Engineering Design of On-Track Machines in Running Synopsis This document mandates requirements for the design of on-track machines in running mode. Copyright in the s is owned by Rail Safety and Standards Board Limited. All rights are hereby reserved. No (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 Standards, 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 s may be reproduced. Published by: Block 2 Angel Square 1 Torrens Street London EC1V 1NY Copyright 2013 Rail Safety and Standards Board Limited
record Date Comments One January 1996 Original document Two December 2002 Replaces issue one Three December 2010 Replaces issue two Includes requirements for on-track machines previously contained in GM/RT2100 issue three Four September 2011 Replaces issue three Small scale change amendment revision of 3.6 to align with the requirements in BS EN 14033. September 2013 Replaces, issue four, GM/RT2476, issue one GM/GN2575 issue two and GM/GN2576 issue one Document aligned with Conventional Rail Locomotives and Passenger Technical Specification for Interoperability (CR LOC & PAS TSI) and BS EN 14033 series. All requirements for on-track machines in running mode are now contained within this document or with specific references to other documents. Revisions have not been marked by a vertical black line in this issue because the document has been revised throughout. Superseded documents The following Railway Group documents are superseded, either in whole or in part as indicated: Superseded documents issue four, September 2011 Track Machines GM/RT2476 issue one, August 2003 On-Track Machine Requirements for Demonstrating the Reliable Operation of Track Circuits GM/GN2575 issue two, June 2004 Guidance on the Engineering Acceptance of On-Track Machines GM/GN2576 issue one, August 2003 Guidance on Vehicle Requirements for Reliable Track Circuit Operation Sections superseded Date when sections are superseded All December 2013 All December 2013 All December 2013 All December 2013 Supply issue four, GM/RT2476 issue one GM/GN2575 issue two and GM/GN2576 issue one cease to be in force and are withdrawn as of 07 December 2013. The authoritative version of this document is available at www.rgsonline.co.uk. Uncontrolled copies of this document can be obtained from Communications,, Block 2, Angel Square, 1 Torrens Street, London EC1V 1NY, telephone 020 3142 5400 or e-mail enquirydesk@rssb.co.uk. Other Standards and associated documents can also be viewed at www.rgsonline.co.uk. Page 2 of 25
Contents Section Description Page Part 1 Purpose and Introduction 4 1.1 Purpose 4 1.2 Introduction 4 1.3 Approval and authorisation of this document 5 Part 2 Design Requirements for On-track Machines 6 2.1 Structure and mechanical parts 6 2.2 Track interaction and gauging 8 2.3 Braking 10 2.4 Environmental conditions and aerodynamic effects 10 2.5 External lights and visible and audible warning devices 11 2.6 Traction and electrical equipment 11 2.7 Driver's cab and driver-machine interface 12 2.8 Fire safety and evacuation 14 2.9 Design for rescue purposes 14 2.10 Marking and registration 14 2.11 Demountable modules 15 Part 3 Documentation 16 3.1 Maintenance 16 3.2 Operating instructions 16 Part 4 Application of this document 17 4.1 Application - infrastructure managers 17 4.2 Application - railway undertakings 17 4.3 Health and safety responsibilities 17 Appendices Appendix A Track Twist Geometry 18 Appendix B Obstacle Deflectors 19 Appendix C List of s for which On-Track Machines are removed from scope 21 Definitions 22 References 23 Figures Figure 1 Exhaust outlet 12 Figure 2 Track twist geometry 18 Page 3 of 25
Part 1 Purpose and Introduction 1.1 Purpose 1.1.1 This document mandates requirements for the design of on-track machines when they are in running mode. 1.1.2 This document is the national technical rule (NTR), which is able to be used as an alternative standard instead of the CR LOC & PAS TSI as permitted by the CR LOC & PAS TSI clause 7.1.1.3. 1.2 Introduction 1.2.1 Background 1.2.2 Principles 1.2.1.1 The production of issue five takes into account the Technical Specifications for Interoperability (TSI) and Euronorms (ENs). has been rewritten using the headings set out in the CR LOC & PAS TSI and mandates the requirements of BS EN 14033-1:2011, BS EN 14033-2:2008+A1:2011 and BS EN 14033-3:2009+A1:2011 and a number of other ENs. 1.2.1.2 Where ENs are considered complete and a suitable substitute for Railway Group Standards, reference to the EN is made. 1.2.2.1 The requirements of this document are based on one of the following principles: a) All new on-track machines are manufactured in compliance with the CR LOC & PAS TSI for running mode. Or b) The new on-track machine is designed to this standard as permitted by CR LOC & PAS TSI clause 7.1.1.3. 1.2.2.2 Notwithstanding the stated scope of other s (see Appendix C), this document provides all the necessary technical requirements for the design of on-track machines. 1.2.3 Related requirements in other documents 1.2.3.1 On-track machines are out of scope of all RGSs except for RGSs explicitly mandated in this document. For information, Appendix C sets out a list of the RGSs for which on-track machines are removed from scope following the compliance date of this standard. 1.2.3.2 The following RGS, which describe processes, remain applicable to on-track machines as the situation arises: GE/RT8106 GE/RT8250 GE/RT8270 GM/RT2273 Management of Safety Related Control, Command and Signalling (CCS) System Failures Reporting High Risk Defects Assessment of Compatibility of Rolling Stock and Infrastructure Post Incident and Post Accident Testing of Rail Vehicles 1.2.4 Supporting documents Page 4 of 25
