Integrated management of resources, risks and dependability of railway infrastructure facilities at lifecycle stages. Case studies of the methodology application in Russian Railways divisions Zamyshlyaev A.М. Head of R&D Complex for Traffic Safety and Station Automation Systems, Dr. Sci. Session II – 12th October 2015 QUOTES A lot of yesterday's solutions are today's problems. Sam Nunn The wheel that squeaks the loudest is the one that gets the grease. Henry W. Shaw 2 PATTERN OF THE MODERN COMPANY’S WORK Increase of income Compliance Management Cost reduction 3 INFRASTRUCTURE AND ROLLING STOCK FACILITIES OF JSC RZD Infrastructure:: Length of operational tracks 85 200 km Length of electrified lines 43 100 km Lines equipped with signalling equipment 62 196 km Railway stations 5 428 Traction substations 1 402 Service units (track divisions) 742 Rolling stock fleet: Freight locomotives (electric and diesel) 11 191 Freight cars of all types and owners 1 600 000 Shunting engines (diesel) 6 016 Long-distance passenger cars 24 100 Commuter cars 15 600 Motive power and car depots 411 4 URGENT ISSUES TODAY ° Technical maintenance of the network of Russian railways requires tremendous expenditures related to maintaining the dependability of infrastructure facilities and ensuring the safety of transportation process. ° The share of railway infrastructure basic funds is more than 60% of total JSC RZD fixed assets value. ° The share of OPEX for infrastructure facilities is about 35% of total scope of JSC RZD OPEX. 5 TRANSFORMATION OF RAMS METHODOLOGY INTO URRAN SYSTEM - THE SYSTEM OF DECISION-MAKING SUPPORT What are consequences How often does failure occur? of some events? RELIABILITY SAFETY RAMS What operation facility How well/badly can volume is given the system at the disposal? be maintained? AVAILABILITY MAINTAINABILITY 6 SYSTEM FOR DECISION MAKING SUPPORT TRANSFORMATION OF THE RAMS METHODOLOGY INTO URRAN SYSTEM OBJECT LIFE CYCLE SAFETY DEPENDABILITY RESOURCES Prolongation Risk Life cycle cost Indicators Reliability Maintainability Availability Durability of a set service management management life Operation Utilization Installation Acquisition Development RAMS URRAN 7 URRAN – SET OF STANDARDS, METHODS AND GUIDELINES USED FOR MANAGEMENT OF LIFE-CYCLE PROCESSES OF RAILWAY SYSTEMS OBJECTS OF TECHNICAL BASIC PROCESES REGULATION OF RAILWAY TRANSPORT Track facilities TECHNICAL MAINTENANCE Technical maintenance of Facilities of infrastructure facilities and electrification rolling stock and power supply Modernization of infrastructure and rolling stock Facilities of signaling and remote control Procurement management Telecommunication facilities Management of environmental, fire, industrial and labor safety Locomotive facilities URRAN normative and methodological framework — 109 documents Purpose of URRAN introduction: increase of the efficiency of railway transport operation based on adaptive management under the conditions of scarce resources 8 RESOURCE MODEL OF TRACK LIFE CYCLE OPTIMIZATION ON THE BASIS OF PHISICAL DEPRECIATION EVALUATION OF INFRASTRUCTURE ELEMENTS 9 D ИC LIFE CYCLE OF RAILWAY TRANSPORT FACILITY Stage 1 INCLUDING THE PROCESS OF MANUFACTURING Concept of RT facility Analysis of the existing Stage 13 state of RT facilities, D ИC Monitoring of market research operational Specification of project parameters scope and purpose Stage 2 Collection, analysis and evaluation of data on Development of RT facility Definition of RT facility performance indicators concept variants and their and its application feasibility studies conditions (initial Collection, analysis and requirements D C evaluation of data on Project management specification) dependability and safety arrangement C Definition of maintenance Monitoring of hazards and conditions influencing RT threats, updating of hazards Revisions of previously facility operation and threats list reached dependability and Stage 3 safety indices (including Monitoring of costs and profits analogs) Specification of RT facility Risk analysis technical parameters of RT facility operation, LCC analysis Report on concept Specification of maintenance Identification of risks and D C C D M CB C M development and design and repair hazards (including application cyberthreats) Specification of safety policy C D M Definition of risk criteria Development of dependability and safety Risk level definition (rate Stages 10 и 11 Stage 12 Stage 15 plans for design stages and consequences Stage 4 analyses) Validation and Operation and De- Specification Risk estimation Acceptance maintenance commissioning D C CB Check of conformity with RT facility use for intended and Disposal Risk evaluation Specification of RT facility all contract specification purpose Stage 9 requirements Decommissioning