GM/GN2646. Guidance on Axle Bearing Maintenance. Issue One: March 2011 Rail Industry Guidance Note for GM/RT2004 Issue Four

Transcription

1 GN Published by: Block 2 Angel Square 1 Torrens Street London EC1V 1NY Copyright 2011 Rail Safety and Standards Board Limited GM/GN2646 Issue One: March 2011 Rail Industry Guidance Note for GM/RT2004 Issue Four

2 Issue Record Issue Date Comments One 5 March 2011 Supersedes GM/RT2030 issue two (All except Parts C1.1 and C3.1 first paragraph, (no bullets)) and GM/RC2516 issue two Superseded documents Supply The following Railway Group documents are superseded, either in whole or in part as indicated: Superseded documents GM/RT2030 issue two October 2002 Axle Bearing Maintenance GM/RC2516 issue two October 2002 Approved Code of Practice - Training Requirements for Personnel who Undertake Maintenance and Overhaul of Axle Bearings Sections superseded All except Parts C1.1 and C3.1 first paragraph, (no bullets) Date when sections are superseded 4 June 2011 All 4 June 2011 GM/RT2030 issue two (All except Parts C1.1 and C3.1 first paragraph, (no bullets)) and GM/RC2516 issue two cease to be in force and are withdrawn as of 4 June The authoritative version of this document is available at Uncontrolled copies of this document can be obtained from Communications,, Block 2, Angel Square, 1 Torrens Street, London EC1V 1NY, telephone or enquirydesk@rssb.co.uk. Other Standards and associated documents can also be viewed at Page 2 of 21

3 Contents Uncontrolled When Printed Section Description Page Part 1 Introduction Purpose of this document Copyright Approval and authorisation of this document 4 Part General recommendations Axle bearing maintenance policy Rail vehicle maintenance plan 6 Part 3 Competence of Personnel Involved in Axle Bearing Maintenance Competence Records Competence assessors 14 Appendices 15 Appendix A Competence for Personnel and Supervisors Responsible for the Overhaul of Axle Bearings 15 Appendix B Competence for Personnel and Supervisors Responsible for the Maintenance of Axle Bearings or any Activities which may Disturb the Axlebox / Axle Bearing Assembly 17 Appendix C Competence for Personnel and Supervisors Responsible for Work Activities which may Influence the Condition of Axle Bearings 18 Appendix D Multiple Training Modules 19 Definitions 20 References 21 Tables Table D.1 Duration for multiple training modules 19 Page 3 of 21

4 Part 1 Introduction 1.1 Purpose of this document This document gives guidance for the maintenance of rail vehicle axle bearings. There is also detailed guidance for the training and competence assessments of personnel and supervisors, who influence, maintain or overhaul axle bearings Relevant requirements in GM/RT2004 are reproduced in the sections that follow. Guidance is provided as a series of sequentially numbered clauses prefixed GN immediately below the text to which it relates. Where there is no guidance given, this is stated Specific responsibilities and compliance requirements are laid down in the Railway Group Standard itself. 1.2 Copyright Copyright in the Railway Group documents is owned by Rail Safety and Standards Board Limited. All rights are hereby reserved. No Railway Group document (in whole or in part) may be reproduced, stored in a retrieval system, or transmitted, in any form or means, without the prior written permission of Rail Safety and Standards Board Limited, or as expressly permitted by law members are granted copyright licence in accordance with the Constitution Agreement relating to Rail Safety and Standards Board Limited In circumstances where Rail Safety and Standards Board Limited has granted a particular person or organisation permission to copy extracts from Railway Group documents, Rail Safety and Standards Board Limited accepts no responsibility for, nor any liability in connection with, the use of such extracts, or any claims arising therefrom. This disclaimer applies to all forms of media in which extracts from Railway Group Standards may be reproduced. 1.3 Approval and authorisation of this document The content of this document was approved by Rolling Stock Standards Committee on 21 January This document was authorised by on 27 January Page 4 of 21

