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Edinburgh gets its trams

In Edinburgh, there is enthusiasm about the introduction of the city’s tram service on 31 May. Writes David Shirres

This much is clear from Twitter and correspondence columns in the Scottish Press. As an example, an appeal for a thousand volunteers for a tram crowd exercise was fulfilled within 24 hours and massively over-subscribed.

However, there are also many who are not so enthusiastic and consider the trams to be an unnecessary waste of money. This is understandable as the project opened three years late, was almost £300 million over budget and delivered only 14.2 km of the original 18.5 km network as a result of a 2011 decision not to build the section from Newhaven and Leith to Edinburgh.

Background

In 2007, the Scottish Parliament voted to fund the tram project and authorised £490 million for a tram service between Newhaven and Edinburgh Airport which was to open in 2011. However the project ran into difficulties with almost twice the number of expected utility diversions and disputes with the infrastructure contractor. With these resulting in significant delays, the project team advised Edinburgh City Council in June 2010 that it was prepared to terminate the infrastructure contract should this be necessary.

The turning point for the project was the Council’s decision in November 2010 to support independent mediation. This led to talks being held the following March at which the mediator was successful in facilitating a mutually- agreed resolution. Shortly afterwards, the contractor re-mobilised staff at priority locations. A settlement agreement was signed in June 2010 which incorporated a revised budget of £776 million and a programme to deliver passenger services in summer 2014. So, whilst there are project lessons to be learnt up to the mediation, the project has been successful in keeping to time and cost since the revised agreement. Furthermore, its initial difficulties do not detract from the case for a tram network or the quality of its engineering.

Leaving the city

From its terminus in York Place, the tram runs through the city streets, including Princes Street, for 2.6 kilometres to an interchange at the new Haymarket station (issue 105 – July 2013). There are five tram stops in this section.

The track is the Rheda City system supplied by the German company RailOne. This has two concrete sleeper pads separated and located by an integral steel lattice-girder embedded in a poured concrete slab. The track sits on a 250mm-thick ground improvement slab which is designed to span a one metre void. In the city, black concrete is used for the final pour so the track blends into the city’s streets.

Ensuring that the tram system does not detract from Edinburgh’s status as a World Heritage City was a challenging task. To both meet this requirement and improve the quality of streets and open spaces, the Council produced a Design Manual which was used as a reference point for all planning consent applications.

On the streets

It was on and under the city’s streets that the project faced perhaps its greatest challenge – the diversion of utilities. This was undertaken under a Multi-Utilities Diversion Framework Agreement (MUDFA), the scope of which was based on information provided by the utilities. This contract was let in 2006 with the intention that utility work would be complete prior to commencement of the main works in 2008.

In the event, the difference between actual work and the original scope was 295 chambers instead of 190 and 46.5 km of ducts /pipes instead of 27.2 km. As a result, utility work continued into 2012 and, while it resulted in extra costs and delays, it did result in a significant improvement to the city’s infrastructure.

The extended utility work and tram works required an extensive programme of closures of the city’s main thoroughfares. The required diversions were planned on the basis of traffic modelling. Track work was also planned to minimise disruption with work cut into small sections of, typically, 40 metres. Nevertheless, this work inevitably involved extended periods of disruption.

E Depot [online]

The tram works also uncovered a number of archaeological finds. In Constitution Street in Leith, 390 graves were unearthed in a former graveyard dating between the late fifteenth and eighteenth centuries, and the remains of a sixteenth century leper hospital were discovered. Close to the airport, prehistoric and Dark Age settlements were found.

Of more recent vintage, an 80 metre long underground Second World War bunker was discovered at Haymarket. This had started life as a pulley room for Edinburgh’s nineteenth century cable powered trams. The modern tram system’s foundations were redesigned to preserve the structure of this bunker.

The railway corridor

The off-street section starts at the interchange stop at Haymarket station and then runs parallel to the Edinburgh to Glasgow railway for six kilometres, crossing it by two bridges. It goes around the back of Haymarket depot, passes Murrayfield stadium and makes use of a former guided busway. The route leaves the railway at Edinburgh Park where there is another interchange tram stop.

With its proximity to the railway, immunisation work was required to address Network Rail’s concerns that the tram’s 750V DC power supply might interfere with signalling equipment. The tram design also had to make passive provision for Network Rail’s electrification proposals.

The 55-metre-long low viaduct at Haymarket was built on the site of the Caledonian Ale House. This unfortunately had to be demolished to accommodate a tram station that sits on the viaduct. This is one of 12 bridges on the off-street section with a combined length of 566 metres – there is another 232-metre-long viaduct at Edinburgh Park station.

The Murrayfield tram stop is on raised ground at the back of Haymarket depot. Here, poor ground conditions required a combination of ground improvement work and the use of Leca LWA lightweight fill and a Tensar Geogrid wall system.

To the airport

From Edinburgh Park, the tram line crosses a dual carriage to the Gyle shopping centre after which there is an underpass under the A8 road. Just after this the line passes the Gogar tram depot whose construction was reported in issue 82 (August 2011). The route then goes over open country to its terminus at the airport.

Close to the depot is the planned Edinburgh Gateway station which will provide an interchange with the railway to Fife and Aberdeen. Work on this station, which is being built by Transport Scotland on behalf of the Scottish Government, is expected to start in September for completion in 2016 at a cost of around £30 million.

This section also involved significant construction challenges. The underpass under the A8 necessitated significant utility diversions including data cables for the nearby Royal Bank of Scotland headquarters complex.

The line’s passage through the Gogar landfill area required a reinforced earth batter which incorporated around 400 twelve-metre-long soil nails.

The design contract was awarded in 2005 to System Design Services, a joint venture between Halcrow and Parsons Brinckerhoff. Part of the requirement was the early identification of utility works, land purchase and traffic management.

The infrastructure construction works were undertaken under the INFRACO contract which also includes infrastructure maintenance. In 2008 this was awarded to BBS, a consortium of Bilfinger Berger and Siemens. BBS operated as a management contractor letting out packages which included the depot (Barr Construction), track (BAM Rail) and general civil engineering (Raynesway, Graham, McKenzie Construction, Crummock, Farrans Construction and McKean Group).

Once the mediation settlement of 2011 was in place, Turner and Townsend, which had previously worked on the Croydon, Dublin and Nottingham tram systems, were appointed to assist the City of Edinburgh Council in the project management of the works.

The last contract to be awarded was to Parkeon for the supply and maintenance of the ticketing machines, platform validators and hand-held terminals with back office software support. These will accept Lothian Buses’ Ridacards and ITSO cards.

At the airport, the required road alterations involved the diversion of the Gogarburn river, 310 metres of piled retaining wall, road re- location including a new 32 metre bridge and provision of a signal controlled level crossing.

Infrastructure contracts

EdinburghTramRoute [online]As with any large scale infrastructure project, a number of companies were involved. The first works contract to be let in 2006 was the MUDFA contract – awarded to Alfred McAlpine Infrastructure Services which were subsequently taken over by Carillion. Following the 2011 mediation settlement, utility work was awarded to McNicholas.

