(Name and address of the vehicle maintenance workshop)

Transcription

1 Technical Assessment and Approval by VPI in Consideration of EU Reg. 445/2011 (Sub-Functions I and IV) (for freight/tank wagons based on the VPI maintenance manual) (Name and address of the vehicle maintenance workshop) The technical assessment took into consideration the requirements/principles of the Directive 2008/110/EC of the European Parliament and of the Council from 16 December 2008 amending Directive 2004/49/EC on safety on the Community s railways as well as the recommendation of the ERA (European Railway Agency) on the certification of maintenance workshops (ERA/REC/ NT). In preparation for the technical assessment, the workshop is required to compile documents (in German) according to the list in Part B concerning the technical assessment - required documents and verifications and submit or transmit them in advance (3-4 weeks) of the onsite assessment. The technical assessment and approval is performed for evaluation of the competence in the performance of maintenance / repair work on freight wagons and components in accordance with the appended overview in table form. The implementation of the requirements of the maintenance manual and its distribution are evaluated in the assessment. The content of the maintenance manual is not evaluated within the scope of the technical assessment. The technical assessment and approval cover the following areas 1. Organisation Information (employees) Personnel Quality assurance / quality management system 2. Technical equipment 3. Measurement and testing equipment 4. Maintenance system / technical regulations 5. Qualifications in joining techniques 6. Qualifications in non-destructive testing 7. Scope of the technical assessment 8. Execution of the technical assessment 9. Inspection result 10. Deviations, measures and recommendations 11. Term of validity The maintenance of the systems subject to monitoring in accordance with Article 33 of the German Ordinance on the Construction and Operation of Railways ( 33 EBO) is not subject to this technical assessment and approval. In regard to the compliance with the criteria for the maintenance of freight wagons, the technically assessed and approved maintenance workshop is subject to inspection by the keeper and/or its agents as well as the additional requirements of the keeper. FTB; version 20/06/2014 Page 1 of 14

2 The following prerequisites must be met for the technical assessment and approval of a maintenance workshop: 1. Organisation / information / personnel Organisation of the maintenance workshop to be technically assessed and approved (organisational chart) Description of an effective quality management system / presentation of certificate and QM manual Naming of the managing director / station director / technical director Naming of the technical supervisors of the respective maintenance areas Naming of other responsible persons: persons responsible for hazardous goods and for regulations Naming of the persons responsible for final inspection / workshop departure (delegation of the responsibility for acceptance inspection according to 32 EBO and for signing of the verification of work performed) Verification of the conclusion of a corresponding training by the brake mechanics Verification that responsibility has been delegated in writing to the technical supervisors (on the basis of appointment letters or job descriptions) Training system for the education / qualification / continued training / retraining in the areas for which the workshop has been technically assessed and approved; documentation of the training measures Insurance coverage of at least EUR 5 million (product liability / comprehensive general liability) 2. Technical equipment Ensuring proper maintenance by means of technical equipment and facilities that must be present on the basis of the site itself and in accordance with the scope of the maintenance tasks Overview of the most important machinery and equipment 3. Measurement and testing equipment and facilities The measurement and testing equipment and facilities must exhibit the metrological properties required for the intended use and purpose, e.g. precision, measurement stability and range as well as resolution) A system must exist for the monitoring of testing equipment Performance of the calibration by a recognised testing and calibration body The corresponding requirements apply to the legally regulated area FTB; Version 20/06/2014 Page 2 of 14

