Engineering Standard Track Vehicles Version: 8 Issued: December 2016 Owner: Chief Engineer Approved By: Phil Ellingworth Chief Engineer PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 22/02/2013 1 Initial Issue under MTM. Replaces MainCo documents: TR/SAFETY/0013 Track Vehicle Operator, MGWI 0015 On Track Machines, & MGWI 0018 Interface Co-ordination Plan Track Access for Road/Rail Vehicles and On Track Machines 18/06/2013 2 An agreement between MTM and V/Line to adopt a common Standard for Road Rail Vehicles 08/08/2014 3 Changes to Section 7.2 and Section 9 04/02/2015 4 Added Section 8.3 statement covering re-inspection after an incident or damage 16/04/2015 5 Add Section 10 and Attachment A 15/06/2015 6 Amended Section 10.3. 25/06/2015 7 Section 10.3. further amended and clarified 12/12/2016 8 Updated to reflect the use of PlantGUARD to administer Track Vehicle Management and consolidation of supporting documents PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 14
Table of Contents 1 Purpose... 4 2 Scope... 4 3 Definitions and Abbreviations... 4 4 References & Legislations... 4 4.1. General... 4 4.2. MTM References... 4 4.3. Australian References and Legislation... 4 5 Accountabilities and Responsibilities... 5 6 Documentation Structure Supporting Track Vehicle Management... 5 7 Specific Requirements... 6 7.1. Safety Requirements... 6 7.2. Environmental Requirements... 6 7.3. Functionality... 6 8 General Track Vehicle Parameters... 7 8.1. Track Vehicle 1 (TV 1) Requirements... 7 8.2. Track Vehicle 2 (TV 2) Requirements... 7 8.3. Track Vehicle 3 (TV 3) Requirements... 8 8.4. Road Rail Vehicle (RRV) Requirements... 8 8.5. Excluded Machines... 8 8.6. Track Vehicle Maintenance... 8 8.6.1 Daily Running Sheet/Usage Report... 9 8.6.2 Plant Risk Assessment... 9 8.6.3 Safe Work Method Statement (SWMS)... 9 9 Track Vehicle Registration... 9 9.1. Registration Period... 9 9.2. Restriction Codes... 9 9.3. Provisional Registration... 10 9.4. Track Vehicle Accidents/Incidents... 10 10 Compliance Testing Companies... 10 11 Decommissioning, Disposing or Gifting MTM Track Vehicles... 10 12 Decommissioning or Transfer of Ownership of Non-MTM Track Vehicles... 10 13 Modification of Track Vehicles... 10 13.1. Gauge Modifications... 11 13.2. Permitted Track Vehicle Configurations... 11 14 Audit... 11 15 Related Documents... 11 16 Appendix A Extended List of Track Vehicle Definitions... 13 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 14
1 Purpose To define the Standards for Track Vehicles to be used on the Melbourne Metropolitan Rail Infrastructure Lease. 2 Scope This document defines the requirements with which Track Vehicles (owned or leased by MTM or by Third Parties) shall comply with for use on the Melbourne Metropolitan Rail Infrastructure Lease (MTM Network). This Standard does not apply to: Rolling Stock, or Road vehicles used on the Infrastructure Lease which are not designed for rail mounting. The provisions of this Standard are mandatory. 3 Definitions and Abbreviations The extended list of definitions and abbreviations associated with the management of Track Vehicle management is contained in Appendix A. 4 References & Legislations 4.1. General All Track Vehicles shall be designed and constructed to comply with this Standard and relevant MTM Standards and Australian Rail Industry Standards. 4.2. MTM References Document Number N/A STD_R0009 Title 1994 PTC Book of Rules and Operating procedures Standard Drawing Maximum Rolling Stock Outline Kinematic Diagram Type 1 Single Deck Cars 4.3. Australian References and Legislation Document Number Title N/A Rail Safety National Law (SA) 2014 AS 7500 Series Rail Safety National Law National Regulations (SA) 2014 Motor Vehicles Standards Act 1989 Australian Design Rules administered under Motor Vehicle Standards Act 1989 Railway Rolling Stock PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 14
5 Accountabilities and Responsibilities The overall accountability for the management of Track Vehicles is the responsibility of the Chief Engineer within the Engineering Division. Other accountabilities and responsibilities for elements of the Track Vehicles registration are contained within the Track Vehicle Registration Process (L1-CHE-PRO-033). 