COT&S Extension Process for Rail Transit Friction Brake Systems. Charles Turner STV Incorporated Engineering Specialist Philadelphia, PA

Transcription

1 COT&S Extension Process for Rail Transit Friction Brake Systems Charles Turner STV Incorporated Engineering Specialist Philadelphia, PA 1

2 Key Presentation Take-Aways COT&S Extension Terminology Condition Assessment Program COT&S Extension Process Reference COT&S Extension Program Lessons Learned Transit Authority Benefits 2

3 COT&S Extension Terminology Clean, Oil, Test and Stencil (COT&S) Refurbishment/Overhaul of equipment Regulatory Agency Federal Railroad Administration (FRA) Code of Federal Regulations (CFR) 3

4 COT&S Extension Terminology Condition Based Maintenance Monitoring System Performance Real-time functionality Condition Assessments System & component level Testing & teardown evaluations Optimize Maintenance Schedule Intervals based upon component condition 4

5 COT&S Extension Terminology Control Group Assets Dedicated sample of test cars from fleet Contain properly qualified equipment New fleets - OEM equipment Existing fleets Overhauled equipment Non-Control Group Assets Remainder of cars in fleet May contain a combination of OEM/overhauled equipment 5

6 Condition Assessment Program System Reliability Factors Component failure rates Performance degradation External Influences System mileage Component duty cycle Operating environment Maintenance practices 6

7 Condition Assessment Program Traditional Maintenance Strategies Corrective Maintenance Failure based maintenance Initiated when assets break down Results in unpredictable maintenance activities Preventive Maintenance Use based maintenance Initiated by time or distance intervals Developed from past experience 7

8 Condition Assessment Program Condition Based Maintenance Strategy Specific operational environment Maintenance is performed when indicators show Signs of decreasing performance Anticipated failure condition Approaching wear out vs. replace criteria 8

9 Friction Brake Systems Modern systems contain Electronic control systems Real-time status monitoring Diagnostics/annunciation capabilities Technological improvements Materials System / Component design 9

10 Friction Brake Systems Equipment Performance Monitoring CFR Requirments Daily brake test Inspection of truck mounted components Friction Brake Control System Sensors monitor braking functions Detects and annunciates faults Identifies out of specification values Identifies conditions the operator may not detect 10

11 COT&S Extension Process Establish COT&S Evaluation Team Transit Authority (TA) FRA OEM supplier Team Member Continuity Consistency in process/evaluations throughout the evaluation period 11

12 COT&S Extension Process Test Documentation On-Car Test Procedure Joint OEM/Transit Authority procedure Bench Test Procedures OEM Component Acceptance Test Procedures Teardown/Inspection OEM maintenance procedures Acceptance (wear) criteria 12

13 COT&S Extension Process Component Failure Reporting Control Group All COT&S failures evaluated for root cause COT&S Team participates in test/teardown Non-Control Group All COT&S failures tracked for review COT&S Team not required to participate in evaluation Quarterly Reporting Fleet failure reports submitted to FRA for review 13

14 COT&S Extension Process On-Car Testing System Functional Test Test to new car standard Document system parameters at all brake modes PWM, BC pressures, electrical (voltages/currents), temperatures, dew points Verify brakes apply/release 14

15 COT&S Extension Process On-Car Testing Component Functional Test Portable Test Equipment Laptop, pneumatic test box, dew point meters, digital meters, brake force tester Verify output response to a controlled input Compare with valid ranges/limits Determine pass/fail status Remove from car if fail criteria is determined 15

16 COT&S Extension Process Off-Car Testing Bench Tests (OEM Facility) OEM Bench Test Equipment OEM Test Documentation Acceptance Test Procedures Verify performance to specification New component standard Identify variations from specification Assist in determination of wear conditions or failure root cause during teardown 16

17 COT&S Extension Process Teardown/Inspections Teardown (OEM Facility) Evaluate external surfaces for impact damage May result in damage to the internal components Carefully disassemble assemblies Ensure all internal/external components can be evaluated 17

