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2014 ARS, Europe: Paris, FranceRed Room, Session 5
Reliability, Availability, Maintainability and Safety (RAMS) - Application for
Self-Contained Power Supply of Gotthard Base Railway Tunnel
Dr. Andreas van LinnAmstein+Walthert ProgressAndreasstrasse 118050 Zürich
Begins at 3:30 PM, Wednesday, April 23rd
PRESENTATION SLIDESPRESENTATION SLIDESThe following presentation was delivered at the:
International Applied Reliability Symposium, EuropeApril 23 - 25, 2014: Paris, France
http://www.ARSymposium.org/europe/2014/
The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitioners within industry and government to discuss their success stories and lessons learned regarding
the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open"Call for Presentations" at http://www.ARSymposium.org/europe/presenters/index.htm and the presentations
delivered at the Symposium are selected on the basis of the presentation proposals received.
Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the presentation is solely the responsibility of the author. Publication of these presentation materials in the
ARS Proceedings does not imply that the information and methods described in the presentation have been verified or endorsed by the ARS and/or its organizers.
The publication of these materials in the ARS presentation format is Copyright © 2014 by the ARS, All Rights Reserved.
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Agenda
Project - Introduction 5 min
Requirements 10 min
Reliability Prediction 20 min
RAMS - Life Cycle Management 10 min
Conclusion 5 min
Questions 10 min
Introduction Requirements Life Cycle ConclusionReliability
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Project - Introduction
Introduction Requirements Life Cycle ConclusionReliability
© AlpTransit Gotthard AG
Gotthard Base Tunnel
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Project - Introduction
Gotthard Base Tunnel North portal: Erstfeld
South portal: Bodio
2 x 57 km single-track tubes
Crossways all 325 m
Considering all connecting tunnels, the system length measures 152 km
Rock cover: 2300 m
2 x multifunctional sites (MFS)
with emergency stops
Introduction Requirements Life Cycle Conclusion
© AlpTransit Gotthard AG
Reliability
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Project - Introduction
Introduction Requirements Life Cycle ConclusionReliability
© AlpTransit Gotthard AG
The first flat trajectory railway through the Alps
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Project - Introduction
Introduction Requirements Life Cycle ConclusionReliability
Tunnel System of the Gotthard Base Tunnel
© AlpTransit Gotthard AG
Emergency stop
Emergency stop
Shaft Shaft
Multifunctional site (MFS)
Multifunctional site (MFS)
Access tunnel
Cable tunnel
Access tunnel
Intermediate excavationand shafts Sedrun
Crossway
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Project - Introduction
Organisation
Operator: SBB AG
Client: Alp Transit Gotthard AG
General contractor rail-engineering: Transtec Gotthard:
General partner:
Alpiq Alcatel-Lucent/Thales Renaissance Construction Balfour Beatty Rail
Introduction Requirements Life Cycle ConclusionReliability
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Project - Introduction
Maintenance Group / Lot
Introduction Requirements Life Cycle Conclusion
Sub-Contractor Area of Expertise
Sub-Arge BBR / RC
Rail track
Power supply 50 Hz and cables
Sub-Arge BBR / K+M
Rail power supply 16.7 Hz
Sub-Arge ALU / TRSS
Signalling, control andcommunication
Reliability
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Project Partner
Introduction Requirements Life Cycle Conclusion
Company Area of Expertise Service Package (LP)Andrew Radio communicaton LP70
Avesco No Break LP22; LP40
Ascom Service communication (BKA) LP61
Hirschmann Access; telecommunication LP61
Keymile UMUX; network components LP80; LP81; LP82; LP83
ABB Secheron Medium-high voltage LP40
Siemens Control system; IT LP60
Swisscom Solutions Cisco; network components LP61
Leoni-Studer Cable systems LP22; LP40; LP41; LP42; LP43; LP44
Swibox Electrical connection cabinets LP45
Pöyry Planning-coordination, management support LP10
Grunder Ingenieure Survey and mapping LP30; LP31; LP32; LP33
ABB Schweiz Transformer LP40
Planning, RAMS, PQM,… LP40; LP41; LP42; LP43; LP44; LP45; LP46; LP47
Scheuchzer Realisation LP30; LP31
Alpha Plan Planning LP40; LP41; LP42; LP43; LP44; LP45; LP46; LP47
Hefti, Hess, Martignoni Planning; consulting LP40; LP41; LP42; LP43; LP44; LP45; LP46; LP47; LP22
Reliability
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Requirements According To Reliability
Introduction Requirements Life Cycle ConclusionReliability
Based on EN 50126:
Railway applications –
The specification and demonstration of
Reliability, Availability, Maintainability and
Safety (RAMS)
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Requirements According To Reliability
Introduction Requirements Life Cycle Conclusion
Rail Track 50Hz and Cables
Rail Power Supply 16,7Hz
TC-Fixed Network
TC-Radiocom.
