Rail Industry Standard for the Design of On- Track Machines in Travelling and Working Modes

Transcription

1 Supersedes Iss 1 with effect from 01/09/2018 for the Design of On- Track Machines in Travelling and Working Modes Synopsis This document sets out requirements and guidance for the application of the BS EN 14033:2017 series for On-Track Machines (OTMs) in their travelling and working modes on railway infrastructure in Great Britain (GB). 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. RSSB 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. Published by RSSB Copyright 2018 Rail Safety and Standards Board Limited

2 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 Issue Record Issue Date Comments One 07/09/2013 Original document. The requirements related to working and travelling modes in GMRT2400 issue four and GMRT2307 issue one have been transferred to this document. Two 01/09/2018 Replaces issue one. To align the document with BS EN series, updated in 2017, to avoid any mismatch in requirements. This document will be updated when necessary by distribution of a complete replacement. Superseded Documents The following is superseded, either in whole or in part as indicated: Superseded documents Sections superseded Date when sections are superseded issue one Rail Industry Standard for the Design of On-track Machines in Working and Travelling Modes All 01/09/2018 Supply The authoritative version of this document is available at Enquiries on this document can be submitted through the RSSB Customer Self-Service Portal Page 2 of 20 RSSB

3 Supersedes Iss 1 with effect from 01/09/2018 Contents Section Description Page Part 1 Purpose and Introduction Purpose Application of this document Health and safety responsibilities Structure of this document Approval and Authorisation 5 Part 2 General Machine Requirements General machine requirements 6 Part 3 Specific GB application of BS EN :2017 and guidance Maximum wheel loads: Clause of BS EN : Stability and safety against derailment: Clause 5.2 of BS EN : Proof of stability by test: Clause of BS EN : Working gauge: Clause of BS EN : Exhaust gases: Clause of BS EN : Minimum safety distance between machine parts and overhead line equipment: Clause of BS EN : Marker lights for warning in travelling mode: Clause of BS EN : Braking - General: Clause of BS EN : Braking Stopping distances: Clause of BS EN : System for warning in travelling mode: Clause of BS EN : Recovery conditions: Clause 5.14 of BS EN : Data recording: Clause 5.15 of BS EN : Remote control: Clause 5.19 of BS EN : Conformance to the lateral limit of work: Clause of BS EN : Maintenance instructions: Clause of BS EN : Part 4 Additional requirements to BS EN : Safety related parts of control systems Parameters which influence ground based systems Wheel entrapment guards 14 RSSB Page 3 of 20

4 Supersedes Iss 1 with effect from 01/09/ Warning notice Inter-machine electrical connections Machines fitted with toilet facilities 15 Part 5 Requirements for Compliance with the Machinery Directive Machinery directive 16 Part 6 Modifications to Machines Modifications 17 Definitions 18 References 19 Page 4 of 20 RSSB

5 Supersedes Iss 1 with effect from 01/09/2018 Part 1 Purpose and Introduction 1.1 Purpose This document provides a standard for the design of on-track machines and infrastructure inspection machines in travelling and / or working modes, for the rail industry to use if it so chooses Specific requirements for the design of on-track machines and infrastructure inspection machines in running mode are set out in GMRT Requirements for the verification of compliance to this standard are set out in RIS-1710-PLT. 1.2 Application of this document Compliance requirements and dates have not been specified because these are the subject of internal procedures or contract conditions If you plan to do something that does not comply with a requirement in this RIS, you can ask a Standards Committee to comment on your proposed alternative. If you want a Standards Committee to do this, please submit your deviation application form to RSSB. You can find further advice in the to applicants and members of Standards Committee on using alternative requirements, available from RSSB s website Health and safety responsibilities Users of documents published by RSSB 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. RSSB does not warrant that compliance with all or any documents published by RSSB is sufficient in itself to ensure safe systems of work or operation or to satisfy such responsibilities or duties. 1.4 Structure of this document This document sets out a series of requirements that are sequentially numbered. This document also sets out the rationale for the requirement, explaining why the requirement is needed and its purpose and, where relevant, guidance to support the requirement. The rationale and the guidance are prefixed by the letter G Some subjects do not have specific requirements but the subject is addressed through guidance only and, where this is the case, it is distinguished under a heading of and is prefixed by the letter G. 1.5 Approval and Authorisation The content of this document was approved by Plant Standards Committee on 12 July This document was authorised by RSSB on 31 July RSSB Page 5 of 20

