ISBN 978-0-626-21015-1

SANS 3000-2-3:2008
Edition 1

SOUTH AFRICAN NATIONAL STANDARD

Railway safety management

Part 2-3: Technical requirements for

engineering and operational standards —
Rolling stock

WARNING — Can only be read

in conjunction with SANS 3000-2-1

Published by Standards South Africa

1 dr lategan road groenkloof private bag x191 pretoria 0001
tel: 012 428 7911 fax: 012 344 1568 international code +27 12
www.stansa.co.za
© Standards South Africa
SANS 3000-2-3:2008
Edition 1

Table of changes
Change No. Date Scope

Foreword
This South African standard was approved by National Committee StanSA TC 5120.66, National
steering committee for railway safety standards, in accordance with procedures of Standards
South Africa, in compliance with annex 3 of the WTO/TBT agreement.

This document was published in Xxxxxxxx 2008.

SANS 3000 consists of the following documents, under the general title Railway safety
management:

Part 1: General.

Part 2-1: Technical requirements for engineering and operational standards – General.

Part 2-2: Technical requirements for engineering and operational standards – Track, civil and
electrical infrastructure.

Part 2-3: Technical requirements for engineering and operational standards – Rolling stock.

Part 2-4: Technical requirements for engineering and operational standards – Train control
systems and equipment. (In course of preparation)

Part 2-5: Technical requirements for engineering and operational standards – Train operations
management. (In course of preparation)

Part 2-6: Technical requirements for engineering and operational standards – Interoperability,
inter-modal and utilities management. (In course of preparation)

Part 3: Railway occurrence management. (In course of preparation)

Part 4: Human factors management. (In course of preparation)

Annex A is for information only.

 SANS 3000-2-3:2008
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Contents
Page

Foreword

1 Scope ......................................................................................................................................... 3
2 Normative references ................................................................................................................. 3
3 Definitions................................................................................................................................... 3
4 General....................................................................................................................................... 4
5 Independent evaluation .............................................................................................................. 4
6 Design ........................................................................................................................................ 5
7 Operating parameters ................................................................................................................ 5
8 Rolling stock items...................................................................................................................... 5
9 Manufacturing............................................................................................................................. 7
10 Inspection, testing and commissioning ...................................................................................... 7
11 Monitoring, maintenance and in-service inspections ................................................................. 8
12 Modification ................................................................................................................................ 9
13 Decommissioning and disposal.................................................................................................. 9
Annex A (informative) Detailed description of rolling stock items .................................................... 10
Bibliography....................................................................................................................................... 14

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 SANS 3000-2-3:2008
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Railway safety management

Part 2-3:
Technical requirements for engineering and operational standards —
Rolling stock

1 Scope
This section of SANS 3000-2 covers requirements for the development of regulator, industry and
local standards. It includes the asset life cycle components of design, construction/manufacturing,
commissioning, monitoring and maintenance, modification, and decommissioning and disposal of
rolling stock.

2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies. Information on currently valid national
and international standards can be obtained from Standards South Africa.

SANS 3000-1, Railway safety management – Part 1: General.

SANS 3000-2-1, Railway safety management – Part 2-1: Technical requirements for engineering
and operational standards – General.

SANS 10007, Quality management systems – Guidelines for configuration management.

3 Definitions
For the purposes of this document, the definitions given in SANS 3000-1 and the following apply.

3.1
validation
confirmation that particular requirements for a specific use are fulfilled

3.2
verification
testing and evaluation of an item of equipment or a system to assure compliance with its
specification or other requirements

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4 General
4.1 Standards and procedures shall be established, developed or adopted, implemented and
maintained for the

a) design (see clause 6),

b) operating parameters (see clause 7),

c) rolling stock items (see clause 8),

d) manufacturing (see clause 9),

e) inspection, testing and commissioning (see clause 10),

f) monitoring, maintenance and in-service inspections (see clause 11),

g) control of the process of modification or reconstruction (see clause 12), and

h) decommissioning and disposal (see clause 13),

of rolling stock, including rolling stock systems, sub-systems and components to ensure that the
appropriate safety requirements and standards are met.

