RöschConsult
Group
The european regulations for railway safety - conclusions for maintenance of rolling stock
2nd National Conference on Science and Technology - Tarnowskie Gory
November, 18th, 2014
Prof. Dr.-Ing. Wolfgang Roesch
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Introduction of the lecturer
Prof. Dr.-Ing. Wolfgang Roesch, (59) has fourty years experience in operation and maintenance of railway rolling stock.
He has studied at the university of traffic Hochschule für Verkehrswesen (HfV) „Friedrich List“ Dresden (today part
of Technical University of Dresden) and got the doctoral degree in power plants of railway rolling stock at the same
university.
He was in charge in responsible functions for rolling stock maintenance in the DBAG headquarter, as head of DBAG
rolling stock workshops and as general manager of private railway companies. He is founder, partner and general
manager of the RoeschConsult Group.
Prof. Dr. Roesch works as court appointed expert for operation and maintenance of railway rolling stock, as expert
of the german national railway authority EBA and the german accreditation body DAkkS.
He is professor for railway rolling stock at the Wilhelm-Buechner-University of Applied Science Darmstadt, Germany,
professor at Beijing Jiaotong University, China and official senior advisor for ministry of high speed traffic network in
China.
He is member of german societies for traffic science „Deutsche Verkehrswissenschaftliche Gesellschaft (DVWG) and
technical railway science Deutsche Maschinentechnische Gesellschaft (DMG).
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RoeschConsult Group GmbH
RöschConsult
Group
Services for Manufacturing, Operation
and Maintenance of Railway Rolling Stock
Technical Consulting
Services
RCT Rail
GmbH
SachverständigenBüro
Prof. Dr.-Ing. Rösch
Court appointed Expert
Experts Reports
Engineering Services
Research for Maintenance
of Railway Rolling Stock
Safety and Quality
Audits and Certifications
International Management
Consulting for Railways
International Ltd.
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our markets
5
Maintenance embedded in safety management systems
integrated
safety
management
basic rule: regulation 2004/49/EC
targets and the structure of european railway safty
management system
common
safety
targets
CST
common
safety
methods
CSM
common
safety
indicators
CSI
technical regulations for manufacturing,
operation and maintenance
of rolling stock and infrastructure
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Maintenance embedded in safety management systems
safety management requirements are valid for all kinds
of railway rolling stock and for all players in the life cycle:
•
•
•
TSI: Manufacturers are responsible for safety in design and construction
•
1169/2010/EC: Operators of infrastructure are responsible for safe operating of
infrastructure
•
352/2009/EC, followed by (EU) 402/2013 valid from may 2015: risk evaluation for all
participants (RU and ECM)
•
1078/2012/EC: Monitoring for all participants (RU and ECM)
445/2011/EC: ECM are responsible for safe condition of railway rolling stock
1158/2010/EC: Operators of railway rolling stock are responsible for safe operating of
rolling stock
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Maintenance embedded in safety management systems
new sharing of responsibility for safety of railway rolling stock:
manufacturer:
operator:
entity in charge
of maintenance:
responsible for
safe design and
manufacturing of
rolling stock
responsible for
safe operation
of rolling stock
responsible for
safe condition
of rolling stock
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Maintenance embedded in safety management systems
integrated
safety
management
safety regulation 2004/49/EC
manufacturer
national
authorisation
by NSA
european
authorisation
TSI
operator
under
national
law
under
european
law CSM
ECM
audited by
contractor
european
certification
CSM
CSM for risk evaluation by the RU
CSM for validation by the NSA and RU
technical regulations for manufacturing, operation and
maintenance of rolling stock and infrastructure (TSI)
ECM - Entity in Charge of Maintenance
RU - Railway Undertaking
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What does this mean?
