Signalling Maintenance Testing

Transcription

1 Date Feb 1997 Signalling Maintenance Testing Signatures removed from electronic version Synopsis This standard defines the testing requirements for previously working and commissioned signalling systems during maintenance, renewals and faulting where the design remains unchanged. Submitted by Richard Genner Nominated Responsible Manager Approved by Philip Wiltshire Chairman, Train Control & Communications Subject Committee Authorised by MH Walter Controller, Safety Standards This document is the property of Railtrack PLC. It shall not be reproduced in whole or in part without the written permission of the Controller, Safety Standards, Published by Safety & Standards Directorate Railtrack PLC Fitzroy House 355 Euston Road London NW1 3AG Copyright 1997 Railtrack PLC

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3 Testing Date Feb 1997 Page A1 of 5 Part A Issue Record This standard will be updated when necessary by issuing replacement pages. Amended or additional parts of revised pages will be marked by a vertical black line in the adjacent margin. Issue Date Comments One June 1994 Supersedes GS/MT0001 and updates SMT sections. Cancels GK/EH H203. Two Feb 1997 Supersedes issue 1 and all associated SMT sections. Responsibilities and Distribution Compliance Health & Safety Responsibilities Supply s are mandatory on all members of the Railway Group* and apply to all activities which fall within the scope of each individual s Railway Safety Case. If any of those activities are performed by a contractor, the contractor s obligation in respect of Railway Group Standards is determined by the terms of the contract between the respective parties. Where the contractor is himself a duty holder of a Railway Safety Case then s apply directly to the activities described in his Railway Safety Case. * The Railway Group comprises Railtrack, the duty holders of Railway Safety Cases accepted by Railtrack, and the British Railways Board as long as it owns train operators. The provisions of this are mandatory and apply from Controlled copies of this standard shall be complied with by all personnel responsible for testing alterations to previously working and commissioned signalling systems where the design remains unchanged. In authorising this standard Railtrack plc makes no warranties, express or implied, that compliance with all or any of s is sufficient on its own to ensure safe systems of work or operation. Each user is reminded of its own responsibilities to ensure health and safety at work and its individual duties under health and safety legislation. Controlled and uncontrolled copies of this standard may be obtained from The Catalogue Secretary, Railtrack Safety & Standards Directorate, Floor 2, Fitzroy House, 355 Euston Road, London, NW1 3AG. R A I L T R A C K A1

4 Railway Group Date Feb 1997 Page A2 of 5 Testing Telephone: or (BT) Facsimile: or (BT) A2 R A I L T R A C K

5 Testing Date Feb 1997 Page A3 of 5 Contents Section Description Page Part A Issue 2, 02/97 Issue Record Responsibilities and Distribution Compliance Health & Safety Responsibilities Supply A1 A5 A1 A1 A1 A1 A1 Part B Issue 2, 02/97 B1 B23 1 Purpose B1 2 Scope B1 3 Definitions B1 4 Objective of Maintenance Testing B3 5 Testing Management B4 5.1 Maintenance Tester B4 5.2 Testing Work B4 5.3 Testing Where No Maintenance Test Plan Exists B4 5.4 Handover Where Testing Cannot Be Completed B5 5.5 Testing For Correct Operation B5 5.6 Testing After Replacement of Missing Equipment B5 5.7 General B5 6 Staffing B6 6.1 Competence B6 6.2 Independence B6 7 Site and Test Records B6 7.1 Testing With Site Records B6 7.2 Testing Where Site Records Have Been Amended B6 7.3 Testing Where Site Records Differ From Wiring B7 7.4 Testing Where There are No Site Records B7 7.5 Test Records B8 R A I L T R A C K A3

6 Railway Group Date Feb 1997 Page A4 of 5 Testing Section Description Page Appendices A Maintenance Testing Guidance B9 A.1 Scope B9 A.2 Operationally Equivalent B10 A.3 Method Statement Considerations B10 A.4 Specific Operationally Equivalent Alterations B11 A.5 Special Arrangements B13 B Test Plan Requirements B15 B.1 General B15 B.2 Maintenance Test Plans B15 B.3 Missing Equipment Test Plans B16 C Test Record Requirements B17 C.1 Routine Test Records B17 Fig. 1 Logbook Example Test Record B18 C.2 Pre planned Work Records B18 Fig. 2 Mtce. Test Plan List Example Pre planning Test Record B19 C.3 Recording Maintenance Test Plan Steps B21 Fig. 3 Tick Sheet Example B21 D Work on Operational Equipment B23 D.1 Working on Equipment Which Is In Service B23 D.2 Making Disconnections B23 D.3 Changing Electric Tokens B23 C Testing Techniques & Procedures Issue 2, 02/97 C1 C74 1 General C1 2 Defined Checks C1 3 Defined Tests C1 4 Temporary Diversion of Circuits C2 5 Links C2 Appendices A Defined Checks C3 A.1 Check For Correct Type C3 A.2 Check For Damage C5 A.3 Check For Safe Insulation C7 A.4 Check For Correct Installation C9 A.5 Check For Isolation C11 A.6 Check For Correct Labelling C13 A4 R A I L T R A C K