1.2.4.1 The following Rail Industry Standard complements this : RIS-1702-PLT Rail Industry Standard for the Design of On-track Machines in Working and Travelling s 1.3 Approval and authorisation of this document 1.3.1 The content of this document was approved by Plant Standards Committee on 12 June 2013 and Rolling Stock Standards Committee on 28 June 2013. 1.3.2 This document was authorised by on 23 July 2013. Page 5 of 25
Part 2 Design Requirements for On-track Machines 2.1 Structure and mechanical parts 2.1.1 Mechanical interfaces 2.1.1.1 The intention of section 2.1.1 of this document is that the end coupling system of on-track machines, where fitted, is designed to transmit, safely and without suffering significant permanent deformation all sustained and shock loads that arise between it and other rail vehicles, including on-track machines associated with: a) Coupling and uncoupling. b) Traction and braking. c) Traversing curved track. d) Vertical changes in alignment. e) Shock loads caused by play and flexibility in the train coupling, drawgear and buffers, if fitted. 2.1.1.2 The coupling system, with the exception of buffers, shall engage positively with the coupling system of any rail vehicle to which it is intended to couple. 2.1.1.3 The design of the system shall ensure that it is possible to determine that the coupling systems are positively engaged, either directly or by a suitable system of indication. 2.1.1.4 Except as set out in 2.1.1.5 of this document, the coupling systems, with the exception of buffers, shall be designed to remain positively engaged over the limiting values for track features set out below, for each feature separately: a) Minimum horizontal track radius of 80 m. b) Minimum horizontal track reverse radii each of 80 m with a 3 m intermediate straight. c) Minimum vertical track radius, concave and convex of 500 m. d) Maximum installed cant of 200 mm. e) Maximum cant gradient of 1 in 400. f) Maximum track twist as set out in Appendix A. 2.1.1.5 Where an on-track machine is unable to meet the limiting values set out in 2.1.1.4 of this document, the limitation(s) shall be stated in the operating instructions, as set out in Part 3. 2.1.1.6 The limiting value of track features that coupling and uncoupling is possible for the particular on-track machine shall be stated in the operating instructions. 2.1.1.7 Systems that control the operation of the coupling or uncoupling system shall be protected from reasonably foreseeable interference that could result in the system's inadvertent or malicious operation. 2.1.1.8 The design of the coupling system shall allow manual uncoupling of the coupling system when the systems normally required for uncoupling are unavailable. Page 6 of 25
2.1.1.9 Drawgear and its attachments to an on-track machine body shall be designed to fail at a lower tensile load than that for the primary structure of the machine. 2.1.1.10 Drawgear designed to be capable of transferring shear forces between adjacent vehicles shall withstand, without significant permanent deformation, the transfer of 100 kn in both the vertical and transverse directions simultaneously. 2.1.1.11 Inner couplings between different on-track machines of a fixed formation train shall be designed to withstand the forces due to the intended operating conditions, as stated in the operating instructions, see Part 3 of this document. 2.1.1.12 If vehicles of an on-track machine are permanently coupled together, the coupling systems between the vehicles shall be designed to withstand forces greater than the couplings and buffers at the ends of the on-track machine. 2.1.1.13 For articulated on-track machines, the joint between two parts of a machine which share the same running gear shall comply with the requirements of BS EN 12663-1:2010 clause 6.5.3 and clause 6.7.5. 2.1.1.14 On-track machines not equipped with any end coupling feature shall be capable of being attached to a rescue railway vehicle in the event of failure or breakdown. The design shall include an operable failsafe through brake system between the on-track machine and the rescuing rail vehicle that automatically applies the brakes in the event of a breakaway. 2.1.1.15 The coupling system shall, as a minimum, be designed such that it does not require any human presence between them whilst either the on-track machine or vehicle is moving. Note: The Supply of Machinery (Safety) Regulations 2008 sets out the requirement that the coupling system is designed such that employees are not exposed to undue risk during coupling and uncoupling, or rescue operations. 