6 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 Part 2 General Machine Requirements 2.1 General machine requirements Except as set out in Part 3, machines shall comply with BS EN :2017. G G G G The EN series has been prepared as a complementary suite of European Standards for On-Track Machines (OTMs) or infrastructure inspection machines. EN :2017 specifically covers the technical requirements for OTM or infrastructure inspection machines in their travelling and working modes. This document includes additional requirements and guidance; it is intended to be read in conjunction with BS EN :2017. The exceptions to BS EN :2017 are set out in this document. The definitions used in BS EN :2017 are used in this document as amended by the Definitions section. For the rest of this document, where the term machine is used, it is to be taken to mean OTM and infrastructure inspection machine. It is advantageous for machines used in the GB market to be produced to the ENs written specifically for them; the ENs have been written with considerable GB input. Page 6 of 20 RSSB

7 Supersedes Iss 1 with effect from 01/09/2018 Part 3 Specific GB application of BS EN :2017 and guidance 3.1 Maximum wheel loads: Clause of BS EN :2017 G For wheel diameters and rail with an ultimate tensile strength not set out in Tables 2 and 3, the formula given in Annex J of BS EN :2017 is used to derive the maximum load permitted for the wheel. 3.2 Stability and safety against derailment: Clause 5.2 of BS EN : Where machines incorporate lifting sub systems utilising component parts of machinery, the sub system shall have a declaration of conformity to one or more of the following: a) BS EN 280 mobile elevated work platforms. b) BS EN loader cranes. c) BS EN mobile cranes. d) BS EN cranes general design. G G The relevant European Standards are also applicable where component parts of machinery are incorporated into machines. In addition, RIS-1530-PLT sets out further guidance on lifting requirements when machines are used on rail, such as using parts of earth-moving machinery for lifting. 3.3 Proof of stability by test: Clause of BS EN : It is permissible to test the stability of a machine against less onerous track conditions than those set out in Annex F of BS EN :2017 provided this is recorded as a limitation of use when working. G G It is considered that testing on the most unfavourable track conditions is not necessary where, for example, a machine is intended only to be used on operational track. For testing of stability the most unfavourable track condition is the cumulative condition of cant, gradient and twist on degraded working track (parameters set out in Annex F of BS EN :2017). RSSB Page 7 of 20

8 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/ Working gauge: Clause of BS EN :2017 G GB has a special national condition, set out in Annex A of BS EN :2017, to not use Annex D of BS EN :2017. For Network Rail infrastructure, the gauging methodology is set out in GMRT2173. In each case the manufacturer will state the exceedance to one of the referenced profiles set out in GERT8073, for example W6a. 3.5 Exhaust gases: Clause of BS EN :2017 G G G GB has a special national condition set out in Annex A of BS EN :2017, which states 'track construction machines are to be fitted with a diesel engine'. This is only applicable where it is intended to fit an internal combustion engine. Diesel engines are required for railway use to avoid the build-up of carbon monoxide in confined spaces. The term 'track construction machines' includes all machines within the scope of EN : Minimum safety distance between machine parts and overhead line equipment: Clause of BS EN :2017 G G G G Machines in running mode are permitted to have machine parts stowed up to the maximum height of the W6a profile. The minimum energised wire height used for consideration of design of GB machines is 4165 mm as permitted by GLRT1210. Any moving part of a machine used in working mode that is capable of moving towards the overhead contact line (OCL) system that is greater than 3565 mm above rail level (which is the minimum wire height minus the 600 mm clearance) will cause that part of the machine to be declared not permitted to be used under live OCL. The use of machine parts in working modes under live OCL will need to be carefully considered. The manufacturer will provide working instructions for use of the machine, these will include: a) When only to be used with the OCL isolated and earthed b) Limitations of use for the machine under live OCL. All machines need to be operated in accordance with a safety plan accepted by the machine operating company and the infrastructure manager. Page 8 of 20 RSSB

