ECP functionality acceptance test (pdf 83KB)

ECP functionality acceptance test (pdf 83KB)
EPR 029
ECP FUNCTIONALITY
ACCEPTANCE TEST
Version 1.0
Issued October 2012
Owner:
Chief Engineer Rolling Stock
Approved
by:
Stephen White
Technical Specialist Rolling
Stock Performance Standards
Rolling Stock Access Integrity
Authorised
by:
Michael Uhlig
Manager,
Rolling Stock Access Integrity
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
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Engineering Procedure
Engineering Procedure
Rolling Stock
RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
EPR 029
Document control
Version
1.0
Draft B
Draft C
1.0
Date
August 2011
December 2011
July 2012
October 2012
Summary of change
Draft
Overlay system added
Reference to recording form added
Issued
Summary of changes from previous version
Summary of change
© RailCorp
Issued October 2012
Section
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RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
EPR 029
Contents
1
Introduction .............................................................................................................................4
2
Scope........................................................................................................................................4
3
Application...............................................................................................................................4
4
References...............................................................................................................................4
5
Notes on testing ......................................................................................................................4
6
Equipment................................................................................................................................5
7
Train set-up..............................................................................................................................5
8
8.1
8.2
8.3
Pneumatic back-up .................................................................................................................5
Brake pipe leakage test.............................................................................................................5
Emergency brake cylinder pressure .........................................................................................6
Emergency brake with reduced BP pressure............................................................................6
9
Train sequencing ....................................................................................................................6
10
10.1
10.2
10.3
10.4
10.5
ECP run mode .........................................................................................................................7
Minimum service .......................................................................................................................7
Graduated application ...............................................................................................................7
Graduated release ....................................................................................................................8
ECP emergency ........................................................................................................................8
Cut-out brakes...........................................................................................................................9
11
11.1
ECP cut-out mode ...................................................................................................................9
Manual cut-out ..........................................................................................................................9
12
12.1
ECP switch mode (Stand alone systems only) ....................................................................9
Operation without EOT..............................................................................................................9
13
Completion ............................................................................................................................10
© RailCorp
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RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
1
EPR 029
Introduction
Before any rail vehicle is permitted to operate on the RailCorp network, the vehicles must
comply with the RailCorp Minimum Operating Standards for Rolling Stock ESR 0001.
The braking performance of a vehicle or train is measured to confirm compliance with the
Minimum Operating Standards for Rolling Stock.
2
Scope
This procedure is for the purpose of confirming the functionality of the brake system on a
train made up of ECP equipped vehicles.
The ECP brake system may be stand alone or overlayed with a conventional pneumatic
brake system. This procedure concentrates on the operation of the ECP brake system
and thus does not check all aspects of the operation of the pneumatic brake system on
trains with overlayed systems.
The full train consist proposed to operate on the RailCorp network must be tested
according to this document.
3
Application
This procedure is to be used by rolling stock manufacturers, owners, operators and
testing personnel when assessing an ECP train for operation on the RailCorp network.
4
References
EPR 029 FM01 ECP Functionality Test Recording Form
5
Notes on testing
It is assumed that all vehicles (including locomotives) on the train have been individually
tested and pass their appropriate single car test procedures before this procedure is
carried out.
In the case of trains with overlayed ECP brake systems it is assumed that the pneumatic
system on each wagon has been single car air tested.
Four wagons must be chosen at random for monitoring purposes with the first in the first
quarter, second in the second quarter, third in the third quarter and the fourth in the last
quarter.
This procedure assumes that each vehicle is fitted with load compensation equipment.
When entering ECP RUN mode “LOADED” must always be entered when the operator is
prompted to enter “LOADED or EMPTY”.
This procedure does not require interference with the 230 Volt ECP trainline when
energised.
CAUTION
The ECP trainline cable is energised at 230 Volts when active.
Do not interfere with the cabling during testing.
The form at the end of this document must be fill in as each test is completed.
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RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
6
EPR 029
Equipment
Calibrated pressure gauges are to be fitted to the four monitored wagons to read actual
brake cylinder pressures.
The empty/load compensation valve on the vehicles being monitored must be blocked to
force the wagon to apply loaded brake cylinder pressure.
