Class 799 Fatigue Cracks Inspection - Auditor User Guide

Overview

This guide provides step-by-step instructions for railway inspectors and auditors conducting fatigue crack inspections on Class 799 trains.

The Class 799 Fatigue Cracks Inspection is a critical safety process designed to:

• Detect cracks in train bodywork and structural components
• Track crack severity and location
• Determine safe operational intervals for the train
• Manage repair scheduling and completion

Key Safety Information

Critical Safety Thresholds

Inspection Methods

Visual Inspection:

• Inspector visually examines locations with a light/magnifier
• Cost: £0 (staff time only)
• Time: ~0.1-0.2 hours per location
• Allows re-inspection intervals up to 90 days if no cracks found

Non-Destructive Testing (NDT):

• Advanced ultrasonic, X-ray, or magnetic particle testing
• Cost: £625 per location (specialist contractor)
• Time: ~0.5 hours per location
• Allows re-inspection intervals up to 180 days if no cracks found
• Use NDT when visual inspection found cracks or high-risk areas

Pre-Inspection Checklist

Before starting an inspection, confirm:

• ☐ Train unit is positioned in the depot inspection area
• ☐ Train has been cleaned (if required)
• ☐ Adequate lighting available for visual inspection
• ☐ Inspection equipment ready (magnifier, light, measuring tape, NDT equipment if needed)
• ☐ You have your digital signature credentials ready
• ☐ CheckIt application is open and responsive
• ☐ Previous inspection records reviewed (know which areas have history of issues)

Step-by-Step Inspection Process

Step 1: Open the Inspection Record

1. Launch the inspection application on your mobile device or tablet

2. Navigate to: "Class 799 Fatigue Cracks Inspection"

3. Select: "Create New Inspection" or select existing train unit

4. Enter Train Information:

   • Train Unit: Enter the Class 799 unit number (e.g., 799001)
   • Inspection Date: Today's date (auto-populated)
   • Inspector Name: Your name (auto-populated from login)
   • Inspection Type: Select "Visual" or "NDT" or "Combined"

5. Click: "Start Inspection"

Step 2: Understand the Inspection Layout

You will see:

Main Inspection Area:

• Visual representation of the train unit with interactive areas
• 4 critical inspection hotspots (clickable areas):
  • Bolster 1 (front-left)
  • Bolster 2 (front-right)
  • Bolster 3 (rear-right)
  • Bolster 4 (rear-left)
• Color-coded status indicators for each location (shows current findings)

Findings Summary:

• List of all findings recorded so far
• Status: "Raised", "Under Remediation", "Complete"
• Summary totals (cost, time, maximum crack size, next inspection due)

Step 3: Inspect Each Location

For each of the 4 bolster locations, follow this process:

At Bolster 1:

1. Click the hotspot labeled "Bolster 1" on the image grid

2. New finding record opens with dropdown selectors

3. Select Category (dropdown):

   • "No Fatigue Crack" if no cracks found
   • "Fatigue Crack Detected" if cracks are found

4. Select specific Finding Description (dropdown appears after category):

   • For NO CRACKS, options include:
     • "👁️ Visual Inspection - No cracks detected" (90-day interval)
     • "🔍 NDT - No cracks detected" (180-day interval, £625)
   • For CRACKS FOUND, options include:
     • "👁️ Visual Inspection - Crack 0-2mm" (60-day interval)
     • "👁️ Visual Inspection - Crack 2-25mm" (30-day interval)
     • "👁️ Visual Inspection - Crack 25-50mm" (10-day interval)
     • "👁️ Visual Inspection - Crack 50-100mm" (1-day interval)
     • "👁️ Visual Inspection - Crack 100-200mm" (1-day interval)
     • "🔍 NDT - Crack detected (various sizes)" (£625, longer intervals)
     • "⚠️ Fast Fracture Risk - Crack > 200mm (IMMEDIATE REMOVAL)"

5. System auto-fills parameters based on the finding selected:

   • Cost (£): Estimated inspection/remediation cost
   • Time (Hrs): Estimated staff hours required
   • Crack (mm): Measured or estimated crack length
   • Interval (days): Next mandatory inspection due
   • Notes: Leave blank or add observations