7 Testing Date Feb 1997 Page A5 of 5 Section Description Page B Defined Tests C15 B.1 Wire Count C15 Fig. 1 Wire Count Grid Sheet Example C16 B.2 Continuity Test C17 B.3 Insulation Test C19 B.4 Cable Function Test C21 Fig. 2 Cable Function Test Schematic C23 B.5 Earth Test (d.c. up to nominal 120V) C24 Fig. 3 Acceptable & Safety Values (D.C.) C25 B.6 Earth Test (a.c. up to nominal 110V) C25 Fig. 4 A.C. Earth Test Circuit C25 Fig. 5 Acceptable & Safety Values (A.C.) C26 B.7 Aspect Test C27 B.8 Point Detection & Correspondence Test C29 Fig. 6 Point Permutation Chart Grids C31 Fig. 7 Point Permutation Chart Grids C32 Fig. 8 Point Permutation Chart Grids C33 Fig. 9 Point Permutation Chart Grids C34 Fig. 10Point Permutation Chart Examples C35 B.9 Absolute Block Controls Test C37 B.10 Tokenless Block Controls Test (BRB Type) C41 B.11 Tokenless Block Controls Test (Open/Sealed Cancel Type) C43 B.12 Tokenless Block Controls Test (Direction Lever) C47 B.13 Token Block Controls Test C49 Fig. 11Token Block Controls Test Table C50 B.14 Tablet Block Controls Test C51 Fig. 12Tablet Block Controls Test Table C51 B.15 No Signalman Key Token Block Controls Test C53 Fig. 13No signalman Key Token Block Controls Test Table C54 B.16 Absolute Block Recovery Test C55 B.17 Tokenless Cooperative Cancel Test (Direction Lever) C59 B.18 Dog Chart Comparison Test C61 B.19 Mechanical Locking Function Test C63 C Diversion of Circuits C65 C.1 Reasons for Diversion C65 C.2 Diversion of Circuits in Faulty Cables C65 C.3 Diversion of a Circuit to an Alternative Relay Contact C66 C.4 Emergency Repositioning of Equipment C66 C.5 Rectification C66 R A I L T R A C K A5

8 Railway Group Date Feb 1997 Page A6 of 5 Testing C.6 Permanent Adoption of Temporary Alterations C66 A6 R A I L T R A C K

9 Testing Date Feb 1997 Page A7 of 5 Section Description Page C1 Code of Practice For Monitoring A Damaged Cable C67 D Releases C69 D.1 Principles Of Giving A Release C69 D.2 Seals C70 D.3 Sealed Releases C70 E Useful Values C71 E.1 Introduction C71 E.2 Values C71 Fig. 14Signal Arm Adjustment C72 R A I L T R A C K A7

10 Testing Date Feb 1997 Page B1 of 24 1 Purpose 2 Scope 3 Definitions Part B This standard defines the mandatory tests and procedures necessary to ensure that the replacement or renewal of previously working signalling equipment is tested with sufficient depth and independence to assure safe working when returned to service. This standard applies to the testing of all alterations to previously working and commissioned signalling systems, during maintenance, renewals and faulting, where the design remains unchanged. Alterations may take the form of like for like replacement of equipment, replacement of missing equipment and temporary diversion of circuits and normally apply to individual items of equipment. The standard may be applied to multiple items as long as the principles are followed. The standard for testing alterations where the installation is new or the design has changed, except where allowed for as a specific operational equivalent in Appendix A, is published as GK/RT0221 Signalling Works Testing. The standard is based on the principle that the equipment was tested properly at commissioning and has been working correctly. The design may therefore be taken to be correct and the work shall not require a change to diagrams unless permitted in the Maintenance Test Plan or required as a result of correlation. Appendices for this standard are arranged sequentially within the particular Part of the standard to which they are most relevant. Guidance on the scope of Maintenance Testing and clarification of operational equivalence are included in Appendix A. Adequate sighting Ensuring that the driver s view of a signal is not obstructed, eg. by trees, bushes, buildings or other structures, and can be seen for the minimum required time on approach (7 seconds 2 and 4 seconds uninterrupted with no banner signal). Alignment is detailed in the Signalling Maintenance Specifications. Affected lever/locking Any locking affected by the removal or potential release of any part which could alter the setting or integrity of the locking. This could vary between the need to test only levers interlocked with the lever being worked on, up to the need to test the complete frame. Any locking which has had holding down straps or covers removed shall be considered as affected and be tested. Where complete locking trays have not had their covers removed and no connection into the tray has been disturbed the locking within that tray may be considered as not affected. If there is any doubt as to the limits of affected locking then additional testing shall be carried out to cover the locking over which doubt exists. R A I L T R A C K B1