4.2 Standards and procedures shall be established, developed or adopted, implemented and
maintained for the validation and verification of

a) the design (see clause 6),

b) all stages of manufacturing (see clause 9), and

c) all other life cycle phases

of rolling stock, including rolling stock systems, sub-systems and components.

4.3 Standards and procedures shall be based on the consideration of detailed selection and
design recommendations.

4.4 Consideration shall be given to the inclusion of the items listed in this section of SANS 3000-2
in the operator’s safety management system, based on the operator’s risk assessment and the type
of operation being undertaken by the operator.

4.5 The operator should consider including the relevant items listed in clause 8 and annex A in
his/her safety management system in accordance with SANS 3000-1.

5 Independent evaluation
The validation and verification processes shall be performed at an appropriate level of
independence. The degree and the nature of independence shall be determined by at least the
following factors:

a) the risk of errors, omissions and biases being perpetuated; and

b) the risk of interference between the new and existing systems.

NOTE Independence does not necessarily imply the usage of an external party.

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6 Design
Design and construction of rolling stock should aim not only at eliminating faults which will lead to
failures, but also at ensuring that the consequences arising from any failure will be minimized.

7 Operating parameters
Operating parameters shall be determined in accordance with SANS 3000-1 and SANS 3000-2-1.

8 Rolling stock items

8.1 Standards and procedures for the selection and design of rolling stock shall include the
following items, where relevant:

a) Vehicle body:

1) body structure;

2) exterior aesthetics;

3) exterior doors and steps;

4) couplers and draw gear;

5) gangways;

6) window units;

7) body additions;

8) visibility.

b) Bogies and running gear:

1) bogie structure;

2) suspension;

3) wheel set;

4) traction link;

5) bogie additions.

c) Motive power supply:

1) line voltage system;

2) electric power conditioning;

3) electric power conversion;

4) engine system;

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5) mechanical power conversion.

d) Train system control.

e) Propulsion:

1) drive system;

2) traction controller;

3) adhesion optimization.

f) Braking:

1) braking system;

2) braking control;

3) adhesion optimization;

4) braking performance.

g) Auxiliaries:

1) air system;

2) hydraulic system;

3) battery system;

4) electric supply system.

h) Communication:

1) fault and diagnostic systems;

2) data communications;

3) information/voice communication.

i) Coach interior or driver/operator cab interior:

1) interior architecture;

2) heating, ventilating, and air conditioning (HVAC);

3) interior doors;

4) water services;

5) catering;

6) ticketing;

7) lighting;

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8) ergonomics.

j) Special:

1) tilt system;

2) maintenance vehicles;

3) remote control;

4) fire and vandalism.

NOTE A detailed description of the items above is given in annex A.

9 Manufacturing
9.1 General
The items listed in 9.2, including those in annex A, should be included in the operator’s safety
management system and determined in accordance with SANS 3000-2-1 and this section of
SANS 3000-2.

9.2 Requirements
Standards and procedures for the manufacturing of rolling stock (see clause 8) shall include the
following:

a) process control in accordance with SANS 3000-1;

b) appropriate manufacture and installation practices and specifications;

c) procedures to ensure the use of approved and current plans; and

d) preparation of operating and maintenance procedures and instructions.

10 Inspection, testing and commissioning

10.1 General
Inspection, testing and commissioning of rolling stock are essential elements in ensuring safety
integrity. Inspection, testing and commissioning should complement and in no way substitute,
quality control of the design, production and installation.

The inspection and testing requirements of rolling stock in 10.2, including those items given in
annex A, should be included in the operator’s safety management system and determined in
accordance with SANS 3000-2-1.

10.2 Inspection and testing requirements

Standards and procedures shall include inspection, testing requirements and checking of the
following, where applicable:

a) Independence in the performance of inspection, testing and commissioning.