9 Supersedes Iss 1 with effect from 01/09/ Marker lights for warning in travelling mode: Clause of BS EN : For category 3, 5 and 7 machines that are self-propelled in travelling mode, in place of clause of BS EN :2017, marker lights shall meet the requirements of rail mode lighting set out in clause of RIS-1530-PLT issue six Machines in category 1, 2, 4 and 6 which do not have a cab at each end (and hence do not have marker lights in running mode) shall have marker lights meeting the requirements of rail mode lighting set out in clause of RIS-1530-PLT issue six Machines in travelling mode, shall have headlamps fitted to the outer ends of a consist of coupled machines. The headlamps in travelling mode shall comply with either clause 13.2 of BS EN :2017 or clause of RIS-1530-PLT issue six. G G The lighting requirements for use in GB when in travelling and / or working modes are set out in RIS-1530-PLT. For example, this includes the ability to display red tail lights at each end when stationary. 3.8 Braking - General: Clause of BS EN : Any operating position that controls movement along the track in travelling mode and / or working modes shall meet the requirements of category 1, 2, 4 or 6 machines in Table 5 of BS EN : In addition to the requirements in clause of BS EN :2017 there shall be a separate independent brake capable of stopping the machine in an emergency that is available at every operating position that can initiate movement along the track Where the travelling and / or working mode direct brake operates on more than one machine the inter-machine connection shall be protected from foreseeable damage. G G G Clause of BS EN :2017 does not explicitly state that any position capable of initiating movement needs to have the means to stop this movement. There have been instances where short formation machines have had brakes rendered inoperable by collision with vegetation and debris (RAIB report 1/2018). Where clause 9 of BS EN :2017 refers to driving position, this is also considered applicable to any operating positions which control the brake in travelling and / or working mode. RSSB Page 9 of 20

10 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 G The inter-machine connection requirements are also applicable to articulated and semi-permanently coupled machines. 3.9 Braking Stopping distances: Clause of BS EN : Where the machine or consist of coupled machines / vehicles is unable to meet the slow speed braking requirements set out in Table 9 of BS EN :2017, then the instruction handbook shall include safe working instructions, which might include the need for a personnel exclusion zone around the machine. G G Track workers in a possession will generally consider that any machine is capable of achieving the slow speed braking requirements System for warning in travelling mode: Clause of BS EN : The requirement to operate a warning horn shall also include any operating position that controls movement along the track in travelling mode The warming horn shall operate at the leading end of the machine in the direction of travel. G G Clause of BS EN :2017 does not explicitly state that any position capable of initiating movement needs to be capable of sounding a warning horn Recovery conditions: Clause 5.14 of BS EN : The working limit line as specified in Annex D shall be taken as exceeding the selected GB reference profile. G G GB has a special national condition not to use BS EN :2017 Annex D. For Network Rail infrastructure, the referenced profiles are set out in GERT8073, for example W6a. Page 10 of 20 RSSB

11 Supersedes Iss 1 with effect from 01/09/ Data recording: Clause 5.15 of BS EN : The requirement for recording an overload on a machine fitted with a rated capacity indicator / limiter (RCI/RCL) shall also include the data logging values set out in clause of RIS-1530-PLT issue six. G G The recording of the lifting information is to aid post-incident investigation Remote control: Clause 5.19 of BS EN : Remote control devices that are carried shall cause the machine to cease all movements and apply the brake when the device is dropped, the person falls over, or the machine moves out of range. G G G The intention of the EN is ambiguous and this clarifies the requirement. The second paragraph of clause 5.19 of BS EN :2017, states stop machine which means cause the machine to cease all movements and apply brakes Conformance to the lateral limit of work: Clause of BS EN : The lateral limit of work given in Annex D shall be taken as laterally exceeding the selected GB reference profile. G G GB has a special national condition not to use Annex D of BS EN :2017. For Network Rail infrastructure the referenced profiles are set out in GERT8073, for example W6a Maintenance instructions: Clause of BS EN : In addition to the requirements of clause of BS EN :2017, the maintenance instructions shall cover systems and equipment used in travelling and / RSSB Page 11 of 20

12 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 or working modes, utilising the format set out in clause 20.4 of BS EN :2017 and the requirements for maintenance instructions set out in GMRT The maintenance instructions shall specifically include procedures for the dissipation of stored energy to enable safe access for maintenance. G G Clause of BS EN :2017 does not adequately cover the maintenance of machines. Page 12 of 20 RSSB

