CODE OF PRACTICE FOR THE DEFINED INTERSTATE RAIL NETWORK VOLUME 5

ROLLINGSTOCK Part 2: Common requirements Section 1—Design and construction RCP-2102: Vehicle structure and identification Requirements for the structural design of vehicles together with environmental and electrical safety vehicle identification AROU VERSION 1 DRAFT FOR CONSULTATION PURPOSES ONLY NOVEMBER 2002 DISCLAIMER: This document is a draft only and has been issued solely for the purposes of consultation with the rail industry. The document incorporates feedback from the Australian rail industry and will be finalised following further feedback on its accuracy and appropriateness. The document is not intended for implementation in its draft form and no reliance should be placed on the accuracy or appropriateness of its content. The Commonwealth disclaims any liability or responsibility to any person in respect of any consequences flowing from the use of this document in whole or in part for any purpose other than the purpose of providing comments to the Commonwealth on its content. © Commonwealth of Australia

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. i

SCHEDULE OF AMENDMENTS Amendment Number

Pages amended

AROU V1 Consultative Draft

Summary of amendments

November 2002

Date issued

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. ii

TABLE OF CONTENTS Page 1

INTRODUCTION .......................................................................................................................... 1 1.1 SCOPE ............................................................................................................................... 1 1.2 APPLICATION .................................................................................................................... 1

2

DEFINITIONS............................................................................................................................... 2

3

VEHICLE TO VEHICLE INTERFACE .......................................................................................... 3 3.1 END EQUIPMENT .............................................................................................................. 3

4

STRUCTURAL REQUIREMENTS................................................................................................ 4 4.1 FUNCTIONAL REQUIREMENTS ....................................................................................... 4 4.2 DESIGN LOADS—GENERAL ............................................................................................ 4 4.3 ALLOWABLE STRESSES .................................................................................................. 4 4.3.1 Load/stress limits ................................................................................................. 4 4.3.2 Maximum stresses ............................................................................................... 5 4.4 FATIGUE ............................................................................................................................ 5 4.5 CENTRE OF GRAVITY ...................................................................................................... 5 4.6 CURVE STABILITY—BOGIE L/V RATIO ........................................................................... 5 4.7 MATERIALS ....................................................................................................................... 6

5

AUTOMATIC EQUIPMENT IDENTIFICATION (AEI) ................................................................... 7 5.1 INTRODUCTION ................................................................................................................ 7 5.1.1 Scope .................................................................................................................. 7 5.1.2 Purpose ............................................................................................................... 7 5.1.3 General Principles ............................................................................................... 7 5.2 AEI SYSTEM REQUIREMENTS......................................................................................... 7 5.3 LOCATION OF TRANSPONDER TAGS—ROLLINGSTOCK.............................................. 8 5.4 LOCATION OF TRANSPONDER TAGS—CONTAINERS .................................................. 9 5.5 PASSIVE ALARM TAGS .................................................................................................... 9

6

PERFORMANCE REQUIREMENTS .......................................................................................... 13

7

ELECTRICAL INSTALLATIONS ............................................................................................... 14 7.1 GENERAL REQUIREMENTS ........................................................................................... 14 7.2 PREVENTION OF ELECTRIC SHOCK ............................................................................ 14 7.2.1 Direct contact—normally live components ......................................................... 14 7.2.2 Contact—components not normally live............................................................. 14 7.3 THERMAL PROTECTION ................................................................................................ 14 7.4 FAULT PROTECTION ...................................................................................................... 14 7.5 EARTHING SYSTEM........................................................................................................ 15 7.6 INSULATION .................................................................................................................... 15 7.7 SAFETY SIGNS................................................................................................................ 15

8

HAZARDOUS MATERIALS ....................................................................................................... 16 8.1 UNACCEPTABLE MATERIALS ........................................................................................ 16 8.2 SAFETY DATA SHEETS .................................................................................................. 16

9

VEHICLE IDENTIFICATION, CLASSIFICATION AND NUMBERING........................................ 17 9.1 FREIGHT CARS ............................................................................................................... 17 9.2 LOCOMOTIVES AND PASSENGER CARS ..................................................................... 17

10

NOISE AND VIBRATION ........................................................................................................... 18 10.1 GENERAL REQUIREMENTS ........................................................................................... 18 10.2 INTERIOR NOISE ............................................................................................................ 18

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. iii

10.2.1 Drivers cabs....................................................................................................... 18 10.2.2 Passenger compartments .................................................................................. 18 10.2.3 Non-passenger areas ........................................................................................ 18 10.3 EXTERNAL NOISE........................................................................................................... 18 10.4 VIBRATION ...................................................................................................................... 18