6 Documentation Structure Supporting Track Vehicle Management Document No. Document Name Description Track Vehicle Standard The principal document that lists the Track Vehicles requirements L1-CHE-PRO-033 L4-CHE-FOR-058, L4-CHE-INF-003 L4-CHE-INF-004 L2-TRK-PRO-025 L4-FIN-FOR-010 Track Vehicle Registration Process Victorian Metropolitan and Regional Railway Road Rail Vehicle Acceptance Checklist Road Rail Restriction Codes Approved Compliance Testing Companies Track Vehicle Road Rail Operation The document that describes how Track Vehicles are managed The combined application and TV1/2/3 checklist that now sits behind the PlantGUARD software removing the need for paper applications The codes applied during the assessment process to indicate what restrictions apply to the Track Vehicle A list of approved companies who can assess Track Vehicles against MTM s requirements. The testing companies are selected by the applicant as part of the application within PlantGUARD A document that supports the practical use of Track Vehicles on MTM s Network Fixed Asset Disposal Form The form used to support the disposal of Track Vehicles L4-TRK-FOR-070 Plant Hazard Check List Powered Mobile Plant L0-SQE-PRO-042 Safe Working Method Statements The form used to identify hazards with the plant. This is completed by the applicant and submitted with the initial application To be used when carrying out work in the corridor PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 14
7 Specific Requirements 7.1. Safety Requirements Track Vehicles shall be safe at all times and in all modes of operation and functionality. In working mode, the Track Vehicle shall comply with all OH&S legislation and codes. The Track Vehicles shall be fitted with devices to protect persons and assets as necessary. Specific protection shall be provided to protect personnel from Track Vehicle swing areas, Track Vehicle overturning with changes in centre of gravity during operation, fall prevention from heights and all other matters arising from the functionality of the Track Vehicle. Track Vehicles used at night shall have flashing lights fitted and operating and lighting of the environment at a level appropriate to the work being performed. Compliance plates shall be fitted to Track Vehicle equipment. 7.2. Environmental Requirements Track Vehicles shall be designed and constructed to be safe and suitable for transit and use for their intended functionality under all environmental conditions experienced in the greater Melbourne metropolitan area served by the railway. Self-propelled Track Vehicles intended for use in the MURL shall be powered by diesel engines or by electricity. Diesel powered Track Vehicles shall be fitted with diesel carbon filters and meet Euro 5 emission standards or if of an earlier design, be fitted with scrubbers. 7.3. Functionality Track Vehicles shall: Be designed, constructed and certified as safe for their specific functionality; Have propulsion and braking capabilities so as to be in control of the movement of the Track Vehicle at all times; and Be designed and constructed to prevent Track Vehicle run away on grades. Track Vehicles with multiple functionalities shall be designed, constructed and certified as safe and suitable for use in each functional mode. Track Vehicles with components that may move outside the rolling stock outline shall be fitted with devices to secure the components whilst the Track Vehicle is in transit. Track Vehicles with booms, jibs and lifting devices which alter the Track Vehicles centre of gravity when in use shall be provided with a means to prevent unloading of the rail wheels and over turning. Only Track Vehicles which are specifically designed to access the overhead traction wiring system shall be capable of approaching the wiring system. When in transit, the work platforms, booms, jibs and similar components shall be secured. Track Vehicles with booms, jibs and similar components not designed for overhead wiring works shall be fitted with a device to prevent the component coming within 500mm of the minimum overhead wiring height. The booms, jibs and similar components shall not be capable of reaching to a height greater than 3920mm above top of rail. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 14
8 General Track Vehicle Parameters The Track Vehicle shall: a. In transit, remain within the Rolling Stock Outline, Standard Drawing STD_R0009, Static Condition; b. In transit, have a maximum height above top of rail of not more than 4120 millimetres; c. Be capable of negotiating curves of 100 metres radius; d. Have a means of being moved in the event of disablement; e. Be fitted with jacking points for safe jacking of the Track Vehicle; f. As appropriate to the Track Vehicle design, be fitted with lifting points for crane lift; g. Be fitted with movement limiting devices as necessary to prevent any components of the Track Vehicles coming into proximity of the overhead wiring system (within 500 mm); h. Be fitted with movement limiting devices as necessary to prevent wheel unloading and Track Vehicle over turning; i. Have a maximum axle load of 19 tonnes; j. Be fitted with a service brake to bring the Track Vehicle to a stand; k. Have a braking effort to stop the Track Vehicle from 50 km/ph in a distance of 140 metres on level tangent track in dry conditions; l. Be fitted with a holding brake to hold the Track Vehicle at rest on a 1 in 30 grade; m. Be fitted with lights for transit and working modes; n. Not be propelled by rubber tyre friction drive directly onto rail wheels unless the rail wheels are fitted with independent fail safe brakes; and o. A Track Vehicle qualified as providing roll over protection & fall on protection a Manufactures Compliance plate shall specify the relevant Australian Standard. 