7
Train set-up
The train must be located in a safe area where testing staff can safely move along the full
length of the train as required.
The train must be secured with the correct number of handbrakes as required for that
location.
Locomotive handbrakes: ON
CAUTION
All brakes will be released at various times during the functionality test.
The train must be correctly secured with handbrakes.
The brakes on all wagons shall be cut in and operational in both ECP mode and
pneumatic mode.
EOT is to be attached to the rear wagon and correctly connected to brake pipe and ECP
trainline.
The tests must be carried out from the leading driver’s cab. All locomotives except the
leading locomotive are to be set in TRAIL.
Independent brake handle: FULL APPLICATION
Automatic brake handle: RELEASE
Brake pipe pressure: 500 kPa
ECP: Off
8
Pneumatic back-up
These tests are to check the health of the back-up pneumatic brake system without ECP.
8.1
Brake pipe leakage test
Reduce brake pipe pressure by 100 kPa by moving the automatic brake handle into the
SERVICE RANGE.
Note: On trains with ECP stand alone systems the brakes will not apply on any wagon.
On trains with overlayed systems the brakes will apply on each wagon.
Isolate the automatic brake valve by screen commands or closing the appropriate
isolating cock.
Observe the brake pipe pressure over a period of 1 minute.
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RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
EPR 029
OBSERVE & NOTE ON FORM:
The brake pipe pressure must not drop by more than 35 kPa.
Move the automatic brake handle to RELEASE and fully recharge brake pipe to 500 kPa.
8.2
Emergency brake cylinder pressure
Note: it is necessary that a person be located at the rear of the train for tests 8.2 & 8.3 to
read the pressure gauge.
Move the automatic brake handle to EMERGENCY.
OBSERVE & NOTE ON FORM:
The emergency brake cylinder pressure of the last wagon shall be 420 ± 20 kPa.
Move the automatic brake handle to RELEASE and fully recharge brake pipe to 500 kPa.
8.3
Emergency brake with reduced BP pressure
Knorr/NYAB equipment
Move the automatic brake handle to HANDLE OUT and reduce brake pipe pressure to
260 kPa.
OBSERVE & NOTE ON FORM:
ECP brake stand alone: All brakes shall apply. The brake cylinder pressure on
the last wagon shall be 420 ± 20 kPa.
ECP overlay:
A full service brake application will occur on all wagons as the
brake pipe is reduced to 350 kPa. The further reduction shall cause the
emergency brake to apply on all wagons. The brake cylinder pressure on the last
wagon shall be 420 ± 20 kPa
Move the automatic brake handle to RELEASE and fully recharge brake pipe to 500 kPa.
Wabtec equipment
Move the automatic brake handle to HANDLE OUT and reduce brake pipe pressure to
250 kPa.
Immediately move the automatic handle to EMERGENCY
OBSERVE & NOTE ON FORM:
ECP stand alone: All brakes shall apply. The brake cylinder pressure on the last
wagon shall be 420 ± 20 kPa
ECP overlay:
A full service brake application shall occur on all wagons as the
brake pipe is reduced to below 350 kPa. The emergency brake should not apply.
The further reduction shall cause the emergency brake to apply on all wagons.
The brake cylinder pressure on the last wagon shall be 420 ± 20 kPa
Move the automatic brake handle to RELEASE and fully recharge brake pipe to 500 kPa.
9
Train sequencing
This test is to ensure the ECP system correctly sequences the train consist.
Set-up ECP in RUN mode.
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RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
EPR 029
Train consist will be sequenced before automatically entering RUN mode.
OBSERVE & NOTE ON FORM:
Train consist is correctly sequenced.
ECP automatically enters RUN mode.
Move the automatic handle in RELEASE.
Ensure brake pipe pressure is fully charged to 500 kPa.
10
ECP run mode
These tests are to ensure the ECP system operates as designed when in the normal
RUN mode.
10.1
Minimum service
Move the independent handle to RELEASE
Move the automatic handle to MINIMUM (Train Brake Command (TBC) = 10%)
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
All brakes shall apply on the train.
Brake cylinder pressures on the four monitored wagons shall be 35 ± 20 kPa.
Locomotive brakes shall apply (note pressure)
10.2
Graduated application
Move the automatic handle to TBC of 30%.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 105 ± 20 kPa.