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. iv

PRINCIPAL REFERENCES Australian Standards AS/(NZS) 1269

Occupational noise management

1319

Safety signs for the occupational environment

1649

Acoustics—Noise rating numbers

2377

Airborne sound from railbound vehicles

2670

Human exposure to whole body vibration

3000

Wiring rules

Codes of Practice for the Defined Interstate Rail Network Volume 2 Glossary Volume 5

Rollingstock Part 1: Introduction RCP 1011 Standard terminology for rollingstock Part 2: Common requirements Section 1—Design and construction RCP 2101 Interface requirements 2102 Vehicle structure and identification 2103 Vehicle components 2104 Rollingstock outlines 2105 Train brake systems Section 2—Commissioning and recommissioning RCP 2201 Performance acceptance requirements Section 3—Inspection and maintenance RCP 2305 Single car air test (SCAT) procedures Section 4—Decommissioning and disposal 2401 General requirements Part 3: Freight cars—Specific requirements and recommendations Section 1—Design and construction RCP 3110 Classification and numbering freight cars and bogies 3111 Lettering and marking

Association of American Railroads AAR Manual of Standards and Recommended Practices

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 1

1

INTRODUCTION

1.1

SCOPE

1.1.1

This document describes the structural design, construction and identification requirements for vehicles of all types on any part of the defined interstate rail network. Requirements for rollingstock components are given in RCP-2103.

1.1.2

These requirements are directed towards the achievement of an acceptable level of vehicle performance and protection for persons, rollingstock, infrastructure and the environment.

1.1.3

General requirements for non-interchange vehicles are provided to define an acceptable minimum level of structural and dynamic performance to suit any particular service and operating environment.

1.1.4

In order not to restrict vehicle development, nothing in the Code precludes the use or introduction of new or alternative methods, materials or technology which differ from anything described herein, provided always that the vehicle complies with the applicable minimum requirements for strength, compatibility and performance. New practices and procedures should be supported by a hazard identification and risk analysis as recommended by clause 1.8 of AS-4292.3, Rollingstock.

1.2

APPLICATION

1.2.1

The requirements specified in this Standard shall be applied to all new and substantially modified vehicles operating on the DIRN. They apply to all vehicles in this category including both interchange and non-interchange freight cars except where these sub-groups are specifically provided for in the text.

1.2.2

Certain requirements of this Standard are designated as interface requirements. These are part of a complete listing of interface requirements set out in RCP-2101, compliance with which is a requirement of any access and/or operating agreement between an access provider and a rail operator on the DIRN. NOTE: It is recommended that vehicles intended for operation in intrastate services also be designed in accordance with these requirements. This is particularly important in the case of those cars that could operate in the same service as interchange cars. Designers of other intrastate vehicles should establish the load combinations and parameters most appropriate to the particular service, vehicle configuration and method of operation.

1.2.3

Requirements are indicated by the words “shall” shown in bold.

1.2.4

The Rollingstock Code is a live document and therefore is subject to regular review. The information contained herein is applicable at the date of issue but may be amended after any of the review processes.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 2

2

DEFINITIONS

2.1.1

Definitions of terms used in this document are given in RCP-1011 and in the Glossary in Volume 2.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 3

3

VEHICLE TO VEHICLE INTERFACE

3.1

END EQUIPMENT

3.1.1

End equipment includes couplers, uncoupling mechanisms, air cocks and hoses, vehicle structure, attachments and other inter-vehicle connections.

3.1.2

The end structure, components and fittings of a vehicle shall be designed so as not to foul or interfere, when coupled, with the end structure, components or any fittings of a similar vehicle or of any other vehicle to which it is likely to be coupled.

3.1.3

For interchange vehicles, the location of the end equipment shall be as recommended in the relevant sections of this Code.

3.1.4

For restricted (non-interchange) vehicles, the end equipment shall be compatible with that of the vehicles with which they will normally operate.

3.1.5

Where freight vehicles are fitted with main reservoir and/or independent brake pipes, the connecting hoses shall be of a type and location that ensures they will readily couple with the corresponding equipment on similar vehicles and locomotives.

3.1.6

Trains that include vehicles with couplers and/or end equipment that is not operationally compatible with interchange locomotives and freight vehicles shall carry suitable emergency, transition or adaptor couplers for the terminal (first and last) vehicles in each consist. These couplers shall interface mechanically with the equivalent components on an interchange locomotive to enable individual vehicles, part or complete consists to be coupled to an interchange vehicle or locomotive for recovery purposes.

