RIS RIS-2704-RST. Rail Industry Standard for wheelsets handling and storage. Rail Industry Standard. Issue One: June 2015

Transcription

1 RIS This document contains one or more pages which contain colour. Published by: Copyright 2015 Rail Safety and Standards Board Limited RIS-2704-RST Issue One: June 2015 Rail Industry Standard

2 Issue record Issue Date Comments One June 2015 Original document This document has been developed to provide requirements and guidance on the handling and storage of wheelsets to protect their serviceability. Superseded or replaced documents The following Railway Group documents are superseded or replaced, either in whole or in part as indicated: Superseded documents Sections superseded Date when sections are superseded GM/GN2498 issue one All 06 June 2015 Supply The authoritative version of this document is available at Uncontrolled copies of this document can be obtained from Communications,, Block 2, Angel Square, 1 Torrens Street, London EC1V 1NY, telephone or enquirydesk@rssb.co.uk. Other Standards and associated documents can also be viewed at Page 2 of 18

3 Contents Section Description Page Part 1 Introduction Purpose of this document Application of this document Health and safety responsibilities The structure of this document Copyright Approval and authorisation of this document 4 Part 2 Wheelsets handling and storage General requirements for handling and storage of wheelsets 5 Part 3 Handling of wheelsets Introduction Wheelset handling general Complete wheelsets Components Unserviceable components Unserviceable wheelsets 9 Part 4 Storage of wheelsets Introduction Wheelset storage general Storage of wheelsets inside buildings Storage of wheelsets in the open air Unserviceable complete wheelsets Serviceable wheelset components Unserviceable components 16 Definitions 17 References 18 Figures Figure 1 Prohibited lifting and securing area 7 Figure 2 Inline wheelset storage 10 Figure 3 Staggered wheelset storage 11 Figure 4 Storage of wheelsets on concrete surfaces using wooden blocks 11 Figure 5 Protection of journal bearings 12 Figure 6 Axle storage in stillage 16 Page 3 of 18

4 Part 1 Introduction 1.1 Purpose of this document This document is a standard on wheelset handling and storage, for the rail industry to use if they so choose This document provides requirements, supported by guidance, to ensure railway wheelsets are handled and stored to protect their serviceability. 1.2 Application of this document A member of may choose to adopt all or part of this document through internal procedures or contract conditions. Where this is the case the member of will specify the nature and extent of application Therefore specific compliance requirements and dates have not been specified since these will be the subject of internal procedures or contract conditions. 1.3 Health and safety responsibilities Users of documents published by are reminded of the need to consider their own responsibilities to ensure health and safety at work and their own duties under health and safety legislation. does not warrant that compliance with all or any documents published by is sufficient in itself to ensure safe systems of work or operation or to satisfy such responsibilities or duties. 1.4 The structure of this document This document is set out as a series of requirements, in some cases followed by relevant guidance. The guidance is indicated by prefixing the paragraph number with the letter G. 1.5 Copyright Copyright in the Railway Group documents is owned by Rail Safety and Standards Board Limited. All rights are hereby reserved. No Railway Group document (in whole or in part) may be reproduced, stored in a retrieval system, or transmitted, in any form or means, without the prior written permission of Rail Safety and Standards Board Limited, or as expressly permitted by law members are granted copyright licence in accordance with the Constitution Agreement relating to Rail Safety and Standards Board Limited In circumstances where Rail Safety and Standards Board Limited has granted a particular person or organisation permission to copy extracts from Railway Group documents, Rail Safety and Standards Board Limited accepts no responsibility for, nor any liability in connection with, the use of such extracts, or any claims arising therefrom. This disclaimer applies to all forms of media in which extracts from Railway Group documents may be reproduced. 1.6 Approval and authorisation of this document The content of this document will be approved by Rolling Stock Standards Committee on 12 March This document will be authorised by on 29 April Page 4 of 18