Locomotive brake cylinder pressure shall increase (note pressure)
______________________________________________________________________
Move the automatic handle to TBC of 50%.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 180 ± 20 kPa.
Locomotive brake cylinder pressure shall increase (note pressure)
______________________________________________________________________
Move the automatic handle to FULL SERVICE (TBC of 100%).
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 350 ± 20 kPa.
Locomotive brake cylinder pressure shall increase (note pressure)
© RailCorp
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Version 1.0
RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
10.3
EPR 029
Graduated release
Move the automatic handle back to TBC of 80%.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 280 ± 20 kPa.
Locomotive brake cylinder pressure shall decrease (note pressure)
______________________________________________________________________
Move the automatic handle back to TBC of 20%.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 90 ± 20 kPa.
Locomotive brake cylinder pressure shall decrease (note pressure)
______________________________________________________________________
Move the automatic handle back to TBC of 10%.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be 35 ± 20 kPa.
Locomotive brake cylinder pressure shall decrease (note pressure)
______________________________________________________________________
Move the automatic handle to RELEASE.
Wait at least 30 seconds.
OBSERVE & NOTE ON FORM:
Brake cylinder pressures on the four monitored wagons shall be zero.
Locomotive brake cylinder pressure shall be zero.
10.4
ECP emergency
Move the automatic handle to RELEASE.
Wait at least 30 seconds.
Move the automatic handle to EMERGENCY
OBSERVE & NOTE ON FORM:
Brake pipe pressure rapidly falls to zero
PCS opens
Warning displayed “Multiple loss of brake pipe”
Brake cylinder pressures on the four monitored wagons shall be 420 ± 20 kPa.
Locomotive brake cylinder pressure shall be 350 ± 20 kPa.
Re-set penalty and re-charge brake pipe to 500 kPa
© RailCorp
Issued October 2012
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Page 8 of 10
Version 1.0
RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
10.5
EPR 029
Cut-out brakes
This test is to ensure that as brakes are cut-out the driver is warned and that a penalty
application will occur when the cut-outs exceed 15% of the wagons on the train.
Ensure percent operable brakes on the screen reads 100%.
Pick a random wagon and pneumatically isolate the brake system by closing the isolating
cock and operation the manual release.
OBSERVE & NOTE ON FORM:
The percent operable brakes on the screen will reduce to x% where:
x = 100 – (wagons cut-out / wagons on train) * 100
Pneumatically isolate another brake system.
OBSERVE & NOTE ON FORM:
The percent operable brakes drops further.
Continue pneumatically isolating more wagons.
OBSERVE & NOTE ON FORM:
A warning will be displayed when the percent operable goes below 95%.
A warning will be displayed when the percent operable goes below 90%.
A warning will be displayed and a TBC=120% penalty will be applied when the
operable brakes goes below 85%.
Cut the wagons back in and re-set the penalty application.
11
ECP cut-out mode
11.1
Manual cut-out
Move the automatic handle to FULL SERVICE
End ECP by entering the appropriate commands on the locomotive screen.
OBSERVE & NOTE ON FORM:
ECP stand alone: All brakes release.
ECP overlay:
The pneumatic brakes on each wagon shall apply as the brake
pipe pressure falls after ending ECP.
All brakes release.
12
ECP switch mode (Stand alone systems only)
This test is to ensure the wagons electrically attached to locomotives can apply and
release their brakes without an EOT.
12.1
Operation without EOT
Move the automatic handle to RELEASE
With ECP still cut-out disconnect the electrical trainline between two mid-train wagons.
Set-up ECP in SWITCH mode.
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Page 9 of 10
Version 1.0
RailCorp Engineering Procedure — Rolling Stock
ECP functionality acceptance test
EPR 029
Move the automatic handle to FULL SERVICE
OBSERVE & NOTE ON FORM:
All brakes apply on wagons in front of the disconnected trainline
The brakes on wagons behind the disconnected trainline remain released.
13
Completion
End ECP SWITCH mode by entering the appropriate commands on the locomotive
screen.
Re-connect the disconnected ECP cable.
Remove pressure gauges and load compensation valve chocks from the monitored
vehicles.
END OF TEST
© RailCorp
Issued October 2012
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