Maintenance of EMU - a new approach for management and technology

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1 RöschConsult Group Maintenance of EMU - a new approach for management and technology Beijing Jiaotong University May, 8th 2013 Prof. Dr.-Ing. Wolfgang Roesch

2 2 RoeschConsult Group GmbH RöschConsult Group Group Holding Technical Consulting for Process Optimization RöschCert GmbH & Co. KG Safety and Quality Audits and Certifications RöschEngineering Maintenance Optimization Depot and Workshop Planning Research for Maintenance of Railway Rolling Stock SachverständigenBüro Prof. Dr.-Ing. Rösch Court appointed Expert Experts Reports International Ltd. International Management Consulting for Railways

3 3 our markets

4 our customers (selection) 4 RöschEngineering RöschCert GmbH & Co. KG SachverständigenBüro Prof. Dr.-Ing. Rösch consulting and engineering services for: German Railway DBAG Switzerland s Railway SBB Bombardier Transportation Siemens Alstom... auditing for safety certifications and expert s services appointed by the german NSA for: DB Schenker Rail DB S-Bahn Berlin private ECM s private RU s

5 5 Introduction Wolfgang Roesch - round about 40 years experience in operation and maintenance of railway rolling stock. - study at the university of traffic Hochschule für Verkehrswesen (HfV) Friedrich List Dresden (today part of Technical University of Dresden), doctoral degree in power plants of railway rolling stock at the same university, - 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, - founder, partner and general manager of the RoeschConsult Group, - court and NSA appointed expert for operation and maintenance of railway rolling stock, - professor for railway rolling stock at the Wilhelm-Buechner-University of Applied Science Darmstadt, Germany, - adjunct professor at Beijing Jiaotong University, China and official senior advisor for ministry of high speed traffic network in China, - member of german societies for traffic science Deutsche Verkehrswissenschaftliche Gesellschaft (DVWG) and technical railway science Deutsche Maschinentechnische Gesellschaft (DMG)

6 6 Agenda 1 Maintenance embedded in safety management systems 2 Opportunities of condition based maintenance 3 Optimization circuit 4 Targets and tasks of maintenance research 5 Targets for practical maintenance

7 7 1 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

8 8 1 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 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 1169/2010/EC: Operators of infrastructure are responsible for safe operating of infrastructure

9 9 1 Maintenance embedded in safety management systems new sharing of responsibility for safety of railway rolling stock: manufacturer: responsible for safe design and manufacturing of rolling stock operator: responsible for safe operation of rolling stock entity in charge of maintenance: responsible for safe condition of rolling stock

10 10 1 Maintenance embedded in safety management systems integrated safety management safety regulation 2004/49/EC manufacturer operator ECM national authorisation by NSA european authorisation TSI under national law under european law CSM audited by contractor CSM for validation by the NSA and RU european certification CSM technical regulations for manufacturing, operation and maintenance of rolling stock and infrastructure (TSI) ECM - Entity in Charge of Maintenance CSM for risk evaluation by the RU RU - Railway Undertaking

11 11 1 Maintenance embedded in safety management systems That means each entity in charge of maintenance needs a maintenance management system based on the safety regulation 2004/49/EC. A Maintenance Management System (MMS) is a special kind of a Safety Management System focused on safe condition of rolling stock.

12 12 1 Maintenance embedded in safety management systems A Maintenance Management System (MMS) covers: - management of organisation and responsibility - management of competence - management of ressources - management of risks - management of information, communication and documentation - management of processes, procedures and technologies - management of process optimisation

13 13 1 Maintenance embedded in safety management systems The main focus of all these parts of the maintenance management system is: written procedures with clear tasks, responsibilites and interfaces reproducible results of the maintenance procedures monitoring of effectiveness of procedures and of acceptable risks

14 14 1 Maintenance embedded in safety management systems characteristic of a procedure input, sources, interfaces (push or pull) responsible owner, participants, ressources description of procedure (work flow) figures for measuring (target/actual comparison) output, results, interfaces (push or pull)

15 15 1 Maintenance embedded in safety management systems The responsibility of an ECM for safe condition of rolling stock needs a condition based maintenance. Condition based maintenance needs a connection of management procedures and technical regulations.