The design contract was awarded in 2005 to System Design Services, a joint venture between Halcrow and Parsons Brinckerhoff. Part of the requirement was the early identification of utility works, land purchase and traffic management.

The infrastructure construction works were undertaken under the INFRACO contract which also includes infrastructure maintenance. In 2008 this was awarded to BBS, a consortium of Bilfinger Berger and Siemens. BBS operated as a management contractor letting out packages which included the depot (Barr Construction), track (BAM Rail) and general civil engineering (Raynesway, Graham, McKenzie Construction, Crummock, Farrans Construction and McKean Group).

Once the mediation settlement of 2011 was in place, Turner and Townsend, which had previously worked on the Croydon, Dublin and Nottingham tram systems, were appointed to assist the City of Edinburgh Council in the project management of the works.

The last contract to be awarded was to Parkeon for the supply and maintenance of the ticketing machines, platform validators and hand-held terminals with back office software support. These will accept Lothian Buses’ Ridacards and ITSO cards.

The trams

The contract for the supply and maintenance (for 30 years) of 27 trams was let to Construcciones y Auxilar de Ferrocarriles (CAF) in 2008. These trams were built at the CAF factory in Irun, northern Spain, and were delivered between 2010 and 2012 in accordance with the original project programme. Since then, they have been subject to a CAF-specified conservation maintenance regime which included the requirement to move each tram once a month. A 200-metre section of the route adjacent to the depot opened in 2011, enabling the trams to be tested on delivery, some driver training and the required monthly movement.

At 42.9 metres, these are the longest trams in the UK and have been designed to negotiate Edinburgh’s tight curves and steep gradients. They are 2.65 metres wide, weigh 56 tonnes and consist of seven articulated modules. Four of the modules have a single bogie. The three other modules have no wheels and are suspended between adjacent bogie modules.

The trams are supplied by a 750V DC overhead catenary and have twelve 80kW traction motors on three powered bogies which also have regenerative braking – one of the intermediate bogie modules is unpowered.

Speed is restricted to 30 mph on-street and 45 mph off-street. The trams have a 100% low floor, 300mm above rail height, throughout. To achieve this, auxiliary equipment is roof mounted and bogies are rigidly fixed to the bogie vehicles with wheels on stub axles which are accommodated under seats together with the longitudinally-fitted traction motors. This arrangement also reduces the cornering squeal as it allows for differential wheel speeds.

Other systems provided onboard the vehicles include CCTV and passenger counting as well as tram detection and positioning.

Testing, Testing, Testing

For weeks prior to service introduction, Edinburgh’s residents have seen empty trams run on their streets. This is part of a rigorous testing and commissioning (T&C) plan which must satisfy a safety verification assessment under the ROGS (Railway and Other Guided Transit Systems) regulations by the Independent Competent Person (ICP) who was appointed in 2007. This early appointment was necessary so that the safety assessment process met the ICP’s requirements.Long Report Template release 7.0

To commission the tram system, the T&C plan requires factory acceptance tests, installation completion tests, site acceptance tests and sub-system integration tests. The sub-systems are civils, track, signalling system, communication system, electrification, depot equipment, traffic light control and rolling stock.

The route was commissioned in three stages: from the depot at Gogar to the airport in March 2013, then from the depot to Edinburgh Park in December, and finally, in March 2014, from Edinburgh Park to York Place.

After commissioning, a series of system acceptance tests are required to confirm the tram system’s capability. The first of these tests, T1, requires 40 movements by a single tram, 95% of which must be within the target runtime. T1 tests tram priority at junctions and was done at night to minimise the effect of road traffic. The T2 test requires 95% of end-to-end tram movements to meet the required punctuality during three consecutive days of tram operations to the full operational timetable.

T3 is final test before passenger service can be authorised. This requires five consecutive days of the normal timetable and five consecutive days of an enhanced timetable during which a 99% punctuality standard must be achieved. This test also includes confirmation of ride quality.

During this T3 test period, exercises with the emergency services were undertaken which included tram evacuation at various locations, a derailment scenario and crowd management at Murrayfield Stadium. Lessons from these exercises and other aspects of the system acceptance tests were used to refine operational procedures.

Edinburgh joins the club

Edinburgh now has its trams and follows Nottingham (2004), Croydon (2000), Birmingham (1999), Sheffield (1994), Manchester (1992) and Blackpool (1885, modernised 2012) whose tram schemes have proved popular and promoted local economic growth. For example a West Midlands Passenger Transport Executive study indicated that Midland Metro expansion would create around 15,000 jobs and add nearly half a billion pounds to the West Midlands economy.

With the addition of Edinburgh’s 14 km tram network, the UK now has 200km of light rail. This is some way behind France (632 km) and Germany (2,921 km) which clearly believe in the benefits of light rail.

The trams’ advantages would seem to be clear and no doubt Edinburgh’s trams will benefit the city despite their troubled start. Hopefully their comfortable, quiet and pleasant ride should soon ensure that they are as popular as the trams south of the border.

Signal Engineering Resources Seminar

At the end of March, Network Rail unveiled its programme of works for CP5, covering the five years from 2014 to 2019. Writes David Bickell

Introducing the £38 billion programme, Mark Carne, Network Rail’s Chief Executive said: “As a result of the investments we will be making in the next five years, by 2019 the country’s rail network will be delivering 225 million more passenger journeys each year. More trains per day will run between our northern cities. 170,000 extra seats will be available on trains going into our large cities nationwide. 500 more level crossings will be closed.

“In London, the Thameslink programme, and in Birmingham the New Street development, will both be completed, as will main line electrification in Wales and the West Country. In Scotland, the Borders project will reconnect the Scottish Borders to Edinburgh for the first time in 50 years.

“At the same time, we will be trying to deliver ‘more for less’ in the way we operate and run the railway on a daily basis. In the next 10 years, passenger and freight traffic is forecast to increase by over 30 per cent. Simultaneously, we are aiming to reduce the cost of running the railway. In the next five years, our target is a 20 per cent reduction on top of the 15 per cent reduction achieved in the last five years – a saving of over 30 per cent in a decade.”

Signalling in demand

Within Network Rail’s £38 billion, signalling will have £3.2 billion to spend over the next five years, within which an efficiency gain of £580 million will be expected – a significant challenge. Major work will be undertaken to develop a national traffic management system, migrate signalling control to Rail Operating Centres (ROCs) and install modular signalling on secondary lines and ERTMS/ETCS on the main trunk routes.

On top of all this there will be signalling work on London Underground (which has a £1 billion budget), the installation of signalling in Crossrail’s new tunnels and its integration with national systems at either end, and the planning of HS2.

In the summer of 2013, Network Rail commissioned the National Skills Academy for Railway Engineering (NSARE) to undertake a detailed review of existing signal engineering resources in the light of the planned workload for CP5. Recently, one hundred delegates from the industry gathered in London to hear the results of this review and to participate in a discussion on the key issues.