3 4. Maintenance system, technical regulations Application of the existing and valid technical regulations: - EBO Applicable EN / DIN standards / UIC leaflets (e.g. UIC 700) - VPI maintenance manual - Accepted principles of engineering that are reflected in an applicable maintenance system - Maintenance regulations and maintenance instructions of keepers (e.g. tank wagon overhaul instructions of VTG, technical instructions of GATX, etc.) 5. Qualifications in joining techniques A verification of manufacturer qualifications is required for the area of joining techniques (e.g. welding). For recognition as a welding operation, qualifications are therefore required by means of a certification verifying the suitability for welding freight wagons and their components according to DIN EN by a recognised body. Special regulations must be taken into account for the welding of systems and hazardous goods tanks subject to monitoring. The testing/inspection supervisor must be assigned appropriate authority to give instructions as well as decision-making authority independent of practical assembly constraints. 6. Qualifications in non-destructive testing Verification of recognition by a technically competent authority (TCA) is fundamentally required for the area of non-destructive testing. A TCA must participate in recognising the suitability for performing non-destructive testing according to DIN For maintenance workshops residing in Germany, DIN , which requires the inclusion of a technically competent authority, provides a suitable basis. VPI assumes that all maintenance workshops resident in Germany that are active in the area of non-destructive testing and apply for a technical assessment and approval by VPI / DB Schenker can also present an approval by the technically competent authority according to DIN Fundamentally equivalent technical requirements also apply to maintenance workshops resident outside of Germany. In such cases, however, other approvals in the area of NDT based on local practices or legislation shall be recognised. The requirement concerning the training of the NDT personnel in the railway sector shall also only apply in locations where the competent NDT organisation (in Germany: DGZfP) has established such a sector. In all other countries, VPI recognises many years of NDT experience or a company-internal supplemental training in the railway sector. Where no approval procedures of any sort are implemented but where customer orders require work in compliance with VPI manuals the services of the German technically competent authority must be retained in order to obtain an approval equivalent to that of DIN (equivalent safety level). The maintenance workshop must provide the relevant verification. Should doubt exist as to whether the presented documents are sufficient to guarantee an equivalent safety level, the services of a German technically competent authority must also be retained. FTB; Version 20/06/2014 Page 3 of 14

4 7. Scope of the technical assessment of (check all that apply) Maintenance measures according to EN / DIN standard, ISO 9000, UIC leaflets, VPI maintenance manuals, maintenance regulations and maintenance instructions of keepers Inspections according to 32 EBO para. 2, 3 and 4 (revisions) G 4.0 G 4.2 G 4.8 Mobile repair via workshop wagon Brake revisions Br 0 Br 2 Br 3 Repair (refurbishment) of components according to VPI maintenance manual Wheelset and wheelset bearing work in the maintenance levels IL IS 1 IS 2 IS 3 Mechanical machining of wheelset axles acc. to VPI 04, Annex 13 via grinding or lathing V 1 V 2 V 3 V 4 Mechanical brake parts (slack adjuster, air shut-off valve) on (check all that apply) Freight wagons of standard and special models (including on-demand repairs to tank wagons without work on the tank and equipment) Tank wagon (class Z) / special wagon (class U) FTB; Version 20/06/2014 Page 4 of 14

5 8. Execution of the technical assessment Ser. no. (445/11) Requirement Implementation / verifications / measures Date of the assessment x Company / complete address Bank account / VAT ID Participants in the assessment: Persons: Company: Person: Company: Person: Company: VPI DB Schenker Rail AG Company profile (General information on company structure, founding, number of employees, offered maintenance scope, customers, references, etc.) 1. Organisation / personnel 1.1 Company organisational chart (445/2011, Annex III, sub-function I, item 5) 1.2 Managing director / station director Technical director Contact person Person: Person: Person: Telephone: 0 Fax: 0 FTB; Version 20/06/2014 Page 5 of 14

6 Responsible 1.3 Technical supervision Freight wagon maintenance Component refurbishment of Wheelset / wheelset bearing Brake, mechanical 1.4 Other responsible persons Person responsible for hazardous goods Person responsible for regulations Person responsible for measurement and testing equipment 1.5 (6) (8c, 9c) (9a) Final inspection / workshop departure / release to service (concluding vehicle inspection and release to service) (Inspection of performed work acc. to maintenance orders) Implementation / verifications / measures 1.6 ECM-certified? (Presentation of a certificate from a notified or accredited body and test report, if applicable) Quality management system Certified acc. to DIN EN ISO 9001? (Certificate and presentation of QM manual) Name of QM manager (Implementation of the ISO requirements) Name of QM officer (Annual management review) Effectiveness of the QM system (spot checks) Certified acc. to DIN EN ISO 14001? 1.7 Verification of the assignment of responsibilities (445/2011, Annex III, sub-function I, items 5.1 and 5.3) Technical director Person responsible for hazardous goods Person responsible for regulations Person(s) responsible for final inspection / workshop departure QM manager & QM officer Person responsible for measurement and testing equipment FTB; Version 20/06/2014 Page 6 of 14