3.1.7

Detailed requirements for couplers, draft gear and coupler height are given in RCP-2103.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

4

RCP-2102: Vehicle structure

Page No. 4

STRUCTURAL REQUIREMENTS Specific structural requirements and recommendations for locomotives and passenger cars are specified in Part 5, Locomotives and Part 6, Passenger Cars. Additional requirements for freight car underframes and superstructure components are specified in RCP-2103. Recommended practices for the design of freight car underframes and superstructure are given in RCP 3104.

4.1

FUNCTIONAL REQUIREMENTS

4.1.1

Each vehicle structure, associated structural components and attachments shall — (a)

comply with the prescribed rollingstock outline for the intended routes and service;

(b)

be suitable for the intended loading and service, including adequate load retention and securement facilities;

(c)

withstand without failure or permanent distortion the forces due to the loading and the dynamic effects experienced during normal loading, unloading, transit, shunting and marshalling operations;

(d)

be operationally compatible with the other vehicles with which it is intended to operate;

(e)

be capable of normal operations, and of negotiating the prescribed minimum curves, without fouling of or interference between the vehicle structure, bogies, attachments and other components;

(f)

be compatible with the bogies used for normal operation; and

(g)

provide the static and dynamic performance required to comply with the vehicle acceptance requirements prescribed for the particular route or service.

4.2

DESIGN LOADS—GENERAL

4.2.1

All vehicles shall be designed to withstand the static and dynamic loads, and the possible combinations of such loads acting simultaneously, expected to be encountered in the intended service. Appropriate consideration shall be given to the anticipated trailing load, track profile and condition, and train handling.

4.2.2

Structural design criteria and procedures shall be generally in accordance with the AAR Manual, M-1001 Chapter IV and Section C, Parts I. II and III.

4.2.3

The use of “safety factors”, loads and allowable design stresses other than those given in Clauses 4.3 and 4.4 and in AAR M1001 is permitted where these have been determined from first principles or otherwise conclusively justified eg. by instrumented testing. This allows for the legitimate realisation of the benefits afforded by sophisticated computational tools such as FEA and other modelling techniques.

4.3

ALLOWABLE STRESSES

4.3.1

Load/stress limits

4.3.1.1

Every vehicle when loaded to its maximum gross mass on rail in its intended configuration shall be capable of supporting that load in the static condition without exceeding the prescribed maximum static stress.

4.3.1.2

Vehicles shall be designed to withstand longitudinal loads applied through the front and rear draft stops, at and along the centre line of the coupler as follows:

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

4.3.2

RCP-2102: Vehicle structure

Page No. 5

(a)

The specified draft (tensile) and buff (compressive) load without exceeding the prescribed maximum working stress for the material.

(b)

The specified moderate impact end load without buckling or exceeding the critical design stress in the material.

(c)

The specified high impact end load without exceeding the ultimate tensile stress or buckling stress of the material.

Maximum stresses (a)

Maximum static stress The maximum static stress shall be one half of the yield stress of the material or 1/3 of the ultimate stress whichever is the lesser.

(b)

Maximum working stress The maximum working stress shall be 66% (2/3) of the yield stress of the material.

(c)

Critical Design Stress The critical design stress shall be the yield stress of the material or 80% of the ultimate stress whichever is the lesser.

4.4

FATIGUE

4.4.1

A rational fatigue analysis shall be performed for all new vehicle designs.

4.4.2

The owner or purchaser should prescribe in the vehicle specification the required fatigue life. In the absence of any prescribed life, the designer shall assume a fatigue life of not less than 30 years or 10 million kilometres.

4.4.3

Fatigue analysis shall consider both the failure of joints and that of sections, plates and castings. A major cause of fatigue failures has been the torsional effects produced by twisting in service. Particular attention shall therefore be given to this aspect.

4.5

CENTRE OF GRAVITY

4.5.1

The theoretical height above rail level of the Centre of Gravity (COG) of a fully loaded vehicle, other than a rail tank car, shall not exceed 2 500 mm (98.5") for normal operations. The actual COG of any loaded vehicle in transit shall not exceed the limit of 2 500 mm without evaluation by the operator and access provider(s) prior to departure. The access provider may impose operating conditions or restrictions.

4.5.2

The limiting height for the COG of loaded rail tank cars is 2130 mm.