Industry view

Setting the scene, Jeremy Candfield of the Railway Industry Association (RIA) explained that there was considerable apprehension about skills shortages for signalling and that this was a particular concern with particular significance in the context of the delivery of CP5 works. In the RIA Business Survey of 2010, 50% of business respondents indicated that they would be affected by a skills shortage. By the 2012 and 2013 surveys, that had risen to 100%.

At a recent meeting of the RIA Infrastructure Clients Interface Group, two major signalling companies spontaneously made a clear statement of the difficulties of securing and retaining skilled staff. Why should this be?

Jeremy alluded to the investment history of ‘feast and famine’, not helped by the major upheavals of privatisation and Railtrack going into administration. Electrification “has been lumpy” since the 1940s with periods of no new work. Orders for new rolling stock have been hugely variable. All sectors have been affected by what was described as an investment roller coaster without the fun.

The review

Elaine Clark, NSARE’s head of training and skills, introduced the report by explaining that its scope had been to baseline existing resources and compare them against both renewals and maintenance projects, to identify the effects of international work by UK companies and of international resources available to work on UK projects, to review the IRSE (Institution of Railway Signal Engineers) Licensing Scheme and to identify any skills gap.

The study was specific to signal engineering, not including telecommunications. A steering group was set up and 45 supply chain companies were invited to provide input via a questionnaire.

The results highlighted problems that suppliers faced with up to 30% rework at the project design stage, poor visibility of future workload, a lack of detailed information from projects that would aid understanding of future resources and the need for better processes to support non- licenced trainees gaining experience on site.

Training and assessment issues were also identified with a lack of consistent training programmes and no standard training modules, not all training provision being ‘quality assured’ and a shortage of partnerships with training providers, colleges, universities.

The IRSE Licensing Scheme was seen as providing a positive contribution. Assessment and accreditation was seen as being independent and the rigour/regime of the log book works well. It has a good modular approach and, in general, the ‘levels’ of categories of licence were correct. However, a few issues were identified. The recertification process could be simplified, there is a variation in the time and cost of competence assessment, and there are difficulties with cross-licensing for signalling design and testing.

The current situation

At present, there are over 900 projects in the forthcoming workbank and an existing workforce of around 9,200 people (4,200 doing maintenance and 5,000 engaged on projects). Of these, 4,539 hold IRSE licences. The age profile is such that 400 are over 60 years old and another 700 are in the range 55-59.

In 2013/14, the industry is just about coping but there is going to be a significant shortfall in two years time with an identified work gap of 2,600 – 3,400 of which 47% are at technician/ engineer level.

Delegates discussed the problem of design rework and inefficiencies within the Governance for Railway Investment Projects (GRIP) process. Mark Southwell of Network Rail explained that these issues were being tackled with the ‘TARDIS’ initiative, the benefits of which will be a new GRIP 1-4 process which will:

  • Improve the robustness of client remits with clear scopes and outputs identified and ‘locked down’, minimising the risk of subsequent scope change;
  • Reduce GRIP 1-4 timescales resulting in lower project costs and shorter project duration between first authority and commissioning;
  • Help to deliver the stretched efficiency target within the strategic business plan (SBP) submission over and above the 16% identified through existing initiatives;
  • Increase expectation that there will be further benefits in the future as a result of ORBIS due to improved/easier-to-access asset and condition data being available without the need for ‘walking the ballast’, thus reducing the level of seed funding required;
  • Facilitate undertaking these works early which will also help to de-risk the programme/project;
  • Minimise the risk of abortive costs as these schemes are condition-driven projects and therefore the likelihood of these schemes progressing to full authority once the GRIP work has been undertaken is very high.

IRSE Licensing Scheme

Colin Porter of IRSE outlined the principles of the scheme. He explained that it came into being in 1994 following the setting up of a cross industry group facilitated by the IRSE to address competence issues flagged up in the report of the Rail Accident at Clapham Junction (issues 111 and 112, January and February 2014).

The Scheme is considered to provide useful benefits and is a non- profit making venture for the IRSE. However, as it is twenty years old, recommendations for improvement include modularisation to facilitate mobility and multi-tasking, the introduction of new categories for train-borne systems, other software based systems and signal sighting, and a common standard for competence at specific equipment/task level and the issuing of Authority to Work. 6,000 people (many of them overseas) hold competence certificates issued by the IRSE of which 5,020 are members.

Delegates suggested there should be more transparency on the basis of charging as there was some variation of time/cost of assessments. The need for higher level categories such as ‘Senior Engineering Manager’ was also challenged and some perceived the scheme as overly complicated and complex and this needs to change.

Colin stressed that the IRSE is keen to continue to work within the industry and make sure that the Scheme should not be a barrier to increasing the workforce.

Aspirations

Following the presentations and discussions, the things that the industry needs to do can be summarised as:

  • Plan better to remove the boom and bust and smooth out the work profile;
  • Collaborate better and share best practice;
  • Reduce rework by improving specifications;
  • Solve the brain drain and stop talented people leaving the industry;
  • Attract good people into the industry including more graduates and apprentices;
  • Have better utilisation of people within the industry;
  • Improve the IRSE Licensing Scheme.

If it adopts these actions, the signalling industry should go a long way towards meeting the challenges of CP5, and beyond.

Issue 116 – June 2014

The Rail Engineer 116 - June 2014

Traffic Management Systems – Train Regulation Made Easy?

Regulating trains so that they run in the right order and do not delay other services has been a challenge ever since railways started in business. In early times, the decision-making was left to local signalman who, by their intricate knowledge and years of experience, got it right most of the time. Writes Clive Kessell

Everything was relatively easy if trains were running to the timetable, but the challenge came when disruption occurred, maybe a failed locomotive, a section of track needing maintenance, a member of crew not being available, even the insertion of an extra train at the last moment. At such times, the capability of signalmen to sort things out was severely stretched, and running order mistakes could quickly cripple a train service.

Early steps

The advent of Traffic Control Offices in the early part of the twentieth century helped considerably, but having only telephones and telegraph instruments at their disposal severely limited what these offices were aware of and the ability to get things changed.

With the introduction of power signalboxes in the 1950s, a much greater area of control could be viewed with all train movements actively seen on a display diagram. The positioning of regulators at ‘back row’ desks enabled much greater accuracy in the regulating process but, even here, it was a human decision as to how trains should be scheduled to minimise disruption. Big as they became, power boxes still had a limited area of operation and the ability to see the order of approaching trains was restricted.

In later years, computerised systems have been developed to aid the decision making by signallers and controllers. These include:

  • ARS (Automatic Route Setting) whereby trains signal themselves according to the timetable and their train description, thus minimising signaller intervention but with limited facilities for prioritising the order in which trains are processed;
  • JOT (Junction Optimising Technique) in an attempt to look at the order of trains approaching a junction point and then signalling trains through the junction according to type, speed and importance;
  • Computerised Train Graphs – produced primarily for timetable compilation but used in real time for modifying the train service on a daily basis according to need, including the insertion of additional trains;
  • TD NET (Train Describer Networking) whereby Train Describer systems in the various power boxes have their information distributed to a common database so that other signalling centres and control offices can see the real time movement of trains over extended distances;
  • Timetable and train describer interaction for the updating of passenger information.

