Impact assessment for change to a Railway Group Standard, new Rail Industry Standard and withdrawal of associated RACOPs and Guidance Note

Transcription

1 Impact assessment for change to a Railway Group Standard, new Rail Industry Standard and withdrawal of associated RACOPs and Guidance Note Version: Publication Date: 05 September 2017 Relevant Railway Group Standard Title: Railway Wheelsets Number: Issue: Three Synopsis: This document mandates requirements for the design, manufacture and maintenance of wheelsets and their compnts. Updated Railway Group Standard Title: Railway Wheelsets Number: Issue: Four Synopsis: This document sets out requirements for the design, manufacture and maintenance of wheelsets and their compnts. New Rail Industry Standard Title: Rail Industry Standard for Wheelsets Number: RST Issue: One Synopsis: This document supports and is harmonised with and sets out requirements for the design, manufacture and maintenance of wheelsets and their compnts. 1 Executive summary 1.1 The change updates Railway Group Standard (RGS) i Railway Wheelsets and publishes a new Rail Industry Standard (RIS) Rail Industry Standard for Wheelsets. Content currently in i has been reviewed to identify content that can be retained or should be withdrawn as it is now outdated or no longer applicable. 1.2 The following documents are to be withdrawn: a) GMRC2494 issue two Recommendations for Railway Wheelsets Design. b) GMRC2495 issue Recommendations for Railway Wheelset Manufacture and Assembly. c) GMRC2496 issue two Recommendations for Railway Wheelset Maintenance. d) GMGN2497 issue Guidance on Railway Wheelset Tread, Gauging and Damage Identification. 1.3 Content in the withdrawn documents set out above has been reviewed, with some of the content being integrated into and. Outdated content is withdrawn. RSSB Impact Assessment Page 1

2 1.4 Existing requirements have also been reviewed to identify those that are in scope of being included in an RGS in accordance with the RGS Code and Standards Manual (only requirements in scope of being a national rule according to European railway legislation can be included in an RGS). 1.5 Where requirements are in scope of National Technical Rules (NTRs), they are retained in. Requirements not in scope, but considered valid and useful for industry, are retained in. 1.6 Requirements that are now covered by TSI or European standards are signposted in the updated document; however, the content is reviewed so that requirements do not duplicate or conflict with European requirements where not appropriate. 2 Initiators of change 2.1 The five-year review of i, and associated documents, identified that it required updating to align with updated standards and experience gained. 2.2 Following publication of i, both the LOC&PAS TSI and Freight Wagons TSI have been revised. These TSIs now cover the entire mainline railway system, not just the trans- European network; therefore, Great Britain (GB) national rules concerning wheelsets need to align with these requirements and only include requirements that close open points, fill specific cases or are needed for technical compatibility with the GB legacy mainline network. Other requirements set out in i that do not fulfil this scope need to be either retained in an industry standard or withdrawn if they no longer represent industry practice. 2.3 In addition, there is an opportunity to incorporate the latest knowledge and good practice relating to wheelset manufacture and maintenance, including from recent research projects where new information is available that can be considered for inclusion in standards. This includes the recent work d on Economic Tyre Turning (ETT). 3 Key changes and implications for industry 3.1 New RST A significant number of requirements included in the current i have been identified as no longer being in scope of being included in an RGS. Only requirements filling the specific cases (LOC&PAS TSI clause and WAG TSI clause ) or for wheelsets permitted for national use per the provisions set out in the respective TSIs are permitted to be included in an RGS. Other requirements included in i that are considered valid and useful to industry are retained in. 3.2 New structure Requirement, Rationale, Guidance Both and have been written in the current standards document templates. Therefore, for each requirement, a rationale explaining the purpose of that requirement has been included This aims to help the user understand which requirements are relevant to their project, and should aid any hazard identification and risk assessment work that needs to be carried out when making a modification to wheelsets In addition, guidance relating to a specific requirement is now included underneath the respective requirement, rather than in a separate Guidance Note (GN). Appropriate recommendations currently included in the Wheelset RACOPs have also been integrated into the guidance where they are considered useful. RSSB Impact Assessment Page 2