4.6

CURVE STABILITY—BOGIE L/V RATIO

4.6.1

The bogie L/V ratio is the calculated ratio between the total lateral force per bogie side and the total vertical load per bogie side. For standard gauge vehicles, the combination of bogie centres, end overhang and coupler length should be prescribed so that L/V does not exceed a recommended value of 0.82.in the tare condition and when the vehicle is travelling on a curve. If the L/V exceeds 1.0 a curve stability test is required. Recommended design procedures are given in Clause 5.2.2. Test procedures are defined in RCP-2201.

4.6.2

The L/V ratio for vehicles to be used on the DIRN shall be determined under the following conditions: (a)

A draft force of 890 kN.

(b)

Coupled to a base vehicle at the front (leading) end and a “long” vehicle at the rear (trailing) end, both as specified in RCP-2201.

(c)

On a horizontal curve of 175 m radius with 12 mm maximum superelevation and no track twist.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

(d)

RCP-2102: Vehicle structure

Page No. 6

The subject vehicle is to be unloaded (ie at tare).

4.6.3

Calculation of the L/V ratio for other vehicles shall use parameters appropriate to the conditions that are expected to be encountered in service.

4.7

MATERIALS

4.7.1

All materials used in rollingstock manufacture shall comply with the appropriate Australian Standards or an internationally recognised equivalent.

4.7.2

Structural failure due to brittle fracture is usually catastrophic. Accordingly, the vehicle designer and/or builder shall specify, in the material specification for critical structural members, a minimum requirement for nil ductility transformation temperature (NDTT) o of -(minus)15 Celsius.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 7

5

AUTOMATIC EQUIPMENT IDENTIFICATION (AEI)

5.1

INTRODUCTION

5.1.1

Scope

5.1.1.1

This Section specifies a system of electronic automatic equipment identification (AEI) for rail vehicles and equipment in operations on the DIRN. The requirements are applicable to freight cars, locomotives, rail-compatible trailers, end-of-train units and, where relevant, other road vehicles and containers regularly transported on rail. It also specifies requirements for the location and fitting of AEI transponders on vehicles and equipment.

5.1.1.2

The use of this equipment is optional, but where AEI is used it shall comply with the requirements of this Section.

5.1.1.3

The use of the interstate identification system for intrastate vehicles and operations is recommended to reduce the investment in associated infrastructure and support systems.

5.1.2

Purpose

5.1.2.1

The AEI system and output data prescribed by this Clause shall be used to identify vehicles and equipment by the individual alpha-numeric identifying codes (classifications) together with any other pre-determined information. The output data should be transmitted via the users’ relevant communications network to the appropriate work areas.

5.1.3

General Principles

5.1.3.1

For automatic equipment identification purposes, each vehicle, locomotive or unit of equipment shall be fitted with one or more electronic identification (ID) transponder tags containing the identifier codes and other related information.

5.1.3.2

An interrogation unit (or reader) operating on UHF radio waves shall decode the modulated radio waves reflected by the transponder tag. The tag itself shall not be a transmitter, but shall act only as a field disturbance device, modifying and reflecting the signal transmitted by the reader system.

5.2

AEI SYSTEM REQUIREMENTS

5.2.1

The design, construction, operation, performance and coding principles for the AEI system shall comply with the requirements of Association of American Railroads (AAR) Standard S-918 in Section L of the AAR Manual of Standards and Recommended Practices.

5.2.2

Certain administrative provisions of AAR Standard S-918 are not applicable. Clauses relating to the approval of changes in tag position are examples.

5.2.3

Tag coding data for freight vehicles, locomotives and other types of equipment shall be as prescribed in AAR Standard S-918, Appendices A to J. Coding details for freight vehicles are summarised in Table 1, for locomotives in Table 2 and for containers in Table 3. All dimensions shall be in metric units.

5.2.4

Rail compatible trailers with separable rail bogies, such as roadrailer units, shall be tagged as road trailers or chassis in accordance with AAR Standard S-918 para. 9.2, 9.5 and 9.6. Coding details are given in Appendices C and D of S-918.

5.2.5

Bogies for rail compatible trailers shall be tagged as freight cars, with the coding details given in AAR Standard S-918, Appendix A and summarised in Table 1.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 8

5.2.6

In addition to the application of standard ID transponder tags, some vehicles and equipment may also be fitted with passive alarm tags (see Clause 6.5).

5.2.7

Freight cars and locomotives shall be fitted with a standard beam powered transponder tag as described in Section 6 of AAR Standard S-918. The tags fitted to all other vehicles and equipment shall have a performance equivalent to that of a battery powered tag.