Various uses

Other systems have been developed to make use of this computerised information external to the signalling centre and control office. Project Darwin is one example. An ATOC (Association of Train Operating Companies) initiative, it captures real time train running information and links this into web sites and social media systems as well as improved displays / announcements at stations. The intention is that customers receive current and relevant data for their intended journey (issue 83, September 2011).

DAS (Driver Advisory Systems) give guidance to drivers on the optimum speed to be observed such that a train arrives at a particular timing point on time having used the least amount of energy by avoiding excessive acceleration and braking (issue 104, June 2013).

Traffic Management Systems

With past developments yielding so much relevant data, what further work is foreseen and needed to improve on the present situation? Current information systems have been designed as separate entities with the potential for data to be both disparate and missed, thus causing inconsistency. There are, however, many other factors that impact on train service performance which need to be integrated into the decision management process.

The result is the Train Management System (TMS) and it is not just a UK requirement as many other railways have invested in the development of such systems. The concept is to produce a single source of data for train timetabling, rolling stock allocation and train crew deployment and to use this data for operations planning and comparison to real time operational events, thus automating the signalling of trains in the optimum way. Included is the detection of potential conflicts and their best resolution, plus probing ‘what if’ scenarios on train running with consequent decision support.

Such a task is clearly challenging and effective results will be most needed at times of severe disruption. Achieving this will essentially be by marrying the signalling control panel with the computerised train planning graph. This will yield a map of train whereabouts over a wide area, derived from both traditional train describers and GPS radio tracking, from which information can be sent to a variety of systems that react to the data.

The result will have impact way beyond the basic objective of running trains to time. The overall TMS will include:

  • Web based distribution with configurable information management applications;
  • Travel information dissemination including display maps to show disruption;
  • Possession management and reduction of human based protection methods;
  • On-site communication to local terminals and smart phones;
  • Rolling stock re-planning;
  • Train crew scheduling and re-assignment when needed;
  • Insertion of additional trains and optimum pathing of these;
  • Feeding of live train running data to DAS so as to alter driver advice to take account of potential junction conflicts.

Network Rail plans and trials

Network Rail operates 24,000 trains per day and passenger demand is expected to increase by 30% in the next 10 years. Around 8,000 people are employed to operate the railway and a high percentage of operator’s time is unproductive. Managing these quantities so as to achieve maximum efficiency will be a challenge. Network Rail thus wants a TMS facility that is already proven on other rail networks.

Trial applications are underway with three providers: Hitachi, Thales and Signalling Solutions Ltd (SSL). All have reached the stage where demonstration systems have been set up, modelled on a particular operating area and including simulations of SSI interlockings and train movements. This is allowing Network
Rail engineers and operators to evaluate the effectiveness of the offering.

Part of the testing is to see whether the decision-making algorithms are better than an experienced railway controller. Unsurprisingly, controllers see this as something of a challenge!

The trials aim to show various combinations of how TMS might assist signallers, ranging from full intervention to advising on the best route settings. The chosen area for modelling is Leeds, as this contains a multitude of routes and a complex station layout. The Rail Engineer was shown all three systems by Richard Beddow, Network Rail’s project manager, and Gary Pierce, one of the ‘challenged’ controllers, in conjunction with the three manufacturers.

Hitachi TRANISTA

The Hitachi TMS, known as Tranista, is based on experience in Japan where Hitachi systems are used on both Shinkansen high-speed lines and busy commuter and mixed traffic lines, notably in the Tokyo area. On this simulation, trains are shown on entry and exit routes as the next three in running timetabled order. This list is displayed adjacent to the appropriate train describer window.

If a train fails or is stopped for an unduly long time at a platform, then that train is ‘suspended’ from the system and the next three trains are re-ordered. This process takes account of the types of train, their permitted speed, the ongoing stopping patterns and the impact of delay. Thus the recommended sequence of dispatch may not be the same as per the timetable. Once the problem with the ‘stopped’ train is rectified, then it is re-inserted into the system and a revised running order calculated.

Thales ARAMIS

Thales offers a similar simulation structured around a single operating information system that gives re-configurable control and use of decision support tools. The system is branded ARAMIS and has a modular architecture that can be structured for links to interlockings, radio block centres, fringe train describers, alarms and so forth. It is aimed at providing help in several rail activities: planning, station management, passenger information, controllers and train crew, and will cover timetable, despatch, movement authorities, network availability, incident / delay management and service information.

To link to the several types of interlocking that currently exist, Thales intends to use the WestCad system originating from Invensys (now Siemens Rail Automation) as a programmable interface. The Leeds simulation includes for normal, degraded and emergency working as defined by the nominated controllers.

ARAMIS will not optimise train crew or rolling stock diagramming / rostering, these being achieved by links to other systems.

SSL ICONIS

The proposal from SSL centres around Alstom’s ICONIS and Atos’s Integrale products with the emphasis being on the management of a mixed traffic railway. This offering is based on a consortium approach involving Alstom (one of two parent companies of SSL), Atos (an international IT organisation that acquired significant elements of CAP and SEMA Group) and Parsons Brinckerhoff.

The ICONIS TMS system is used in a number of countries but the deployment in Bologna, which is one of 12 signalling centres in Italy using different manufacturers’ equipment, equates best to the Network Rail scene. Here, TMS has enabled a significant improvement in punctuality whilst having to cope with a 30% increase in traffic. A shadow system is included to allow final validation of upgrades and changes in the live environment before loading to the operational system with no down time.

The Atos Integrale product provides a high level, national management solution to co-ordinate local TMS systems provided at individual signalling centres. For the UK proposal, linkage to other existing IT and signalling equipment such as rolling stock, crew rosters, etc. will be via the LINX integration layer, this feeding both local and overview TMS architecture.

Train running is shown by + or – minutes for early or late against the individual train descriptions on the signaller’s route setting screen. From this, optimised ARS will be advised. Any change to planned timetable routing will require human intervention. A mouse click on the description will establish a voice call to the train using GSM-R.

Conflict detection currently compares only one train to another (Pair Wise Comparison) but more variables will be developed as the system matures. A key factor will be the time taken to assess what options are available; the optimum solution might not be best if too much time is taken.

Common elements

All three suppliers envisage electronic train graphs on the signallers’ desks so that they can compare the dynamic timetabling to the normal route setting screen. This element will potentially give the signallers more information and expert advice on the optimum routing of trains. The train graph will show both the planned path and the real time actual running time of a train. From this, future conflict points will be determined with advice as to the best running order to be followed.

The use of this facility is likely to be split between the signallers who have around a 10 minute window to change things, and the train planners on the ‘back row’ desks who will view the likely changes and train movements at greater distances from the immediate station area. The train graph can be used to block out sections of route if a major problem is encountered. Options will then be to terminate, turnback or divert according to the nature of the blockage. Dealing with a suicide or a broken rail are instances where this can occur inside a normal day.

The TMS programme will be aligned to the introduction of the Regional Operating Centres (ROCs). Current plans show 12 of these nationally, with 5 already open and the remainder all due to be in partial service by the end of 2015. The ROCs are intended to cover the majority of Network Rail but it will take many years before all rail routes are controlled from these places.