5 Part 2 GM/RT2004 issue four Axle bearings The maintenance plan shall contain maintenance and overhaul instructions for axle bearings The maintenance plan shall, as a minimum, set out the requirements for: a) Floats, clearances. b) Grease (if applicable) Further guidance for axle bearing maintenance is given in GM/GN General recommendations GN01 To assist in meeting the requirements of GM/RT2004, a railway undertaking should have an axle bearing maintenance policy. Axle bearings should be maintained and overhauled in accordance with that policy. GN02 Where the maintenance and / or overhaul of axle bearings is contracted to a third party, the railway undertaking should ensure that they are qualified suppliers. Axle bearings are safety-critical equipment. Incorrect maintenance or overhaul can introduce faults which have the potential to cause wheelset seizure and possible derailment. 2.2 Axle bearing maintenance policy GN03 The purpose of the axle bearing maintenance policy is to ensure that the axle bearings remain in a safe and reliable operating condition at all times whilst in use. The objective is to ensure that the axle bearings remain in a safe and reliable operating condition. This should be identified by means of a structured process and should be stated in the maintenance policy. The policy should also define each of the following and state how it is to be implemented: a) Objectives and targets for the safety performance of all axle bearings fitted to all rail vehicles used by the railway undertaking should be developed from a safety assessment of the vehicles and axle bearings used by the railway undertaking. b) A procedure defining how the safety performance of the axle bearings should be monitored. This should identify: i) The information that is to be recorded and kept, including the information which defines the performance of the assembly in service and the condition of the axle bearing parts when they are overhauled. ii) iii) How the information on the axle bearings and parts is to be processed and analysed. The actions to be taken if the axle bearings fail to operate within the target level set. c) The maintenance policy for determining and reviewing: i) The criteria (bearing age, mileage or distance) at which the axle bearings should be scrapped. ii) iii) The periodicity of maintenance attention. The periodicity of overhaul. Page 5 of 21

6 d) Where applicable, the procedures for assuring continued safe operation of axle bearings which are condition monitored by rail vehicle mounted equipment. e) The involvement of any third parties carrying out work associated with axle bearing maintenance activities covered by the maintenance policy and how they are qualified and controlled. f) Measures to maintain the axle bearings in a safe condition if they are stored unfitted, or are fitted to a wheelset which is unused for an extended period of time. g) States the maximum time before the maintenance policy is reviewed and updated and any specific circumstances which will trigger an early review. h) The basis on which a review of the maintenance policy will be undertaken. i) Identify the maintenance plan for each type or family of axle bearings covered by the maintenance policy. j) Identify the procedure for review and updating the maintenance plan(s). k) State the maximum time before the maintenance plan(s) are normally reviewed and updated and any specific circumstances which will trigger an early review. GN04 The axle bearing maintenance policy should be produced by competent personnel and identify the manager(s) or representative responsible for executing the policy. 2.3 Rail vehicle maintenance plan GN05 Rail vehicle maintenance plans, approved in accordance with the requirements set out in GM/RT2004, should contain specific axle bearing maintenance and overhaul requirements applicable to each individual type or family of axle bearings used by the railway undertaking. The purpose of the rail vehicle maintenance plan is to state all the actions and standards that are necessary to meet the requirements of the maintenance policy, for that type of bearing fitted to a particular rail vehicle type. GN06 Each rail vehicle maintenance plan should identify the following: a) The maximum time or distance between visual examinations of the complete assembly on the wheelset. b) Where applicable, the maximum time or distance between rotational and end float checks. c) The method to be used and the maximum interval between the injection of a measured quantity of new grease into a cartridge bearing, or introduction of new grease into an axlebox bearing. d) The maximum time or distance at which the axle bearings should be overhauled. e) The grease type to be used. f) The criteria (if any) at which the axle bearings should be scrapped. g) The documents specifying the relevant standards for examination and acceptance at overhaul. h) Where applicable, the documents specifying the working instructions for each action in the maintenance plan. i) The minimum engineering maintenance facilities required for the specified maintenance and overhaul of the axle bearings. j) The minimum level of competence for staff engaged in the execution of the specified maintenance and overhaul of axle bearings. Page 6 of 21