5.2.8

For Australian applications, the allocation of data values for platform identification in Clause 1.9 of Appendix A of AAR Standard S-918 is not appropriate, and shall be amended as follows: (a)

For conventional two-bogie or single platform vehicles, the ID code shall be “0".

(b)

For articulated or multi-unit vehicles (permanently coupled sets), platforms shall be numbered consecutively from one end to the extreme opposite end ie. 1, 2, 3, 4, 5, etc. Accordingly, the ID code (data value) for each platform shall be its platform number, regardless of the handbrake position, as follows: Value

Platform number

0

Single vehicle

1

Platform 1

2

Platform 2

3

Platform 3

4

Platform 4

5

Platform 5

etc.

5.3

LOCATION OF TRANSPONDER TAGS—ROLLINGSTOCK

5.3.1

Transponder tags shall be located on freight cars and locomotives as specified in AAR Standard S-917, on a flat surface or a flat or hat-shaped mounting plate, and mechanically fastened to the structure using a permanent type fastener, either— (a)

blind rivets, minimum diameter 5 mm, minimum head diameter 12 mm;

(b)

steel bolts minimum diameter 5 mm, with two lock nuts per bolt; or

(c)

swage lock blind fasteners, minimum diameter 5 mm.

No portion of the rear face of the tag shall stand out more than 6 mm clear of the mounting surface. 5.3.2

Tags shall not be fastened with self-tapping, self-drilling or drive screws. The use of adhesive tape, pressure sensitive adhesive or other types of adhesive is unacceptable for the fastening of transponder tags.

5.3.3

Where the tag mounting plate is not mounted directly on the vehicle side with rear support, eg. where it is suspended below the side sill or boundary member, it shall be positioned so as not to be liable to damage or distortion in normal service.

5.3.4

Detailed requirements for the location and mounting of tags on various types of vehicles and equipment are prescribed in Clauses 9.1 to 9.7 of AAR Standard S-918 and illustrated in Figure 1.

5.3.5

For rail tank cars, tags and their mounting plates shall not be attached to the tank shell. Tags shall be attached only to the tank car underframe or boundary members.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 9

5.3.6

Tags on rollingstock shall be mounted so that they will respond to an interrogating signal that is horizontally polarised.

5.4

LOCATION OF TRANSPONDER TAGS—CONTAINERS

5.4.1

In general, the location and fitting of transponder tags to containers shall conform to the requirements of AAR Standards S-918 and S-917. Only one (1) standard ID tag is to be fitted to containers. The right hand end referred to below is the end without doors (the “blind” end). In the case of containers without end doors or without solid sides and/or without fixed ends, the right hand end is determined when facing either side of the container. Location of transponders on containers is illustrated in Figure 2.

5.4.2

When applied to containers with a length of 12.2 metres (40 feet) or less, the tag shall be positioned on the side wall of the container, with the centre of the tag located 300 mm (1 foot) inboard from the right hand end post and 300 mm (1 foot) below the top of the roof line of the container.

5.4.3

On containers which are more than 12.2 metres (40 feet) long, the tag shall be positioned on the side wall of the container, with the tag located immediately inboard of the right hand end post and 300 mm (1 foot) below the top of the roof line of the container.

5.4.4

For containers without solid side walls, such as curtain-siders, tank containers, platforms and other open configurations, the tags may be located on or immediately adjacent to the right hand side corner post, facing toward the outside of the container.

5.4.5

Tags on containers shall be mounted so that they will respond to an interrogating signal which is vertically polarised.

5.5

PASSIVE ALARM TAGS

5.5.1

Passive alarm tags are used to provide an interface between the track-side reader and on-board equipment, and are either activated (able to be read) if there is an alarm condition or disabled (unable to be read) if there is no alarm condition.

5.5.2

Tag data format shall be as prescribed in Appendix J of AAR Specification S-918. Polarisation of the alarm tag shall be the same as prescribed for the standard ID tag, ie. horizontal for freight cars and road trailers and vertical for containers.

5.5.3

When fitted to freight vehicles, the passive alarm tag shall be located directly opposite one of the standard ID tags, as shown in Figure 3.