11 Railway Group Date Feb 1997 Page B2 of 24 Testing Check Ensure correct by visual, audible and/or physical inspection. Correspondence Ensuring that the following all agree: 1. The controlling device, eg. relay or SSI telegram, AND 2. The operated function, AND 3. The associated signalbox indication(s), eg. repeat relay or SSI telegram. Disarrangement of interlocking The interlocking can no longer be relied on to operate safely because of the removal or disturbance of component parts. Extraneous lighting An external light source affecting a signal aspect, eg. from an open signal head door or nearby street lamps. Infrastructure Controller That part of an organisation which is responsible for the control and operation of railway infrastructure including the track, structures, plant, telecommunication and control equipment. An Infrastructure Controller may either own of lease the infrastructure concerned. Independent Checking Independent checking means that one person undertakes the work and another person checks it. In some cases testing may be started before the work is completed. In other cases, the work may allow two staff to work on two tasks and then change over to test each other s work (as long as both are Maintenance Testers). Maintenance Testing may often be quite interactive within the guidelines of independence. Like for like replacement The removal and restoration of an item of equipment, including a cable, in a previously working and commissioned system where the work does not change the design. This may involve restoring the original item of equipment or replacing it with an operationally equivalent new item. Local manager A person with line management or appropriate engineering supervisory responsibility for staff using the Maintenance Testing standard. [Note: Specific levels of authority may be defined locally and in some cases require the approval of the Infrastructure Controller.] Maintenance Tester A person certificated as competent in the application of Maintenance Testing. Missing equipment Equipment which was previously working and which is physically missing or separated from its normal position. B2 R A I L T R A C K

12 Testing Date Feb 1997 Page B3 of 24 4 Objective of Maintenance Testing Operationally equivalent The replacement item of equipment is functionally identical to the item it replaces. Tail cable An external cable running from either: 1. An apparatus case, relay room or disconnection box to an item of equipment, OR 2. An apparatus case or relay room to a disconnection box. OR 3. An item of equipment to another item of equipment. Temporary diversion of circuits The short term reallocation of cores/contacts or emergency repositioning of an item of equipment which has been operating correctly. Test Ensure correct by measurement using test equipment, gauge or tool or by operation. The objective of testing shall be to ensure that the signalling equipment is safely returned to service. The vital test requirements necessary to ensure SAFE working of equipment are listed to ensure that none are overlooked. Checks directed at ensuring reliable operation, but which are not directly involved in the safe working of the equipment, are not listed but should still be carried out. Equipment covered by this standard shall be tested in accordance with the Maintenance Test Plans or Missing Equipment Test Plans contained in Code of Practice GK/RC0729 unless an equivalent or better alternative is approved by a competent engineer nominated by the Infrastructure Controller. This approval process shall include a risk assessment and shall be required to demonstrate that the proposed alternative is no less safe. The requirements for a Maintenance Test Plan and Missing Equipment Test Plan are given in Appendix B. Wrong Side Failures, accidents and other serious incidents shall be investigated using the guidelines contained in Code of Practice GK/RC0731 SIGNALLING FAILURE INVESTIGATION unless an equivalent or better alternative is approved by a competent engineer nominated by the Infrastructure Controller. This approval process shall include a risk assessment and shall be required to demonstrate that the proposed alternative is no less safe. Code of Practice GK/RC0731 is not exhaustive but is intended to ensure that reported failures are thoroughly investigated, that information is adequately recorded and that vital evidence is not destroyed by the testing. R A I L T R A C K B3

13 Railway Group Date Feb 1997 Page B4 of 24 Testing 5 Testing Management The standard allows for safe testing to suit the varied circumstances of equipment replacement following damage, faulting and maintenance. The testing framework is provided as a mandatory support tool for those undertaking the work. Where time is available prior to the replacement work, typically for renewals, it is advisable to pre plan the work and associated testing. This minimises unforseen problems and allows competent testing staff to be arranged. 5.1 Maintenance Tester Testing shall only be carried out by competent staff. A Maintenance Tester shall be in overall charge of the testing. The Maintenance Tester shall determine the extent of the work, confirm that the work can be undertaken using the Maintenance Testing standard and decide which Maintenance Test Plans are appropriate. 5.2 Testing Work An appropriate Maintenance Test Plan(s) for the work shall be selected and activities carried out in sequence: Before Installation tests, checks or preliminary work The replacement or diversion work itself After Installation tests or checks. Any errors found in the work during testing shall be corrected by the person doing the work. This shall be rechecked by the Maintenance Tester along with anything that could have been affected by the remedial work. Before the equipment is returned to service, the work and all testing shall be completed and a record of test produced unless exempted in the Maintenance Test Plan. If the available diagrams have previously been amended by hand, eg. with a temporary diversion, details shall be noted as part of the record of test. Maintenance Test Plan steps which are required but cannot be carried out shall be noted as part of the record of test and advised to the local manager whose permission shall be obtained before equipment is returned to service. If a Maintenance Test Plan is considered deficient in any way, details shall be noted as part of the record of test and any additional tests carried out before the equipment is returned to service. The query shall be reported to the local manager as soon as possible. The local manager shall arrange to have the equipment retested if a Maintenance Test Plan is considered deficient. The local manager is responsible for ensuring the deficiency is notified to the Infrastructure Controller who shall in turn notify Railtrack Safety & Standards Directorate if the Maintenance Test Plan is contained in GK/RC Testing Where No Maintenance Test Plan Exists Where no suitable Maintenance Test Plan exists for the work to be undertaken, and unless an exemption is stated, a new Maintenance Test Plan shall be produced by the Maintenance Tester. The requirements for a Maintenance Test Plan and Missing Equipment Test Plan are given in Appendix B. B4 R A I L T R A C K