3 3.3 Withdrawal of Wheelset Guidance Note and Wheelset RACOPs As a result of guidance for GB wheelset requirements now being integrated into issue four and, the separate wheelset GN (GMGN2497 issue ), and the Wheelset RACOPs (GMRC2494 issue two, GMRC2495 issue and GMRC2496 issue two) are withdrawn. Content from these documents no longer considered up to date has not been retained in the new documents Where appropriate and as detailed in the disposition table, some of the contents from the RACOPs has been reformulated as requirements rather than guidance. 3.4 Alignment with BS 5892 and BS EN A careful review of the content of has been carried out to check consistency with other applicable standards concerning wheelsets. In particular, the standard concerning materials for rolling stock compnts (BS 5892) and the European Standard on Wheelset product requirements (BS EN 13260) Where appropriate, references have been included in, as this document is intended to be able to integrate and be consistent with these requirements. The disposition table in the appendix of sets out the various clauses where such references have been added These standards represent the current domestic and European practice concerning wheelset design, manufacture, assembly and maintenance. 3.5 Updated Appendix A - Wheel Tread Profile Design Appendix A has been significantly updated to now not only include the profile in a graphical form but the coordinates for the wheel profiles are also produced. The profiles cover the wheel profiles used on the GB mainline railway. An additional new profile has been added, P10/RD9 hybrid profile, which was developed for the Class 66 freight locomotives. 3.6 Appendix D - Quenched and Tempered Monobloc Wheels Manufactured to UIC (withdrawn) Appendix D has been withdrawn as it refers to a UIC leaflet (UIC 812-3), which has now been withdrawn and is superseded by European Standards. 3.7 New Appendix B Economic Tread Turning Appendix B provides guidance on Economic Tread Turning. Significant research has been conducted on this process and guidance provides industry with the initial outputs in this area Appendix B acknowledges that there is still further research and outputs in this area to be identified. 3.8 New Clause 3.3 in A new clause is to be added, which aims to clarify where a new or modified design of a wagon can use existing wheelset designs without having to submit the wheelset to the validation requirements for new wheelset designs Wagons were not previously covered in i, and this clause supports the TSI WAG conformity assessment requirements in clause 6.2 of the WAG TSI. 4 Predicted impacts 4.1 The new structure of and the new aims to ensure GB standards: a) Requirements that serve as NTRs for wheelsets are provided in a consolidated form. RSSB Impact Assessment Page 3

4 b) Align with requirements in the LOC&PAS TSI and WAG TSI. c) Align with other British Standards and European Standards. d) Retain existing GB practice that are useful for industry to use to ensure wheelsets are constructed and maintained to an acceptable standard for use on the GB mainline railway. e) Provide rationale for each requirement to aid design and risk assessment processes. 4.2 The expected benefits of this structure ensure GB wheelset requirements do not conflict with other standards, which may cause uncertainty to industry and lead to increased costs in design and assessment. 4.3 Updated guidance and rationale provide clearer interpretation for the requirements, aiming to reduce the possibility of misinterpretation that can lead to increased costs for design and assessment. The consolidation of requirements and guidance in two documents, rather than five, should make it easier for industry to implement the requirements, and reduce administrative burdens. 4.4 Appendix A should provide industry with easier forms to utilise the wheel profiles accepted for use on the GB mainline railway, and is capable of being inputted into design software and equipment used in the industry for wheelset production and maintenance. 4.5 The requirements in the updated and new can be used to help control risks and hazards associated with wheelset design, assembly, manufacture and maintenance as these requirements are based on existing GB industry practice. Industry can adopt these documents through their safety or quality management systems. 4.6 Clause 3.3 in should help to reduce the need for freight operators and wagon manufactures to undergo costly certification and assessment processes for wheelsets that are already in use on the GB mainline railway and have a proven safety record. This should help retain the competitiveness of this sector. RSSB Impact Assessment Page 4

5 Appendix A Disposition Table and Editorial change Withdrawn Withdrawn Requirement not considered necessary to be retained as this issue is covered throughout the document Requirement not considered necessary to be retained as this issue is covered throughout the document Withdrawn Pointer to GMRC2494 superseded Updated to require the use of a consistent set of standards for axle design Added requirement to specify NDT requirements in the technical documentation Retained No change Clarified that this is wheel rim width range is for national use only as TSI is more restrictive Minor editorial change Retained No change (a) Retained (b) Retained (c) Retained Reference added to BS ISO 281 which is an accepted method for determining axle bearing design life. Improved clarity Minor editorial change to improve clarity Minor editorial change to improve clarity Minor editorial change to improve clarity Reference added to BS EN Withdrawn Pointer to sections no longer needed and Requirement split between two clauses. Clause requires BE EN A1T, A4T or A1N. Clause requires BS 5892 Part 1 Grade A1T or A4T RSSB Impact Assessment Page 5