5.5.4

When fitted to containers, the passive alarm tag shall be located directly opposite the standard ID tag, ie. at the same end but on the opposite side as shown in Figure 4.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 10

TABLE 1 DATA FIELDS FOR FREIGHT CARS Bits required

Tag data sequence

Minimum value

Maximum value

Units

Equipment Group Code—Note 1

5

0-4

0

31

Type Code

Tag Type

2

5-6

1

4

Type Code

Vehicle Class (Code)

19

7-25

A__

ZZZZ

Alpha

Vehicle Number

20

4-45

0

999999

Numeric

Side Indicator Code— Note 2

1

46

0

1

Side Code

Length—See Note 3

12

94-96 47-55

0 [0

4095

Decimeters

1343

Feet ]

1

32

Axles

Entry

Number of Axles

5

56-59, 64

First Check Sum

2

60-61

Reserved Frame Marker

2

62-63

Bearing Type Code

3

65-67

0

7

Type code

Platform Identifier Code

4

68-71

0

15

Platform Code

Owners Identification

5

72-76

Alpha

Spare #2

10

77-86

Available for Owner’s Use

Spare #3

7

87-93

Available for Owner’s Use

Reserved

9

97-105

Reserved for future allocation

Security

12

106-117

Reserved for Future Allocation

Data Format Code

6

118-123

Second Check Sum

2

124-125

Frame Marker

2

14-27

NOTES: 1 Data values for the equipment group code shall be 19 for revenue freight vehicles and 14 for nonrevenue (service) vehicles. 2 Data values are 0 for the left side of the vehicle and 1 for the right side. 3 This field records the vehicle length in both feet and decimeters. Bit order shall be 94, 95, 96, 47, 48, 49, 50, .............55.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 11

TABLE 2 DATA FIELDS FOR LOCOMOTIVES Entry

Bits required

Tag Data sequence

Minimum value

Maximum value

Units

Equipment Group Code— Note 1

5

0-4

0

31

Type Code

Tag Type

2

5-6

1

4

Type Code

Equipment Initial (Mark)

19

7-25

A__

ZZZZ

Alpha

Locomotive Number

20

4-45

0

999999

Numeric

Side Indicator

1

46

0

1

Side Code

Length

9

47-55

0

510

Decimeters

0

167

Feet

1

32

Axles

0

7

Type Code

Number of Axles

5

56-59, 64

First Check Sum

2

60-61

Reserved Frame Marker

2

62-63

Bearing Type code

3

65-67

Owners Code (Initials)

5

68-72

Alpha

Spare

25

73-97

Available for Owners Use

Reserved

8

98-105

Reserved for Future use

Security

12

106-117

Reserved for Future allocation

Data Format Code

6

118-123

Second Check Sum

124-125

Frame Marker

14-127

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 12

TABLE 3 DATA FIELDS FOR FREIGHT CONTAINERS Entry

Bits required

Tag data sequence

Minimum value

Maximum value

Units

Equipment Group Code— Note 1

5

0-4

0

31

Type Code

Tag Type

2

5-6

1

4

Type Code

Owner’s Code (Initial)

19

7-25

A__

ZZZZ

Alpha

Identification Number

20

4-45

0

999999

Numeric

Check Digit

4

46-49

0

9

Numeric

Length

11

50-59, 64

0

2 000

Centimetres

[0

805

Inches]

First Check Sum

2

60-61

Reserved Frame Marker

2

62-63

Height

9

65-73

0 [0

500 392

Centimetres Half Inches]

Width

7

74-80

200 [78

300 118

Centimetres Inches]

Container Type Code

7

81-87

1

128

Type Code

Maximum Gross Weight

9

88-96

45 [99

455 1004

Hundred kg Hundred lbs]

Tare Weight

7

97-103

0 [0

91 200

Hundred kg Hundred lbs]

Spare

2

104-105

Available for owner’s use

Security

12

106-117

Reserved for future allocation

Data Format Code

6

118-123

Second Check Sum

124-125

Frame Marker

14-127

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 13

6

PERFORMANCE REQUIREMENTS

6.1

All rollingstock shall be designed and constructed so that it is able to meet the performance requirements of this Code.

6.2

Performance requirements are specified as follows: (a)

Static and dynamic vehicle performance requirements—RCP-2201.

(b)

Static and kinetic rollingstock outline testing—RCP-2201. (The requirements to be met by these tests are specified in RCP-2104.)

(c)

Train and vehicle braking performance tests—RCP-2105 and RCP-2305.

(d)

Additional interface performance requirements in the following categories: (i)

Environmental interface.

(ii)

Overhead electric power interface.

(iii)

Electrical safety— RCP-2101.

AROU V1 Consultative Draft

November 2002

outline

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 14

7

ELECTRICAL INSTALLATIONS

7.1

GENERAL REQUIREMENTS

7.1.1

These requirements shall be applied to the installation of electrical wiring and components to provide a safe on-train environment and protection against damage or injury to persons and equipment.