Safety Devices
Complete System – Railway Technology
Disturbance rate per year
Disturbance Class (SK)
SK 1 SK 2 SK 3 SK 4
40 20 5 0.4
Rail System
Switch Points
Switchgear panels
Cable systems
El. Lighting
El. Cabinets
Signs
Handrail
Overhead contact lines and cables
Switching Stations
Control and comm. sytem
El. grounding
Protective section north
Tunnel controlsystem
Data network
Service comm.
TC- Radiocomm. Railway controlsystem
ETCS Level 2
Train control andcomm. system
Reliability
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Disturbance Classes (SK)
Definition of disturbance classes 1-4
Factors
Influence on train’s schedule
Elimination with/without intervention on trail
Blocking of route sections
Introduction Requirements Life Cycle ConclusionReliability
© AlpTransit Gotthard AG
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Disturbance Classes
Introduction Requirements Life Cycle Conclusion
Class Influence On Railway System Example
1 No longer than 1h influence on timetable stability. The sum of delays of directly affected trains is less than 10 minutes.
• Emergency braking of a train because of system failure.
• Local outage of GSM-R for one minute.
2 More than 1h influence on timetablestability. The sum of delays of directly affected trains is more than 10 minutes.
• Disturbance of wheel-countingapparatus driving on sight.
3 Immediate blocking of one track sectionas result of failure or for fault repair.
• Switch points not in final position and impassable.
• Railbreakage (ultrasonic failure).• Enduring outage of overhead
contact line.
4 Immediate blocking of more than one track sections (one track) or total blocking (both tracks).
• Total failure of signalling / safetydevices
• Total outage of GSM-RReliability
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Requirements for 50Hz and Cable
Introduction Requirements Life Cycle Conclusion
Subsystem Availability1: Standard power supply centre Sedrun
(medium voltage) 99.941 %
2: Standard power supply centre Sedrun(low voltage)
99.936 %
3: Standby power supply centre Sedrun(low voltage)
99.937 %
4: Standard power supply transverse tunnel(low voltage)
99.852 %
5: Standby power supply transverse tunnel(low voltage)
99.976 %
Reliability
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ReliabilityIntroduction Requirements Life Cycle Conclusion
Example: Subsystem 3
Circuit Breaker
Transformer
Static Transfer System (STS)
FuseConsumer Load
No Break Diesel:Uninterruptible Power Supply (UPS)
Cables
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Requirements
Additional requirements on Maintainability
o Based on maintainability concepts of SBB
Safetyo Based on Quantitative Risk Analyses (QRA) from SBB
Introduction Requirements Reliability Life Cycle Conclusion
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Reliability Prediction
The basic principle of reliability prediction and integration of single results of one Subsystem into the complete tunnel system is described. This includes:
o Basic component data
o RAM-interfaces
o Reliability calculations
o Disruption protocol
The bottom up approach
The Causer principle
Introduction Requirements Reliability Life Cycle Conclusion
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Reliability Prediction
Introduction Requirements Reliability Life Cycle Conclusion
1 Components 2 RAM-interfaces
3 Reliability calculation
singlefailures
single & multiple failures
additional failures
singlefailures
failures
4 Disruption protocol
singlefailures; SK
Bottom
Up
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Bottom
Up
Components – Single Failure List
Introduction Requirements Reliability Life Cycle Conclusion
2 RAM-interfaces
3 Reliability calculation
singlefailures
single & multiple failures
additional failures
singlefailures
failures
4 Disruption protocol
singlefailures; SK
1 Components
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Up
Bottom
Components – Single Failure List
Circuit Breaker
Transformer
Static Transfer System (STS)
Fuse
No Break Diesel:Uninterruptible Power Supply (UPS)
…
Describe Failure Mode, Cause, Effects
Certificate Producer Specifications
Benchmarks
Statistics
Basic Data MTBF (Mean Time Between Failure)
MTTR (Mean Time To Repair)
Introduction Requirements Reliability Life Cycle Conclusion
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Up
Bottom
Components – Basic Data
No Break Diesel:Uninterruptible Power Supply (UPS)
Example 1:Certificate
Producer Specifications
Basic Data
MTBF [a] = 42.2
MTTR [h] = 8
Introduction Requirements Reliability Life Cycle Conclusion
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Up
Bottom
Components – Basic Data
Example 2:Certificate
Producer Specifications
Basic Data
MTBF [h] = 2.5 10+6
MTTR [h] = 4
Introduction Requirements Reliability Life Cycle Conclusion
Static Transfer System (STS)
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RAM-Interfaces
Bottom
Up
1 Components
3 Reliability calculation
singlefailures
single & multiple failures
additional failures
singlefailures
failures
4 Disruption protocol
singlefailures; SK
2 RAM-interfaces
ReliabilityIntroduction Requirements Life Cycle Conclusion
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RAM-Interfaces - Matrix
Introduction Requirements Reliability Life Cycle Conclusion
• High complexity • Hundreds of technical interfaces
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RAM-Interfaces - Causer Principle
Introduction Requirements Reliability Life Cycle Conclusion
• Investigate each component failure and combinations (source) on the effect of each consumer (sink).
• Determine disruption class. • Protocol in RAM-interfaces lists.