14 Testing Date Feb 1997 Page B5 of 24 Before use, the new Maintenance Test Plan shall be checked by a Maintenance Tester not involved in writing it. This check shall be undertaken on site with reference to the equipment concerned except where the person concerned is sufficiently familiar with the equipment, in which case the new Maintenance Test Plan may be agreed by telephone or checked off site. If there is any doubt about the testing required, and whether it can be covered by Maintenance Testing, the local manager shall be contacted. On completion of the work and testing, the new Maintenance Test Plan shall be forwarded as part of the record of test. The local manager shall arrange to have the equipment retested if the Maintenance Test Plan is considered deficient. The local manager is responsible for ensuring the new Maintenance Test Plan is notified to the Infrastructure Controller who shall in turn notify Railtrack Safety & Standards Directorate. The same procedure shall apply to the production of new Missing Equipment Test Plans. 5.4 Handover Where Testing Cannot Be Completed If work is partially tested when the work is directly or indirectly handed over to someone else to complete, the record of test shall be completed for the testing that has been done. A copy shall be forwarded to the person continuing the testing. The person completing the testing shall establish their own record of test, noting down the tests done by the first team Maintenance Tester to ensure a clear understanding of the state of work at handover. Tests documented as satisfactorily completed need not be repeated but any which are not listed as complete shall be assumed not done. Both records of test shall be submitted to the local manager after completion. 5.5 Testing for Correct Operation On completion of the required testing defined in the Maintenance Test Plan(s) the part of the signalling system affected by the work shall be checked to ensure correct operation. This check may, for example, involve watching a train pass through a signalled route and observing that the track circuits occupy and clear in the correct sequence, signals are restored to danger, etc. It may involve observing that points move in correspondence with the signalman s controls. 5.6 Testing After Replacement of Missing Equipment Missing equipment shall be replaced using Maintenance Testing principles and Missing Equipment Test Plans. To qualify for replacement the missing equipment shall have been present and working prior to its damage or removal. Complete and accurate diagrams shall be available and the work shall not require any change to diagrams. An operationally equivalent replacement item shall be used. When dealing with missing equipment any other equipment nearby should be checked for damage or disturbance. 5.7 General On completion of the maintenance testing work the Maintenance Tester shall ensure that the installation / equipment is left in a secure condition and that adequate arrangements have been made for the prompt removal from site of any displaced equipment. R A I L T R A C K B5

15 Railway Group Date Feb 1997 Page B6 of 24 Testing 6 Staffing 7 Site and Test Records The primary requirements for persons undertaking Maintenance Testing shall be independence and competence. 6.1 Competence Maintenance Testers shall be competent in accordance with Railway Group Standard GK/RT0101 Competence Standards for S&T Staff. 6.2 Independence Independent checking shall apply throughout Maintenance Testing, except for some straightforward replacements where it is specifically exempted on the Maintenance Test Plan. The nominated Maintenance Tester shall be wholly responsible for ensuring that the work is restored to use in a safe condition. Therefore the Maintenance Tester cannot carry out (but may assist) the work which will subsequently be verified by the testing. This does not prevent the Maintenance Tester from either leading the fault diagnosis or directing the installation work. The standard is based on the assumption that equipment is correctly wired and correctly documented before work commences. Complete and accurate site records shall be available at each installation. A record of test shall be provided by the Maintenance Tester for each replacement or alteration unless exempted in the Maintenance Test Plan. The requirements for test records are given in Appendix C. 7.1 Testing With Site Records The installation shall be checked against the diagrams before work is started and again after work is complete to check that the installation is correct. The extent of this correlation activity shall be defined in the Maintenance Test Plan or Missing Equipment Test Plan. 7.2 Testing Where Site Records Have Been Amended If, when needed for fault rectification or renewal work, diagrams are available but have an unsigned and undated amendment which affects that work, the work shall STOP. Advice shall be sought from the local manager. This shall also apply to any diagrams found marked Installation Copy. The action to be taken shall be as follows: If the diagram shows amendments it shall be thoroughly checked to the wiring on site. If the diagrams are clear and in agreement with the wiring the local manager may allow work to continue. Arrangements shall be made to obtain revised diagrams within six weeks. If revised diagrams cannot be supplied within six weeks, the Infrastructure Controller shall be advised and suitable arrangements made to ensure that any risks are reduced to as low as reasonably practicable. In both cases a note shall be included with the record of test. B6 R A I L T R A C K

16 Testing Date Feb 1997 Page B7 of 24 If the diagrams are unclear, or if a discrepancy with the wiring is found, the local manager shall arrange for the discrepancy to be resolved and determine an appropriate method for the work to be completed. Design assistance to produce any revised diagrams shall be arranged. Diagram amendments reported which are unrelated to the work shall be dealt with using the local procedures for arranging revised diagrams. 7.3 Testing Where Site Records Differ From Wiring If a difference is discovered between the wiring being worked on and the diagram, the work shall STOP. Advice shall be sought from the local manager. The action to be taken shall depend on the extent of the difference. In all cases where the diagrams are related to the work in hand a note shall be included with the record of test and arrangements made to obtain revised diagrams within six weeks: If the difference only involves the looping arrangement or contact / terminal allocation detail and is otherwise electrically identical, the local manager may permit the work to proceed. The diagram shall be suitably amended, signed and dated in red. If any other discrepancy is found the local manager shall arrange for the discrepancy to be resolved and determine an appropriate method for the work to be completed. Design assistance to produce any revised diagrams shall be arranged. Diagram discrepancies reported which are unrelated to the work shall be dealt with using the local procedures for arranging revised diagrams. 7.4 Testing Where There Are No Site Records If site records are missing, the work shall STOP. Advice shall be sought from the local manager. The action to be taken shall depend on the work being done. Where work is permitted to continue, as outlined below, the appropriate Maintenance Test Plan(s) shall be used. In all cases a note shall be included with the record of test and arrangements made to obtain revised diagrams: If the equipment being changed is a pin coded plug in component, the local manager may allow the work to proceed omitting any requirement to check to the wiring diagram. If the component is a simple piece of equipment not involving control circuitry, the equipment may be changed on the authority of the local manager who shall take into consideration the experience of the staff doing the work and testing. A sketch drawing shall be produced showing the wiring connected to the equipment which shall then be used in lieu of the proper diagram. The sketch shall be left on site, signed and dated in red. Transformers and lampholders are typical of the equipment that can be dealt with in this way. R A I L T R A C K B7