16 16 2 Opportunities of condition based maintenance Basic activities are inspections on fixed intervalls (kilometer or time based) for example CRH 3 maintenance program:

17 17 2 Opportunities of condition based maintenance Example condition based maintenance: failure information on drivers desk Display information about failure in breaking system Developed version of EMU 423

18 18 2 Opportunities of condition based maintenance wear progress simplified:

19 19 2 Opportunities of condition based maintenance failure statistics collecting data regarding maintenance findings and failures configuring data systems to store all data

20 20 2 Opportunities of condition based maintenance empirical prognostics: thickness of break pads

21 21 2 Opportunities of condition based maintenance empirical prognostics dissipation of probability distributions on basis of Gaussian, Weibull and exponential distribution based on failure statistics

22 22 2 Opportunities of condition based maintenance empirical prognostics these results are only valid for one type of EMU under its specific operation conditions, comparison between different types of EMU under different operation conditions is not possible

23 23 2 Opportunities of condition based maintenance empirical prognostics conclusion: a preview of wear, aging and failures of EMU s under different operational conditions is not possible only on the basis of empirical prognostics, safety, reliability, availability and efficiency can be optimised only in case of knowledge of the detailed reasons and relevant parameters of the wear progress, aging and failure characteristics

24 24 3 Optimisation circuit vehicle inspection system flexible time packages component and parameter based maintenance program system change strategy maintenance technologies and methods determining of relevant parameters for each component with OptiRail : line and track conditions vehicle selection operation plans traffic and operation conditions maintenance system OptiTime part of OptiRail OptiRail vehicle design and construction vehicle maintenability component changeability component reliability service requirements law restrictions OptiBase part of OptiRail depot system sparepart/ component availability depot location network vehicle park and service facilities workshop processes and logistics workshop design and building workshop track system and working levels inspection and maintenance equipmnt

25 25 3 Optimisation circuit equation of wear, aging and failure characteristic for each component: W, A, F = f f 1 S 1 S 1,nom,f 2 S 2 S 2,nom...f n S n S n,nom S 1...n determined stress parameter

26 26 3 Optimisation circuit stress profile of the same component covered in four different EMU types

27 27 3 Optimisation circuit the variables in the equations of the several stress parameters f 1... fn can be determined under use of different boundary conditions covered in the stress profile W, A, F = f S 1 S 2 f 1,f 2...f n S 1,nom S 2,nom S n S n,nom

28 28 3 Optimisation circuit the wear, aging and failure characteristic of a component can be deduced for each stress level and each operational condition on the basis of the determined equation, the same kind of components covered in different types of EMU s will be comparable, the prognostic of wear, aging and failures of different operational conditions will be possible. W, A, F = f S 1 S 2 f 1,f 2...f n S 1,nom S 2,nom S n S n,nom

29 29 3 Optimisation loop determine relevant parameters under use of OptiRail method determine the stress profile for the different parameters calculation of the variables of the equations of the parameters validation of calculated prediction of wear, aging and failures in practice variation of the equation for different stress levels and operational conditions calculation of the complete equation for each component

30 30 4 Targets and tasks of research target: determine stress profiles, parameters and equations of wear, aging and failure characteristics of the main components of the different types of high speed EMU s for optimization of maintenance W, A, F = f S 1 S 2 f 1,f 2...f n S 1,nom S 2,nom S n S n,nom

31 31 4 Targets and tasks of research Task of research: To find one equation for each component, valid for all types of trains which are covering this component and for all operational conditions! W, A, F = f S 1 S 2 f 1,f 2...f n S 1,nom S 2,nom S n S n,nom

32 32 5 Targets of practical maintenance

33 33 5 Targets of practical maintenance Manufacturers: including on-board-diagnostics in design of rolling stock based on TSI - pantographs and high voltage equipment - train control systems - traction systems - break systems - door control systems - bogie, axle boxes

34 34 5 Targets of practical maintenance Operators of rolling stock: train inspection before starting and train controlling during operations based on operational regulations and TSI traffic operation and management - bogies, wheel sets - brake system - loading requirements -...