planning Expertise of RT facility C M Various types of specification CB Installation Acceptance testing maintenance and repair as to the rules or RT facility state Documentation preparation, deregistration Patent researches Stages 5 и 6 Conformity proof (by Apportionment of Installation planning acceptance) Material and technical Development of technical M C Stage 8 Tender support Development of Safety Plan status map requirements, for Decommissioning and procurement Revision of Safety Policy Documentation Development of Disposal stage Review and revision of Design and for further operation preparation, registration Dependability and Safety Dependability and Safety Plans for Operation and Plans Implementation Dismantling of components Conceptual design development Preparation of Maintenance stage Development of acceptance requirements for RT facility Revision of Dependability Commissioning testing plan (validation Stage 7 or its components to be and Safety Plans for Disposal plan) Engineering design development procured Manufacture stage Safety case revision Preparation of maintenance Manufacture and service manuals and Development, agreement and Development of instructions for operators (production) Bid notice approval design specifications, Dependability and Safety operational and maintenance Manufacture of Plans for Manufacture manuals preproduction batch Analysis and comparison of stage upon acceptance manufacturers (suppliers) results Development of SW for functional offers components and program Supervised operation of documentation preproduction batch (if required) Selection of manufacturer (supplier) Stage 14 Integration of SW and HW Qualification testing of Preparation of supply Modification and Review and revision of preproduction batch contract specification and retrofit Dependability and Safety Plans contract signing Safety case preparation Approval of design documents upon results of Manufacture and customization qualification testing of prototypes Factory testing of prototypes Safety Policy revision for To stage 2 Manufacture stage Approval of design documents upon results of factory testing Development of Dependability and Safety Acceptance testing of prototypes Plans for Manufacture stage Supervised operation of Conformity proof (for mass prototypes (if required) production) Approval of design documents upon results of acceptance C - Customer testing Conformity proof (of single products, prototype batch) D - Designer M - Manufacturer Verification CB - Certification body Validation 10 URRAN NORMATIVE AND METHODOLOGICAL FRAMEWORK GOST – 2 Provide for: Terminology GOST R – 5 subject matters: • Procurement with consideration – risk management; of a life cycle cost. – classification of dependability and functional safety indicators • Repairs according to technical STO RZD corporate standards – 16 condition based on risk subject matters : assessment. – risk management including professional risks management; – requirements and indicators of dependability and functional safety ; • Improvement of reliability and – life cycle cost management; safety of technical devices – assessment of cyber security of control systems SW under the conditions of scarce resources. Methodology instructions – 78 subject matters : • Improvement of efficiency of the – technical devices risk assessment; resources redistribution over life – calculation of reliability and functional safety; cycle stages – economics and procurement; – performance assessment of structural divisions Classifiers – 8 subject matters : – pre-failures; – procurement 109 documents in total 11 GOST R 54505-2011. FUNCTIONAL SAFETY. RISK MANAGEMENT ON RAILWAY TRANSPORT The standard outlines the approach and guidelines for risks management on railway transport related to traffic safety and railway operation. The standard will allow to use a new approach towards the management of dependability and functional safety of railway transport facilities based on risks management. Also, Guidelines are developed for practical application of this national standard where one can find the standard clauses clarified, the methods of risk analysis examined and the examples of risk calculations provided. 12 RISK DEFINITION ACCORDING TO RAMS METHODOLOGY According to IEC 62278 (the international standard on RAMS): RISK is a combination of the probability of harm occurrence and the severity of that harm 13 TYPICAL LEVELS OF EVENT RATES Event frequency Rate Description per year, f Frequent f > 10 -3 Can occur frequently. Continuous hazard Probable 5×10 -4 ≤ f < 10 -3 Repeated occurrence. Frequent occurrence of hazard is anticipated. Occasional 10 -4 ≤ f < 5 ×10 -4 Probability of repeated occurrence. Repeated occurrence of hazard is anticipated. Probability of the event occurring