7 1.8 (8) Training verification (basic training) of the brake mechanics Verification of the training/instruction in VPI 07, presentation of the verified authorisation / naming of the brake mechanic(s) (VPI 07, item 2(1)) (procedure for training and continued training of the brake mechanics, practical testing at workshop) Naming of the container expert (VPI 07, Annex 9, item 3.1(2)) including training verification (e.g. acc. to TRBS 1203) 1.9 Insurance verification 1.10 If applicable: certification by EBA and/or other railway authority exists (informative) 1.11 Competence management (445/2011, Annex III, sub-function I, item 1h and 6) - Qualification plan (competence matrix, training plan) If ECM-certified, no further inspection required! For combined audits, this inspection takes place in the scope of the ECM certification (2a-c) 1.13 (3a-b) 1.14 (9b) - Quantification plan (substitute rules) Procedure for supplier selection, overview of the most important suppliers including supplier evaluation (use, storage, transport, receipt inspection, quarantine storage) Procedure for compliance with national regulations for safety and health protection (existing processes according to Directive 89/391/EEC) Information processes - Safety-relevant errors and defects If ECM-certified, no further inspection required! For combined audits, this inspection takes place in the scope of the ECM certification. If ECM-certified, no further inspection required! If ECM-certified, no further inspection required! 1.15 (10a) a) Procedure for determination of safetyrelevant activities (EU Reg. 445/2011, Annex III, part I, items 2 and 2.1) b) Verification(s), of how employees who perform safety-relevant actions are instructed regarding the consequences of violations of safety requirements (documentation of regular trainings and instruction - preventive) c) Monitoring of risks, processes and procedures for identification of hazards, evaluating risks, defining strategies to limit damages, assessing the effectiveness, record-keeping for every action/activity (ERA/REC/ NT) General process inspection at ECM certifier, (implementation) inspection at VPI (e.g. quality inspection of finished wagon.) FTB; Version 20/06/2014 Page 7 of 14

8 1.16 (10a) (10b) (10c) (10d) (10e) Documentation processes a) Listing of facilities, equipment, tools for safety-relevant activities b) Listing of personnel, tools, interchange parts, materials for maintenance work c) Listing of monitoring measures for release to service d) Documentation of the results of calibrations and inspections / verifications e) Documentation of measures / decisions after identifying deviations from calibrations and inspections If ECM-certified, no further inspection required! For combined audits, this inspection takes place in the scope of the ECM certification. 2 Technical equipment Implementation / verifications / measures 2.1 (2b, 8d) (7) (5) Freight wagon maintenance (practical implementation in the framework of the workshop inspection (e.g. brakes, component handling, etc.)) a) Inspect work environment for safety b) Lifting equipment, sling gear, etc. c) Workshop (maintenance hall and facilities) d) Measurement benches for e) Brake Bogie and/or suitable measurement equipment Underframe and/or suitable measurement equipment Wagon body and/or suitable measurement equipment Track with pit f) Brake testing device Pdr 3 Pdr 4 Pdr 5 Pdr 6 (or device with same functionality) g) Offering of mobile repair of freight wagons via Workshop wagon h) Field workshops / external stations (info also important for ECM certifier since processes for external stations must be inspected) FTB; Version 20/06/2014 Page 8 of 14

9 2.2 (2a-b) 2.3 (8c) (8e) Component refurbishment Wheelset and wheelset bearing Brake, mechanical (slack adjuster, air shut-off valve Maintenance of tanks, containers and tank containers (vehicle inspection) (special areas) Rules and procedures for work on uncleaned/loaded tank wagons within workshops or for mobile workshop service Option of tank and container cleaning of Mineral oil tank wagons Chemical tank wagons Pressurised gas tank wagons Inspection of tanks, containers and tank containers - Instructions for inspecting and climbing on? - Inspection certificate with description of the type of measurement and the tank interior condition? - Instruction on measurement performance? (Oxygen meter, device for EX measurement, DRÄGER tubes) - What information is available on the measurement performance? (Product information, safety data sheet) - Person responsible for inspection approval? - Emergency plan, emergency team and/or emergency organisation exists? - Emergency exercises FTB; Version 20/06/2014 Page 9 of 14

10 3 Measurement and testing equipment / tools (4a-e) (5, 10d) (10e) Testing equipment monitoring (procedures, documentation, handling, storage, monitoring, marking) Testing and calibration body/ bodies (accreditation acc. to DIN EN ISO / IEC 17025) Traceability of measurement actions (implementation) Minimum measurement and testing equipment Track measurement device Buffer height gauge or suitable measuring equipment Wheel profile measuring device Torque spanner Implementation / verifications / measures If ECM-certified, then no further procedure inspection required (only inspect practical implementation)! Other measurement equipment as required Measuring equipment for the tread diameter Dial gauge (wheelset concentricity) for (required for workshops without wheelset workshop within G 4.8) Suitable measuring device for measuring bogie/undercarriage (Tape measure or yardstick/folding yardstick not suitable) Gauge for measuring the bolt middle spacing on suspension springs or suitable meas. equipment (rev.) Track scale Suitable gauges for testing bushings and bolts (mandrel gauges, gap gauges) Spring testing machine Buffer head wear Brake shoe gauge Replacement of suspension spring blocks Measurement bar for axle guide stay or gauge for spring block replacement (Weikmann measuring bar) FTB; Version 20/06/2014 Page 10 of 14