8.1. Track Vehicle 1 (TV 1) Requirements The Track Vehicles of the TV 1 Classification shall: a. be a trolley, b. not be self-propelled, and c. have a mass at tare of more than 100 kg. 8.2. Track Vehicle 2 (TV 2) Requirements The Track Vehicles of the TV 2 Classification shall: a. be self-propelled, b. not be relied on to operate track circuits, c. be fitted with flashing warning lights, and d. carry a first aid kit. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 14
8.3. Track Vehicle 3 (TV 3) Requirements The Track Vehicles of the TV 3 Classification shall: a. be self-propelled, b. be fitted with wheel profiles in use on rolling stock of the MTM Network, c. be proven to reliably operate track circuits and comply with AS 7505.4, d. be fitted with an operator Vigilance Control and forward facing Closed Circuit Television system in use during transit, e. be fitted with flashing warning lights, and f. carry a first aid kit. TV 3 Track Vehicles designed to be coupled to rolling stock shall be fitted with couplers and a braking system compatible with the class of rolling stock. 8.4. Road Rail Vehicle (RRV) Requirements RRV s may be of Track Vehicle or TV 2 or TV 3 classification. In addition to the particular requirements for TV 2 and TV 3 Track Vehicles, RRVs shall: a. Be fitted with rail wheels and rail operating systems of proven reputable manufacture; b. Not be of a form that allows the Track Vehicle to be without brakes during the transition from road to rail operation and vice versa; c. Be road worthy and registered for road use during the period of registration as a Track Vehicle; d. Where the Track Vehicles are used on the road network they shall be road worthy and registered for road use during the period of registration as a Track Vehicle; e. Front-end loaders, tractors and similar machines fitted with wheels or guides that enable part or all of the Track Vehicles to be mounted on or guided by rails are to be registered as a TV 2; and f. Front-end loaders, tractors and similar machines shall comply with the relevant Australian or International Standard applicable to the type of machine. 8.5. Excluded Machines Specific track maintenance and condition measuring machines being spike pullers, spike drivers, Pandrol applicators, track gauge and clearance measuring trolleys, emergency use trolleys for the MURL together with all trolleys of 100kg or less are not required to conform to this Standard. 8.6. Track Vehicle Maintenance Track Vehicles shall be supported by a formal maintenance regime appropriate to the type of Track Vehicle. A maintenance log of all planned and reactive maintenance for the Track Vehicle shall be established and maintained by the supplier. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 14
8.6.1 Daily Running Sheet/Usage Report A daily running sheet/usage report shall be maintained and kept with the Track Vehicle at all times. 8.6.2 Plant Risk Assessment All Track Vehicles shall have a plant risk assessment completed covering generic use of the Track Vehicle. This shall be kept with the Track Vehicle at all times. 8.6.3 Safe Work Method Statement (SWMS) As per Safe Work Method Statement (L0-SQE-PRO-042), MTM requires a SWMS to be used when carrying out work in the rail corridor. The Track Vehicle operator shall use the plant risk assessment when developing the task specific SWMS and this shall be checked and communicated during the prestart. 9 Track Vehicle Registration MTM will utilise the PlantGUARD online software system for: Initial registration of Track Vehicles, Assessment of Track Vehicles, Re-Assessment of Track Vehicles, and Management of accidents and incidents associated with of Track Vehicles. The Track Vehicle Registration Process (L1-CHE-PRO-033) describes how PlantGUARD manages these 4-steps. 9.1. Registration Period Track Vehicles registered for use on the MTM Network shall have registration periods applied to the Track Vehicles as follows: Vehicle Age (Months from Manufacture) Maximum Period of Registration (Months) Less than 60 36 61 to 120 24 121 months or more 12 9.2. Restriction Codes Restriction Codes shall be used to manage specific risks of Track Vehicle on MTM s Network. Road Rail Restriction Codes (L4-CHE-INF-003) shall be used during the assessment process. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 14