18 COT&S Extension Process Teardown/Inspections Teardown (OEM Facility) New component standard Evaluate metal/plastic components Wear, contamination, lubrication, discolorization Evaluate elastomer components Wear, flexibility, dryness, lubrication 18

19 COT&S Extension Process Teardown/Inspections QA Inspection (OEM or lab Facility) Test equipment to perform QA inspections Gauges, micrometers, microscopes, measurement devices Perform inspection on all components that have defined wear criteria Dimensional Surface Finish Hardness Electrical, Timing 19

20 COT&S Extension Process Annual Review Testing, Teardown/Inspection Results Component results for cars evaluated during year Comparison/trends with results from other years Control Group vs Non-Control Group Results Determine if Control Group data represents fleet data Recommendations Continue or modify waiver activities, or Terminate - determine if component limits are met 20

21 COT&S Extension Process Design Improvement Opportunities Identify component weaknesses Develop design improvements Alternate component Component redesign Material change Assembly process change Enable components to extend life & performance 21

22 Reference COT&S Extension Program LIRR/MNR M-7 EMU Knorr KB-CT1 Brake System 1172 cars in joint fleet (836 LIRR, 336 MNR) Fleet acceptance dates Initial CFR Requirement - CFR 49 Section (b)(2) 2 year COT&S interval COT&S 24 component types (total 116 items) 22

23 Reference COT&S Extension Program LIRR/MNR M-7 EMU Petition for 5 year waiver submitted to FRA in 2003 Evaluations performed in 3 rd, 4 th, 5 th and 6 th years Results indicated components in good condition FRA approved 5-year COT&S interval KB-CT1 brake system listed in CFR (b)(2) for 1840 day interval 23

24 Reference COT&S Extension Program LIRR/MNR M-7 EMU Petition for Age Exploration waiver submitted in 2008 Evaluations performed in 6 th, 7 th, 8 th and 9 th years Results indicated components in good condition Some components showing signs of increased wear Formal Petition for Waiver for 8.5 year COT&S interval submitted to FRA in 2015 FRA approved 8.5-year COT&S interval 24

25 Reference COT&S Extension Program LIRR/MNR M-7 EMU Continuing Petition for Age Exploration waiver submitted in 2008 Evaluations performed in 10 th year Evaluations currently scheduled for 10.5 th year Goal to obtain a 10 year COT&S interval Final determination of KB-CT1 system performance to be decided by 1 st quarter or

26 Reference COT&S Extension Program LIRR/MNR Component Failure Data Fleet Failure Percentages 26

27 Reference COT&S Extension Program LIRR/MNR M-7 EMU Total of 27 carsets (54 cars) evaluated in 8 years Follow-on COT&S program for MNR M-8 EMU KB-CT1A brake system Car level control vs. M-7 truck control Similar brake system components Incorporated M-7 improvements Different operating environment Currently in 4 th year of test & evaluation 27

28 Lessons Learned Friction Brake System Performance Modern brake system designs Provide better reliability than previous generations Technological advances allow for real-time monitoring of brake system functions A Condition Assessment Program can support the extension of COT&S intervals Components may have different reliability when operated by different Transit Authorities or on different train routes 28

29 Lessons Learned A Condition Assessment Program can provide benefits to any Transit Authority Regional or major EMU/DMU fleets under FRA control Extend COT&S intervals in CFR Subway, Light Rail fleets (not under FRA control) Currently no APTA guidelines for PM intervals Need for APTA COT&S Extension Standard 29

30 Transit Authority Benefits An effective COT&S Extension Program Optimizes fleet maintenance intervals Increases maintenance efficiency Optimizes manpower and facility resources Reduces maintenance costs, saves money Improves fleet availability Minimizes unnecessary maintenance (fewer shop visits) Reduces chance of collateral damage 30

31 Transit Authority Benefits Team Partnerships Improve communications between FRA, TA and OEM organizations Increase understanding of component O&M conditions in the TA s environment Resolve any design or supportability concerns Provide organic design improvement opportunities 31

32 COT&S Extension Process for Rail Transit Friction Brake Systems Thank You 32