7 Part 3 Competence of Personnel Involved in Axle Bearing Maintenance 3.1 Competence Levels of competence GN07 Personnel should be competent for the duties in which they are employed when maintaining or overhauling axle bearings. This should be done in accordance with the following: Level 1 Level 2 Level 3 Competence for personnel and supervisors responsible for the overhaul of axle bearings (see Appendix A). Competence for personnel and supervisors responsible for the maintenance of axle bearings or any activities which may disturb the axlebox / axle bearing assembly (see Appendix B). Competence for personnel and supervisors responsible for work activities which may influence the condition of axle bearings (see Appendix C). GN08 To provide appropriate training to those who influence, maintain or overhaul axle bearings and to cover all needs, it is recommended that the persons covered by this document are identified against the most appropriate category shown in to and receive the training recommended for that level Training - general GN09 Classroom and workshop training modules should be developed which are appropriate to the tasks to be performed. The content and duration of the training may be scaled to match the competence requirements and the specific needs of individual candidates. The training need should include, as a minimum, only those axle bearing type(s) and manufacturer(s) which are part of the work carried out. GN10 GN11 Competence gained in this way should be limited to the axle bearing type(s) and manufacturer(s) for which there has been training and assessment. Personnel should only be permitted to work on the axle bearing type(s) and manufacturer(s) for which they are competent, except as part of further training. Level 1 and level 2 training should: a) Be split into classroom and workshop sessions. b) Be in modules to cover each axle bearing type and level of attention. c) Give both general and specific instructions. GN12 GN13 GN14 Practical training may be carried out between classroom sessions, if appropriate. All classroom and workshop training should be given by a competent trainer. Level 1 and level 2 classroom training should be made effective by use of the following aids and teaching techniques, where appropriate: a) Axle bearing models and specimens. b) Films and video. c) Visual aids. d) Question and answer sessions. e) Expert descriptions of axle bearing topics. Page 7 of 21

8 GN15 It is assumed that supervisors are already competent in the supervision of workshop personnel and it is not the purpose of this document to cover training for those general aspects Extent and duration of training GN16 Level 1 personnel and their supervisors should be given: a) A recommended minimum of eight hours of technical / classroom training. b) Practical demonstrations in the workshop. The trainer should demonstrate the correct practices for all the activities to be undertaken. GN17 GN18 For level 1 supervisors, no further training is required. For other level 1 personnel, a period of monitored workshop activity is required to complete the training. For the first axle bearing type, this should include: a) A minimum of one week under direct supervision. b) Three weeks where the quality of the trainees work on axle bearings is monitored. c) Two months under occasional supervision, with quality checks on work performed on axle bearings, as appropriate. GN19 GN20 GN21 For subsequent new axle bearing types, the training may be of reduced duration, as set out in Appendix D. The three periods set out in GN18 may be reduced on a pro-rata basis. A period of not less than three months training experience is recommended before competence assessment. Level 2 personnel and their supervisors should be given: a) A recommended minimum duration of four hours of technical / classroom training. b) Practical demonstrations in the workshop. The trainer should demonstrate the correct practices for all the activities to be undertaken. GN22 GN23 GN24 GN25 For level 2 supervisors, no further training is required. For level 2 personnel, a period of monitored practice should be included to complete the training. During this time, the trainee should undertake all the activities to be carried out until competence in each activity can be demonstrated. It is recommended that the initial performance of each activity should be under the direct supervision of a competent person. For repetitions of each activity, the level of supervision should be appropriate to the risks involved. Level 3 activities are those which will cause contamination or physical damage if incorrectly carried out near to the axle bearing or axle bearing parts. The list identifies some activities that may produce contamination or physical damage to the axle bearings. This list is not exhaustive and the risks of any other operations should be considered based on knowledge of damage / failure mechanisms: a) Use of pressurised water sprays. b) Processes producing dust / debris near to axle bearings that are not fully sealed. c) Handling / transportation of axle bearing parts, assembled axle bearings or wheelsets. d) Storage of axle bearing parts, assembled axle bearings or wheelsets. e) Welding operations. Page 8 of 21