TMS however, to be effective, must take account of the whole railway so TMS information and applications must be made available to the existing Integrated Electronic Control Centres (IECCs), older style Power Boxes (PSBs) and even to the remaining mechanical signalboxes whilst they remain in service. Current thoughts are to display optimised train running orders at these places with instructions to signallers to maintain this order unless exceptional circumstances intervene. This will need careful handling and a lot of lessons will no doubt be learnt in the process.

Capacity

With the ever increasing ridership and the need to run more trains, capacity on the network is becoming a real problem. Building more infrastructure is expensive and takes time, so are there any quick fixes that can help?

TMS is envisaged as a tool for improving train running sequences and minimising delay at pinch points and from this, more train paths should become available, thus increasing capacity. Exactly how beneficial this can be will be part of the evaluation period but a broad order assessment is that 10% more throughput can be obtained at the busiest parts of the network.

Other applications and the future

Once train operation is known in real time on a national scale, it will enable much improved information to be given to travellers at times of disruption. The portrayal of information by digital maps on displays boards at stations has been tried in the past (at Peterborough) and was judged to be successful. By using TMS the maps can be made more dynamic and can show for example a line being closed and the diversionary routes that trains will be taking.

Getting information into web sites and social media will continue to be a feature of Project Darwin, but the feeds to the system will have greater accuracy.

DAS is a technology that is being adopted by many of the train operating companies, but it is currently limited to the provision of data for a specific train journey. It has always been foreseen that information given to drivers on optimum running speeds needs to take account of other train movements and TMS will be a natural feeder in the accomplishment of this aim. DAS set-up information such as train set, platform diagramming and suchlike will be fed into TMS, whence the data will have to be centralised at some kind of hub and then distributed in processed form to trains via a 3G or 4G mobile network.

Information on freight trains will be particularly important as the locomotive type, speed, weight and loading all vary from train to train. Since freight trains rarely run to the same rigorous timetable of passenger services, ‘queue paths’ may be created to show available capacity if a freight train is running late or indeed to offer a path to another train should a cancellation or significant late running occur.

Possession Management is an ongoing challenge with the present methodology seen as inefficient and carrying big safety risks caused by human error. With the ability to know the real and predicted whereabouts of every train within an area plus the capability of networking this information to a local terminal (iPad or tablet), it should become possible to present more timely information to persons responsible for managing a possession. This will be aimed at planned possessions in the first instance but could potentially be useful in enabling work to be done between trains and taking emergency possessions.

Another consideration is how TMS will fit in with the future ERTMS (European Rail Traffic Management System) programme, and some form of integration will be necessary. By electing to have a TMS system that is already in service, it is anticipated that this will have been used in conjunction with ERTMS on another rail administration.

Deployment

Once the test room simulation period is completed, one of the TMS products will be chosen for deployment in Cardiff and Romford (Essex Thameside section) ROCs to gain real- time experience. These will become operational in Dec 2015. At some stage, a high-level national system has to be included to get a UK overview on how trains are running. An individual ROC will probably only need to see approaching trains within a 60 minute time period for conflict detection purposes but a three hour window will be possible if required

Just how the ultimate procurement will evolve has still to be worked out but if a multi-supplier scenario is chosen then interoperability will be required between the different products. The single national overview system must be capable of seamlessly linking all of the ROC-based equipment.

A collaborative effort from suppliers will be needed. There is a lot at stake so keen eyes will be watching progress with interest.

UPDATE: Thales has been awarded the TMS contract for ROCS in Cardiff and Romford.

Treating gas with respect

The recent twenty-third technical seminar to be organised by the Institute of Rail Welding focussed, not on technical matters, but safety and welfare. Writes Chris Parker

Mick Downing of Renown Rail Welding Services chaired the day which was entitled “Gas Safety – Risks, Remedies and Requirements” and was held at BOC’s premises in Wolverhampton.

Acetylene cylinders and fire – don’t panic!

The first presentation of the day was possibly the most important presentation. Jointly delivered by Doug Thornton, chief executive of the British Compressed Gases Association (BCGA) and Peter Gustafson of the London Fire Brigade, it concerned the question of the safety of acetylene cylinders when involved in fires.

The BCGA represents the compressed gas industry and has some 78 member companies. One of its major roles is the development and publication of guidance about the handling and use of compressed gases. Some 99 such publications have been issued, all endorsed by the Health and Safety Executive (HSE), and some are even incorporated into UK law, making compliance a legal requirement.

Liaising with regulatory authorities such as the HSE and the Department for Transport, the BCGA works to drive necessary changes in the law. New UK Regulations covering all aspects of Acetylene manufacture, storage, transportation and use will come into force in October 2014 – including an important new provision, making flame arrestors mandatory in oxy-acetylene sets.

Everyone will have heard horror stories about what has happened when acetylene cylinders have been involved in fires. Motorways, stations and railway lines have been closed down because a nearby fire involved acetylene. The infamous example quoted by Doug closed King’s Cross Station for a long period when four acetylene cylinders were in a fire eight storeys above ground on a nearby construction site. Following this event there was even talk of  the Mayor of London banning acetylene from the area under his jurisdiction. As a result, the BCGA and the London Fire Brigade co-operated to establish what could be done.

Any gas cylinder will explode if heated sufficiently in a fire. The material of the cylinder weakens as it gets hotter whilst the compressed gas expands and increases the pressure within. Steel cylinders will fail due to this combination of events at around 3000C. Cooling is an effective remedy, as it reverses both the weakening of the cylinder and the increase in gas pressure.

The good news is that gas cylinders are all heat-treated during manufacture so that, if they fail, they do so in a ductile fashion. They do not shatter into pieces throwing “shrapnel” around, but peel apart, releasing their contents relatively gently (though it’s not good to be close when this occurs).

Decomposition

The cause of the fear over acetylene is the process called ‘decomposition’. This refers to the splitting up of the acetylene molecule into solid carbon and hydrogen gas under the influence of heat. Decomposition is exothermic, that is it releases heat as it occurs, in much the same way as burning coal or other fuels in air. The reaction can therefore become self-sustaining once it starts, the heat from the process causing further gas to decompose, releasing yet more heat, and so on.

In addition to the heat, there is a significant increase in the cylinder pressure. The acetylene in cylinders is not held as compressed gas, rather it is dissolved under pressure in a solvent (normally acetone). The solvent is itself locked up in a porous ceramic foam material. The cylinder is therefore under relatively low pressure compared with, say, an oxygen or LPG cylinder.

However, when decomposition creates free hydrogen, this is gaseous. Being subjected to the heat generated during the process, this gas rapidly raises the cylinder pressure. So, whereas for other compressed gases removal of the heat and appropriate cooling removes the risk of explosion, this isn’t necessarily the case with acetylene. Stories abound of acetylene cylinders that have been removed from the heat of a fire exploding hours later without warning, or becoming hot again after being cooled. There have even been claims that physical shocks to hot cylinders have resulted in explosion.