5 Part 2 Wheelsets handling and storage 2.1 General requirements for handling and storage of wheelsets The condition of wheelsets and wheelset components shall be preserved during handling and storage, including unserviceable wheelsets being returned for maintenance. G G Environmental and atmospheric conditions that the wheelset or component will be exposed to during handling or storage influences the packaging and protection to be used. The detrimental effects that can be experienced during handling and storage include: a) Climatic conditions, for example, rain and water ingress, contamination, temperature and effects of sunlight. b) Dirt, such as contamination by airborne debris or contamination from lifting equipment and securing straps. c) Abrasion, for example, damage resulting from loose covering sheets, loose ends of securing straps and contaminated padding material beneath securing straps. d) Contamination, for example, resulting from the use of inappropriate protection materials When applying protective materials to mitigate the effects of environmental conditions, an assessment shall be undertaken to ensure there are no adverse effects from the materials or the application / removal processes. G G G The protective materials, and the process to apply and remove them, can cause damage or deterioration of the components, including: exposed surfaces, adjacent equipment, other protective coatings or lubricants. The use of protective tape, such as Denso, leaves a residue on the protected surface which frequently needs to be removed before further assembly or fitting to a vehicle. The application of cleaning products, to remove the residue, can have detrimental effects on components, such as bearings, where contamination of the grease results in breakdown of the lubrication, leading to premature failure. The sealing of orifices and connections prevents ingress of debris and water, mitigating damage, repair or premature failure. Coloured temporary weatherproof plugs, covers or similar sealing arrangements provide protection from dirt and water ingress. Such protective plugs or covers provide a visible warning of their presence and reminder for removal before reassembly. The use of protective tapes can be overlooked or incompletely removed in preparation for reassembly, which can cause parts of the tape to become trapped within assemblies, resulting in malfunctions of the systems in service. Page 5 of 18

6 Part 3 Handling of wheelsets 3.1 Introduction This section relates only to the handling of loose wheelsets and their components, including within depots or works and between sites. 3.2 Wheelset handling general The handling processes and equipment employed shall not cause damage to the wheelsets or wheelset components or their protective coatings. 3.3 Complete wheelsets Any exposed journals, bearings, gears and similar exposed surfaces shall be protected from corrosion and mechanical damage The methods employed for handling shall not damage the wheelsets. G Direct metallic contact between the wheelset and lifting or restraining equipment can damage the finished surface and protective coating. This potentially results in: a) Mechanical damage that can initiate fatigue fractures. b) Damage to the protective coating leading to corrosion of the finished surface and potential for corrosion fatigue. (Some protection systems once damaged can allow the propagation of corrosion beneath the coatings, producing ribbons of corrosion across the surface that are only visible once the coating is removed.) c) Unplanned rectification work. Or d) Scrapping of the damaged component. G The types of wheelsets lifting equipment commonly used include: a) Non-damaging fibre slings around the axlebox housing. b) Hooks or clamps with rounded corners that locate under the wheel rim. c) Padded cradles (for example, lined Vee-blocks), under plain axles or the suspension tubes of motored axles (taking care to avoid high loads through sharp lifting or traversing rough surfaces that will cause damage to the bearing). d) Mechanisms supporting the wheel tread, including cradles. G Methods of securing wheelsets to flatbed vehicles include wooden chocks and tensioned fibre webbing straps. These provide a means of location and restraint on the vehicles although care is needed to prevent damage to the protective coating, as highlighted in G b), whilst ensuring security. To avoid damage to the axle protective coating the fibre strapping may be applied over the axleboxes, taking care to prevent contact with the axle journal transitions Wheelsets shall not be lifted or secured with equipment contacting the wheelseat to axle body transitions, stress relieving groove or other transition. Contact shall not occur 150 mm of the wheelseat / hub or other raised seats (including raised brush tracks), refer to Figure 1. Page 6 of 18

7 Figure 1 Prohibited lifting and securing area G The transitions between wheelseat and axle body are some of the highest stressed areas of the axle and easily damaged by lifting or securing equipment. Damage in the transition can initiate fatigue fractures Except for dedicated lifting equipment supporting the wheel tread or rim, metallic lifting equipment shall not directly contact the wheelset. G G G G G Powered wheelset transmission drives can be damaged if allowed to contact the workshop floor or other equipment. The use of a support cradle prevents contact with the floor and maintains the transmission in the correct orientation to prevent oil loss or seals being immersed in lubricant. Attaching jockey wheels to the transmission is a means of supporting it when moving powered wheelsets on rails within a workshop. The protection of connections to transmission units, including mechanical drive connection, torque reaction links and electrical terminals, prevents damage and costly repairs / rectifications. Contact with the protective coating during handling can be detrimental to its integrity, particularly before the coating has cured or hardened, increasing the potential for corrosion to be initiated when in service. Wheelsets removed from vehicles for overhaul or repair will contain components that have further serviceable life such as: axles, bearings and transmission components. Careful handling prevents further damage of wheelset components and consequential rectification or scrapping. 3.4 Components Finished and part-finished components shall not be damaged during handling. G Loading and unloading of finished or part-finished components, such as bearings, axles and transmission components in the open air exposes them to contamination from environmental and atmospheric conditions. Page 7 of 18

