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Design
Engineering Procedure
EPD 0001
Version 2.1
Disclaimer
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Document control
Version Date Summary of change
1.0 First issue
Section numbering updated, Reference corrections and Document Control
1.1
Page added.
Replace reference from RIC to RailCorp – reference made to RailCorp
1.2
Safety Management System
1.3 Standardising Format
Formatted to TMA 400
Update of cross references, general editing
2.0 May 2009 Alignment with SMS and other EPD documents.
Update information on verification
Update of glossary
2.1 June 2012 See Table below
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Design Management Process EPD 0001
Contents
1 Introduction .............................................................................................................................4
2 Scope........................................................................................................................................4
3 Application...............................................................................................................................4
4 Referenced documents ..........................................................................................................4
5 Terms and definitions.............................................................................................................5
6 Glossary...................................................................................................................................7
7 Design management documentation system ......................................................................7
8 Scope of design work .............................................................................................................8
8.1 General......................................................................................................................................8
8.2 Key requirements ......................................................................................................................8
9 Design process model............................................................................................................9
9.1 General......................................................................................................................................9
9.2 System requirements specification (SRS) ..............................................................................11
9.3 Design inputs ..........................................................................................................................11
9.4 Design development phases and stages (new and altered assets) .......................................11
10 Reviews and acceptance......................................................................................................12
10.1 Network design authority (NDA) .............................................................................................12
10.2 Technical reviews....................................................................................................................12
10.3 Design verification...................................................................................................................12
10.4 Design output approval and acceptance.................................................................................13
10.5 Design validation.....................................................................................................................13
10.6 Configuration management.....................................................................................................13
11 Related design tasks ............................................................................................................13
11.1 Safety in design.......................................................................................................................13
11.2 RAM and integrated support provisions..................................................................................14
12 Responsibilities.....................................................................................................................14
12.1 General Manager Chief Engineers Division............................................................................14
12.2 General Manager Professional Services Division...................................................................14
12.3 Chief Engineers.......................................................................................................................14
12.4 Design Heads..........................................................................................................................14
12.5 Design personnel ....................................................................................................................15
12.6 Project design managers ........................................................................................................15
Appendix A Engineering standards..........................................................................................16
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1 Introduction
RailCorp has a primary responsibility as an ‘owner’ and ‘operator’ under the New South
Wales Rail Safety Act 2008 (Rail Safety Act) for the safe construction, operation and
maintenance of rail infrastructure. RailCorp also has a range of additional obligations
under the NSW Work Health and Safety Act 2011 (WHS Act) and Regulation and other
legislation covering topics such as environment and heritage.
2 Scope
This procedure provides an overview of the engineering design management process
described in detail in other RailCorp engineering design procedures. The procedure
covers the engineering design stages Feasibility, Concept Design and Detail Design.
3 Application
This procedure supports the RailCorp Safety Management System Requirements and
Procedures in particular —
4 Reference documents
Acts and regulations
New South Wales Rail Safety Act 2008 (Rail Safety Act)
New South Wales Work Health and Safety Act 2011 (WHS Act)
New South Wales Work Health and Safety Regulation 2011 (WHS Regulation)
Standards Australia
AS 4292 Railway safety management (series)
AS/NZS ISO 9001 Quality management systems – Requirements