9.3. Provisional Registration Track Vehicles may, under exceptional circumstances, be granted provisional registration where MTM or a Track Vehicle owner/operator requires the Track Vehicle to be available for a critical works or works program. Refer the Track Vehicle Registration Process (L1- CHE-PRO-033) for details on how to apply for provisional registration. 9.4. Track Vehicle Accidents/Incidents Where a Track Vehicle has been involved in a rail safety incident on track, has sustained damage to the road rail equipment or has been involved in an incident/accident off track, the Track Vehicle shall undergo a full reassessment before it can return to service on the MTM rail network. Any Track Vehicle involved in an accident/incident shall undertake a full reassessment prior to being permitted back on the MTM Network. In support of this, MTM will change the status of the Track Vehicle within PlantGUARD to indicate the Track Vehicles requires reassessment. 10 Compliance Testing Companies All companies listed on the Approved Compliance Testing Companies Information Sheet (L4-CHE-INF-004) shall have Independent Competent Persons (ICP) assessed as follows: ICP s verifying designs of, or modifications to Track Vehicles, shall have their competence assessed in accordance with AS 7501:2013, Section 4, Independent Competent Person. (5.5.1.10, 5.5.1.12, 5.5.1.45, 5.5.1.46). 11 Decommissioning, Disposing or Gifting MTM Track Vehicles If a Track Vehicle has been determined by management that it is unable to operate safely or cost effectively or the Track Vehicle is to be gifted, the Track Vehicle shall be disposed of in accordance with the Track Vehicle Registration Process (L1-CHE-PRO-033). 12 Decommissioning or Transfer of Ownership of Non-MTM Track Vehicles Non-MTM Track Vehicles shall be decommissioned or transferred in accordance with the Track Vehicle Registration Process (L1-CHE-PRO-033). 13 Modification of Track Vehicles Once a Track Vehicle has been assessed, no modifications of any description are permitted to the Track Vehicle without prior approval of MTM. The only exceptions are Gauge and Permitted Track Vehicle Configurations (refer paragraph 13.1 & 13.2). MTM will review a proposed modification against the Assessed Configuration Baseline and determine if the Track Vehicle requires reassessment. If the Track Vehicle requires reassessment, MTM will change the status of the Track Vehicle within PlantGUARD to indicate the Track Vehicle is to be reassessed. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 14
13.1. Gauge Modifications If a Track Vehicle has been registered for use on MTM s network and another network with a different gauge, MTM shall be notified to confirm the Track Vehicle has been restored to the Assessed Configuration Baseline. PlantGUARD has been configured to support this notification process, refer to the Track Vehicle Registration Process (L1-CHE-PRO-033) for further explanation. 13.2. Permitted Track Vehicle Configurations All Track Vehicles that are capable of being operated in a different configuration shall have each configuration assessed and registered as a stand-alone item. Refer to the Track Vehicle Registration Process (L1-CHE-PRO-033) for further explanation on permitted configuration changes. 14 Audit MTM will undertake the following audits and inspections: Suppliers providing Track Vehicles shall be audited as part of MTM s corporate audit schedule under high risk supplier audits. The selection and frequency of shall be as per the corporate audit schedule; All Approved Compliance Testing Companies shall be audited as per the corporate audit schedule and no less than once per year. As per Planning Worksite Protection in the Rail Corridor (L1-SQE-PRO-054), it is the responsibility of the Work Group Supervisor to verify the Track Vehicle is certified for use on the MTM Network; and In accordance with MTM s Supplier Management Procedure (L1-CPO-PRO-002) and Internal Safety, Environment and Quality Audit Framework (L0-SQE-PRO- 044), any Third Party company (supplier and or assessor) that refuses an audit/inspection or does not comply with any corrective action issued, will have their registration status cancelled and Avetta company flag status changed to red. 15 Related Documents The related documents are: L1-CHE-PRO-033 Track Vehicle Registration Process L4-CHE-FOR-058 Victorian Metropolitan and Regional Railway Road Rail Vehicle Acceptance Checklist L4-CHE-INF-003 Road Rail Restriction Codes L4-CHE-INF-004 Approved Compliance Testing Companies L2-TRK-PRO-025 Track Vehicle Road Rail Operation L4-TRK-FOR-070 Plant Hazard Check List Powered Mobile Plant L0-SQE-PRO-044 Internal Safety, Environment and Quality Audit Framework L1-CPO-PRO-002 MTM s Supplier Management Procedure PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 14