6. Measure and verify:

   • Use measuring tape to confirm crack length
   • Note location precisely (e.g., "left side of bolster, 30mm from top")
   • If crack is larger than initial estimate, update the measurement

7. Optional: Add evidence

   • Attach photo of the location/crack
   • This is optional but highly recommended for:
     • Cracks > 25mm
     • Any unusual findings
     • First-time problem areas

8. Click: "Sign and Save Finding"

   • Your digital signature is recorded
   • Role: "C-Mech" (Mechanical Competency) automatically assigned
   • Date/time recorded automatically
   • Finding is "Frozen" (locked, cannot be edited at this stage)

Repeat for Bolsters 2, 3, and 4:

Follow the same process for each remaining bolster location.

Key Point: You must inspect ALL 4 locations before closing the inspection, even if some have no cracks.

Step 4: Review Summary Dashboard

After all 4 locations are inspected and findings are recorded, the system displays a summary:

INSPECTION SUMMARY - Train 799001, Audit 1
=============================================
Total Locations Inspected: 4
Total Cost: £625 (NDT at Bolster 2)
Total Time: 0.9 hours
Maximum Crack Found: 50mm (at Bolster 4)
Minimum Re-Inspection Due: 10 days (Bolster 4 critical)
Status Summary:
 Bolster 1 (No cracks, Visual): ✓ Recorded
 Bolster 2 (No cracks, NDT): ✓ Recorded
 Bolster 3 (No cracks, Visual): ✓ Recorded
 Bolster 4 (Crack 25-50mm, Visual): ✓ Recorded
Train Status:
 Out of Service: NO (continue operation)
 Repair Required: YES (Bolster 4 - 50mm crack)
 Completion Status: INSPECTION STAGE SIGNED OFF ✓
Next Scheduled Inspection: 10 days (driven by Bolster 4)

Step 5: Confirm Findings

Review the summary:

1. Verify accuracy:

   • Are all 4 locations recorded?
   • Do crack sizes match your physical measurements?
   • Are any cracks > 200mm (which would require immediate action)?

2. Check "Out of Service" status:

   • If any crack is 50-200mm → Set "Out of Service" to YES
   • If any crack is > 200mm → STOP - Remove train from service immediately
   • If all cracks < 25mm or none found → Train can remain in service

3. Repair decision:

   • Cracks > 25mm → "Repair Required: YES"
   • Cracks < 25mm → Can monitor with shorter inspection intervals
   • No cracks → "Repair Required: NO"

Step 6: Sign Off Inspection

1. Click: "Complete Inspection" button

2. Confirm your digital signature (your password/PIN)

3. Add any overall notes about the inspection:

   • Environmental conditions
   • Train condition observations
   • Special instructions for repair shop
   • Example: "Train 799001 has recurring crack at Bolster 4 - recommend reinforcement during repair"

4. Select your role: C-Mech (Mechanical Competency) - auto-populated

5. Click: "Sign Off Inspection"

Result: Inspection record is now locked for editing. You cannot change findings after this point without supervisor approval.

Handling Special Situations

If Crack > 200mm Found (CRITICAL)

IMMEDIATE ACTIONS:

1. STOP inspection immediately
2. Do NOT continue with other locations (train is no longer safe to operate)
3. Document the finding:
   • Select: "⚠️ Fast Fracture Risk - Crack > 200mm"
   • Mark: "Out of Service = YES"
   • Add note: "CRITICAL - Immediate removal from service"
   • Photograph the crack with a scale reference
4. Notify supervisor immediately - Do not wait to finish the inspection
5. Mark train: Out of Service status in railway system
6. Report to: Fleet Engineering and Safety Officer

If Crack 100-200mm Found

1. Document the finding clearly
2. Mark: "Out of Service = YES"
3. Next Inspection Interval: AUTOMATICALLY SET TO 1 DAY
4. Notify supervisor - Train requires repair within 24 hours
5. Continue inspection of remaining locations (train is still in depot, can be repaired)

If Previous Location Had Cracks (Check History)

Before inspecting a location that had cracks last time:

1. Review previous inspection findings

2. Measure carefully - Compare to previous crack size

3. If crack is LARGER:

   • Urgent - needs immediate repair
   • Reduce inspection interval to 1 day
   • Escalate to supervisor