17 Railway Group Date Feb 1997 Page B8 of 24 Testing If the equipment involves control circuitry, such as a shelf type relay, additional testing resource shall be involved in the change. Design assistance to produce any revised diagrams shall be arranged. The work shall be tested using the Signalling Works Testing standard. 7.5 Test Records The Maintenance Tester shall complete a record of the testing carried out and forward it to the local manager at the first opportunity after the end of the shift. The local manager shall check and retain the record of test in a way that permits the location of specific records at a later date. A system shall be in place to routinely check returns from each team as well as a more thorough check at least once every three months. This check shall determine that the appropriate Maintenance Test Plans have been used and that sufficient detail has been recorded. Deficiencies shall be followed up by appropriate corrective action such as monitoring or retraining. The record of test shall be retained for a minimum of five years. B8 R A I L T R A C K

18 Testing Date Feb 1997 Page B9 of 24 A.1 Scope Appendix A Maintenance Testing Guidance Maintenance Testing shall be used to test equipment replaced into a previously working and commissioned system during maintenance, renewals and faulting. The replacement shall be like for like and any new item shall be operationally equivalent to the original item which it replaces. The design of the control system shall remain unchanged. The following specific alterations may be tested using the Maintenance Testing standard: Relay base changing, signalling cable replacement, track circuit disconnection for relaying (if track/ibj layout and circuit design do not change). The temporary diversion of circuits (using the correct Maintenance Test Plan). A cable or wire found cut, separated from its connection or with a length missing (as a like for like replacement). Other previously working equipment found physically missing or separated from its normal position may be replaced using Missing Equipment Test Plans following the principles of this standard. Work on communications systems carrying safety related data required for railway operations shall be undertaken following the requirements of standard GK/RT0105. This work and the applicable test requirements shall be defined and documented by the Infrastructure Controller. Signalling circuits in cables shared with telecoms functions must be identified and tested in accordance with local procedures. A Maintenance Test Plan shall not be required for adjustment activities where electrical circuits are designed to be adjusted eg., transformer tappings, track circuit feed set or resistor block strapping, wire wound resistors with a tapping ring. Care shall, however, be taken to ensure that adjustment straps are correctly terminated and no stray connections are possible. Similarly Maintenance Test Plans shall not be required for mechanical adjustments but care must be taken to ensure equipment is left secure eg., bolts tightened, pins correctly fitted. During any other work, including fault diagnosis, which involves disconnections or substitutions, the applicable Maintenance Test Plans shall be used. Non vital equipment, or parts of it, shall not normally have an associated Maintenance Test Plan. The disconnection or replacement of cables and wires associated with non vital equipment shall be carried out in a controlled manner with all wires or cores correctly labelled before removal. Cable and wire insulation shall be checked for damage but the use of the associated Maintenance Test Plans shall not be required. R A I L T R A C K B9

19 Railway Group Date Feb 1997 Page B10 of 24 Testing A.2 Operationally Equivalent A.3 Method Statement Considerations Renewals or the replacement of obsolete equipment, including cables, with the current operationally equivalent type may be undertaken as a like for like replacement where the electrical integrity of the circuitry and interlocking remains unchanged. Any required site diagram amendments to maintain correlation shall be undertaken as described in this standard and available on site whilst applicable. The local manager shall ensure that any temporary alteration is permanently rectified. Where a temporary arrangement / alteration is required to become permanent the Infrastructure Controller shall be advised. Where any (temporary) arrangement / alteration remains in service for more than a month any related diagrams shall be verified by an independent licenced designer and permanent diagrams arranged. The specific alterations listed in section A.4 below may be regarded as operationally equivalent and therefore tested using the Maintenance Testing standard. In each case the most relevant Maintenance Test Plan(s), or relevant parts, shall be used. The work and testing shall be planned and documented by a Maintenance Tester before it is started. The special nature of the alterations may require an additional method statement as part of the pre planning to document the entire process and ensure all hazards are considered and risks minimised. All pre planning and testing documentation, including method statements, shall be independently checked and authorised by the local manager before use and shall be retained as part of the record of test. All work shall be independently designed, checked, installed and tested by appropriately competent staff. Consideration shall particularly be given to site records update (including removal of superseded records), testing of additional affected equipment, the extent of wiring correlation required (including consideration of internal wiring configurations and terminal numbering), ensuring the correct connection of wiring, any special tests or drawings required, the competence and understanding of staff involved, any requirements for protective disconnections, Rule Book requirements like handsignalling and any special circumstances at the work site. References to specific additional tests in equipment or manufacturer manuals may be required. Where the alteration is temporary or not immediately brought into operation a testing plan for the introduction or withdrawal from service shall be established. The names of the author, tester and authorising manager shall be included. B10 R A I L T R A C K