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1 Components
RAM-Interfaces – Example
Introduction Requirements Reliability Life Cycle Conclusion
3 Reliability calculation
4 Disruption protocol
singlefailures
single & multiple failures
failures
additional failures
singlefailures; SKsingle
failures
2 RAM-interfaces
ID
Source
Sink
Single or combined failures
Location Failure mode
Cause
Effect
Criticality disruption class
(Failure mode, effects and criticality analysis) FMECA
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Reliability Calculation
Bottom
Up
1 Components 2 RAM-interfaces
singlefailures
single & multiple failures
additional failures
singlefailures
failures
4 Disruption protocol
singlefailures; SK
3 Reliability calculation
Introduction Requirements Reliability Life Cycle Conclusion
Reliability Block Diagrams (RBA)
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Bottom
Up
Reliability Calculation – Basic Formula
Reliability Availability
In Series
www.eventhelix.com
Introduction Requirements Reliability Life Cycle Conclusion
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Bottom
Up
Reliability Calculation – Basic Formula
In Parallel
www.eventhelix.com
Introduction Requirements Reliability Life Cycle Conclusion
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Up
Bottom
Reliability Calculation – Basic Formula
Considering Common Cause Failures in Parallel Systems
Determine β-factor according to (61508-6 © IEC:2010)
Introduction Requirements Reliability Life Cycle Conclusion
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Bottom
Up
Reliability Calculation – Basic Formula
Considering Common Cause
Failures in Parallel Systems
β = 1 %
Example: R1=R2=R
Introduction Requirements Reliability Life Cycle Conclusion
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Bottom
Up
Disruption Protocol
1 Components 2 RAM-interfaces
3 Reliability calculation
singlefailures
single & multiple failures
additional failures
singlefailures
failures singlefailures; SK
4 Disruption protocol
Introduction Requirements Reliability Life Cycle Conclusion
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Disruption Protocol
Introduction Requirements Reliability Life Cycle Conclusion
Description
Location
Source function
Interfaces
Source lot
ID
1 row for each source – sink –interface with disturbance class > SK0
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Disruption Protocol
Introduction Requirements Reliability Life Cycle Conclusion
FMECA
Failure mode
Cause
Effect
Criticality disruption class
Detection
Interfaces sink
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Disruption Protocol
Introduction Requirements Reliability Life Cycle Conclusion
Disruption Rate
Failure rate per Element/Subsystem
Quantity Total failure rate [1/h]
MTTR
Total failure rate [1/a]
Availability
∑ of all rowsbelonging to thesame disturbanceclass (SK1-4): Total
Disruption rate per SK forrailway technique
∑
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RAMS - Life Cycle Management
It is not only the prediction of reliabilities but also the monitoring of the project from a RAMS point of view during the whole life cycle of the GBT.
The management comprises:
o Verification
o Validation
o Integration of RAMS-process into the general project management to practically use synergy
effects.
Introduction Requirements Life Cycle ConclusionReliability
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RAMS - Life Cycle Management
Introduction Requirements Life Cycle Conclusion
V-Modell
operation
1 Concept
2 System definition
3 Risk analysis
4 System requirements
5 Assignment
6 Construction 8 Installation
9 System validation
10 Approval; acceptance
11 Operation; maintenance 14 Suspension; disposal
7 Fabrication
12 Capture performance
13 Change; retrofiting
Reliability
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Verification - Validation
Introduction Requirements Life Cycle Conclusion
V-ModellV-Modell
operationoperation
1 Concept
2 System definition
3 Risk analysis
4 System requirements
5 Assignment
6 Construction 8 Installation
9 System validation
10 Approval; acceptance
11 Operation; maintenance 14 Suspension; disposal
7 Fabrication
12 Capture performance
13 Change; retrofiting
Specification Validation
Verification
Implementation
Reliability
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RAMS - Other Management Systems
Introduction Requirements Life Cycle ConclusionReliability
RAMS
ServiceabilityOperating system
ValidationQualityProject specific
PQM
RAMSOperating system
Supporting Systems:• FRACAS (Failure Reporting, Analysis and Corrective Action System)
• MSMT(Maintenance Service Management Tool)
• Risk Management
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Conclusion
Project still ongoing.
High complexity.
Different calculation methods (Fault Tree Analysis - FTA, ReliabilityBlock Diagram – RBD,…) for different subsystems / lots.
Not one calculation model for the whole system.
Quantities are implicitly resolved by the interfaces analysis and the Causer Principle.
Requirements for reliability (50Hz and cable system) met by direct RBD calculations.
RAMS is one management system in addition to others, but each with its own focus.
Use synergies with PQM, Validation,…
Introduction Requirements Life Cycle ConclusionReliability
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Outlook
Application of the RAMS method is also interesting in fields other than railway engineering.
Data centers
Roads
Research
Introduction Requirements Life Cycle ConclusionReliability
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Contact
Andreas van Linn
Dr.-Ing.
Senior Consultant, Risk Management
Amstein + Walthert Progress AG
Andreasstrasse 11, Postfach, CH-8050 Zürich
andreas.vanlinn@amstein-walthert.ch
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Questions
Thank you for your attention.
Introduction Requirements Life Cycle ConclusionReliability
Do you have any questions
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