11 4 Management of information Implementation / verifications / measures (1a) (1a) (1a) (1b) (1a) (1a) (1c, 1d) (1d, 1d) (9a) (10d) (9a, 9b) (10b) Information process, maintenance regulation(s) a) EBO, EN / DIN standards that must be present for use of the VPI maintenance manual (VDE-TB 461 & 462), DIN EN (replaces UIC 700), GCU (for commissioning by TOC) b) Process for how changes to national and international requirements are discovered, integrated and implemented? (Association membership, EBA newsletter, etc.) c) VPI maintenance manual (customer number) d) Translation quality (EN 15038) e) Changes, revisions, updates and VPI circulars, (observance, translation if necessary, integration and application) f) Maintenance regulations and maintenance instructions of vehicle keepers (enacting/ordering by the ECM) g) Presence of a system for updating, distributing and controlling regulations and technical maintenance-related instructions of keepers (verified) h) Work-accompanying documents, such as work plan lists (Who performed what activity (when)), workplace-specific instructions, measurement sheets (bogie), test reports (brake revision), logs on the start of work and the vehicle final acceptance etc. i) Existence of a system for notifying the keeper (ECM) concerning all discoveries and measures within the scope of the workshop visit (operating experience feedback) j) Procedure for archiving, storing records and maintenance documents (VPI 01, Annex 9) k) Protection of the copyrights of maintenance regulations and instructions of the respective keeper (if customer uses the VPI manuals, he must also possess these, inquiries by contractors at the business office of VPI or via VPI website) If ECM-certified, then no further procedure inspection required (only inspect practical implementation according to ECM Reg. 445/2011, Annex 3, sub-function IV, item 6 and 9)! FTB; Version 20/06/2014 Page 11 of 14

12 5 Qualifications in joining techniques Implementation / verifications / measures (8a) Certification of welding operation for the welding of rail vehicles and vehicle parts acc. to DIN EN and DIN by a recognised body For part classes CL1 CL2 CL3 CL4 If necessary recognition for the welding of tanks acc. to RID by a national authority Basis is a welding approval acc. to DIN EN ISO 3834 (formerly EN 729) and HP0 (in Germany) by a recognised body (TÜV, DEKRA, SLV etc.) (for German workshops, the recognition is provided by EBA in connection with GGVSEB 15 para. 1) 6 Qualifications in non-destructive testing Implementation / verifications / measures (8b) Verification of recognition by the technically competent authority (TCA) according to DIN (for NDT on safety-relevant parts) for the testing methods: VT UT MT PT FTB; Version 20/06/2014 Page 12 of 14

13 9. Inspection result Based on the technical assessment, the maintenance workshop (Name and address of the vehicle maintenance workshop including the field workshops / external stations) for (check all that apply) Revisions (inspections) Workshop code: XXX G 4.0 G 4.2 G 4.8 Maintenance acc. to EN / DIN, VPI maintenance manual, etc. Mobile repair via workshop wagon Brake revisions Br 0 Br 2 Br 3 Repair (refurbishment) of components according to VPI maintenance manual Wheelset and wheelset bearing work in the maintenance levels IL IS 1 IS 2 IS 3 Mechanical machining of wheelset axles acc. to VPI 04, Annex 13 via grinding or lathing V 1 V 2 V 3 V 4 Mechanical brake parts (slack adjuster, air shut-off valve) on (check all that apply) Freight wagons of standard and special models (including on-demand repairs to tank wagons without work on the tank and equipment) Tank wagon (class Z) / special wagon (class U) is technically approved. FTB; Version 20/06/2014 Page 13 of 14

14 10. Deviations, measures and recommendations We reserve the right to visit the workshop without advance warning during the approval period and inspect the implementation of the listed measures and recommendations. 11. Term of validity (initially 3 years, with periodic inspection) until x Changes to the named persons must be reported.... (Place / Date) (Signature) FTB; Version 20/06/2014 Page 14 of 14