20 Testing Date Feb 1997 Page B11 of 24 A.4 Specific Operationally Equivalent Alterations Renew damaged or life expired single apparatus case (not multiples, REBs or combining cases) new case/layout without wiring change. Elements of Mtce. Test Plans to be used: depends on equipment in the apparatus case use Equipment Index. The work is not appropriate for testing using this standard if any wiring alterations are included or link numbers are to change. Conversion of binding posts to links may be undertaken as part of the work. Testing shall include all tests specified in the Mtce. Test Plans for the individual items of equipment affected. Checked modification diagrams are required before the work starts based on a physical check of existing equipment/wiring to the existing diagrams. Method statement required. Records shall be updated to show any layout changes. Point detector box one electrical type to another. For conversions where no change to the wiring arrangement and relay outside the detector box is required. The circuitry shall already be double cut if microswitch detection is being fitted. Terminal or contact numbers may change. Elements of Mtce. Test Plans to be used: PB05. Testing shall include Point Detection & Correspondence Test. Checked modification diagrams are required before the work starts showing the circuit modification (specifying the type of detector, terminal numbers and wiring of any microswitches) and the position of the detector (mechanical drawing). Design shall be specific enough for the testing to verify that the intended equipment is being used. Method statement required. Records shall be updated with detector type and contact numbers where different. Point machine one type to another For conversions where no change to the wiring arrangement outside the machine is required. Machine terminal numbers may change. Mtce. Test Plan to be used: PC01. Testing shall include Point Detection & Correspondence Test and FPL test. Standard drawings are required before the work starts. Method statement required. Records shall be updated with machine type and terminal numbers where shown or a standard drawing included. Disconnection box remove or install Elements of Mtce. Test Plans to be used: CA04 Testing shall include carrying out Mtce. Test Plan steps marked with an asterisk * for all equipment fed via the disconnection box. Method statement required. Records shall be updated to show the installation or removal of the disconnection box. R A I L T R A C K B11

21 Railway Group Date Feb 1997 Page B12 of 24 Testing Track leads single to double. Elements of Mtce. Test Plans to be used: CA01, CA04. Testing shall include a full test of affected track circuits. Method statement required. Records shall be updated to show the additional cables. Cable terminations upgrade, eg links for binding posts Elements of Mtce. Test Plans to be used: CA01, CA04, EL06. Testing shall include a Wire Count and ensure the items fed via the affected terminations operate correctly. Method statement required. Records shall be updated to show the new terminations and numbering where different. Power supply electrically equivalent but polarity labels in conflict with diagram. Elements of Mtce. Test Plants to be used: PW01, PW02, TC01, TC02. Testing shall include ensuring the items fed via the replacement unit operate correctly. Method statement NOT required. Records shall be updated to show the new labelling where different. Lead acid (unsealed) cells change to sealed cells (including any requirement to change charger). Elements of Mtce. Test Plans to be used: CE01, PW01. All cells making up the affected battery shall be changed. Refer to manufacturer details for charger requirements, eg. constant voltage. The current rating (amps) and battery capacity (ampere/hours) shall be checked as appropriate for the application. The work is not appropriate for testing using this standard if power off proving circuitry is required and not already in place. Testing shall include voltage and polarity checks, a test of standby arrangements and, for track circuits or signal lamps fed from the cells, a track circuit or signal lamp test. Checked modification diagrams are required before the work starts. Method statement required. Records shall be updated to show the change. Lock and Controller combine or uncombine. Elements of Mtce. Test Plans to be used: LV01, LV02. Combined lock and controller can only be uncombined when either the lock or controller is to be taken out of use. Testing shall include ensuring the correct operation of the lock and the circuits operated by the controller contacts. Method statement required. Records shall be updated to show the change. Mechanical interlocking tappet renew omitting redundant notches. Redundant locks shall have been previously recovered. Elements of Mtce. Test Plans to be used: LV05. Testing shall include Mechanical Locking Function Test and Dog Chart Comparison Test of affected locking. Checked modification diagrams are required before the work starts. Method statement required. Records shall be updated to show the change. B12 R A I L T R A C K

22 Testing Date Feb 1997 Page B13 of 24 A.5 Special Arrangements Colour light signal head one make to another. Applies only where the replacement has the same number of aspects and same method of operation. Wiring alterations shall be limited to the signal head (eg. using converted A.C. head for D.C. operation or filament proving circuit arrangement). Elements of Mtce. Test Plans to be used: SG01. Testing shall include Aspect Test. Checked modification diagrams are required before the work starts. Method statement required. Records shall be updated to show the new terminations and numbering where different. The specific alterations listed below may be undertaken when specially authorised by the local manager in order to facilitate train movements. The principles for performing the work are the same as for operationally equivalent replacements (above) including the requirements for planning, independent testing, diagrams and a method statement. Temporary wiring/straps shall be of a suitable type and distinctive colour. Detection strapping out due to damage or adjacent works. For temporary arrangements when specially authorised by the local manager. Elements of Mtce. Test Plans to be used: CA01. Testing shall include Point Detection & Correspondence Test for all remaining ends sharing a detection circuit with the affected end. This must be repeated, including the affected end, when the straps are removed. Method statement required which shall clarify the means of controlling the point ends (eg. preventing remaining ends of multi ended points from moving or disconnecting routes), the controls on the fitting and removal of the straps and the arrangements for reminding the signalman (eg. indication change, train register entry). Records shall be updated to show the change. Checked modification diagrams are required before the work starts and straps shall only be used on contacts within the point operating mechanism or local apparatus case. Damaged track plain line S&C and alter bonding. For temporary arrangements when specially authorised by the local manager. Elements of Mtce. Test Plans to be used: CA01. Testing shall include a full test of the affected track circuits. Checked modification diagrams are required before the work starts. Method statement required which shall clarify the requirements for maintaining clearance points, the controls on the removal of the temporary bonding arrangements and the arrangements for reminding the signalman (eg. indication change, train register entry). Records shall be updated to show the change. R A I L T R A C K B13