6 Updated table to include BS 5892 Part 7 as an accepted choice for wheel steel grades. Minor editorial changes also made Withdrawn Retained No change Requirement updated to refer to hydrogen content limit set out in BS EN Required material properties are included in BS 5892 or EN Withdrawn Pointer to sections no longer needed Part and Retained Withdrawn Incorporated throughout Part 3 on Wheelset Manufacture and Assembly Clarifies which standards should be used. Clarifies which standards should be used. Added hydrogen content requirement. Minor editorial changes to improve clarity Editorial change to merge replacement tyre and retaining ring requirements into the same section Editorial change to merge replacement tyre and retaining ring requirements into the same section Editorial change to merge replacement tyre and retaining ring requirements into the same section Requirement not considered necessary as duty to for wheelsets to be produced to a safe design is a fundamental legal requirement Minor editorial changes Retained No change Minor editorial changes Part 2 Incorporated into part 2 sections on Axle Design Incorporated into maintenance sections RSSB Impact Assessment Page 6

7 Minor editorial changes Minor editorial changes Added material grades and minor editorial changes Added specific material class requirements and minor editorial changes i defines the limit for rejection, defines the limit for acceptance Minor editorial changes Withdrawn Wheelsets are already required to conform to the applicable back-to-back measurements to be approved for service. Maintenance requirement now covered in clause Wheelset Wear Measurement Updated to include additional details to improve clarity and consistent interpretation Updated to include additional details to improve clarity and consistent interpretation Clarified that the re-used wheelsets must still comply with requirements set out in clause Withdrawn Pointer to sections no longer needed Includes references to BS , and Content also incorporated from GMRC2495 issue RC020 and GMRC2495 RC022 Updated to include specific references to BS 5892 Part 6 and Part 8 and BS EN Added reference to BS 5892 Part Withdrawn This clause is made redundant by the preceding clause if of references is followed. e.g. EN states max 50g.m if V>200 RSSB Impact Assessment Page 7

8 Editorial changes to improve clarity Mainly editorial changes with references to UIC 813 removed Editorial changes to improve clarity Minor editorial changes and Part Withdrawn and Withdrawn Withdrawn Withdrawn Updated to include additional details to improve clarity and consistent interpretation Updated to include reference to Wheelset Handling RIS-2704-RST which has been published since the last issue of New part included in which sets out requirements for wheelset records Pointer removed as reference now superseded Updated to set out requirements for what the maintenance plan must detail in terms of wheelset measurement Editorial changes Pointer removed as reference now superseded Pointer removed as reference now superseded Pointer removed as reference now superseded Significant editorial changes and detail added in terms of re-profiling to provide industry with best practice for reprofiling Minor editorial changes G Retained as guidance and subsequently re-worded Minor editorial changes to table Withdrawn Pointer removed as reference now superseded Minor editorial changes to table RSSB Impact Assessment Page 8

9 Minor editorial changes to table and ; (c) and Editorial - content split between clause and for clarity Inspection of tread damage is incorporated in the section on wheel tread damage. Toe radius build up requirement retained in (c) and general buildup requirement retained in Minor editorial change and (c) Part and and and mm limit on false flange retained in Pointer to this requirement included (c) Editorial changes, mainly references updated to align with new document Now covered in updated Part 4 maintenance requirements Requirement retained in Withdrawn Editorial changes Retained No change Retained No change Requirements updated to provide more clarity on types of cracks that must be identified Background information no longer considered relevant and therefore withdrawn References updated and other minor editorial changes Withdrawn Now covered by Maintenance Plan requirements set out RST Part 4 Now presented as a table rather than bulleted list (editorial change only) Dimension ranges for steam locomotives and Eurostar removed as no longer relevant RSSB Impact Assessment Page 9