2.1.1.16 If an on-track machine is fitted with buffers, then under all load conditions, the buffer height shall be within the range of 940 mm and 1065 mm. 2.1.2 Strength of vehicle structure 2.1.2.1 The static frame strength of on-track machines shall comply with BS EN 14033-1:2011, clause 6.2. In addition on-track machines with a driving cab shall meet the requirements of BS EN 12663:2010 clause 6.2.3 and for Table 6 and Table 7 only shall be considered as category L. 2.1.2.2 The dynamic frame strength of on-track machines shall comply with BS EN 12663-1:2010, clause 6.6. 2.1.2.3 Attachments to the on-track machine frame, including bogie attachments, shall comply with BS EN 12663-1:2010 clause 6.5.2 and clause 6.7. 2.1.2.4 Bogies and axlebox equipment shall comply with BS EN 13749:2011 clause 4. Axleboxes and equipment fitted to non-bogied on-track machines shall also comply with BS EN 13749:2011 clause 4. The validation of these requirements shall comply with BS EN 13749:2011 clause 6.2. 2.1.2.5 For on-track machines that include a bogie frame, the integrity of the structure of the bogie frame, all attached equipment and body to bogie connections shall be demonstrated using one of the methods set out in BS EN 13749:2011 clause 6.2. 2.1.2.6 In the application of the load cases referred to in BS EN 13749:2011, the exceptional payload shall be taken as the fully laden condition. Page 7 of 25
2.1.2.7 The hypothesis taken to evaluate the loads due to bogie running (formulas and coefficients), set out in BS EN 13749:2011 Annex C, shall be stated in the technical file. 2.1.2.8 All roofs over areas designed to be occupied by people shall resist the penetration into the on-track machine of a concrete cube weighing 100 kg dropped from a height of 3.0 m above the roof. The cube shall be dropped so that a flat surface hits the roof. 2.1.3 Lifting and jacking 2.1.3.1 Lifting and jacking points on on-track machines shall comply with BS EN 14033-1:2011 clause 6.3. Brackets used for re-railing shall either conform to the options given in pren 16404:2012 or if different to those choices the, brackets shall be carried on the on-track machine. 2.1.4 Access doors 2.1.4.1 External on-track machine doors and their mountings shall withstand the following separate proof load cases without significant permanent deformation or loss of normal function: a) A concentrated perpendicular load of 2.5 kn applied over an area of 0.1 m x 0.1 m, acting from within the vehicle. The door structure shall be capable of withstanding this load at any position on the surface of the door. b) An external surface pressure load of 2.5 kpa. c) The inner surface pressure load of 2.5 kpa, applied over the internal surface of the door plus a concentrated perpendicular load, acting from within the vehicle, of 0.8 kn applied over an area of 0.1 m x 0.1 m. The structure shall be capable of withstanding the concentrated load at any position on the surface of the door. 2.1.4.2 External doors for use by personnel for access and egress directly from and to the track shall withstand as an ultimate load case a sustained pressure of 3 kpa over its internal surface. It is permissible for the door and associated components not to remain operational after the application of this load. 2.1.4.3 In addition, on-track machine personnel access doors shall comply with BS EN 14033-1:2011 clause 14.2.3 and clause 15.2 (second paragraph). 2.1.5 Mechanical characteristics of glass (other than windscreens) 2.1.5.1 All side windows shall comply with BS EN 14033-1:2011 clause 14.3.5. In this case 'safety' glass shall either be laminated or toughened glass. 2.1.5.2 Glass used in roofs shall comply with 2.1.2.8 of this document. 2.1.6 Obstacle deflectors 2.1.6.1 If a self-propelled on-track machine is designed with a maximum speed in excess of 145 km/h, it shall be fitted with obstacle deflectors that comply with Appendix B. 2.2 Track interaction and gauging 2.2.1 Gauging 2.2.1.1 The swept envelope of on-track machines in running mode shall be determined by the process set out in GM/RT2149. Page 8 of 25
2.2.1.2 When the on-track machine is in running mode, any equipment capable of moving outside its normal swept envelope shall comply with BS EN 14033-1:2011 clause 5.2 and clause 15.2, fourth sentence. When in use, all retention devices of the equipment being retained shall withstand the foreseeable forces encountered during normal operation or accidental operation. 2.2.1.3 Pantographs shall not be deployable in running mode. 2.2.2 Axle load and wheel load 2.2.2.1 Axle loads and track loading forces in running mode shall comply with BS EN 14033-1:2011 clause 7.6 and GM/TT0088. Note: GE/RT8006 (which is referred to in BS EN 15528:2008 which itself is referred to in BS EN 14033-1:2011 clause 7.6) sets out specific requirements for the assessment of compatibility between the static load characteristics of the on-track machine and the capacity of underline bridges to carry the vertical static and dynamic loads imposed by the on-track machine. 2.2.3 Parameters which influence ground based systems 2.2.3.1 For the ability to actuate track circuits, axle-counters and treadles, on-track machines intended to self-propel outside possessions shall comply with BS EN 14033-1:2011 clause 7.6 and clause 11. In addition the following standards shall apply to on-track machines where applicable: a) GE/RT8018. b) GE/RT8026. c) GE/RT8075. d) GE/RT8080. e) GK/RT0028. f) GK/RT0036. g) GK/RT0054. h) GM/RT2461. 