13 Supersedes Iss 1 with effect from 01/09/2018 Part 4 Additional requirements to BS EN : Safety related parts of control systems Safety related parts of control systems shall meet the requirements of clause 5.15 of BS EN :2017. Although BS EN ISO :2015 calls up the use of BS EN ISO 12100:2010, it is permitted that a similar process to that used in the Common Safety Method on Risk Evaluation and Assessment (CSM RA) used for railway locomotives and rolling stock is used to identify the safety related control systems (those not set out in Table 1 of BS EN :2017). G G G G G G Clause 5.15 of BS EN :2017 requires that safety related parts of control systems, not specifically called up in Table 1, are assessed to the requirements of BS EN ISO on compliance with the CSM RA is given in the GEGN8646. The method for validation of the safety functions and categories is set out in BS EN ISO :2012. The manufacturer needs to present an analysis that has been made to identify additional safety related parts of controls systems and associated performance levels, and for the validation of such safety related parts of the control system and overall control system safety performance. This could be achieved by using failure modes and effects analysis (FMEA), failure modes, effects and criticality analysis (FMECA), decision tree etc, which could also be supported by physical testing, as appropriate. The plant assessment body (PAB) needs to check that such analysis has been undertaken / documented and take a professional view to be satisfied that the assessment is sensible; but it is not intended that the PAB would need to repeat or carry out additional analysis to verify accuracy and completeness. The BS EN ISO :2015 process needs to be done at the initial design phase of the machine. 4.2 Parameters which influence ground based systems Where the machine in travelling or working mode is not able to comply with the requirements for safety systems, as set out in clause of GMRT2400 issue six, which operate in running mode, this shall be stated in the instruction handbook. G For operational purposes GB has recorded those safety systems that do not operate in travelling or working mode. RSSB Page 13 of 20

14 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 G Wheel entrapment guards Where any rail wheel poses a danger to the feet of personnel being trapped between the rotating wheel and rail, there shall be additional guards to prevent the trapping. G G To prevent injury GB has required fitment of wheel entrapment guards The device set out in clause 7.9 of BS EN :2017 (lifeguard) is designed for clearing the track of small obstacles. The Machinery Directive requires an assessment to mitigate personnel being trapped by moving parts. A rail wheel is an example where if it is not protected when it is in an exposed position, forward of the structure of the machine, it could trap a foot. The manufacturer needs to carry out an assessment, for example as set out in the third paragraph of clause 5.13 of BS EN : Warning notice In addition to the requirements of BS EN :2017, where the machine is not permitted to travel, self-propelled, outside of a possession, it shall be fitted with a notice(s) visible from each operating position stating, 'This machine is not permitted to be driven from this position outside of a possession'. G G This warning notice is only applicable to GB. The concept of a machine being in a possession is not generally utilised outside GB. 4.5 Inter-machine electrical connections Where inter-machine electrical connections are intended to be uncoupled (excluding for maintenance), pilot protection shall be provided where the voltage in the intermachine connectors exceeds 50 V AC or 120 V ripple free DC whether between conductors or between conductors and the frame / body of the machine Re-energisation of the power supply shall not be possible solely by the restoration of the inter-machine connectors. Page 14 of 20 RSSB

15 Supersedes Iss 1 with effect from 01/09/2018 G G The pilot protection prevents arcing and exposure of live conductors by disconnecting the supply at source if any attempt is made to separate the inter-machine connectors, and in any event before the main power-carrying contacts are separated. 4.6 Machines fitted with toilet facilities Where a machine is fitted with toilet facilities and is intended for emptying at a servicing point, the toilet system and interface connections shall comply with BS EN 16922:2017. G G This requirement provides compatibility with depot-based toilet servicing equipment. RSSB Page 15 of 20

16 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 Part 5 Requirements for Compliance with the Machinery Directive 5.1 Machinery directive The manufacturer's statement of compliance to the machinery directive shall include the manufacturer's statement confirming compliance with BS EN :2017. G G G G The EN series has been prepared as a complementary suite of European Standards for OTMs or infrastructure inspection machines. EN :2017 has been specifically published to address the hazards associated with the use of OTM or infrastructure inspection machines in the railway environment. Compliance of all machines with the Machinery Directive 2006/42/EC (enacted in GB by The Supply of Machinery (Safety) Regulations 2008) is self-declared by the manufacturer. The Machinery Directive permits the manufacturer to self-declare compliance of this type of machinery. BS EN :2017 is a harmonised standard published to provide a presumption of conformity to the Machinery Directive. The manufacturer is statutorily permitted to decide their own compliance with the Machinery Directive without reference to the harmonised standard; however, compliance with this Rail Industry Standard is contingent on compliance with BS EN :2017. The ergonomic design requirements of clause 5.3 of BS EN :2017 include the necessity to review the design of the machine in areas where personnel are permitted in travelling and / or working modes. The review needs to show that interior passive safety has been considered. Page 16 of 20 RSSB