8 G G G G The use of open transport exposes wheelset components to the environment, potentially resulting in damage and deterioration from corrosion, impact or abrasive debris. The cleanliness of all materials and surfaces, including hands, clothing, tables and lifting straps, coming into contact with finished components helps prevent premature damage and deterioration. Contamination of machine finished surfaces by lubricant, dirt, dust or even finger prints can prevent the adhesion of protective coatings. Abrasive material on transmission components or entering bearings can result in wear, damage and premature failure. Handling of finished components, such as wheels, wheel centres, gearwheels, tyres and brake discs by either non-damaging fibre lifting straps or rounded lifting hooks helps prevent damage. Contact with the protective coatings can be detrimental to its integrity, particularly before the coating has cured or hardened, increasing the potential for corrosion to be initiated when in service. The use of padding materials between straps and coating helps to prevent damage. Handling techniques for axles commonly used by industry include: a) Hooks attached to temporary lifting attachments fitted on the axle ends. b) Non-damaging equipment that comes into contact with the axle surface, such as lined Vee-blocks and fibre slings. G G Components transported on pallets where part of the surface can protrude beneath the supports, such as axles, have the potential to contact lifting forks resulting in damage to the component and consequential repair or scrapping. Experience has shown that some practices can be detrimental to wheelset components, as indicated below: a) Use of open transport, even for a short journey, for any component or assemblies having unprotected parts, such as axlebox guide posts, bearings, and transmission components, even if covered by a tarpaulin. b) Use of open transport for unprotected products having machine finished parts. c) Failure to provide adequate and secure chocks for wheels or wheel centres. G Unmachined components, such as rough rolled tyres, are tolerant of being handled by fork lift or chains, provided that subsequent machining of all surfaces removes any damage Exposed surfaces such as wheelseats, journals, axle ends gearwheel seats, bearing seats, brake disc seats or current return brush tracks shall be protected from corrosion and mechanical damage. G Finished and part-finished axles are susceptible to corrosion and mechanical damage, such as wheelseats, journals, axle ends, gearwheel seats, bearing seats, brake disc seats or current return brush tracks which may come into contact with supporting surfaces and other adjacent materials. Page 8 of 18

9 G G The use of cradles or bespoke pallets / stillages provides a secure and stable platform for the handling of axles fitted with transmission equipment, preventing damage from contact with the workshop floor or adjacent materials. The protection of particularly vulnerable areas of the axle and use of cradles or bespoke pallets / stillages will assist in preventing damage and subsequent costly rectification or scrapping of the axle or service failure Magnetic hoists shall not be used to handle wheelset components unless the components are subsequently demagnetised or confirmed as scrap. G G The residual magnetism in the wheelset or component from the use of magnetic hoists is likely to be detrimental to adjacent components and systems, such as: axlebox bearings, on-board systems, and signalling systems. Magnetic hoists can result in metal to metal contact that could cause damage to the machined surfaces. 3.5 Unserviceable components The condition of unserviceable components shall be preserved during handling processes. G Poor handling increases the opportunity of damaging potentially serviceable components within the wheelset. This increases repair costs or scrapping of potentially serviceable components. 3.6 Unserviceable wheelsets The management of unserviceable wheelsets shall preserve their condition until subjected to further maintenance or investigation. G G G Unserviceable wheelsets contain components that have a further service life following maintenance. Handling unserviceable wheelsets in the same manner as defined for serviceable wheelsets will preserve their condition. Powered wheelsets contain transmission equipment that may have further service life following maintenance. It is important to preserve the condition of this equipment by using appropriate cradles, sealing orifices against ingress of foreign matter and protecting from damage. Preserving the condition of wheelsets that have been removed from vehicles for further investigation will ensure the best possibility of resolving the fault condition. Page 9 of 18

10 Part 4 Storage of wheelsets 4.1 Introduction This section relates only to the storage of loose wheelsets and their associated components. 4.2 Wheelset storage general Serviceable and unserviceable wheelsets or components shall be stored in separate dedicated areas The storage of wheelsets and components shall preserve their condition. G G Contamination of the wheelset by water, solid debris or other materials is likely to cause corrosion and / or deterioration during storage. The frequency of wheelset and wheelset component inspections will be determined by local conditions, including: environmental and atmospheric conditions, protections and time of year Wheelsets shall be protected from mechanical damage during storage. G To optimise storage space the industry best practice is to store wheelsets either: a) In line wheels align, any wheel to wheel contact may only be flange to flange, taking care to avoid damage during movements, see Figure 2. Figure 2 Inline wheelset storage Or b) Staggered where the wheels overlap and each wheelset is chocked to prevent contact with axles, journals or bearings, see Figure 3. Page 10 of 18