Safety Chain
TSI
Component
Overhaul
Parts
Deliverer
TSI
safety certificate
Manufacturer
of rolling stock
Holder
of rolling stock
Maintainer
of rolling stock
Operator
of rolling stock
TSI
2008/110/EC:
responsible for maintenance
2008/110/EC:
responsible for maintenance
2004/49/EC:
responsible for safety
TSI = Technical Specifications of Interoperability
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‣1 EU-Regulation
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12
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‣2 Conclusions for Manufacturers
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• design in accordance to all relevant technical rules (TSI, UIC, national
•
•
•
•
•
•
•
•
rules)
certificate of conformity declared by a notified body
permission of commissioning of the national safety authority
manufacture in accordance to an approved quality standard (IRIS)
design in accordance to RAMS criterias
reliability in accordance to the requirements of the operator
availability in accordance to the requirements of the operator
maintainability to assure safety and efficiency in maintenance
development of maintenance plan and maintenance program in accordance
to design and stress
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‣3 Conclusions for Keepers
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• purchase of licensed rolling stock
• auditing manufacturers in accordance to safety and quality rules
• collecting all needed documents from the manufacturer
• verification of maintenance plan and program
• choice of approved maintainers
• definition of binding requirements for maintenance
• auditing maintainers in accordance to safety and quality rules
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‣4 Conclusions for Maintainers
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• maintaining in accordance to technical rules of maintenance (processes,
•
•
•
•
•
e.g. welding, nondestructive testing, measuring etc.)
supply of all needed resources (informations, documentations, staff,
qualifications, materials, parts, devices and tools, software etc.)
approved service providers (e.g. for component overhaul)
auditing service providers in accordance to safety and quality rules
using MPCDS (Maintenance Planning, Controlling and Documentation
System)
confirmation of all required certifications (from 2010 required by
2008/110/EC at first for freight wagons, following for all other rolling
stock)
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‣5 Conclusions for Operators
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• operating in accordance to all operational rules regarding safety given
•
•
•
•
by the operator of the used railway infrastructure and the national
authorities
safety certificate part A shows the approval of abstract safety
requirements
installation of a risk management for own and shared risks of operation
safety certificate part B several for each railway infrastructure shows
the approval of special safety requirements of these railway
infrastructure
auditing holders and maintainers in accordance to safety and quality
rules
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A Chain is as strong as its weakest link!
Safety of railway rolling stock is a very complex system with influence of
a lot of participants.
All participants have their own responsibilities, but the operator has to
prove safety in general to get the safety certificate.
He has to install processes to assure that all other parties fulfill their
safety criterias.
All other parties have to assure that all deliverers of services or
materials fulfill their safety criterias.
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How to do all this certifications?
The integrated system
(Integrated Railway Management Assessment),
developed by our company, includes all relevant certifications and prepares
you for your needed certifications.
IRIS
certification
SMS
certification
owner
certification
maintenance
provider
certification
IRMA
Integrated Railway Management Assessment
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‣6 How to use the regulations in daily business?
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
Currently the brake actuator
units will be changed mostly
in a fixed time or kilometer
intervall.
But the wear of the
pneumatic brake units is
significant reduced because
of the operational use of the
electro-dynamic brakes or
retarder brakes
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
It is possible to change the
brake units in a condition
based, variable interval, when
the condition is monitored.
Therefore a risk analysis is
needed, based on CSMdirective 352/2009/EC / (EU)
402/2013.
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
F
[kN]
target value of
brake force
condition preventive
based change change
measurements
condition
based change
t [a]
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
It is possible to change the
brake units in a condition
based, variable interval, when
the condition is monitored.
The brake force between brake
pads and brake disc is the most
important condition for safety.
The target value of this figure is
part of the brake calculation.
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
The measurement of the brake
force between brake pads and
brake disc is the best way to
check the condition.
The interval for the
measurement can be defined in
a risc analysis with a FMEA
based on EN 60812
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
The equipment for measuring
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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example for measurement: EMU Desiro ML, 0.5 million km, age 3 a
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
The equipment for
measuring is patented by an
european patent held by
RoeschConsult.
The equipment can be
purchased and used on the
basis of a risk analysis to
define the intervals for
measuring and the field of
tolerance of the figures.
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How to use this legal frame in the daily business?
An example for
maintenance of
brake systems
The benefit is not only the
economic effect of a later
change, it´s also an increase
of safety.
The fact that the brake force
was to less in some cases
can not be detected with the
current maintenance
activities without measuring.
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How to use this legal frame in the daily business?
The use of EU-regulation 352/20097EC / (EU) 402/2013 and EN
60812 for the optimisation of brake maintenance is an example for
the practical application of european safety regulations.
It is an example for the change from preventive maintenance with
fixed intervalls to condition based maintenance.
The practical use of the EU-regulations can decrease maintenance
costs and increase safety.
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Group
Engineering and Consulting Companies
for Operation and Maintenance
of Railway Rolling Stock
RC
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64354 Reinheim
Tel. +49 6162 809 839 -0
Fax +49 6162 809 839 -9
[email protected]
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Thank you for your attention!