17 Supersedes Iss 1 with effect from 01/09/2018 Part 6 Modifications to Machines 6.1 Modifications Any proposed change to a machine shall be assessed for its implications to the safety of the machine, its operating performance and railway operations Any proposed change to a machine shall also be considered in the context of other or previous changes which, when combined, could increase risk. G G G G Changes need to be assessed holistically, as required by RAIB report 09/2016 into the runaway and collision at Bryn, recommendation 3. Changes to machines in travelling and / or working modes, and / or their associated documentation, need to be carried out in accordance with the modification requirements set out in RIS-1710-PLT, with the risk assessment using the principles described in the CSM RA and RIS-2700-RST. on compliance with the CSM RA is given in GEGN8646. Note that machines in travelling and / or working modes are out of scope of RIS-2700-RST and the CSM RA; however, the principles provide good practice. Changes to machines usually also affect their running mode, for example, frame attachments, and hence should be assessed for compliance to GMRT2400. The risk assessment carried out for the proposed change needs to consider the compliance with the Machinery Directive (see 5.1 of this document), and whether a new declaration of conformity to the Machinery Directive is required. RSSB Page 17 of 20

18 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 Definitions Note: The definitions given in BS EN :2017 section 3 shall apply. Page 18 of 20 RSSB

19 Supersedes Iss 1 with effect from 01/09/2018 References The Standards Catalogue gives the current issue number and status of documents published by RSSB. This information is available from RGSC 01 RGSC 02 Railway Group Standards Code Standards Manual Documents referenced in the text Railway Group Standards GERT8073 GLRT1210 GMRT2173 GMRT2400 Requirements for the Application of Standard Vehicle Gauges AC Energy Subsystem and Interfaces to Rolling Stock Subsystem Requirements for the Size of Vehicles and Position of Equipment Engineering Design of On-Track Machines in Running Mode RSSB Documents GEGN8646 RIS-1530-PLT RIS-1710-PLT RIS-2700-RST on the common safety method for risk evaluation and assessment for Technical Requirements for On-Track Plant and their Associated Equipment and Trolleys for Engineering Certification of Railborne Plant for Verification of Conformity of Engineering Change to Rail Vehicles Other References BS EN 12999:2011+A1:2012 BS EN 13000:2010+A1:2014 BS EN BS EN 14033:2017 BS EN :2017 BS EN 16922:2017 Cranes. Loader cranes Machinery Directive 2006/42/EC (enacted in GB by The Supply of Machinery (Safety) Regulations 2008) Cranes. Mobile cranes Machinery Directive 2006/42/EC (enacted in GB by The Supply of Machinery (Safety) Regulations 2008) Cranes. General design Machinery Directive 2006/42/EC (enacted in GB by The Supply of Machinery (Safety) Regulations 2008) Railway applications - Track - Railbound construction and maintenance machines - Parts 1, 2 and 3 (2017) Automation systems and integration. Integration of advanced process control and optimization capabilities for manufacturing systems. Activity models and information exchange Railway applications. Ground based services. Vehicle waste water discharge equipment. RSSB Page 19 of 20

20 Uncontrolled when printed Supersedes Iss 1 with effect from 01/09/2018 BS EN 280:2013+A1:2015 BS EN ISO 12100:2010 BS EN ISO :2015 BS EN ISO :2012 Mobile elevating work platforms. Design calculations. Stability criteria. Construction. Safety. Examinations and tests. Safety of machinery. General principles for design. Risk assessment and risk reduction Safety of machinery. Safety-related parts of control systems. General principles for design Safety of machinery. Safety-related parts of control systems. Validation RAIB report 09/2016 Runaway and collision at Bryn station, Wigan 27 November 2014 RAIB report 01/2018 Runaway of a maintenance train near Markinch, Fife 17 October 2017 Page 20 of 20 RSSB