9 GN26 GN27 GN28 GN29 For level 3 personnel and supervisors, relevant technical instruction / training should be given at the workplace during a short briefing. For level 3 supervisors, no further training is required. For level 3 personnel, a period of monitored practice is required to complete the training. During this time, the trainee should undertake all the activities to be carried out, until competence in each activity can be demonstrated. It is recommended that the initial performance of each activity should be under the direct supervision of a competent person. For repetitions of each activity, the level of supervision should be appropriate to the risks involved Level 1 and level 2 classroom training GN30 Level 1 and level 2 classroom training should include: a) A common module for both levels of training. b) Separate modules for roller bearings and plain bearings. GN31 GN32 Roller or plain axle bearing modules may be deleted, as appropriate, if not applicable to the work being carried out. Classroom modules should incorporate the topics given below and should be structured such that personnel can understand all the information imparted without any specialist knowledge. Level 1 candidates should receive training to cover at least items c) to m). Level 2 candidates should receive training to cover at least items a) to k): a) Risks if vehicle is moved whilst the axle end cap is not in place. b) Protection of axle bearings during welding operations. c) Protection of axle bearings on the assembled wheelsets. d) Axle bearing terminology. e) Principles of axle bearing operation. f) Description of axle bearing types. g) Axle bearing failure mechanisms, their causes and consequences. h) Need for cleanliness. i) Handling and storage of axle bearings. j) Axle bearing contamination. k) Electrical damage. l) Defect records. m) Axle bearing defects and rejection criteria. GN33 Classroom modules for roller bearings should incorporate the topics set out below. Level 1 candidates only overhauling axle bearings which have been fully removed from the axle should, as a minimum, receive instruction to cover items a) to c). Level 1 candidates overhauling axle bearings which are not fully removed from the axle should receive instruction to cover all items. Level 2 candidates should receive instruction to cover all items: a) Axle bearing lubrication. Page 9 of 21

10 b) Axle bearing assembly checks. c) Method and importance of axle bearing sealing. d) Location and securement of the axle bearing. e) Axle bearing and journal examination. GN34 Classroom modules for plain bearings should incorporate the topics set out below. Level 1 candidates should receive instruction to cover all items. Level 2 candidates should receive instruction to cover at least items a) to d): a) Axle bearing lubrication. b) Axle bearing assembly checks. c) Method and importance of axle bearing sealing. d) Location and securement of the axle bearing. e) Pad examination. f) Axle bearing and journal examination. g) Surface finish requirements Level 1 and level 2 workshop training GN35 Workshop training can be in the actual workplace, or alternatively may be carried out in a training facility which has been constructed and equipped to duplicate the range of tasks and facilities present in the actual workplace. GN36 The workshop roller bearing module should demonstrate the correct maintenance techniques on the following bearing types, as applicable: a) Axlebox tapered roller bearings. b) Cartridge tapered roller bearings. c) Axlebox cylindrical roller bearings. d) Axlebox spherical roller bearings. GN37 Appropriate workshop modules should be produced to include the activities shown below. Training should include practical demonstrations of the correct maintenance / overhaul techniques required for each activity: a) Level 1 - roller bearing module: i) Axlebox fitting and removal. ii) iii) iv) Axle bearing fitting and removal from wheelset. Axle bearing dismantling. Axle bearing cleaning. v) Inspection of axle journal and axle bearing components. vi) vii) viii) Criteria for acceptance / rejection of axle journal and axle bearing components. Axle bearing assembly. Assembled axle bearing checks. Page 10 of 21

11 ix) Axle bearing lubrication. b) Level 1 plain bearing module: i) Axlebox fitting and removal. ii) iii) iv) Axle bearing dismantling. Axle bearing manufacture and machining. Inspection of axle journal and axle bearing components. v) Criteria for acceptance / rejection of axle journal and axle bearing components. vi) vii) viii) Axle bearing assembly. Assembled axle bearing checks. Axle bearing lubrication. c) Level 2 - roller bearing module: i) External examination. ii) iii) iv) Identifying axle bearings in distress. Hand rotation check. End float check. v) Lubrication. vi) vii) viii) ix) Removal and refitting of axle bearings. Removal and refitting of axle end cap. Prevention of risks due to handling and storage. Prevention of risks from water jets or other fluids used near the axle bearings. d) Level 2 - plain bearing module: i) General examination of the axlebox and journal. ii) iii) iv) Correct location of axle bearing. Examination of the lubrication pad. Lubrication. v) Permitted wear of axle bearings and journals. vi) vii) viii) Removal and refitting of axle bearings. Wheelset handling and storage. Prevention of risks from water jets or other fluids used near the axle bearings. Page 11 of 21