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b) Compatibility between new or modified rolling stock, rolling stock elements and systems, and
with other functional disciplines and the environment.

c) Validation and verification of the rolling stock, rolling stock systems, sub-systems or
components, as applicable.

d) Safe phasing in of any system change.

e) Procedures for handover and acceptance of rolling stock.

f) Inclusion of rolling stock in the operational vehicle fleet.

g) Provision of relevant documentation, including manufacturing drawings, maintenance manuals

and operating procedures.

11 Monitoring, maintenance and in-service inspections

11.1 General
The items listed below, including those in annex A, should be included in the operator’s safety
management system and determined in accordance with SANS 3000-2-1.

11.2 Requirements for monitoring

11.2.1 General

11.2.1.1 Monitoring shall include the following, where relevant:

a) a system to ensure that rolling stock is available for scheduled inspections;

b) rolling stock inspection and testing in accordance with specified safety requirements;

c) train integrity checking before departure and en route;

d) identification of safety critical faults and abnormal deterioration rates; and

e) notification of reduced serviceability.

11.2.1.2 In-service inspections of rolling stock items as listed in clause 8 shall be considered when
required and as specified in the organization’s safety management system.

11.2.2 Requirements for maintenance

Maintenance processes necessary for rolling stock, including rolling stock systems, sub-systems
and component reliability, availability, maintainability and safety, shall be identified and planned.
Processes shall include the following:

a) Preventive or corrective maintenance plans such as

1) process control in accordance with SANS 3000-1, including record-keeping;

2) procedures to ensure restoration to the required standard; and

3) procedures for configuration management in accordance with SANS 3000-2-1 and

SANS 10007.

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b) Availability of manuals such as those that cover operating, maintenance and components of
rolling stock.

12 Modification
Standards and procedures for the control of the process of modification or reconstruction of rolling
stock, including rolling stock systems, sub-systems and components, shall include consideration of
the following:

a) Effects of the proposed modification on the railway system as a whole.

b) Effects of the environment on the proposed modification.

c) Design, implementation and commissioning of the modification or re-build in accordance with

clause 6 to clause 10 (inclusive).

d) Effective recording, promulgation and communication of changes and modifications where

especially operational safety is affected.

e) Configuration management.

13 Decommissioning and disposal

Standards and procedures shall be established, developed or adopted, implemented and
maintained for the decommissioning and disposal of rolling stock, including rolling stock systems,
sub-systems, components, and means of preventing inappropriate usage before disposal. The
following shall be included:

a) Appropriate marking of each decommissioned item for identification purposes.

b) Procedures for the movement of decommissioned rolling stock, including rolling stock systems,
sub-systems and components, and the identification of persons authorized to allow such
movement.

c) Ensuring safe operations during decommissioning, scrapping and disposal.

d) Ensuring that the condition of decommissioned material and equipment is clearly identified.

e) Prevention of inappropriate reuse of decommissioned material.

f) Minimization of environmental risks, including health, safety and pollution hazards associated
with the decommissioned items, considering both short-term and long-term impact.

The items listed above shall be included in the operator’s safety management system in accordance
with SANS 3000-1.

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Annex A
(informative)

Detailed description of rolling stock items

This annex provides a detailed description of the items listed in clause 8.