2.2.3.2 There are special national conditions contained within BS EN 14033-1:2011, Annex B. Two of the conditions mandate the use of GM/RT2185 and GM/RT2476, on-track machines are not required to comply with these special national conditions. 2.2.4 Dynamic behaviour Note: The on-track machine should be compatible with the signalling system for which it is intended to be operated. Consideration should be given to the need to fit ERTMS / ETCS, and where fitted it should comply with the requirements in RIS-0340-CCS. 2.2.4.1 On-track machines shall comply with BS EN 14033-1:2011, clause 8. The acceptance criteria when carrying out simulation is also permitted to be as detailed in GM/RT2141 Appendix D. 2.2.5 Running gear 2.2.5.1 Wheelsets fitted to on-track machines for use in running mode shall comply with GM/RT2466. Page 9 of 25
2.2.6 Minimum curve radius 2.2.6.1 On-track machines, in running mode, shall be designed to negotiate a 500 m radius vertical curve. 2.2.7 Life guards 2.2.7.1 On-track machines shall comply with BS EN 14033-1:2011 clause 7.8. 2.2.8 Electro-magnetic compatibility 2.2.8.1 On-track machines shall comply with BS EN 14033-1:2011 clause 15.4. 2.2.9 Protection measures from electrical traction equipment 2.3 Braking 2.3.1 General 2.2.9.1 On-track machines shall comply with BS EN 14033-2:2008+A1:2011 clause 5.8. 2.3.1.1 The brakes on on-track machines, in running mode and when working outside of a possession if designed for working at speeds greater than 30 km/h, shall comply with BS EN 14033-1:2011 clause 9. The performance parameters shall be as set out in GM/RT2042 or GM/RT2043 as applicable. 2.3.2 Parking brake Note: BS EN 14033-1:2011 clause 9.2.1 and clause 9.2.3 provides two special national conditions for the United Kingdom to comply with GM/RT2045. 2.3.2.1 Each on-track machine shall be fitted with a parking brake. 2.3.2.2 Any vehicle within an on-track machine, which is permitted to be coupled or uncoupled during normal operation, shall be fitted with a parking brake. 2.3.2.3 The parking brake shall comply with BS EN 14033-1:2011 clause 9.2.5.2. 2.3.3 Brake data 2.3.3.1 Brake force data shall be calculated in accordance with the requirements of GM/RT2040. Note: The brake force data is supplied to the Rolling Stock Library as set out in GM/RT2453. 2.4 Environmental conditions and aerodynamic effects 2.4.1 Environmental conditions 2.4.1.1 On-track machines shall comply with BS EN 14033-1:2011 clause 16.1, clause 16.2 and clause 16.3. 2.4.1.2 Fuel tanks shall not be located ahead of a leading axle. 2.4.2 Aerodynamic effects 2.4.2.1 On-track machines shall comply with the requirements of GM/RT2142. 2.4.2.2 On-track machines, with a maximum speed greater than 130 km/h, shall not generate a peak to peak pressure pulse from any part of the machine (including nose to nose connections) greater than 1.44 kpa. The peak to peak pressure pulse shall be measured in the open air on a calm day at height of maximum body width on the side of a stationary train on a straight stretch of adjacent track. Page 10 of 25
2.4.2.3 For on-track machines with a maximum speed greater than 130 km/h, the most likely maximum pressure loadings, including the transient pressure loadings caused by an on-track machine entering and passing through tunnels, shall be determined. These transient pressure loadings are affected by speed, length and aerodynamic characteristics of the on-track machine and by the tunnel geometry. An on-track machine shall sustain such loadings without damage or significant permanent deformation. 2.5 External lights and visible and audible warning devices 2.5.1 External lights 2.5.1.1 External lighting on on-track machines shall comply with BS EN 14033-1:2011 clause 13.2 and BS EN 14033-3:2009+A1:2011 clause 5.26. 2.5.2 Visible warning 2.5.2.1 On-track machines shall comply with BS EN 15153-1:2013. 2.5.3 Horn (audible warning device) 2.5.3.1 Where intended for use in Great Britain (GB) only, on-track machines shall comply with GM/RT2484. On-track machines intended for international use shall comply with the horn sound pressure levels as set out in in BS EN 15153-2:2013. 2.6 Traction and electrical equipment 2.6.1 Traction drive systems 2.6.1.1 Where provided, the traction drive system shall be capable of moving the on-track machine in both tare and fully laden conditions, independently of any external source of power, in a smooth and progressive manner between 'creep' and 'full' speed, without wheel spin, in normal adhesion conditions ( = 0.1) on level track. 2.6.1.2 Traction drive systems shall be arranged such that identical performance is obtainable in each direction. 2.6.1.3 No single point failure shall result in the unintentional movement of the on-track machine. 2.6.1.4 Traction drive systems designed for multiple working, where the leading on-track machine operates the system in a connected trailing on-track machine, shall be matched to comply with 2.6.1.1 of this document. 2.6.2 Diesel engines used for traction 2.6.2.1 On-track machines shall comply with BS EN 14033-1:2011 clause 16.4. Except where otherwise permitted by BS EN 14033-1:2011 clause 16.4, the exhaust outlets shall be as shown in Figure 1. Page 11 of 25
