.17 Electric towel 1

9.18 WC autocleaning system 1

10 Electrical equipment 1

10.1 Auxiliary electrical energy 1

10.1.1 LV and MV contactors, relay contactors, fuses, automaticcircuit breaker

1

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Page 158 of 158

Documents

ApplGuide for EN50126 -May 02 for SC9XB