11 Figure 3 G Staggered wheelset storage Chocks provide an effective means of securing wheelsets during storage to prevent contact with adjacent wheelsets or other materials. However, chocks may damage the wheel treads; impact against metal chocks can damage the wheel tread and wooden chocks absorb water and moisture which may promote corrosion where contacting the tread. The potential for corrosion and damage of wheel treads, together with the need to move wheelsets, will influence the chocks being used and determine any mitigation necessary. An example of an alternative wheel chocking arrangement is shown in Figure 4. Figure 4 Storage of wheelsets on concrete surfaces using wooden blocks Journal bearings fitted to wheelsets shall be protected from damage and ingress of moisture and other contaminants. G Taper roller journal bearings with integral seals have effective means of preventing the ingress of water and other contaminants. Wheelsets fitted with such sealed journal bearings, and protected from damage by an appropriate cover or axleboxes, are suitable for storage in the open air. Page 11 of 18

12 G G Other types of bearings, such as spherical bearings, are only sealed when the axlebox is correctly assembled to the wheelset. Wheelsets fitted with these types of bearings are only suitable for storage outside when correctly fitted with their axlebox. Plastic protective pots can protect bearing installations and journals primarily from mechanical damage, see Figure 5. The sealing of bearings by plastic bags is considered extremely harmful as the bags can accumulate water which adversely affects the bearing grease, leading to potential failure in service. Figure 5 Protection of journal bearings Facilities storing wheelsets shall have procedures for the management of the wheelsets during storage. G G G G The periodic checking of temporary protection and sealing arrangements will provide assurance of their effectiveness and allow prompt rectification of any identified damage, such as water ingress. Wheelsets stored on rails can experience corrosion at the point of contact between wheel and rail. The movement of wheelsets minimises such localised corrosion and the frequency of these movements is determined to suit local conditions. Regular examination and rotation of wheelset journal bearings will provide an opportunity to check their condition and ensure the lubrication remains evenly distributed through the bearing. Industry good practice recommends intervals of two months between examinations and rotations of journal bearings. The storage of wheelsets and their components will influence their longevity and reliability in service. The following practices can be detrimental to the wheelsets: a) Storage of wheelsets and wheelset components on soft ground, causing contamination and corrosion to surfaces, such as wheel treads. b) Storage of machined parts of wheelsets on sharp cornered metallic supports, resulting in surface damage that can lead to the initiation of fatigue fractures. c) Storage of wheelsets in a manner that allows water or dirt to be retained, causing corrosion of components and damage. Page 12 of 18

13 d) Stacking wheelsets one on top of another can cause damage to components rendering them unserviceable. e) Stacking of wheelsets with parts (other than wheel flanges or treads) of adjacent items in contact. f) Stacking of any finished or part-finished components with direct metallic contact can result in damage or corrosion. g) Failure to rotate stock leading to extended periods of storage, can result in the breakdown of short term protection and the settlement of lubricants in bearings and transmissions causing deterioration of components and increasing the possibility of premature failure. h) Lack of regular wheelset inspections and consequent failure to rectify defects can promote deterioration, such as corrosion of surfaces from damaged protective coatings, which increase the potential for in service problems. i) The attachment of labels, tags or other means of identification to the axle in a manner that damages the axle surface protection, causing corrosion or damage of the axle surface, can result in either premature scrapping or possible initiation of a fatigue fracture. G The storage procedure provides an opportunity to capture good practice such as the following: a) Procedures detailing how risks from storage in the open air are minimised. b) Blanking of access holes. c) Sealing of suspension tubes. d) Drain holes orientated to encourage drainage of moisture accumulations. e) Provision for alternative protection for bearing arrangements where the seals are not fully effective or sealed prior to use. f) Protection of mechanical drives and other connections to transmission systems to prevent mechanical damage, corrosion and other contamination. g) Setting of inspection frequency consideration is given to be taken of at least: the degree of corrosion protection, the packaging applied and the prevailing storage conditions. 4.3 Storage of wheelsets inside buildings The wheelset condition shall be preserved during storage. G Condensation can form on wheelsets and wheelset components stored in enclosed areas resulting in corrosion and deterioration of exposed and unprotected surfaces. Ventilation of storage areas reduces the potential for condensation and consequential corrosion. 4.4 Storage of wheelsets in the open air The condition of wheelsets stored in the open air shall be preserved. Page 13 of 18