As a result, fire brigades were establishing a 200 metre exclusion zone around any acetylene cylinders and either extinguishing the fire or removing the cylinders from it. The cylinders were then cooled with water for 24 hours whilst being kept under observation, only after which time could they be regarded as safe and the exclusion zone removed.

Temporary hazard zone

The investigations by the BCGA and the London Fire Brigade showed these stories to be inaccurate. Extensive and exhaustive research by reputable international bodies eventually confirmed that, in fact, all that is required is to cool the cylinders for an hour and then keep them under observation for a further hour. Decomposition cannot occur below 3500C and, as it occurs near the cylinder walls, it can be reliably detected by checking the cylinder temperature externally. If by this point there is no sign of the cylinders reheating through decomposition, they are totally safe. This shortened timescale means that creating a long-term exclusion zone is unnecessary.

Explosion due to physical shock alone to a cylinder which has not been fire-exposed was also shown to be impossible. To prove this, tests were even conducted in the USA which involved detonating 90g of plastic explosive attached to a cylinder.

A new fire brigade protocol was introduced in November 2012 and has been a great success. It requires the establishment of a temporary 200 metre hazard zone whilst the situation is assessed, not an exclusion zone. Cylinders should not be moved, but cooled where they lie, for an hour only. After a further hour under observation with no sign of heating by decomposition, they can be treated as safe.

Aside from saving fire brigade resources that can now be better deployed elsewhere, this also avoids the problems caused by the exclusion zones. The King’s Cross incident, for example, caused serious safety problems and delays at nearby London Underground stations due to the crowds of displaced passengers from the main line terminus. At  the same time, ambulances had to be diverted from their regular routes. These two examples alone show that there were probably greater risks to society at large from the exclusion policy than there might have been from the potential explosion. Add in the personal and business losses, and it can be seen that the changes of the new protocol will be very beneficial.

Gas equipment testing

Terry Askham of Truflame described the testing of railway gas equipment, referring to the relevant international, national and industry (particularly Network Rail) standards. He looked at the range of equipment used to carry out the CAL 501 tests, from a simple but properly calibrated pressure gauge through to comprehensively equipped test benches as used at his own company facility. Tests include leak tests, pull out tests on connections and axial load tests on flexible hoses, and delegates were shown details of each.

Terry then described the CAL 411 test applicable to Thermit welding pre-heaters, again looking at the test equipment and procedure.

Hazards of compressed gases

Another Terry, in this case Terry Broughton of Gas Safe, gave a thought provoking description of the hazards of compressed gases. He showed examples of typical dangerous situations, acts and equipment, and did his best to frighten everyone into going away to check their own circumstances.

Allowing combustible gas to leak, mixing with air to form an explosive mixture in a confined space, when the necessary spark is all that is needed to cause an explosion, is not a good idea. The potential results were illustrated graphically by Terry’s picture of what was once a mess room and store in a shipping container. Only 2% of gas in air is necessary!

Other bad ideas include oiling threads on gas fittings, failing to treat oxygen with the respect that it deserves as a potential cause of fires, the use of incorrect regulators, the misidentification of gases, the use of incorrect nozzles or other inappropriate equipment, and the use of incorrect gas pressures.

Containers and vehicles used to store or carry gases need sufficient top and bottom ventilation, together with the correct number and type of fire extinguishers. The appropriate gas data sheets should be available and used. Risk assessments and operating procedures should be produced, used and kept up to date. Equipment should be regularly tested and this should be documented. Replacement should be undertaken at recommended intervals.

Staff should be properly trained, equipped with relevant PPE and should know the appropriate emergency procedures.

Terry ended by saying: “Remember, what you permit, you promote”.

New vehicles

Network Rail’s Steve Duffy, Alan Forrester and Isaac Adjei demonstrated how their company is complying with many of Terry’s injunctions by supplying its welders with new vehicles for their work. The seven-tonne IVECO high roof vehicles, one of which was at the conference, are being fitted out by Bri-Star, the first time the two companies have worked together on such a contract.

The original remit was for a vehicle for a three person Thermit welding team, but this is now being adapted to cater for wider welding roles. The plan is to deliver 800 of these vehicles to the company’s teams, about 60 having been made available thus far.

The vehicles are equipped with load indicators which ensure that operators keep below the permitted load limit. Tail lifts are fitted for the safe loading/ unloading of heavy equipment. Network Rail has worked closely with VOSA (Vehicle and Operator Services Agency) over the introduction of these vehicles ensuring that they are registered in the category of ‘Special Vehicles/Engineering Plant’. This puts them outside of the EU regulations on drivers’ hours and operator licensing.

‘Genie’ oxygen cylinders

Piers Capper from hosts BOC introduced the company’s new lightweight ‘Genie’ oxygen cylinders. Using a thin steel cylinder wall reinforced by a carbon fibre wrap, and with a smart, tough HDPE (High-density polyethylene) outer cover, these 20-litre cylinders are 30% lighter than a comparable conventional cylinder and half the weight of a conventional 30-litre ‘BR’ cylinder.

Genie cylinders have digital displays which show both pressure and the quantity of gas remaining (as a percentage of full) and give alarms at 25% and 10% remaining. In July 2014, BOC will be able to fill these cylinders to 300 bar (currently only 230 bar is possible), increasing the quantity of gas that each can carry. It is estimated that whereas four or five welds can be made using the contents of a cylinder charged to 230 bar, the higher fill pressure will increase this to about seven (based on trials completed by Network Rail).

Five Network Rail sites have been using the new cylinders under a trial programme. They have proved very popular due to their reduced weight, good handles and digital displays, and none of the sites apparently wish to return to the old cylinders. There is admittedly some concern that the Genie is less robust than the BR type, and BOC will be keeping a close eye on this. They do consider that the cylinders are likely to be handled more sensitively given their lightness and this should ensure that damage is unlikely.

Weight lifting

The seminar closed with an interesting presentation from an organisation called Pristine Condition. Stuart Cruickshank explained that his company specialises in training companies and their staff in how to manually handle loads in a safe way.

The founder of the company was an Olympic weightlifter who became involved when a friend asked for his help. The friend had problems with manual handling injuries amongst his staff, and wondered why weightlifters handling far greater loads appeared not to suffer the same. From this discussion came a company that now has over 3,000 business clients around the world.

Stuart described such things as the importance of the weight of the torso when lifting, and how this weight means that someone may be injured just picking up a light object like a pen. Pristine Condition takes a realistic approach to the problem, engaging directly with the individuals involved. They can train people directly, or train company trainers, and they will produce training DVDs created in the client’s own environment.

They can focus on one activity at a time and train to eliminate the injuries it causes, making a bespoke DVD for each activity in turn. This might be done on the basis of one activity a month, starting with the worst problematic area and working through all in priority order.

Pristine Condition has a “tracker” system that gives managers and supervisors the knowledge to spot poor behaviours themselves and instruct staff in how to improve their technique. They will back up all of this with appropriate support visits to make sure all is going well. They claim unparalleled success with their unique approach to this ubiquitous problem.