Figure 1 Exhaust outlet 2.6.3 Equipotential bonding 2.6.3.1 On-track machines shall comply with BS EN 14033-1:2011 clause 15.1. 2.7 Driver's cab and driver-machine interface 2.7.1 Driver s cab 2.7.1.1 The driver's cab shall be designed to accommodate, as a minimum, the driver and a second person. 2.7.1.2 Except as set out in 2.7.1.3, the second person's position shall comply with BS EN 14033-1:2011 clause 14.10.3. 2.7.1.3 It is permissible for the second person's position not to have the capability to activate safety system controls. Page 12 of 25
2.7.1.4 For access to and egress from the driving cab(s), on-track machines shall comply with BS EN 14033-1:2011 clause 14.2. It is permissible to: a) Consider BS EN 14033-1:2011 Annex E as an informative annex with regard to the dimensions given. b) Have a walkway headroom of less than 2000 mm as set out in RIS-1702-PLT clause 3.2.1. 2.7.1.5 The forward visibility shall comply with BS EN 14033-1:2011 clause 14.6. Where an on-track machine is not fitted with buffers, the distance in front of the on-track machine shall be taken from a plane 300 mm in front of the front of the on-track machine. 2.7.1.6 The interior layout of the driving cab shall comply with BS EN 14033-1:2011 clause 14.3.3, clause 14.7 and clause 14.8, except that the direction of the power brake controls is permitted to be varied for compatibility with existing machines. 2.7.1.7 The driver's and second person's seats shall comply with BS EN 14033-3:2009+A1:2011 clause 5.5. 2.7.1.8 The driver's cab heating, cooling and ventilation shall comply with BS EN 14033-1:2011 clause 14.4. 2.7.1.9 The driver's cab internal lighting shall comply with BS EN 14033-1:2011 clause 14.5. 2.7.1.10 All forward facing surfaces, except as set out in 2.7.2.1 of this document, of on-track machines occupied by people shall have sufficient impact strength to resist penetration of a sharp cornered hollow steel cube having sides of 70 mm to 75 mm and a mass of 0.9 kg and travelling at twice the maximum operating speed of the on-track machine. 2.7.2 Windscreen 2.7.2.1 The windscreen and forward facing windows in the driving cab and any compartment occupied when in running mode shall comply with BS EN 14033-1:2011 clause 14.3.4. 2.7.3 Driver machine interface 2.7.3.1 The controls in the driving cab shall comply with 2.7.1.6 of this document and BS EN 14033-1:2011 clause 14.10. 2.7.3.2 On-track machine drivers' cabs shall be designed to permit operation by a single driver. 2.7.3.3 The maximum noise level permitted in the cab is set out in the Conventional Rail Noise TSI (CR NOI TSI). 2.7.3.4 The acoustic characteristics of the driving cabs shall be such that exploding detonators, as specified in BR 0640A, are heard inside the cab at any vehicle speed and readily distinguished from background noise. 2.7.4 Onboard tools and portable equipment 2.7.4.1 Each driving cab shall be provided with the equipment set out in BS EN 14033-1:2011 Annex J. Page 13 of 25
2.7.5 Recording device 2.7.5.1 On-track machines with a driving cab shall be fitted with an on-train monitoring recorder (OTMR). The OTMR shall comply with GM/RT2472. 2.8 Fire safety and evacuation 2.8.1 Fire safety and evacuation protection on on-track machines shall comply with BS EN 14033-2:2008+A1:2011 clause 5.9. Note: BS EN 14033-2:2008+A1:2011 clause 5.9 refers to the term 'operator', this means the driver when the on-track machine is in running mode. 2.8.2 The selection of materials used to construct machines shall comply with EN 45545-2:2013. On-track machines shall correspond to operational category 1. 2.9 Design for rescue purposes 2.9.1 To enable the safe removal of the machine clear of the line, failed on-track machines shall be capable of being coupled to a locomotive fitted with a drawhook that complies with BS EN 15566:2009+A1:2010 clause 5.2. 2.9.2 It shall be possible (where not prevented by damage to the brake system) to release and apply the brakes of the combined train when the assisted on-track machine is coupled to the assisting train or locomotive. The brake system shall be designed to apply the brakes in the event of the combined train parting. 2.9.3 Where the on-track machine is designed to be recovered by use of an emergency tow bar, then the emergency tow bar shall: a) Be carried on the on-track machine. b) Be designed to be fitted by one person. c) Accept the forces and movements involved in the recovery of the on-track machine, without significant permanent deformation or damage. 2.9.4 Where the on-track machine is designed to be recovered involving the use of special brake hoses, then the special brake hoses shall: a) Be carried on the on-track machine. b) Be designed to be fitted by one person. 2.9.5 It shall be possible to return the on-track machine to running mode in the event of failure of the primary power source. All equipment required for emergency stowage shall be supplied as part of the on-track machines tool kit, together with suitable provision for it to be carried on the machine. 2.10 Marking and registration 2.10.1 On-track machines shall comply with the requirements for markings set out in BS EN 14033-1:2011 clause 17 and BS EN 14033-3:2009+A1:2011 clause 8.2. 2.10.2 On-track machines shall comply with the requirements for an overhead line equipment warning line set out in GM/RT2181. 2.10.3 On-track machines shall comply with GM/RT2453. Page 14 of 25