12 3.1.6 Level 3 training GN38 For level 3 training, a briefing by the supervisor responsible for the relevant activities will be sufficient in most cases. The training will vary according to the activities but in all cases should: a) Identify the recommended best practices and ensure that these can be correctly carried out by the trainee. b) Explain the risks and consequences involved and show how these can be avoided by use of the recommended best practices Assessment following training GN39 Following training, the trainees should be assessed by a competence assessor to establish that the required competence standard is achieved. GN40 GN41 Personnel covered by levels 1 to 3 training, as set out in this document, should be assessed by a competence assessor. The competence assessor should collect sufficient evidence to enable competence to be assessed against all the criteria covered in this document for the appropriate competence levels and the scope of the candidate s application. This should include: a) Performance evidence obtained by observance of the candidate s performance in a normal work situation undertaking prescribed tasks. b) Inspection of the finished work. c) Evidence of the candidate s knowledge, obtained by either oral or written questions, addressing aspects not covered by the performance evidence. GN42 Items set out in GN41 a) and b) should be supplemented by historical evidence of the candidate s performance, witness testimony from the candidate s superior or other authorised staff and personal accounts by the candidate, either oral or written Direct supervision GN43 Any person failing to achieve the required standards of competence should only work on axle bearings under direct supervision, as part of a training programme aimed at achieving the appropriate competence standard. GN44 GN45 When a candidate fails to demonstrate appropriate competence, the competence assessor should inform the candidate s employer, giving the reasons for failure and the recommendations for further training. Candidates should not undertake any work on axle bearings until competent, except as part of further training Maintaining competence GN46 Systems should be in place to ensure that a person s competence is maintained. GN47 The competence for all personnel covered by this document should become invalid in either of the following circumstances, until refresher training and reassessment has been successfully completed to regain the competence: a) After a period of two years maximum, for levels 1 to 3. b) After a period of six months maximum, for levels 1 and 2, if none of the duties for which competence is held have been carried out in that time. c) After a period of one year maximum, for level 3, if none of the duties for which competence is held have been carried out in that time. Page 12 of 21

13 GN48 GN49 GN50 GN51 All personnel covered by levels 1 to 3 training, as set out in this document, should undertake refresher training and reassessment by a competence assessor, as required. Refresher training and reassessment applies only to those areas for which competence has been previously held. If any new areas of competence are introduced, relevant training as set out in to of this document should be used. For all level 1 and 2 personnel it is recommended that approximately one hour classroom training and one hour workshop demonstrations should be given. The refresher training should be structured in accordance with the level of competence previously held. No period of monitored workshop practice is required to complete level 1 and 2 refresher training. For level 3 refresher training, a briefing by the supervisor responsible for the relevant activities will generally be sufficient. The training will vary according to need but should aim to emphasise the risks involved and to ensure that the candidate is aware of, and can carry out, the best practices to avoid the risks. 3.2 Records GN52 For each person working on the overhaul and maintenance of axle bearings set out in this document, there should be an auditable record of competence. The records should: a) Be available for inspection at all reasonable times. b) Clearly identify the types of axle bearings and / or vehicles on which the person has achieved the necessary competence level. c) Be kept up-to-date and show the current position for each person, reflecting the evidence collected during the training and assessment process and the continued competence of on-the-job experience. d) Be retained: i) At all times that the person is working in areas covered by this document. And ii) For a period of two years beyond the date when the person ceases to work in those areas where axle bearings are maintained and overhauled. GN53 Details in respect of each person working at levels 1 to 3 should be kept in a work log. which should include: a) Name and training category for each person. b) Facility where the work, training or assessment was undertaken. c) Date when work, training or assessment was undertaken. d) Details of classroom training completed. e) Details of workshop training completed. f) Results of competence assessment(s). g) Details of the axle bearing type(s), axle bearing manufacturer(s) and / or vehicle types on which the person is competent, where relevant. h) The start / finish dates and the duties undertaken for all time spent working as a competent person on axle bearing maintenance and overhaul. Page 13 of 21