35 35 5 Targets of practical maintenance Operators of infrastructure: inspection and diagnostics during operations based on operational regulations and TSI - hot axle box detector - catanary system detection - track diagnostic by UT -...

36 36 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance - non-destructive testing procedures VT, UT, MT, ET, RT - new ndt technologies: thermography for surface cracks of wheelsets (Fraunhofer Institute Saarbruecken at InnoTrans 2012) - bearing diagnostic, vibration monitoring - measuring of brake forces directly at the brake pads

37 37 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance based on regulation 445/2011/EC and on technical regulations of maintenance - non-destructive testing procedures VT: European Visual Inspection Catalogue (EVIC) for wheelsets

38 38 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance based on regulation 445/2011/EC and on technical regulations of maintenance - non-destructive testing procedures UT: automated testing of wheelsets like AURA, UFPE or hollow axle testing of Fraunhofer Institute Saarbruecken

39 39 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance - new ndt technologies: on-train-testing of solid axles of freight wagons with mobile equipment without disassembling and paint stripping for use in on-site maintenance services, patent application by Roeschconsult, developed together with NDT Systems & Services and Fraunhofer IzfP Saarbruecken

40 40 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance based on regulation 445/2011/EC and on technical regulations of maintenance - new ndt technologies: thermography for surface cracks of wheelsets (Fraunhofer Institute Saarbruecken at InnoTrans 2012)

41 41 5 Targets of practical maintenance ECM of railway rolling stock: diagnostics in maintenance based on regulation 445/2011/EC and on technical regulations of maintenance - new measuring technologies: direct measuring of brake forces between brake pads and discs (patent application by RoeschConsult)

42 42 5 Targets of practical maintenance All these diagnostic methods have only one target: to minimise the risk of failures in railway transport. They are a strong instrument for all participants in railway traffic to fulfill the european and national safety requirements.

43 43 5 Targets of practical maintenance But: Which technology shall be used? All what we can or a selected couple of diagnostic technologies in accordance to the risk level?

44 44 5 Targets of practical maintenance The risk evaluation based on european rules gives the answer. A selection of available diagnostic technologies shall be used, which reduces the risk level to the accepted figure.

45 45 5 Targets of practical maintenance The effect of these risk minimisation by using diagnostic technologies can be evaluated on the basis of the CSMregulation 352/2009/EC and EN (RAMS) and EN (FMEA).

46 46 5 Targets of practical maintenance CSM-regulation 352/2009/EC:

47 47 5 Targets of practical maintenance for example: EN describes three criterias to evaluate risks: probability of occurrence (O) ( ) probability of discovery (D) ( ) severity of consequences (C). ( )

48 48 5 Targets of practical maintenance The result is the risk priority number (RPN): RPN = O x D x C ( ) Diagnostic methods mostly increase the probability of discovery of failures (D). The effect of risk minimisation by diagnostic methods can be evaluated with this procedure.

49 49 5 Targets of practical maintenance Risk management is the most important instrument of the safety management needs in all parts of railway traffic and in all phases of the life cycle of rolling stock and infrastructure. It s an instrument to choose the right and efficient technologies of diagnostics for maintenance. Safety is a condition free of unacceptable risks!

50 50 5 Targets of practical maintenance Using state of the art in all maintenance technologies is a key condition for safe and efficient maintenance. Connecting modern maintenance technologies with the ECM-management procedures for acceptable risks, higher effectivenes and efficiency is basicly needed to fulfill the requirements of the law and of the customers.

51 51 5 Targets of practical maintenance Maintenance Management System + Modern Maintenance Technologies = Success in Maintenance of Rolling Stock

52 RöschConsult Group Thank you for your attention!

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