7.1.2

This clause is applicable to permanent electrical installations on all new and rebuilt rollingstock. It does not apply to temporary installations or equipment fitted for the purposes of evaluation, testing or recovery. However such installations should comply with these requirements wherever, and to the extent, it is possible to do so.

7.2

PREVENTION OF ELECTRIC SHOCK

7.2.1

Direct contact—normally live components

7.2.1.1

Provision shall be made to protect persons from direct contact with electrical equipment and components that are normally live.

7.2.1.2

This shall be accomplished by the implementation of recognised rail industry standards and methods based generally on the requirements of AS 3000 except where full compliance with that standard is limited by space constraints or their use produces other unacceptable risks.

7.2.2

Contact—components not normally live

7.2.2.1

Provision shall also be made to protect persons from contact with exposed components or surfaces not normally live, but which are electrically conductive and could become live as a result of a mechanical or electrical fault or failure.

7.2.2.2

This shall be accomplished by the implementation of recognised rail industry standards and methods based generally on the requirements of AS 3000 except where full compliance with that standard is limited by space constraints or their use produces other unacceptable risks.

7.3

THERMAL PROTECTION

7.3.1

Electrical equipment shall be so designed and installed that there is no normal risk of ignition, combustion or other thermal damage to the loading, the vehicle or the electrical equipment due to high temperatures or electric arcs.

7.3.2

Electrical equipment shall be so covered and/or thermally insulated that there is no risk of persons suffering burns, injury or distress from contact with or exposure to hot surface or elevated temperatures.

7.4

FAULT PROTECTION

7.4.1

Persons shall be protected from the risk of electrocution, electric shock and injury arising from the occurrence or effects of electrical faults, failures, short circuits and excessive temperatures.

7.4.2

Vehicles, equipment, loading and other property shall be similarly protected from damage due to electrical faults.

7.4.3

All electrical installations shall incorporate protection for persons and equipment by means of appropriately rated circuit breakers or fuses or fusible links.

7.4.4

Conductors and other components intended to carry a fault current shall be rated to carry that current without exceeding the permissible temperature rise.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 15

7.5

EARTHING SYSTEM

7.5.1

All vehicles fitted with permanent or temporary electrical installations or equipment shall be fitted with an effective earthing system.

7.5.2

The earthing system shall incorporate provision for interconnection between the body, underframe, bogie and wheel-sets.

7.5.3

Vehicles not fitted with electrical installations or equipment shall have an earth strap or straps or similar electrical bonding system to provide conductivity between the vehicle structure and the wheel-sets.

7.5.4

All conductors used as part of the earth system shall be clearly and prominently identified as such.

7.5.5

All rollingstock that is likely to operate on any part of the electrified networks shall be fitted with an effective earthing system linking the body, underframe and bogies/wheelsets. The earthing system shall have sufficient capacity to carry without failure the fault current arising from direct contact with the overhead system.

7.6

INSULATION

7.6.1

All electrical installations and components shall incorporate an effective insulation between live elements, between live elements and enclosures and between live elements and earth.

7.6.2

The integrity of insulation systems shall be checked regularly, typically at major overhauls, but at intervals of not longer than 10 years.

7.7

SAFETY SIGNS

7.7.1

All electrical installations, equipment and enclosures shall be fitted with the appropriate safety signs, located in a conspicuous position.

7.7.2

Signs shall comply with the requirements of AS 1319.

7.7.3

Where equipment or enclosures have hinged or removable doors or covers, the signage shall be fitted to the inside as well as the outside.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 16

8

HAZARDOUS MATERIALS

8.1

UNACCEPTABLE MATERIALS

8.1.1

The following materials shall not be used on any type of rollingstock: (a)

Asbestos or asbestos based products.

(b)

Lead or chromate based paints.

(c)

Poly-chlorinated biphenyls (PCB’s).

(d)

Any material using or containing halons or chlorofluorocarbons (CFC’s).

(e)

Any materials prohibited under relevant State or Federal work place health and safety legislation.

8.2

SAFETY DATA SHEETS

8.2.1

Rollingstock builders shall supply the vehicle owner with Material Safety Data Sheets for all hazardous materials used on rollingstock for which they are responsible.

8.2.2

Rollingstock owners shall provide maintainers with relevant safety data sheets for all hazardous materials used on rollingstock for which they are responsible.