Don’t try this at home…

As an aside, Doug Thornton made a brief appeal to people not to get involved, nor permit children to do so, with ‘amusing’ activities with compressed gases. He mentioned helium and carbon dioxide as examples of gases that get abused for fun, and he described the risks attached to things like ‘squeaky voice’ tricks with the former and fogged drinks with carbon dioxide. All very amusing when nothing goes wrong but tragic when someone dies from suffocation or loses their stomach through ingesting liquid gas.

Delivering an engineering advantage

As the drive to reduce the costs of maintenance and replacement components continues to gather pace, the demands on those who supply critical components become more stringent too. Rail operators and maintenance contractors are increasingly seeking to foster partnerships with companies which can guarantee product quality and availability, and an innovative approach based on deep market understanding which can drive performance improvements and reduce operating costs.

One example of this type of company is Norgren, a global market leader in pneumatic motion and fluid control which has more than 30 years’ experience in delivering a combination of high-performance products, innovation and technical excellence to the rail industry.

As simple as drying air

To understand how a company such as Norgren, which is backed by the global resources and expertise of the IMI group, can offer an ‘engineering advantage’, just consider the supply of compressed air. Moisture and other contaminants make operating compressed air applications very problematic in rail. Air dryer packages are widely utilised to clean and dry compressed air before it reaches critical downstream applications, such as brakes, door systems and pantographs.

Two air dryer types – membrane and desiccant – are currently used. Both have their problems when used in rail applications.

Membrane dryers use fibre tubes suspended between two columns to form a semi-permeable membrane, allowing water vapour to pass through to the low concentration outside.

To maintain lower moisture concentration on the fibre bundle’s exterior surface, much of the dry air produced is employed to sweep away collected water vapour into a small vent which releases it into the atmosphere. This sweeping action is continual so the membrane self-regenerates with no cycling, pressure changes or maintenance.

Membrane dryers are lightweight, have no external power requirement and create no dust. However, the fibres are susceptible to contamination and, if one fibre should break, others tend to follow, causing catastrophic failure.

With a life cycle of up to 24 months, membrane dryers require monitoring and replacement through regular maintenance schedules.

VR24Z [online]Desiccant dryers, on the other hand, adsorb moisture and contaminants using two canister towers or columns. These are filled with beads combining adsorbent material mixed with a clay binder, which is formed into spheres of various diameters.

Although tightly packed, train vibration causes the beads to rub together, eroding them and forming dust which can then contaminate the air and damage downstream equipment. An additional downstream filter is usually installed to collect dust near the dryer output, but this is not totally effective.

As the beads erode, they become less tightly packed, allowing more moisture-laden air to pass through gaps in the desiccant bed and flow into downstream equipment. Some manufacturers use a spring to compress the canister stopping the gaps between the beads – this can restrict air flow and cause a pressure drop, making the dryer work harder to push air through, reducing efficiency.

As the desiccant bed’s size reduces, it can become over-saturated, with the beads irreparably damaged. Depending on the application, desiccant air dryers have a life cycle between six and 36 months. The frequent replacements mean additional costs, extra maintenance (it is usually a two-person activity, sometimes requiring special lifting equipment) and unnecessary downtime.

There is a better way

Harnessing the best of existing desiccant and filter drying systems, Norgren’s latest generation of air dryers feature Adsorbent Media Tube (AMT) technology which employs a desiccant substance housed within

an extruded polymer tube. During manufacture, the desiccant crystals are mixed with the polymer – although the polymer plays no part in the drying process, its molecules are wider than the clay binding molecules found in a regular desiccant dryer, allowing moist air to get to the drying agent and be adsorbed more quickly. During regeneration, the moisture is removed just as quickly, leading to a reduction in air volume required for the purge cycle.

The polymer tubes are tightly packed into their housing, but are more uniformly shaped than beads, making them unaffected by vibration. This also means consistent air flow through the tubes, while the unit’s performance does not degrade over time. No clay component also means no dust.

AMT polymer tubes are extruded into a water bath during manufacture so they are essentially ‘born’ in water, meaning there will be no by-product or chemical reaction if they become saturated. The tubes are simply dried, returned to their original state and reused as normal, so no maintenance is required.

These new dryers are lightweight but also flexible, being mountable horizontally or vertically. Tests show they collect more moisture per m3 than traditional desiccant or membrane dryers. They also last up to six years or 18,000 hours in most applications, changing their status from regularly serviced items to major refurbishment items. With a considerably lower cost of ownership, they dry better to ensure a reliable flow of clean air to downstream applications, keeping the railway network moving.

And there’s more…

Having dried the air, Norgren also use it. Developed specifically for use with circuit breakers in electric rail vehicles, VR24Z solenoid valves are direct acting, fast response products delivering optimum reliability and safety for a range of applications including cam shaft contactors, line breaker contactors, vacuum and air blast circuit breakers and shoe gear controls. They have recently been specified by a major international rail operator which was experiencing issues with its existing technology.

Norgren’s approach was to modify one of its proven core technologies based on the specific application requirements, and then supply samples to the customer for testing and validation. These products met all specifications over a four-month live train test, resulting in a highly prestigious contract.

A pioneer in door control systems, another of Norgren’s innovations is a reduced force cylinder for external and internal door control. The cylinder has been developed to meet the needs of purchasers who are finding it hard – and often expensive – to source and service OE products. Already, these products have been specified by major train companies and suburban network operators.

So a dedicated rail sector team with good practical experience, such as the one at Norgren, can make a difference by developing and specifying items which are best suited to a railway application. And that’s how you can gain an ‘engineering advantage.’

Managing obsolescence

The increased use of electronic systems in rolling stock and rail infrastructure undoubtedly improves operational efficiency and safety for the rail operator as well as enhancing the passenger experience. For the rail engineer, however, these electronic systems come with the added challenge of managing obsolescence. Writes Stuart Broadbent

Most component and equipment manufacturers are focussed on their next-generation products and on emerging technologies. This reliance on research and development to provide new revenue streams means that today’s hot new products quickly become commodity and then legacy parts as the manufacturers follow timescales which are driven by fast- moving consumer markets.

Consider the mobile phone industry for example. Mobile-phone users will expect to upgrade their handsets every 18 to 24 months, whereas the planned lifecycle for rolling stock usually stretches to 30 or 40 years.

There is also a significant difference in the volume of units shipped to the consumer and rail industries. Analysts predict that global shipments of mobile handsets will reach 2.5 billion units in 2014. Compare that to the amount of components used in rolling stock, signals, rail infrastructure and passenger information systems and the difference in the production volumes of the two sectors becomes apparent.

The disparity in the expected operational lifetimes and the production volumes means that the focus for most manufacturers will be on the high-tech, high-volume markets rather than legacy, low- volume parts.

The expected lifetime of software also falls short of the life expectancy in the rail industry. Microsoft withdrew support and automatic upgrades for Windows 1998 after just 8 years and ceased support for Windows XP after 12 years.

As Figure 1 shows, the challenge facing rail engineers is to ensure the continued operation of electronic systems far past the point at which the manufacturers no longer produce or support the components within them.