2.11 Demountable modules 2.11.1 A demountable module shall be assessed as part of the on-track machine to all relevant parts of when any of the following apply: a) It has been manufactured or modified to suit the particular on-track machine or type of on-track machine. b) It is used to carry personnel during running or travelling. c) It is positioned on the on-track machine by other than gravity or twist locks. d) It has electrical, pneumatic or hydraulic connections to the on-track machine. e) It is connected to the on-track machine by twist locks and is used for lifting any load. f) It is connected to the on-track machine by twist locks and has moveable components which are able to exceed the gauge profile of the on-track machine. Page 15 of 25
Part 3 Documentation 3.1 Maintenance 3.1.1 Maintenance documentation for on-track machines shall be provided and comply with GM/RT2004. 3.2 Operating instructions 3.2.1 Operating instructions shall comply with BS EN 14033-1:2011 Annex G, BS EN 14033-2:2008+A1:2011 clause 7 and BS EN 14033-3:2009+A1:2011 clause 8. 3.2.2 The operating instructions shall also include the following: a) The limiting value of track features for the coupling system, as set out in 2.1.1.5 of this document. b) The limiting value of track features for the coupling and uncoupling action, as set out in 2.1.1.6 of this document. c) Design operating conditions, as set out in 2.1.1.11 of this document. d) The swept envelope of the on-track machine in running mode, as set out in 2.2.1.1 of this document. e) The fitting instructions and any limitations on movement of the on-track machine and operation arising from the use of the emergency tow bar, as set out in 2.9.3 of this document. f) The fitting instructions and any limitations on movement and operation of the on-track machine arising from the use of the special brake hoses or other connections, as set out in 2.9.4 of this document. Page 16 of 25
Part 4 Application of this document 4.1 Application - infrastructure managers 4.1.1 There are no requirements applicable to infrastructure managers. 4.2 Application - railway undertakings 4.2.1 Scope 4.2.1.1 The requirements of this document apply to all new on-track machines. 4.2.1.2 The requirements of this document apply to all modifications of on-track machines. 4.2.1.3 Where an on-track machine is subject to modification or upgrade and the nature of the modification or upgrade provides a reasonable opportunity to bring the on-track machine into conformity, then the requirements of this document applicable to the alteration apply. 4.2.2 Exclusions from scope 4.2.2.1 There are no exclusions from the scope specified in 4.2.1 for railway undertakings. 4.2.3 General compliance date for railway undertakings 4.2.3.1 This comes into force and is to be complied with from 07 December 2013, except as specified in 4.2.4. Where the dates specified in 4.2.4 are later than the above date, this is to allow railway undertakings sufficient time to achieve compliance with the specified exceptions. 4.2.3.2 After the compliance dates, or the date by which compliance is achieved if earlier, railway undertakings are to maintain compliance with the requirements set out in this. Where it is considered not reasonably practicable to comply with the requirements, permission to comply with a specified alternative should be sought in accordance with the s Code. 4.2.4 Exceptions to general compliance date 4.2.4.1 It is permissible for on-track machines to continue to be built to the standard in force at the time of signing a contract, where that contract has already been signed by the date of implementation of this standard. 4.3 Health and safety responsibilities 4.3.1 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. Page 17 of 25
Appendix A Track Twist Geometry The content of this appendix is mandatory. Figure 2 Track twist geometry 1º = Long wave length track twist angle between running rails = 1:300 2º = Short wavelength track twist angle between running rails = 1:150 T = Semi-span of short wavelength discontinuity 6 m Note: The short wavelength discontinuity can occur at any position relative to the on-track machine as the on-track machine moves over it. Page 18 of 25
Appendix B Obstacle Deflectors The content of this appendix is mandatory. B.1 Technical requirements for obstacle deflectors B.1.1 Obstacle deflectors are fitted with the aim of minimising the risk of derailment in the event of a collision between the train and a large obstacle such as an animal or car on the track. B.1.2 B.1.3 B.1.4 B.1.5 Obstacle deflectors shall be fitted to all leading on-track machines with a maximum operational speed of 145 km/h or above, unless the axleload of the leading bogie is 170 kn or more, or if operation is exclusively on third-rail d.c. lines. For on-track machines with axleloads less than 170 kn, which operate only on third-rail d.c. lines, obstacle deflectors shall be fitted if the maximum operating speed is greater than 160 km/h. Obstacle deflectors shall be