4. If crack is SMALLER:

   • Possible repair already done
   • Update notes: "Repair confirmed - crack reduced from 50mm to 25mm"
   • Schedule follow-up inspection in 3 months

5. If crack is SAME SIZE:

   • Repair was not done or failed
   • Escalate to supervisor
   • Recommend more urgent repair scheduling

If Unable to Reach Inspection Area

1. Document the limitation:

   • Add finding: "Unable to inspect - [reason]"
   • Example reasons: "Boiler lagging covers location", "Train damage prevents access", "Weather conditions"

2. Recommend:

   • Schedule re-inspection with additional access arrangements
   • Request train repositioning
   • Plan for scaffold/lift access if needed

3. Flag for supervisor: This location will require follow-up inspection

After the Inspection

For Auditor (You):

✓ Your role is complete when inspection findings are signed off ✓ Your next task: Attend handover meeting with repair team

Handover Meeting (Same Day if Possible):

1. Review findings with repair mechanic:

   • Show photos of each crack location
   • Point out specific measurements
   • Discuss repair approach

2. Answer questions about crack characteristics

3. Provide context:

   • Is this location a recurring problem?
   • Previous repair history?
   • Any environmental factors (vibration, loading)?

Remediation Phase (Repair Work)

Note: You may not be involved in this phase if you are strictly an auditor. However, understanding the process helps:

Mechanic's Role (Remediation Stage):

The repair mechanic:

1. Opens the inspection record
2. Views the "Remediation" section (which only appears after your signature)
3. Records actual time and cost spent on repair
4. Updates parameters if they differ from estimates
5. Signs off repair work
6. System calculates variance: "Estimated vs Actual"

Example:

Finding: Crack 25-50mm at Bolster 4
Auditor estimated: £2,000 repair cost, 8 hours labor
Mechanic actual: £1,800 repair cost, 7 hours labor
Variance: £200 saved, 1 hour saved ✓

Close-Out Phase (Final Verification)

Supervisor's Role (After Repair):

The supervisor:

1. Opens the inspection record
2. Views the "Close Out" section
3. Reviews:
   • Photos of repair work
   • Comparison of estimated vs actual costs
   • Mechanic's notes on repair
   • Quality of workmanship
4. Signs off final acceptance
5. Marks finding as "COMPLETE"

Only after all findings are complete can the train return to service.

Common Questions & Answers

Q: What if I'm not sure if a mark is a crack or just dirt/paint damage?

A:

• Use a clean cloth to wipe the area
• Check if the mark is on the surface or indented (crack)
• If unsure, use NDT (ultrasonic) testing - it will definitively show cracks
• Document your process: "Visual examination with magnifier, area cleaned, mark is [surface/indented], classified as [finding]"

Q: Can I edit findings after I sign off the inspection?

A:

• NO - Once you sign, the findings are "Frozen" and locked
• If you made a mistake, you must:
  1. Inform your supervisor
  2. Request "Unlock for Edit" (supervisor authority only)
  3. Make the correction with supervisor approval
  4. Document why the change was made
• Audit trail shows all edits and who made them

Q: What if the train isn't due for repair but has cracks < 25mm?

A:

• Don't repair immediately
• Schedule next inspection in 30-60 days (based on crack size)
• Document: "Crack < 25mm, monitoring interval recommended"
• Track trend over multiple inspections
• If crack grows, escalate for earlier repair
• If crack remains stable, can extend inspection intervals

Q: Should I take photos of every location?

A:

• REQUIRED: Photos for any crack > 10mm
• RECOMMENDED: Photos for unusual findings or first-time issues
• OPTIONAL: Photos for "no cracks" locations unless supervisory guidance says otherwise
• Always include: Scale reference in photos (ruler or coin for size reference)

Q: What if the 4 Bolster locations have different findings (some Visual, some NDT)?

A:

• This is common and correct
• Example: "Bolster 1 looks clean (Visual OK), Bolster 2 has suspect area (use NDT to be sure)"
• Cost may vary:
  • All Visual: ~£0 + 0.4 hours
  • 3 Visual + 1 NDT: ~£625 + 0.8 hours
  • All NDT: ~£2,500 + 2.0 hours
• Choose inspection method based on risk and finding:
  • No visible cracks → Visual (cost-effective)
  • Suspect areas or previous cracks → NDT (safety-focused)

Q: How do I determine "next inspection due" interval?