AS/NZS 15288 Systems engineering – System life cycle processes (ISO/IEC 15288)
HB 90.3 The Construction Industry – Guide to ISO 9001:2000
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RailCorp documents
RPMM RAE – RailCorp Project Management Methodology Rail Asset Enhancement
RailCorp Engineering Procedures (A list of RailCorp All discipline Engineering
Procedures is provided in Appendix A)
SMS-09-PR-1473 Application of Network Design Authority for new and altered assets
TMA 421 Glossary for Engineering Design Management
business case core document that defines a business need for a project and is used to
seek management’s approval to proceed
client person that has a business need, and will use the project’s product, service or
result (further information in TMA 421)
configuration item entity within a configuration that satisfies an end use function
design (noun) the product of the process of designing that describes the solution
(conceptual, preliminary or detailed) of the system, system elements or system end items
(further information in TMA 421)
design acceptance the process that sets down controls to ensure that engineering
design undertaken by RailCorp, or by another firm on behalf of RailCorp, is done by
qualified individuals using approved procedures and equipment, under appropriate
supervision
design approval process whereby an authorised person certifies that design outputs
have been verified as meeting design input specifications and requirements and that the
design has been completed in accordance with relevant regulations and standards, prior
to the release of the design for construction or use (further information in EPD 0010)
design approver authorised person who certifies the design has followed authorised
processes and meets requirements and is ready for acceptance (further information in
EPD 0010)
design brief a document (or documents) that describes the required product in sufficient
detail to permit the design task to proceed (further information in TMA 421)
Note: A design brief is functionally equivalent to a specification but is used where a formal
specification has not been prepared by the sponsor. (Further information in TMA 421)
design personnel those involved in the design process making decisions affecting the
design and includes designers, checkers, verifiers and acceptors of designs, and others
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that provide information and recommendations on which designs are based (further
information in EPA 240 and EPA 241)
design records provide traceability of the evolution of the approved design (including
design changes) from the specification to approved configuration documentation
Note: Design records include, but are not limited to, assumptions and calculations,
investigations and reports (such as hazard analyses or reliability models), test and
commissioning records, modelling results and any other data that supports the final
design solution.
drawings include but are not limited to, track, signalling and overhead wiring plans and
layouts, piping layouts and isometrics, civil and structural fabrication details, electrical
schematics, single line diagrams and terminations, instrument loop and hook-up
diagrams and vendor drawings
engineering authority the authority to make and approve engineering decisions (further
information in TMA 421)
ensure to take all reasonable action insofar as controllable factors will allow
integrated support a complete process for identifying the support requirements for a
new or existing rail system asset
project design manager person who manages design and investigation projects to
deliver engineering solutions for projects and programs
project scope of works document describing the business case or specifying the
requirements for elements of a project
Note: Used with some low complexity projects, particularly where decomposition of
requirements will not add value or clarity.
rail infrastructure the facilities that are necessary to enable a railway to operate safely
(other than rolling stock and any facility, or facility of a class, that is prescribed by the
regulations not to be rail infrastructure) and includes, but is not limited to, the following:
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specification a document that fully describes a design element or its interfaces in terms
of requirements (functional, performance, constraints, and design characteristics) and the
qualification (validation) conditions and procedures for each requirement
sponsor person responsible for ensuring the project outcomes deliver the benefits
(benefit realisation) as defined in the sponsor’s brief and business case. Represents the
group with the business need
type testing a specific form of validation carried out to demonstrate that a specific type
of item (i.e. by manufacturer’s part or model number) is capable of meeting the full
operating, performance and environmental design requirements for its intended
application within the RailCorp system (further description in EPD 0012)
validation the process of ensuring that the final product conforms to defined client
requirements (further information in EPD 0012 )
verification the process carried out to ensure that the output of a design stage (or
stages) meets the design stage input requirements (further information in EPD 0011)
6 Glossary
A glossary of terms and definitions used within RailCorp engineering standards is
contained in TMA 421. The glossary also includes a list of acronyms and abbreviations
used within the procedures.
These procedures reflect high level policies, processes and requirements for the
management of design and integrated support tasks within a systems engineering
context, and are intended to provide a stable basis for RailCorp business processes.
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ENGINEERING
DESIGN PROCEDURES
RailCorp design
standards,
instructions and
manuals
(each discipline) RailCorp design RailCorp support
data and data
configuration
records
8.1 General
Design work performed by RailCorp is not confined to major projects. It includes all tasks
that may alter the physical configuration, functional performance or the conditions of use
of any item of rail infrastructure including associated hardware and software elements.