L0-SQE-PRO-014 L4-FIN-FOR-010 L1-SQE-PRO-054 L0-SQE-PRO-042 Safety and Environmental Requirements for Third Parties Working on MTM premises Fixed Asset Disposal Form Worksite Protection in the Rail Corridor Safe Work Method Statement PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 14
16 Appendix A Extended List of Track Vehicle Definitions Assessed Configuration Baseline ICP Infrastructure Lease MURL PlantGUARD QR Code Registration RRV Shall Should Supplier Management Procedure Third Parties Track Vehicles Track Vehicle Compliance Audit Process The baseline of the Track Vehicle on completion of the assessment. Any changes to a Track Vehicle that impacts the configuration baseline means the Track Vehicle shall be reassessed Independent Competent Person The meaning as defined in the Franchise Agreement Melbourne Underground Rail Loop The online system MTM uses to manage the registration and management of RRV s for use on MTM s Network. Is the code printed in the Track Vehicle Registration Sticker and it is individual to each Track Vehicle. When scanned, it provides information such as: status of the Track Vehicle, restriction codes, any information used during the assessment of the Track Vehicle. The acceptance by MTM that the Track Vehicle has been assessed as meeting the requirements of the MTM Safety Management System and has been listed and identified as a Registered Track Vehicle. Road Rail Vehicles Is used as the descriptive word to express a requirement that is mandatory to achieve conformance to the standard. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance to the standard. Should can also be used if a requirement is a design goal but not a mandatory requirement. This procedure requires all Third Party companies to be prequalified to MTM s requirements and this means they must hold a Green Flag status in Avetta. In the case of Track Vehicle Management, no Third Party company will be given access to PlantGUARD, to register Track Vehicles, until they are Green Flagged. Any non-mtm individual or company. Rail mounted Track Vehicles which includes but is not limited to selfpropelled test Track Vehicles, track grinders, ballast regulators, tampers, overhead inspection and maintenance Track Vehicles, hirail vehicles and like machines. Train rolling stock is not classified as Track Vehicles. This procedure defines the requirements surrounding the MTM corporate audit process that will be used to monitor and support ongoing Track Vehicle compliance. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 14
Track Vehicle Classification TV 1 Track Vehicle Classification TV 2 Track Vehicle Classification TV 3 Track Vehicle Registration Process Track Vehicle Operator Competency Track Vehicle Standard Transit Working mode A non self-propelled Track Vehicle which does not reliably operate track circuits and which shall be managed under the operating rules under conditions which exclude the operation of trains whilst the Track Vehicle is on track A self-propelled Track Vehicle which does not reliably operate track circuits and which shall be managed under the operating rules under conditions which exclude the operation of trains whilst the Track Vehicle is on track A self-propelled Track Vehicle which operates track circuits and is managed as a train under the operating rules applicable to the management of metropolitan trains on the network These procedures explain how Track Vehicles are registered and managed. The Track Vehicle Registration Process has been transferred to an online software tool called PlantGUARD. The transition will mean the removal of paper based forms and this information will be transferred, maintaining the same requirements as an electronic system Requirements relating to the operation of Road Rail Vehicles within the Melbourne Metropolitan Rail Network, including competency of MTM employee Track Vehicle Operators is contained in (L2-TRK- PRO-025) Safety and Environmental Requirements for Third Parties Working on MTM premises (L0-SQE-PRO-014) addresses the competency requirements Third Party Individuals shall comply with in order to operate a Track Vehicle on MTM s premises. The standard that a Track Vehicle shall comply with to be registered for use on the MTM Network The movement of a Track Vehicle on the railway between locations The Track Vehicle in use performing the functions for which is designed PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 14 of 14