A:

• CheckIt auto-calculates this based on the comment you select
• The selected comment predetermines the interval:
  • "No cracks - Visual" → 90 days
  • "No cracks - NDT" → 180 days
  • "Crack 25-50mm" → 10 days
  • "Crack 50-100mm" → 1 day
  • Etc.
• You cannot manually override the interval (it's locked by the system)
• If you need a different interval, discuss with supervisor before selecting the comment

Q: What if I start the inspection but must stop (train issue, weather, equipment failure)?

A:

• Don't sign off incomplete findings
• Save the partial work (button: "Save for Later")
• Contact supervisor to reschedule
• When you resume:
  • Open the saved inspection
  • Continue from where you left off
  • Complete remaining locations
  • All findings will have your timestamp from today (when you resume)

Troubleshooting

Digital Signature Information

Your Signature

• Records: Your name, role (C-Mech), date, time
• Purpose: Legal proof you conducted the inspection and sign-off
• Immutable: Once signed, cannot be modified without supervisor unlock
• Audit Trail: All edits after signature are logged with editor name/date

Supervisor Signature

• Typically by H-Supervisor or H-Manager role
• Required at "Close Out" stage after repair is complete
• Approves the variance between estimated and actual costs/time
• Final sign-off before train returns to service

Legal Status

• Digital signatures satisfy railway safety regulations (ORR requirements)
• Equivalent to pen-and-paper signature for audit purposes
• Acceptable in accident investigations and safety reviews
• Part of official train maintenance record

Compliance & Safety Standards

This inspection process complies with:

• ORR Regulations: Office of Rail and Road requirements for rolling stock safety
• RSSB Standards: Rail Safety Standards Board guidelines
• ISO 9001: Quality Management System standards
• UK Rail Industry Engineering Change Procedure

The system enforces:

• ✓ Standardized finding definitions (no ambiguity)
• ✓ Role-based approvals (proper authority at each stage)
• ✓ Digital audit trail (complete traceability)
• ✓ Safety thresholds (automatic removal from service if critical)
• ✓ Supervisor verification (quality control)

Support & Escalation

If You Need Help:

Summary: Inspection Workflow at a Glance

1. PREPARE
 ├─ Review previous inspection history
 ├─ Gather equipment (magnifier, tape measure, camera)
 └─ Confirm train is positioned for inspection
2. INSPECT
 ├─ Open the inspection application
 ├─ Enter train unit & inspection type
 ├─ Click Bolster 1 → Select finding → Sign
 ├─ Click Bolster 2 → Select finding → Sign
 ├─ Click Bolster 3 → Select finding → Sign
 ├─ Click Bolster 4 → Select finding → Sign
 └─ Review summary dashboard
3. VERIFY
 ├─ All 4 locations complete? ✓
 ├─ Out of Service status correct? ✓
 ├─ Crack measurements accurate? ✓
 └─ Next inspection interval appropriate? ✓
4. SIGN OFF
 ├─ Click "Complete Inspection"
 ├─ Provide digital signature
 ├─ Add overall notes
 └─ Inspection FROZEN - locked for editing
5. HANDOVER
 ├─ Brief repair mechanic on findings
 ├─ Answer any questions
 └─ Hand over to Remediation phase

Final Notes

Before You Start Your First Inspection:

• [ ] Complete the Class 799 Fatigue Crack Inspection training module (online)
• [ ] Observe an experienced inspector conducting inspection
• [ ] Practice signing off a test/demo inspection
• [ ] Confirm you can access the inspection application on your device
• [ ] Verify your digital signature works
• [ ] Know your supervisor's extension for emergency escalation

Key Principle:

"Find it. Fix it. Prove it."

• Find it: Thorough visual inspection of all 4 locations
• Fix it: Document findings clearly with measurements and photos
• Prove it: Digital signature and audit trail for regulatory compliance

Document Information

Last Updated: 17 November 2025 Next Review: November 2026

Questions or feedback? Contact: QA@company.com