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engineering authority – all design tasks shall be undertaken by competent persons who
have been allocated engineering authority to undertake those tasks. Refer EPA 241.
design standards – all design work shall be performed to the relevant federal and state
legislation and regulations and to standards approved by RailCorp. Federal and state
legislation and regulations shall have precedence. Refer EPD 0006.
documentation – all design outputs shall be fully and properly documented. Refer
EPD 0017.
verification – design stage output shall be verified to confirm consistency with design
stage inputs. Refer EPD 0011.
validation – design output shall be validated to confirm that requirements set out in the
sponsor’s brief or business case have been met. Refer EPD 0012.
risks and hazards – an evaluation of risks and hazards shall be performed and
documented as part of every design task. Refer EPD 0008.
design approval – all design output shall be approved by an authorised person, i.e. a
design approver, prior to release for construction. Refer EPD 0010.
design acceptance – all design output from sources external to RailCorp shall be
accepted by the relevant Chief Engineer for use by RailCorp prior to release for
construction. Refer EPA 280.
design and configuration records – design and supporting documentation that fully
describe the as-built configuration of rail infrastructure shall be maintained. Refer
EPD 0014.
9.1 General
RailCorp has adopted the systems engineering methodology as the basis for
management of the design process. AS/NZS 15288 provides additional information
related to the systems engineering process.
Application of the RailCorp model will also meet the requirements of the WHS Regulation
in respect of plant and structure design, as well as the requirements of the Rail Safety Act
and associated AS 4292 series of standards.
The top-level model adopted by RailCorp is shown in Figure 2. Sections 9.2 to 10.6
provide a brief description of various elements of the model.
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The project design manager assigned to the task shall ensure that the client or sponsor’s
requirements are specified in sufficient detail to establish clear output requirements for
the task. No design shall commence without a SRS, project scope of works or approved
design brief. EPD 0004 provides further guidance on design briefs, however, as a
minimum the design brief, project scope of works or SRS shall include:
Determining the full set of design inputs, and ensuring sponsor and stakeholder
agreement, represents an essential step for management of the design process, refer
EPD 0013.
The set of design inputs also forms the basis for verification and validation of design
output, i.e. for determining whether the final design has met the sponsor and stakeholder
requirements.
Detail design phase involves three design stages — system definition, preliminary design
and critical design. Projects of less complexity may avoid the concept design phase and
go straight into the detail design phase. Where the design development is carried out in
the two distinctive phases, at the end of the concept design and the detailed design
phases a configuration change request shall be raised to obtain Configuration Control
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Board approval to proceed to the next design phase or project phase. Terms used for the
design phases and stages are shown in Table 1.
RPMM
Feasibility Design and Planning
phase
Design Concept
Feasibility Detail design
phase- design
Design Feasibility Concept System Preliminary Critical
Stage design design definition design design
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More detailed requirements for design verification are provided in EPD 0011.
All design work performed by RailCorp design staff shall be approved by a staff member
who has an engineering authority delegation for the appropriate type of design approval.
All design work performed by external design companies shall be approved by a person
authorised by the design company for that task. For the design approval process, refer to
EPD 0010.
All approved designs shall be accepted by the relevant Chief Engineers for use by
RailCorp prior to release for construction or manufacture as required in EPA 280.
General validation requirements and methods shall be determined and approved by the
Chief Engineer or by his delegated representative for all new design tasks before
commencement of the task, and progressively defined and refined as the task proceeds.
Validation results shall form part of the design record for the item or system concerned
and shall be filed as part of the design data for the item.
More detailed requirements for design validation are provided in EPD 0012.
More detailed requirements for configuration management and record keeping are in
EPD 0014 and EPD 0017.
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Designing for safety requires identifying hazards and risks and eliminating or minimising
risks to ALARP through design. This process is described in EPD 0008.
Integrated support requirements shall be considered as part of each and every design
task, including design changes made as a result of CCR action. Integrated support
requirements to be considered as part of each task shall include the following aspects, in
accordance with the WHS Act and Regulation:
• documentation and manuals including the purpose for which the asset is designed,
installation, commissioning, operation, maintenance, inspection, cleaning,
transport, storage and, if the asset is capable of being dismantled, dismantling of
the asset;
• maintenance requirements, including testing or inspections to be carried out on the
asset;
• systems of work necessary for the safe use of the asset;
• knowledge, training or skill necessary for persons operating or undertaking
inspection and testing of the asset;
• spares support requirements;
• emergency procedures.
Specific requirements for the inclusion of integrated support provisions in all design tasks
are included in EPD 0008, EPD 0009, EPD 0018, EPD 0019 and EPD 0020.
12 Responsibilities
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