10 Now requires compliance with the maintenance plan requirements Retained and transferred to the Design section with reference to new AAR wheelsets removed a Editorial change only Editorial change only Editorial change only Retained No change Retained No change Retained No change Withdrawn and Included in examination requirements for wheelset maintenance Defects now covered in RST Appendix F issue two RC080 References added to applicable parts of BS EN and BS Requirements enhanced to improve clarity and minimise inconsistent interpretation References to applicable parts in standards added; BS 5892 and BS EN 1320 Editorial changes to confirm applicability to GB profiles and improve clarity Appendix A Appendix A New profile data included Appendix B Appendix A Appendix C Appendix C Appendix D - Withdrawn New New This clause sets out guidance for where existing wheelset designs can be used for domestic only vehicles RSSB Impact Assessment Page 10

11 2.1.2 New Appendix A.3 New New New New 3.1.1(d) 3.1.1(e) 3.1.1(f) New New New New New New New New New New New New This requirement added to ensure proven standards are used GB wheelset back to back measurement method for GB profiles clarified to avoid confusion with EN method for EN profiles issue two clause New requirement which is consistent with design requirement for wheelsets in RST clause 2.1 New requirements to demonstrate the dynamic performance of new tread profiles New requirements to demonstrate acceptance of compatibility for new tread profiles. New requirements to demonstrate wear limits to control variation of dynamic performance through the wheelset life issue two RC039 issue two RC039 issue two RC041 issue two RC048 Requires axle box design to comply with BS EN issue two RC020 New requirement which is consistent with design requirement for wheelsets in RST clause 2.1 issue two RC036 issue two RC060 RSSB Impact Assessment Page 11

12 2.7.5 New New New New New New New New New New New New New New New New New New New issue two RC058 issue two RC068 and GMRC2495 issue RC010 Content incorporated from GMRC2495 issue RC005 issue two RC113 issue two RC113 Requires replacement wheelsets to comply with BS EN 5892 Part 6 Content incorporated from GMRC2495 issue RC0017 Content incorporated from GMRC2495 issue RC017 Content incorporated from GMRC2495 issue RC016 Requirement to use the maintenance plan in accordance with BS EN issue two RC018 issue two RC020 issue two RC074 issue two RC075 issue two RC075(c) issue two clause issue two RC050 RSSB Impact Assessment Page 12

13 New New New New New New New New New New New New New New New New New issue two RC055 Requirement to define wheel tread profile inspection intervals in maintenance plan added Requirement sets criteria for when wheelsets can be used in service issue two clause issue two RC046 issue two RC050(g) issue two Table 2 issue two RC205 issue two RC073 issue two RC072 issue two clause This requirement has been added to summarise the permitted defect levels in operational service RSSB Impact Assessment Page 13

14 4.5.2 New Pointer to RIS-2701-RST added New New New New New New New New New New New New New New New New New issue two RC147 issue two RC154 issue two RC169 issue two RC144 issue two RC150 issue two RC140 issue two RC143 issue two RC150 issue two RC036 issue two RC141 issue two RC047 issue two RC166 issue two RC167 RSSB Impact Assessment Page 14

15 4.7.3 New New New New New New New New New New New New New New New New issue two RC105 issue two RC163(a) New clause permitting the use of Economic Tyre Turning for maintenance of wheel treads issue two RC091(d) issue two RC128 issue two RC129 issue two RC129 RSSB Impact Assessment Page 15

16 New New New New New New New New New New New New New New 5.1 New New New 5.3 New 5.4 New Requirement to meet criteria in BS 5892 Part 2 for re-tyring added. issue two RC055(e)(f) Requirement for maintenance plan to include axle maintenance criteria issue two RC078 issue two RC083 issue two RC094 issue two RC079(e) issue two RC016 issue two RC081 issue two RC085 issue two RC086 issue two and issue two RC059 and RC060 issue two RC061 issue two RC061 issue two clause 3.4 RSSB Impact Assessment Page 16

17 Appendix B 6.1 New New New Appendix B New Appendix C New Guidance added on conformity assessment Guidance added on conformity assessment for new wheelset designs New appendix containing requirements and guidance on economic tread turning (ETT). Content is incorporated from GMGN2497 Content is incorporated from GMGN2497 RSSB Impact Assessment Page 17