23 Railway Group Date Feb 1997 Page B14 of 24 Testing Redundant / damaged equipment strapping out relays. Applies only to signals and ground frames. For temporary arrangements when specially authorised by the local manager. Elements of Mtce. Test Plans to be used: depends on equipment affected use Equipment Index. Testing shall include all tests specified in the Mtce. Test Plan for the individual item of equipment affected. This must be repeated when the straps are removed. Checked modification diagrams are required before the work starts and straps shall only be used on contacts within the local apparatus case. Method statement required which shall clarify the means of controlling the fitting and removal of the straps and the arrangements for reminding the signalman (eg. indication change, train register entry). Records shall be updated to show the change. Power supply transformer rectifier for failed charger. For temporary arrangements when specially authorised by the local manager. Elements of Mtce. Test Plans to be used: PW01, TC02. Testing shall include an Earth Test and ensure the items fed via the replacement transformer rectifier operate correctly. Checked modification diagrams are required before the work starts. Method statement required which shall clarify the controls on the removal of the temporary transformer rectifier. Records shall be updated to show the change. B14 R A I L T R A C K

24 Testing Date Feb 1997 Page B15 of 24 B.1 General B.2 Maintenance Test Plans Appendix B Test Plan Requirements Maintenance Test Plans and Missing Equipment Test Plans are the primary test documents required by this standard. Maintenance Testing activities shall not be undertaken without reference to these documents. Maintenance Test Plans are checklists of the minimum safety tests to ensure the safe operation of replaced signalling or telecommunications equipment where the work has operational safety implications. A Maintenance Test Plan shall consist of numbered steps in a logical sequence. Where steps must be carried out in the order stated for safety reasons, or where steps are not required for a particular equipment type, this shall be clearly stated in the document. Maintenance Test Plans shall be divided into two sections covering tests needed before the work and those required after the work. A Maintenance Test Plan need not list every task required to perform the work or list checks purely associated with reliability. Maintenance Test Plans shall be grouped by equipment within the standard for easy reference and allocated a unique reference, eg., AW02, PW01. Each shall, where it assists clarity, include a brief description of the scope (inclusions and exclusions) of the individual Maintenance Test Plan directly beneath the title. Each Maintenance Test Plan shall be comprehensively referenced within the standard by use of an equipment index. The equipment index shall state specific instances where a Maintenance Test Plan is not required. Terms or words used in a Maintenance Test Plan which are described in more detail elsewhere in the standard shall be written in italic text for ease of recognition, eg. check, test. Defined tests shall additionally be written in block capitals, eg. WIRE COUNT. Tests or checking sequences which are already defined in Code of Practice GK/RC0741, Specifications, shall be referenced from this standard when required. The reference shall be contained in square brackets, eg. [Barrier sequence (SMS)]. Where the Maintenance Test Plan for an item requires specific tests or checks on another item as a consequence of the original relacement or alteration, the second Maintenance Test Plan shall be referenced from the first, eg. tests on an item fed by a cable which has been renewed. A note shall be added to the first Maintenance Test Plan and the steps to be carried out in the second marked with an asterisk *. New Maintenance Test Plans, when required, shall be produced using the most appropriate existing Maintenance Test Plan as a guide and independently checked before use. R A I L T R A C K B15

25 Railway Group Date Feb 1997 Page B16 of 24 Testing B.3 Missing Equipment Test Plans Missing Equipment Test Plans shall include enhanced steps to cover the fact that the equipment cannot be checked to the diagram. These steps shall overcome the inability to carry out the normal pre installation checks and tests. They shall include seeking evidence that the equipment was present and of the type shown on the diagram. Missing Equipment Test Plans shall be produced on green paper to differentiate them visually from Maintenance Test Plans. Each shall be comprehensively referenced within the standard by use of a missing equipment index. Missing Equipment Test Plans shall be used in the same way as Maintenance Test Plans. New Missing Equipment Test Plans, when required, shall be produced using the most appropriate existing Maintenance Test Plan as a guide, with reference to existing Missing Equipment Test Plans for the enhanced pre installation tests. The new document shall be independently checked before use. B16 R A I L T R A C K