14 GN54 The railway undertaking should ensure that persons are issued with, or have access to, all relevant publications and equipment necessary for them to undertake their duties when maintaining or overhauling axle bearings. 3.3 Competence assessors GN55 Competence assessors should: a) Have the relevant occupational skills, knowledge and experience to assess the categories of work competence as set out in this document. b) Compile the criteria to be used for competence assessment against the topic areas set out in this document. c) Assess competence against the topic areas set out in this document. Page 14 of 21

15 Appendix A Competence for Personnel and Supervisors Responsible for the Overhaul of Axle Bearings A.1 Technical knowledge required for personnel and supervisors GN56 The railway undertaking should ensure that personnel and supervisors responsible for the overhaul of axle bearings have demonstrated that they have knowledge in the following areas: a) The principles of axle bearing operation. b) Axle bearing failure mechanisms and their causes. c) The importance of achieving correct fit of the axle bearing on the axle journal and in the axlebox bore. d) The terminology used for axle bearings and their overhaul. e) Identification / designation of different axle bearing types. f) The requirements for corrosion protection. g) The importance of using matched components for axle bearing assembly. h) The importance of effective seals at the front and rear of the axlebox. i) The importance of the correct grease type, quantity and method of application. j) The importance of cleanliness during the overhaul of axle bearings and the consequences of dirt or liquid contamination. k) The importance of axle end and journal condition. l) The importance of the security of the axle end cap. m) The consequences of axle bearing failure. n) Knowledge of the documentation covering axle bearing overhaul and its location at the workplace. A.2 Practical skills required for personnel carrying out axle bearing work activities GN57 Uncontrolled When Printed The railway undertaking should ensure that personnel who overhaul axle bearings have demonstrated that they have the skills to perform the following operations, according to documented procedures: a) Overhaul of *: i) Cartridge roller bearings. ii) iii) Non-cartridge roller bearings. Plain bearings. * One or more of these axle bearing types may be excluded from the assessment if not relevant to the overhaul work carried out. In all cases, the competence record should be marked in accordance with GN52 b). b) Use of any special equipment necessary to carry out the overhaul. c) Examination of axle bearing components, to identify any damage present and determine if parts are fit for re-use or need to be scrapped. Page 15 of 21

16 d) Re-assembly of axle bearings, maintaining acceptable standards of cleanliness and handling. e) Applying the appropriate quantity and quality of axle bearing lubricant. f) Reporting any axle bearing damage or defects which are present. g) Maintaining good quality records. h) Handling, storing and protecting the assembled axle bearings. i) Carrying out end float and other assembly checks. j) Removal and refitting of axle bearing assemblies onto axles. A.3 Axle bearing management for supervisors GN58 The railway undertaking should ensure that supervisors who are responsible for the overhaul of axle bearings have demonstrated that they have sufficient knowledge of the following topic areas: a) The resources and equipment required for the activities being supervised. b) Control and calibration of the measuring equipment. c) The skill requirements of the tasks. d) Control of the workplace to ensure axle bearings are correctly overhauled. e) Management of quality records. f) Management of a reporting system covering the nature and cause of rejection of scrapped axle bearings. g) Provision of the documentation to cover axle bearing overhaul and the systems for its updating. Page 16 of 21

17 Appendix B Competence for Personnel and Supervisors Responsible for the Maintenance of Axle Bearings or any Activities which may Disturb the Axlebox / Axle Bearing Assembly B.1 Technical knowledge required for personnel and supervisors GN59 The railway undertaking should ensure that personnel and supervisors who are responsible for the maintenance of axle bearings or any activities which may disturb the axlebox / axle bearing assembly have demonstrated that they have knowledge in the following areas: a) The principles of axle bearing operation. b) Axle bearing failure mechanisms and their causes. c) Axle bearing examination and defects which can be identified with the bearing in-situ. d) Axle end condition and importance of correct security of the axle end cap. e) Axle bearing lubrication. f) Axle bearing assembly checks. g) Identification of the different axle bearing types. h) The need for stringent cleanliness. i) Handling and storage of axle bearings and assembled wheelsets. j) The terminology used for axle bearings. k) The importance of effective seals at the front and rear of the axlebox. l) The consequences and restrictions of moving a rail vehicle with the axle end caps removed. m) Knowledge of the documentation covering the activities to be carried out and its location in the workplace. B.2 Practical skills required for personnel carrying out axle bearing work activities GN60 The railway undertaking should ensure that personnel whose duties are within the scope of Appendix B have demonstrated that they have the skills to perform all tasks for which they are responsible. B.3 Axle bearing management for supervisors GN61 Uncontrolled When Printed The railway undertaking should ensure that supervisors whose duties are within the scope of Appendix B have demonstrated that they have sufficient knowledge of the following topic areas: a) The resources and equipment required for the activities being supervised. b) The skill requirements of the tasks. c) Management of quality records. d) Provision of the documentation to cover the activities being supervised and the systems for its updating. Page 17 of 21

