Fra: Kenneth Hjorth Andersen [mallto:keha@dsb dk] Sendt: 9. september 2016 12:03 Til: Antonius Petrus Adrianus Rovers (TROV); Emne: SV: MR lessons learned participate in MR TT#4 my comments and Even though I was unable additions below, added in Bos! gards/Med venlig hilsen Kenneth Hjorth Anderser ‘echnical Project Manage Fra: Antonius Petrus Adrianus Rovers (TROV) (mailto: TROV@BANE dk) Sendt: 5. september 2016 08:34 Tik: Finn Storm (058) | Emne: MR lessons learned Dear all, ‘this time the completed mail* After the recent completion of the MR4 installation it was agreed on management level (in the Joint Project Management Meeting) that Alstom would schedule a meeting where they would discuss their quality management system with us. Although it was agreed Alstom would organize the meeting, would like to provide them with input from BDK and DSB on the topics we believe should be discussed in this meeting, The meeting is currently scheduled on September 14 between 12:30 and 15:30, but no invitations have been send yet. [KHA: Who from DSB will be invited to join this meeting? The BDK and DSB installation and commissioning people are herby invited to provide topics to the agenda of the MR lessons learned meeting NLT Friday September 9. These topics will be presented to‘Aistom and it will be up to Alstom to create the agenda for the meeting, Alstom determines the scope of the meeting, so I can't guarantee our input will be incorporated in the agenda. ‘To make things easy I have created a list of topics based on our experience from the MR installations. Please comment or supplement. + General ~ Although Alstom came across several issues during installation, the solutions to these issues were ‘not processed in the installation documentation. This led to the same issues causing problems during successive installations. Alstom should be able to make minor updates to the installation documentation during FoC and series roll-out to ensure lessons from earlier installation are secured and mistakes are not repeated. [KHA: 100% agree with BOK. It was agreed back in time that ALS should not update installation procedure for the MR, since this was “testtrain only” in order to save time. Looking into the always bright back-mirror, this decision have caused extreme amounts of resources wasted in discussions, inspections etc. for MR TT#2, TT#3 and TT#4.] ~ Although the installation control procedure does cover most of the installation, we have seen on several occasions that installation related issues were delaying commissioning, issues that should have been detected with the installation control procedure. How could these have been missed? One way of helping Alstom improve their installation control procedure is to witness one of Alstom’s Internal quality checks. [KHA: This is a Very good idea, At least BDK should witness this task, but I prefer that the “end-user” (in this case DSB) is represented also, so everyone agrees on the items, I also note that ALS has been unwilling oF unable to provide their intemal QA- report for their installations, thus I somehow doubt if these actually exists. ~the reason stating this is, that T haven't found any references to these in any documentation and I believe they should have some kind of document number or so. I may be wrong here, but if ALS provides the reports all doubt can be removed immediately. Alternative they could show these to e.g. PROSE who could witness that these actual exists, recommend that BDK invest resources in general quality follow-up going forward for the series installations, in order to guarantee that quality is under control from ALS side. I believe DSB ‘an/wil/should assist BDK in this matter, but I also foresee some discussions, since "you're not cour customer” will be the standard reply from ALS, if DSB argues for something] ‘+ Installation quality = On more than one occasion we have seen badly organized cables and wires. There should be ‘more focus on professionally bundiing cables and wires not leaving any excess length of cable/wires and where possible wires should be routed through small ducts around terminal blocks. = Cable fixation should be around the cable and not around the wire where possible, There should be more focus on this aspect as we have seen several cases where this vas not done properly. IKHA: If ALS would do like Siemens has done in the STM installation on the IC3, many of these “missing fixation’-issues are solved automatically. DSB has proposed this solution to ALS, but so far ALS has not been willing to update their design] = On more than one occasion we have seen that terminal blocks were missing the bridges for pull reliefs or when they were not missing that they were not used. There should be more focus on the proper usage of the bridges. ~ Wires from desk components should be secured to a fixed point after the connection to relief the forces on the connection. IKHA: All these issues can be under better control if the Installation Procedure is detailed enough for the fixations etc. Agreeing on this in the IP including pictures will also make a Q- inspection really easy, since “what you look at should be like the pictures in the IP"] + Installation Control procedure= The wire check only includes Alstom's own wires and not the existing wires that are touched by ‘Alstom during the installation. These ‘touched’ wires should also be included in the wire check. IKHA: Not only wires, also connectors, since they can be “haif-out” causing unstable systems. This can be extremely difficutt to find. (a case in a GSM-R installation took 4 people 2 days to find Just 1 connector that were “touched”)] ~ Furthermore the ETCS wire check needs to be supplemented by visual checks that 1. The ‘wire/plug is connected to the correct terminal and 2. The wire/plug is completely in the terminal. Currenty the wire check only checks the continuity of the wire inside the plug (A-B and C-D) and not the continuity of the wire/plug to the terminal block (A-D). [KHA: A-D testis preferred by DSB 250] = The restoration of power is not included. When power is switched off before installation, elther by disconnection of wires or switching of circuit breakers, this should be noted and checked at the end of the installation as part ofthe installation control procedure. [KHA: It seems like ALS internal rules do not allow the installation team to apply power to the cubicle, but this Is only allowed for the commissioning team. I recommend that that installation team are “upgraded” to allow to add power to the train, but NOT to the cubicle itself (disconnecting the circuit breakers. for the cubicle) in order to test that all power is OK for the train and all systems touched are “good to go")] = Disconnecting of wires outside of the wire check should be noted to ensure they are reconnected again before commissioning. [KHA: Agreed] ‘+ _ Installation Procedure = Cable and conduit solutions (routing, location of spare lenath, fixation method, fixation point, distance between fixations and protection) are not described in detail leading to different ways of fixing and routing during successive installations and Issues with BDK and DSB as they do not see/know the solutions until the joint installation inspection. [KHA: As stated above, if IP is updated property all these issues can be avoided] ~ Torque marking instruction are not included in the installation procedure anymore on the IC3 documentation. This increases the risk these instructions are missed by the technicians. It is recommend they are included in the installation procedure as was the case for the MR documentation. [KHA: Agreed, Why ALS removed this information is to me a mystery, but they ‘may have some good arguments to do so. As long at these torques are under control through their quality inspection procedures I'm OK with this missing in the TP, but T agree with BDK that adding this information will help the craftsmen when installing the system] Best Regards/Med venlig hilsen Ton Rovers Installation manager Fjernbane Onboard Tear Signaling Programme BANEDANMARK Amerika Plads 35,k-2100 Ksbenhavn +45 61965172 eoumbanesdk vow banedanmark dk