Table A.1 — Detailed description of rolling stock items

1 2 3
No. System Characteristic hardware, components, parts, etc.
1 Vehicle body:
Body structure Body sides, body ends, roof, including welded items,
under-frame, including welded items, floor, integrity
of pressure vessels, crashworthiness, structural
partitions, articulation joints/structure, skirt, obstacle
deflector (cowcatchers), anti-climb units, roof
hatches, centre of gravity, static and kinematic rolling
stock profile, fixtures for jacking lifting and towing
Exterior aesthetics Exterior finish panels, paint, decals, stickers, plates
Exterior doors and steps Exterior doors, door gear and control components,
steps (folding/sliding), ladders, hatches, bottom
discharge, securing mechanisms, accessibility
Couplers and draw gear Coupler control components, buffing and draw gear,
supporting components, coupler type, coupler
heights, strength, energy absorption, coupling and
uncoupling operation, recovery of failed trains,
horizontal and vertical coupler angles
Gangways Doors, gates, vestibule enclosure, safety covers and
flooring
Window units Safety glass, window unit design (material and size),
windscreen, stone guards, glare, emergency exit and
demisting
Body additions Exterior fittings (grab rails, etc.), skirt, cab module,
under-frame equipment, under-slung equipment (e.g.
engines, transformers, generators) fixtures (e.g. twist
locks, tarpaulin hooks), tanks (fuel, water, air,
hydraulic, etc.), mirror, horn, windscreen wash/wipe,
identification, signage and antennas
Visibility Exterior lighting (headlights, tail-lights and step
lights) end-of-train markers, reflective material and
colour scheme
2 Bogies and running gear:
Bogie structure Bogie frame and bogie-to-body interface

Suspension Dynamic behaviour (running safety, track loading,

ride characteristics), slewing bracket, springs (coil,
blade, rubber, chevron, airbags), surge reservoir,
bump stops, dampers, resilient components and
motor nose suspension

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Table A.1 (continued)

1 2 3
No. System Characteristic hardware, components, parts, etc.
2 Bogies and running gear:
Wheel set Solid/tyred wheels, resilient/noise reduction wheels,
assembly, geometric tolerances, electrical
resistance, heat dissipation, balancing, identification,
axle bearings (lubrication), axles (material,
identification), wheels (wheel profile, material,
identification), gear wheels, cannon boxes, u-tube
and quill
Traction link Traction rod, centre pivot and slew bracket
Bogie additions Flange lubrication components, sanding
components, inter-bogie control, jacking/lifting points,
life guards/derailment bars/rail sweepers, earthing
and friction liners
3 Motive power supply:
Line voltage system Pantograph and control components (location and
number of pantographs, dynamic behaviour,
isolation, current collection), high voltage filter, main
circuit-breaker, line circuit-breaker, surge/lightning
arrestor, pantograph switch, earthing switch,
measuring transformer, current balance
measurement device (return transformer, resistor,
current balancing relay), contactors, fuses, axle
earthing, high voltage cabling and clearances
Electrical power conditioning Line filter, power factor correction and harmonic filter
Electrical power conversion Main transformer, line converter/rectifier, inverter,
DC-link filter, switchgear, voltage regulator,
discharge and protective resistors, earth fault
detector, earth switch, cooling system (including fan
and pump), air filters, duct, supporting and control
components
Engine system Engine rating, exhaust emissions,
fuel/lubricant/coolant system (filling, tank size, etc.),
control/monitoring components and noise
suppression (engine and exhaust)
Mechanical power conversion Generator/alternator, hydraulic pump, direct drive
and torque converters
4 Train system control: Driver safety device (dead man’s feature), vigilance,
train continuity, door continuity, automatic train
control (ATC), automatic train protection (ATP),
automatic train operation (ATO), communication,
interlocking and remote control of multiple consists
5 Propulsion:
Drive system Traction motor, fans and pumps, heat exchanger, air
inlet, filter, duct, motor supporting components, gear
box, final drive, coupling, drive shaft, transmission,
speed sensor and wheel
Traction controller Traction power controller (inverter, converter,
chopper, hydraulic valves, etc), switchgear and
cooling system (including fans and pumps)

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Table A.1 (continued)