mounted on the on-track machine body structure and not on bogies. Where the maximum operational speed is greater than 160 km/h, the axleloads of the leading bogie of the leading on-track machine shall be at least 120 kn. An obstacle deflector shall: a) Be as wide as practicable within the on-track machine profile, extend as low as safely possible within the infrastructure clearances (GM/RT2149 sets out the clearances) and be angled symmetrically in plan view about the on-track machine centreline to produce an included angle of 160. b) Be vertical in elevation. A concave forward face, symmetrical about a horizontal axis, is permissible. c) Be able to resist as a proof load a static longitudinal force applied uniformly over the complete leading surface of the deflector of: i) 300 kn for a maximum operating speed of 145 km/h. ii) iii) iv) 375 kn for a maximum operating speed of 160 km/h. 450 kn for a maximum operating speed of 175 km/h. 600 kn for a maximum operating speed of 200 km/h and over. d) Be able to resist as a proof load a static longitudinal force, applied at any position along its bottom edge (distributed over a distance of 500 mm) of: i) 300 kn for a maximum operating speed of 145 km/h. ii) iii) iv) 375 kn for a maximum operating speed of 160 km/h. 450 kn for a maximum operating speed of 175 km/h. 600 kn for a maximum operating speed of 200 km/h and over. Page 19 of 25
e) For on-track machines with a maximum operating speed of 200 km/h or less, be designed so that progressive collapse starts at a static longitudinal force applied at any position along its bottom edge (distributed over a distance of 500 mm) of at least the appropriate value in B.1.4 d) and continues with a force of 80 % or more of this value over a longitudinal deflection of at least 150 mm. f) For on-track machines with a maximum operating speed of greater than 200 km/h up to and including 225 km/h, be designed so that progressive collapse starts at a static longitudinal force, applied at any position along its bottom edge (distributed over a distance of 500 mm) of at least the appropriate value in B.1.4 d) and continues so as to absorb at least: i) 100 kj over a longitudinal deflection of at least 150 mm. g) Be designed so that, if it is permanently deformed by an impact, no part of it shall foul the infrastructure or running gear or interfere with the operational performance of the bogie. B.1.6 The underneath of the on-track machine body, forward of the deflector, shall be designed so as not to impede the flow or ejection of debris from the deflector. Page 20 of 25
Appendix C List of s for which On-Track Machines are removed from scope The content of this appendix is for information purposes. C.1.1 From the publication of this standard, the following s do not apply to on-track machines: a) GE/RT8014. b) GE/RT8015. c) GM/RT2000. d) GM/RT2001. e) GM/RT2100. f) GM/RT2130. g) GM/RT2141. h) GM/RT2160. i) GM/RT2161. j) GM/RT2162. k) GM/RT2176. l) GM/RT2185. m) GM/RT2190. n) GM/RT2304. o) GM/RT2483. Page 21 of 25
Definitions Coupling system The mechanical system, including buffers where fitted, drawgear and gangway where fitted, that connects two rail vehicles together, and the electrical and pneumatic connections where fitted between vehicles. Drawgear A set of fittings used to connect railway vehicles for the purpose of transmitting longitudinal forces between adjacent vehicles, connection can be made manually or automatically. Driving Moving the on-track machine self-propelled in running mode. Driving cab The place from where the on-track machine is controlled for movement in running mode when self-propelled. Fixed formation Two or more on-track machines semi-permanently coupled and that can only be worked together. On-track machine Any rail-mounted machine, whose primary function is for the renewal, maintenance, inspection or measurement of the infrastructure. Operating instructions The instruction handbook provided by the manufacturer detailing the on-track machine design options and working instructions, including details of any operating restrictions. Running An on-track machine is considered to be in running mode when its suspension allows movement along the track, all moveable parts stowed within the applicable gauge and the on-track machine interacting with the signalling and control systems. Travelling An on-track machine is considered to be in travelling mode when its suspension allows movement along the working track, all moveable parts stowed within the applicable gauge, the machine does not require to interact with the signalling and control systems (in this condition there is no need to ensure operation of signalling systems or for cab based signalling equipment). An on-track machine in travelling mode does not need to meet the operational requirements for the movement of trains on the railway network Technical Specification for Interoperability (TSI) A TSI is a specification adopted in accordance with the European Interoperability Directive by which each subsystem or part subsystem is covered in order to meet the essential requirements and ensure the interoperability of the rail system. Working The use of an on-track machine to perform any of its permitted design tasks outside and inside of a possession. As soon as a machine is unpacked it is in working mode. Page 22 of 25