8.2.3

Rollingstock maintainers shall obtain safety data sheets for all hazardous materials that they use, or are in use, on rollingstock for which they are responsible.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 17

9

VEHICLE IDENTIFICATION, CLASSIFICATION AND NUMBERING

9.1

FREIGHT CARS

9.1.1

Requirements and recommended practices for the display of freight car and bogie classification codes and identification numbers on vehicles and bogies, together with other optional markings including retroreflective delineators, are given in RCP-3111. A recommended system for the coding of freight vehicles and bogies by type and for the allocation of numbers to individual vehicles is given in RCP-3110.

9.2

LOCOMOTIVES AND PASSENGER CARS

9.2.1

Locomotives and passenger cars shall be marked with a unique identification code, which shall be compatible with train management and monitoring systems used on the DIRN. Identification codes shall be located on both sides of each vehicle using characters not less than 125 mm high. Locomotives shall also be marked with their gross mass in the fully equipped condition. Passenger cars shall be marked with their tare mass.

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 18

10

NOISE AND VIBRATION

10.1

GENERAL REQUIREMENTS

10.1.1

New locomotives and passenger cars shall comply with the limits for noise and vibration prescribed by the applicable State or Federal environmental protection or workplace health and safety legislation.

10.1.2

General guidelines for initial design considerations are prescribed in: ·

RCP-5102 for locomotives;

·

RCP-6102 for locomotive hauled passenger cars; and

·

RCP-6103 for self-propelled passenger cars.

10.2

INTERIOR NOISE

10.2.1

Drivers cabs

10.2.1.1

Noise levels in driver’s cabs and other areas occupied by train staff shall not exceed the recommended limits prescribed by the applicable work place health and safety regulations. Noise levels in driver’s compartments should be measured at ear level in accordance with AS 1269—Hearing conservation code.

10.2.1.2

Typically the noise levels in those areas should not exceed any point on the Noise rating curve of 70, as defined in AS 1649, Acoustics—Methods for the determination of noise rating numbers.

10.2.2

Passenger compartments

10.2.2.1

Noise levels in passenger compartments shall not exceed the applicable limits recommended in AS 1269—Hearing conservation code, for the normal scheduled trip duration.

10.2.2.2

Typically the noise levels in those areas should not exceed any point on the Noise rating curve of 65, as defined in AS 1469—Acoustics—Methods for the determination of noise rating numbers.

10.2.3

Non-passenger areas

10.2.3.1

The noise level in areas not normally occupied by passengers for extended periods, such as toilets, corridors, vestibules, luggage areas, etc. shall not exceed any point on the noise rating curve of 70, as defined in AS 1469—Acoustics—Methods for the determination of noise rating numbers.

10.3

EXTERNAL NOISE

10.3.1

The external noise generated by rollingstock shall be measured in accordance with AS 2377—Methods for the measurement of airborne sound from rail vehicles.

10.3.2

At all speeds up to 100 km/h, the noise level should conform to the access provider’s requirements.

10.4

VIBRATION

10.4.1

Equipment shall be capable of withstanding the vibration and accelerations experienced in normal service.

10.4.2

Passenger seat acceleration (RMS) levels due to vibration in the range of 1 Hz to 80 Hz in the longitudinal (z) plane and the transverse (x and y) planes shall not

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 19

exceed the 4 hour exposure limits prescribed in AS 2670, Vibration and shock—Guide to the evaluation of human exposure to whole body vibration. These limits apply at any location within the vehicle under all operating conditions at any time during normal running. 10.4.3

The vibration measured at the drivers seat shall not exceed the 8 hour exposure limits prescribed in the “Reduced comfort boundary” curves specified in AS 2670.

10.4.4

Instrumentation, test and analysis procedures shall be in accordance with the requirements of AS 2670.

10.4.5

All vehicle components, including traction, engine cooling and air conditioning equipment, car structure and panelling, should be designed to minimise the emission and transmission of noise and vibration.

10.4.6

Vehicle emissions shall comply with the access provider’s requirements.

FIGURE 1 LOCATION OF TRANSPONDERS—FREIGHT CARS

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 20

FIGURE 2 LOCATION OF TRANSPONDERS—TYPICAL FREIGHT CONTAINERS

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102

Code of Practice for the Defined Interstate Rail Network—Volume 5: Rollingstock Part 2—Common requirements Section 1: Design and construction

RCP-2102: Vehicle structure

Page No. 21

FIGURE 3 LOCATION OF PASSIVE ALARM TAGS—VEHICLES

FIGURE 4 LOCATION OF PASSIVE ALARM TAGS—CONTAINERS

AROU V1 Consultative Draft

November 2002

Document No. RCP-2102