1 2 3
No. System Characteristic hardware, components, parts, etc.
5 Propulsion:
Adhesion optimization Wheel slip and slide control (creep control, sanding,
flange lubrication, wheel speed differentiation), and
wheel/rail profile
6 Braking:
Braking system Wheel brakes, disc brakes, and tread brakes,
electric/dynamic brakes, magnetic track brakes,
parking brakes, hand brakes, air/vacuum, brake
rigging and emergency brakes
Braking control Brake controller, emergency brake vent valve, load
sensing, electronic control pneumatic braking (ECPB),
automatic train protection (ATP), single vehicle
manual release/isolation/blow down
Adhesion optimization Wheel slip and slide control, sanding, brake system
interlocking and blending, and set limit adhesion level
Braking performance Stopping distances, brake ratios and holding
capability
7 Auxiliaries:
Air system Main compressor, auxiliary compressor, oil separator,
air dryer, exhausters, filter, protection components
supporting components and control components, main
reservoir and components, shore supply connections
for air supply system, airbags, sanding, door
operating, auto coupler, main circuit-breaker,
pantograph, pneumatic cocks, piping/hoses and test
points for gauges
Hydraulic system Pump, motor, accumulator, cooler, piping/hoses and
controls
Battery system Battery, ventilation, protection, charger, contactors
and controls
Electric supply system Auxiliary transformer, motor generator/alternators,
converter/inverter, filter, protection, earthing,
contactors, control components, shore supply
connections and distribution
8 Communication:
Fault and diagnostic system Vehicle testing, fault detection storage, conditioning
monitoring, maintenance support system, machine
interface and event recorder/accident recorder (”black
box”)
Data communications Train communication network, data link, train and
vehicle bus gateway
Information/voice communication Passenger and crew information, telecommunications,
driver communication, public address system, CCTV,
train crew “bell” signals and emergency passenger to
driver communication
9 Coach interior:
Interior architecture Flooring, wall panels, ceilings, partitions, seats, beds
and bedding, fittings (strength of fixture and fittings),
luggage areas/racks, painting, notices/signage,
facilities for disabled passengers, passenger
emergency communication, grab poles and rails, fire
and emergency equipment, fire retardant and non-
toxic materials, storage compartments and
securing/locking of equipment cupboards

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Table A.1 (concluded)

1 2 3
No. System Characteristic hardware, components, parts, etc.
9 Coach interior:
HVAC Heating, ventilation, air conditioning, air treatment,
ducting and control components
Interior doors Internal doors (including safety interlocking), door
gear and control components
Water services Sanitary equipment, ablution facilities, fresh water
supply and effluent tank
Catering Refrigerator, freezer, oven, stove, hot plate,
microwave ovens, coffee maker, components (work
surfaces, storage, etc.)
Ticketing Equipment for selling and validating passenger
tickets and the necessary communication system
Lighting Seat, emergency, entrance, passageways
Ergonomics Noise and heat/cold insulation, vibration, ride comfort
10 Driver/operator cab interior:
Interior architecture Flooring, windows (composition, tint and protection),
windscreen wipers, demisting, sun visor, side mirrors,
safety panels and doors, ceiling, cab back
wall/bulkhead, seats, fittings (strength of fixture and
fittings), drivers desk, drivers control panel, train
assistants/guards desk, notices/signage, safety
components (warning devices), fire and emergency
equipment, fire retardant and non-toxic materials,
storage compartments
HVAC Heating, ventilation, air conditioning, air treatment,
ducting
Interior doors Internal doors (including safety interlocking), control
components
Water services Sanitary equipment, fresh water supply, effluent tank
Catering Hot plate, fridge, microwave
Ticketing Equipment for selling and validating passenger
tickets and the necessary communication system
Lighting General, seat, emergency, entrance, toilet, drivers
cab lighting, head and tail lights, drivers control panel
lighting
Ergonomics Noise and heat/cold insulation, vibration, ride
comfort, line of sight, position of controls, percentile
person and anthropomorphic considerations
11 Special:
Tilting system Control components
Maintenance vehicles Specialized components
Remote control Shunting
Fire and vandalism

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Bibliography
SANS 3000-2-2, Railway safety management – Part 2-2: Technical requirements for engineering
and operational standards – Track, civil and electrical infrastructure.

© Standards South Africa

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