References The Catalogue of s gives the current issue number and status of documents published by. This information is also available from www.rgsonline.co.uk. RGSC 01 RGSC 02 s Code The Standards Manual Documents referenced in the text s GE/RT8006 GE/RT8014 GE/RT8015 GE/RT8018 GE/RT8026 GE/RT8075 GE/RT8080 GE/RT8106 GE/RT8250 GE/RT8270 GK/RT0028 GK/RT0036 GK/RT0054 GM/RT2000 GM/RT2001 GM/RT2004 GM/RT2040 GM/RT2042 GM/RT2043 GM/RT2045 GM/RT2100 GM/RT2130 GM/RT2141 GM/RT2142 GM/RT2149 GM/RT2160 GM/RT2161 Assessment of Compatibility of Rail Vehicle Weights and Underline Bridges Axlebox Condition Monitoring - Hot Axlebox Detection Electromagnetic Compatibility between Railway Infrastructure and Trains Mechanical Trainstop Systems Safety Requirements for Cab Signalling Systems AWS and TPWS Interface Requirements Train Radio Systems for Voice and Related Messaging Communications Management of Safety Related Control, Command and Signalling (CCS) System Failures Reporting High Risk Defects Assessment of Compatibility of Rolling Stock and Infrastructure Infrastructure Based Train Detection Interface Requirements Transitions Between Signalling Systems Radio Electronic Token Block Engineering Acceptance of Rail Vehicles Design Scrutiny for the Engineering Acceptance of Rail Vehicles Rail Vehicle Maintenance Calculation of Brake Force Data for Rolling Stock Library Braking System Requirements and Performance for Traction Units Braking System and Performance for Freight Trains Braking Principles for Rail Vehicles Requirements for Rail Vehicle Structures Vehicle Fire, Safety and Evacuation Resistance of Railway Vehicles to Derailment and Roll- Over Resistance of Railway Vehicles to Roll-Over in Gales Requirements for Defining and Maintaining the Size of Railway Vehicles Environment Inside Railway Vehicles (Audibility of detonators) Requirements for Driving Cabs of Railway Vehicles Page 23 of 25
GM/RT2162 GM/RT2176 GM/RT2181 GM/RT2185 GM/RT2190 GM/RT2273 GM/RT2304 GM/RT2453 GM/RT2461 GM/RT2466 GM/RT2472 GM/RT2476 GM/RT2483 GM/RT2484 GM/TT0088 documents GM/GN2575 GM/GN2576 RIS-0340-CCS RIS-1702-PLT Traincrew Access to and Egress from Railway Vehicles Air Quality and Lighting Environment for Traincrew Inside Railway Vehicles Overhead Line Equipment (O.L.E.) Warning Line on Traction and Rolling Stock Train Safety Systems Compatibility Requirements for Rail Vehicle Couplings and Interconnectors Post Incident and Post Accident Testing of Rail Vehicles Equipotential Bonding of Rail Vehicles to Running Rail Potential Registration, Identification and Data to be Displayed on Rail Vehicles Sanding Equipment Fitted to Multiple Units and On-Track Machines Railway Wheelsets Data Recorders on Trains - Design Requirements On-Track Machine Requirements for Demonstrating the Reliable Operation of Track Circuits Visibility Requirements for Trains Audibility Requirements for Trains Permissible Track Forces for Railway Vehicles Guidance on the Engineering Acceptance of On-Track Machines Guidance on Vehicle Requirements for Reliable Track Circuit Operation Rail Industry Standard for Onboard ETCS Rail Industry Standard for the Design of On-Track Machines in Working and Travelling s Other references BR 0640A BS EN 12663-1:2010 BS EN 13749:2011 Specification for Railway Detonators, Single Chamber Type for Hand or Machine Placing (1964) Railway applications Structural requirements of railway vehicle bodies, Part 1: Locomotives and passenger rolling stock (and alternative method for freight wagons) Railway applications - Wheelsets and bogies - Method of specifying the structural requirements of bogie frames BS EN 14033-1:2011 Railway applications - Track - Railbound construction and maintenance machines - Part 1: Technical requirements for running BS EN 14033-2:2008+A1:2011 Railway applications - Track Railbound construction and maintenance machines, Part 2: Technical requirements for working BS EN 14033-3:2009+A1:2011 Railway applications - Track Railbound construction and maintenance machines, Part 3: General safety requirements Page 24 of 25
BS EN 15153-1:2013 BS EN 15153-2:2013 BS EN 15528:2008 BS EN 15566:2009+A1:2010 CR LOC & PAS TSI CR NOI TSI EN 45545-2:2013 Railway applications - External visible and audible warning devices for high speed trains - Part 1: Head, marker and tail lamps Railway applications - External visible and audible warning devices for high speed trains - Part 2: Warning horns Railway applications Line categories for managing the interface between load limits of vehicles and infrastructure Railway applications - Railway rolling stock - Draw gear and screw coupling Conventional Rail Locomotives and Passenger Rolling Stock TSI Decision 2011/291/EU, (OJ L139/1, 26.5.2011, p1) Conventional Rail Noise Aspects of Conventional Rolling Stock TSI, Decision 2006/66/EC, (OJ L37, 8.2.2006, p1) Railway applications - Fire protection on railway vehicles Part 2: Requirements for fire behavior of materials and components pren 16404:2012 Railway Applications - Re-railing and recovery requirements for railway vehicles S.I.2008/1597 The Supply of Machinery (Safety) Regulations 2008 Page 25 of 25