14 4.4.2 When deciding on storing wheelsets and their components in the open air, consideration shall be given to the duration of storage and the environmental conditions. G Wheelsets stored in the open air are susceptible to the adverse effects from poor storage facilities and the environmental conditions. The following industry good practice minimises deterioration of wheelsets whilst stored outside: a) Flat, free draining, hard standing surface that is free of puddles. Water in continuous contact with the tread causes corrosion that can lead to discontinuities in the flange and shallow flats or out-of-round of the running area. b) The period of storage in the open air is as short as possible. c) All wheelset surfaces are protected against corrosion. d) Protection of brake disc surfaces, including: friction surfaces and expansion joint sliding surfaces. e) Regular examination of protection arrangements, such as suspension tube protection, will ensure they remain intact and effective. G Before using wheelsets that have been stored outside, inspection of the bearing by removal of the bearing end covers will confirm whether the bearings have been contaminated by water ingress during storage. Bearings with evidence of water ingress are not suitable for service operation. 4.5 Unserviceable complete wheelsets The storage of unserviceable complete wheelsets shall preserve their condition, in preparation for maintenance or further investigation. G The storage of unserviceable wheelsets outside can adversely affect wheelset components, which may increase the cost of repair or result in scrapping of otherwise serviceable components. The protection of components that are to be re-used will reduce repair costs and rejection rates. The protection of wheelsets being retained for further investigation will ensure the best opportunity to establish the cause of defect or fault. 4.6 Serviceable wheelset components The condition of serviceable wheelset components shall be maintained during storage. G The correct storage of wheelset components is essential to their longevity and reliability. The outside storage of finished or part-finished components, not protected against weather, dust and dirt, is detrimental to the following: a) Machined axles, wheels, wheel centres or tyres. b) Traction motor suspension tubes. c) Traction gears or other transmission components. d) Bearings. e) Brake discs. Page 14 of 18

15 f) Axleboxes. G Extended outside storage of rough rolled tyres, wheel centres or rough forged axles can be detrimental, as severe corrosion can erode machining allowances Finished or part-finished components shall be protected from environmental conditions. G The storage of certain wheelset components is particularly important to prevent deterioration, this includes: a) Bearings. b) Axles. c) Components fitted to completed or partially completed wheelsets (including stress relieving grooves and component overhang on axle seats). d) Transmission gears and other similar components. e) Traction current return and equipotential bonding systems. f) Brake discs (including expansion joints and mounting brackets). g) Axleboxes. G Some components are tolerant of being stored outside for limited periods of time, inspections will ensure their condition is maintained. The components that can be stored outside include: a) Monobloc wheels, or wheel centres, with corrosion protection adequate for the method of stacking. b) Brake discs with corrosion protection applied. c) Unmachined axlebox castings. d) Rough rolled tyres and axle forgings Bearings shall be stored in accordance with the manufacturer s and overhauler s instructions. Axles shall be stored indoors, on timber baulks or other non-damaging materials shaped to prevent rolling or sliding and contacting adjacent axles. G Stillages extending at least the length of the axles will assist in providing protection for the axle ends, see Figure 6. Page 15 of 18

16 Figure 6 Axle storage in stillage Part assembled wheelsets shall be stored in such a manner to prevent damage to the axle or other equipment fitted to the axle. G Part assembled wheelsets, where some components are not fitted, such as wheels, will be more susceptible to damage to journals, wheelseats and other components on the axle from contact with the workshop floor and other objects. Such damage can result in expensive rectification or scrapping of the axle The storage of wheelset components shall be subject to stock rotation to minimise deterioration. G Components and materials which remain in store for an extended period due to poor stock rotation, risk deterioration unless subjected to inspection to ensure their condition is maintained. 4.7 Unserviceable components Unserviceable components, awaiting maintenance, shall be stored such that further degradation is prevented. Page 16 of 18

17 Definitions Uncontrolled When Printed Defined term Damage To impair the performance, loss of value, deterioration, contamination, detriment, or mutilation. Handling The process by which a commodity is packaged, loading and unloading, transported, delivered, etc. For example, moving goods within a facility or between facilities especially using mechanical devices. Preserve To keep in an unaltered condition and to prevent from deteriorating. Protect To keep from being damaged, guard, shield, cover, or keep safe. Storage The act of storing or the state of being stored, holding, retention, or keeping. Wheelseat The raised area of an axle onto which a wheel is to be fitted. Wheelset A complete unit comprising an axle and two complete wheels together with any gear wheels, brake discs, etc. The wheelset may or may not be fitted with axleboxes, journal bearings and axle end caps etc. Page 17 of 18

18 References Uncontrolled When Printed The Catalogue of Railway Group Standards give the current issue number and status of documents published by. This information is also available from RGSC 01 RGSC 02 Railway Group Standards Code Standards Manual Other relevant documents Railway Group Standards GM/RT2466 Railway Wheelsets Page 18 of 18