Rams in IR

1. Indian Railways - Transitioning to
Predictive Maintenance
Anirudh Gautam, Amit Srivastava, Arvind Srivastava, Naresh Kr Meena, Avadh Bihari
Resource & Testing Vertical
Research Designs & Standards Organisation
Ministry of Railways – Lucknow
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2. Objectives of IR
• Reduce travel time by half at least
• Increase carrying capacity of goods trains
• On demand passenger trains
• Incorporate road flexibility for goods transport
• Increase availability of assets
• High safety for passengers and goods
• Shift2rail (Europe)
• Export rolling stock, signaling system
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3. IR – Large Inventory of assets
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4. IR Finance (2020-2021, Rs. Crore)
• Goods Earning - 115738.38
• Passenger Earning - 15248.49
TOTAL Earning - 130986.87
• Repairs and Maintenance of Permanent Way and Works - 5,766.34
• Repairs and Maintenance of Motive Power - 5,719.89
• Repairs and Maintenance of Carriages and Wagons - 15,670.86
• Repairs and Maintenance of Plant and Equipment - 8,157.82
• TOTAL Repairs and Maintenance - 45314.91
PERCENTAGE of Repairs and Maintenance of total Earning : 34.60%
Target should be less than 20%
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5. How to achieve these objectives?
• Adoption of structured RAMS (Reliability, Availability,
Maintainability, and Safety) as per International Standards
(EN 50126)
• Adoption of structured PHM (Prognostics & Health
Management of assets as per International Standards (ISO
17359, ISO 13374, ISO 17359, Diagnostics: ISO 13379-1
Prognostics: ISO 13381-1)
• Asset Management as per ISO 55000
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6. RAMS
• Reliability, Availability, Maintainability, Safety
• Reliability – Probability that a component or system will perform its
required function for a given period of time under stated operating and
environmental conditions
• Availability – Probability that a repairable system or system element is
operational at a given point in time under a given set of environmental
conditions
• Maintainability - Probability that a failed component or system will be
restored or repaired to a specified condition within a specified period or
time when maintenance is performed in accordance with prescribed
procedures
• Safety – Ability not to harm people, the environment or any assets during
the whole life-cycle
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7. Life-cycle approach of RAMS
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8. PHM
• Prognostics & Health Management - permits the evaluation of a
system’s reliability in its actual life-cycle conditions.
• Prognostics - is the process of monitoring the health of a product and
predicting its remaining useful life (RUL) by assessing the extent of
deviation or degradation from its expected state of health in its
expected usage conditions.
• Health Management - utilizes prognostic information to make
decisions related to safety, condition-based maintenance, ensuring
adequate inventory, and product life extension.
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9. PHM system development process
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10. System Architecture using IoT
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11. PHM Cycle
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12. An example – System modeling of a hydraulic lifter
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13. Example – Failure diagram of Power System
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14. Expected benefits
• Reduction of maintenance expenditure to Rs.20 thousand Cr
per year from existing Rs. 45 thousand per year
• Increase in availability of assets to 97-98% (International
practice)
• Zero accidents
• Zero train failures due to reliability problems
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15. Action Plan
• Integrated Quality Control – Design, Manufacturing, Maintenance & Operation
• Adoption of International standards for Assets procurement using 16-step vendor
development procedure, based on life cycle costs and not upfront cost (Need of the hour,
see next slide on right price)
• Proof of concept project – Two Vande Bharat trains
• Pilot project (Rs. 400 Cr sanctioned by railway board)
• 100 WAP7
• 50 Vande Bharat
• 125 BCN Wagons
• 100 LHB Coaches
• Bridges monitoring pilots running
• Track monitoring pilot running
• After successful implementation of pilot, wide-scale implementation on all rolling stock
and infrastructure
• Cost of implementation on IR – Rs. 10 to 15 thousand Crore (rough estimate)
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16. What is Right price?
• “There is hardly anything in this world that some man
cannot make a little worse and sell a little cheaper, and the
people who consider price only are this man’s lawful prey.”
-John Ruskin
• “You need to be rich to buy cheap products. Why? Because
you eventually have to buy twice to have the job done
properly.”
-Anonymous
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17. Namaste
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