18 Appendix C Competence for Personnel and Supervisors Responsible for Work Activities which may Influence the Condition of Axle Bearings C.1 Technical knowledge required for personnel and supervisors GN62 The railway undertaking should ensure that personnel and supervisors whose duties are within the scope of Appendix C have demonstrated that they are aware of the potential risks to axle bearings which may arise from the duties carried out. They should demonstrate that they have knowledge in the following areas: a) The basic principles of axle bearing operation. b) An appreciation of the relevant axle bearing failure mechanisms and their causes. c) The need for stringent cleanliness. d) The correct storage and handling of assembled wheelsets (see GM/RT2466). e) The correct storage and handling of partially or fully assembled axle bearings. f) The correct practices for using water jets or other fluids near axle bearings. g) Knowledge of the documentation covering the activities to be carried out and its location at the workplace. C.2 Practical skills required for personnel carrying out axle bearing work activities GN63 The railway undertaking should ensure that personnel whose work activities have the potential to influence the condition of axle bearings, or who are required to handle parts of the axle bearing or its assembly, have demonstrated that they have the skills to perform all tasks for which they are responsible. C.3 Axle bearing management for supervisors GN64 Uncontrolled When Printed Railway undertakings should ensure that supervisors whose duties are within the scope of Appendix C have demonstrated that they have sufficient knowledge of the following topic areas: a) The resources and equipment required for the activities being supervised. b) The skill requirements of the tasks. c) The correct handling and storage of axle bearings. d) Control of the workplace to ensure that axle bearings are not subjected to handling, contamination or other risks which may cause damage. e) Provision of the documentation to cover the activities being supervised and the systems for its updating. Page 18 of 21

19 Appendix D Multiple Training Modules D.1 Multiple training module duration Bearing type Axlebox tapered roller bearings Cartridge tapered roller bearings Axlebox cylindrical roller bearings Axlebox spherical roller bearings First module duration three months three months three months three months Table D.1 Duration for multiple training modules Second module duration one month one month one month one month Each subsequent module duration two weeks two weeks two weeks two weeks Page 19 of 21

20 Definitions Uncontrolled When Printed Axle bearings For the purposes of this document, axle bearings are those bearings, either roller or plain which are mounted on the axle and carry the mass of the vehicle. Competence assessor Person with relevant occupational skills, knowledge, experience and ability, who is qualified to assess competence as defined by the topic areas set out in this document. Competent person A person who has been assessed as competent to undertake specific tasks. Maintenance a) Actions which disturb or change any part of the axle bearing, the grease used in the axle bearing, the assembly on the axle and the parts used to retain or seal the assembly. b) In respect of a maintenance policy, all aspects including overhaul. Overhaul All actions carried out on the axle bearing at completion of a service period to assess if it is in, and returned to, an acceptable condition for further use. This will include disassembly, examination, re-assembly, re-greasing and where applicable, removal and re-fitting the assembly on the axle. Page 20 of 21

21 References Uncontrolled When Printed The Catalogue of Railway Group Standards and the Railway Group Standards DVD give the current issue number and status of documents published by. This information is also available from RGSC 01 RGSC 02 Railway Group Standards Code The Standards Manual Documents referenced in the text Railway Group Standards GM/RT2004 Rail Vehicle Maintenance GM/RT2466 Railway Wheelsets Page 21 of 21