26 Testing Date Feb 1997 Page B17 of 24 C.1 Routine Test Records Appendix C Test Record Requirements Whenever Maintenance Test Plans are used, the test record shall include as a minimum: The date of the work The time of rectification or completion Any fault number The site of work A summary of affected equipment (i.d./serial numbers) Basic details of the work (summary) The reference no. of each Maintenance Test Plan used The names of those doing and testing work. Notes relevent to any of the following shall also be included: Any links slipped during the work which require recording Any details of handover to/from another team (time,date, names) Any testing steps required which have not or cannot be carried out Any suggested Maintenance Test Plan deficiency and any additional testing carried out as a result Any amendments to diagram Any temporary strapping / diversions Any problems encountered during the work or testing. The Testing Logbook is suitable for test records and provides two numbered copies, one for submission to the local manager and one for retention by the Maintenance Tester. An example is given in Figure 1. Additionally site records (eg. signal lamp cards, track circuit cards) shall be completed as appropriate by the Maintenance Tester. R A I L T R A C K B17

27 Railway Group Date Feb 1997 Page B18 of 24 Testing Place: BARTON MILLS Date : 5/6/91 Time : Fault No : Equipment (inc. serial nos): 54 `A' PTS HW MACHINE 65321B Detail of work: REPLACE MOTOR Maintenance Test Plans used: PC02 Work done by: Work tested by: Notes: A. N. OTHER A. TESTER 1 C.2 Pre planned Work Records Figure 1 Logbook Example Test Record This standard is designed to cater for testing where there is little or no time to pre plan. Where time is available it is advisable to use the opportunity to pre plan as much of the work and associated testing as possible. The following guidelines are considered as best practice: Where work and associated testing can be pre planned this should be documented. The minimum requirement should be to list the Maintenance Test Plans to be used, the equipment to be replaced, the work location and the work to be carried out. The list should be used on site as the basis for the work to be undertaken. The pre planning list should be amended by the Maintenance Tester to detail any change in the actual work undertaken or deviation from the listed Maintenance Test Plans. At the end of the work the list should accurately reflect the actual work carried out and record the names of all those involved with the work and testing. The completed list should be submitted as an additional part of the record of test and may be retained as an auditable record at the discretion of the local manager. B18 R A I L T R A C K

28 Testing Date Feb 1997 Page B19 of 24 A system should be in place to routinely check returned pre planning lists, particularly for any recorded deviation to the pre planned work. If the recorded work is considered inadequate the local manager should arrange for the work to be retested. The Maintenance Test Plan List sheets are suitable for pre planning test records and provide two numbered copies, one for submission to the local manager after use on site and one for retention as a record of the work planned. An example of a pre planning test record is given in Figure 2. (Layout shown smaller than actual size) Figure 2 Mtce. Test Plan List Example Pre planning Test Record R A I L T R A C K B19

29 Railway Group Date Feb 1997 Page B20 of 24 Testing This page is intentionally blank. B20 R A I L T R A C K

30 Testing Date Feb 1997 Page B21 of 24 C.3 Recording Maintenance Test Plan Steps Whilst it is not necessary to tick off the numbered steps of each Maintenance Test Plan for auditing purposes, progress may be recorded if it assists the Maintenance Tester in performing the tests. An example of a completed tick sheet is given in Figure 3. A suitable blank tick sheet is provided in the handbook for copying as required. Maintenance Test Plan No.: PW Maintenance Test Plan No.: TC01 (AB TC) Maintenance Test Plan No.: TC01 (DE TC) Maintenance Test Plan No.: Maintenance Test Plan No.: Figure 3 Tick Sheet Example R A I L T R A C K B21

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32 Testing Date Feb 1997 Page B23 of 24 D.1 Working on Equipment Which Is In Service D.2 Making Disconnections D.3 Changing Electric Tokens Appendix D Work on Operational Equipment No work shall be done which will interfere with the normal working of signalling equipment without the agreement of the signalman. The Rule Book defines the arrangements necessary for working on equipment which is in service. Whenever possible the work should be self protecting (for example, whilst a track circuit drop shunt test is being done, the track circuit shows occupied preventing protecting signals from being cleared), or protected by temporarily removing fuses or slipping links (for example, TPR or point detection circuits). Signalling apparatus shall not be manipulated to cause it to work by any means other than the designed arrangement unless special instructions are issued to the contrary. Disconnection of signalling apparatus shall follow the requirements of Rule Book Section E. When it is necessary for a lever or panel switch to be moved during the work, the signalman shall be requested to move it or his permission obtained. When it is necessary to disconnect any electrically operated points or signals or to disarrange their interlocking, the electrical controls of all affected signals shall be disconnected in accordance with the Rule Book. Mechanically worked signals associated with affected electrically operated or detected points or signals shall be disconnected. Any disconnection of a circuit that affects the signalman, including disabled level crossing telephones and other Telecomms circuits, shall be advised to the signalman who shall put in place the necessary method of working. When dealing with electric token instruments of any type the person undertaking the work shall observe the Block Regulations and other relevant instructions. The person undertaking the work shall ensure that no section signals are released when it is necessary for tokens to be withdrawn or inserted into instruments. Any section signal release shall be destroyed by removing two tokens and then replacing one of them. Entries shall be made in both the Train Register and the signalling staff Token Register stating the number of tokens dealt with. When a token is damaged the person undertaking the work shall be in possession of the damaged token before putting the instruments into phase. When a token has been lost the person undertaking the work shall only put the instruments into phase with the written authority of the designated Operations Manager or his representative who shall be present when the instruments are put into phase. R A I L T R A C K B23