Functional or technical

The types of obsolescence which need to be managed can be described as either technical or functional. In technical obsolescence, the correct operation of the equipment cannot be guaranteed because spare parts or technical support is no longer available from the manufacturer. Examples of technical obsolescence occur when a component manufacturer withdraws a legacy part in favour of one built on a newer technology, or when an industry-standard format evolves into a different footprint or data transmission moves to a different protocol.

In addition to the obsolescence of electronic components, the rail engineer may also have to consider the obsolescence of materials, such as asbestos, or changes in production tools and even 42907 [online]workforce skills. As older employees retire, the younger recruits may not have been trained on the legacy systems and technologies which are still operating successfully throughout the rail industry.

Functional obsolescence, on the other hand, occurs when the equipment cannot be adapted to meet new standards or regulations for issues such as quality of service and efficiency. Examples  of functional obsolescence include updated regulations for People of Reduced Mobility (PRM), increased use of the radio network resulting in limitations in capacity, or the lower processing power of a legacy computer being unable to support greater demand for sensor inputs or system intelligence.

Managing obsolescence

Whilst obsolescence will remain a daily reality for rail engineers, the risk, impact and cost of obsolescence can and should be mitigated if rail operators and asset owners are to recoup the investment in new equipment and systems. Obsolescence management falls into two categories: reactive management which occurs after an unplanned obsolescence event, and proactive management which aims to predict future obsolescence events and plans strategies to reduce the impact if and when each event occurs.

Reactive management techniques vary widely in both risk and cost. The lowest risk/cost scenario is to use existing inventory or to take advantage of a Last Time Buy (LTB) from the original supplier. If neither of these options is available, purchasing stock from the grey market can be a relatively low-cost option but will inherently increase the risk of buying components which are counterfeit or which have a higher failure rate due to incorrect storage conditions.

Finding an alternative component with the appropriate fit, form and function certainly minimises risk but could also incur the cost of a minor re-design. If none of these options is available, then a relatively high-cost complete re-design or reverse engineering may have to be considered.

A coordinated obsolescence management plan is essential for proactive management. It is also important to create a business-wide culture of obsolescence awareness, particularly in the R&D, engineering, maintenance and purchasing departments.

Proactive obsolescence management should start during the initial stages of product design. Here, the risk of obsolescence can be mitigated by making technology as transparent as possible and by undertaking technology assessments and risk-mapping. Figure 2 shows a typical risk assessment map. Anticipating and planning for upgrades and considering the road- map for each technology are also crucial.

When the product is in service, obsolescence should be monitored at component, product and system level. This is achieved by periodically reviewing the market for emerging technologies and generating a watch list of critical parts.

Sharing information and best practice

Membership of an organisation such as the Component Obsolescence Group provides opportunities to network with people from other companies and industries and to share information about best practice in both obsolescence management and counterfeit avoidance.

The quarterly COG meetings provide a mix of formal presentations and informal events at which obsolescence engineers, buyers and solution providers can exchange ideas on key issues such as REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals), conflict minerals and counterfeiting. The meetings also provide access to the latest tools and systems developed to reduce the administrative costs of obsolescence monitoring and management.

Alstom Transport has set up an obsolescence management service as a central function to support all of its businesses in rolling stock, signalling and infrastructure, and the associated service business – and Alstom monitors the obsolescence status of more than 75,000 components. Obsolescence services, including audits, monitoring and solutions, are offered to customers for both Alstom and non-Alstom equipment.

As an example, Alstom is currently developing a GTO gate drive for a major customer to replace a 20 year old product for which electronic components are no longer available. The new product uses Alstom’s original design knowledge combined with the latest technology to deliver a more reliable product.

A reactive obsolescence management strategy is appropriate for low risk sub-systems such as bogies, but a proactive Obsolescence Management Plan is needed to protect the most critical and vulnerable systems against the inevitable changes in technologies and software.

Effective obsolescence management also helps rail engineers to ensure that, throughout the rail industry, the operational lifetime of equipment can be extended far beyond the timescales supported by component manufacturers and software suppliers. So, despite the increasingly throw-away culture of consumer markets, the rail industry should still be able to measure the operational lifetime of its equipment in decades, rather than just years.

Stuart Broadbent is obsolescence director of Alstom Transport and member of the Component Obsolescence Group (COG) 

VAB RIP?

Over the past four years, the regulations and standards that govern the assessment of rail  vehicles have progressively changed. Traditional processes based on the accreditation of individuals as technical ‘experts’ (or signatories) have been liberalised to allow a more diverse approach, underpinned by robust management systems. This is paving the way for a more efficient, but equally safe, way of managing engineering change, but is the UK railway industry taking advantage of this?

A change in approach

Before 2010, engineering acceptance by an accredited Vehicle Acceptance Body (VAB) was the mandatory method of confirming that, before they entered service, rail vehicles conformed to UK technical standards. This applied to all types of rolling stock, including passenger, freight and on-track plant and machinery. To establish an industry standard, the Rail Safety and Standards Board (RSSB) created and managed the accreditation of VAB organisations and VAB signatories.

However, Group Standard GM/RT2000 changed in 2010, allowing alternative ways to provide certification for rail vehicle acceptance.

The process fundamentally relies on a competent entity assessing vehicle conformance with a prescribed set of standards. Under the interoperability regulations, this is the function performed by a Notified Body (NoBo) or Designated Body (DeBo) making these organisations now ideally suited to operate in the domestic rail vehicle certification market.

Accreditation of organisations to act as NoBos and DeBos (carried out in the UK by United Kingdom Accreditation Service) is based on a competence management system, rather than unique individuals; so is this a more efficient approach? If so, why are VAB signatories still in demand four years later? Why are so many organisations finding it difficult to move on? Is there uncertainty about the robustness of the standards? Are commercial arrangements lagging behind, using outdated service providers? Or is it because the benefits these changes can bring are simply not understood?

Efficiency and added value

Accreditation of certification bodies, based on rigorously tested competence management systems, allows an approach that’s more flexible and equally robust. Having more people with the required competencies distributed between them increases the reliability of service and reduces costs.

The competence management system can be shared across all certification activities, removing requirements to maintain (and accredit) multiple systems. Many believe that the resulting process is cheaper, more sustainable and just as safe.

Independent bodies – particularly those employing a diverse group of people – can also add value in areas such as compliance assessment with project requirements, general fitness for purpose and vehicle reliability.

The Network Certification Body (NCB) fully understands the fundamental role of a conformance assessment body in maintaining the safety of the railway system. While it is possible to use accredited individuals, NCB prefers to use the management system approach, to provide certification across the full range of vehicle types.

Customers need to have these services delivered efficiently. Using its detailed understanding of the regulations, NCB helps customers explore the best options, always recognising that the final decision must rest with the proposer of the change. In addition, in-built flexibility means that extra services can be added as part of a ‘package’, thus reducing the cost of the project overall.

Those interested in discussing these changes will be able to meet the NCB team at Rail Live 2014, being held at Long Marston, Stratford-upon-Avon, on 18/19 June 2014. For more information visit www.raillive2014.com 

Communications Based Train Control

Communications Based Train Control (CBTC) means different things to different people, so says Tom Lee from the Rail Standards and Safety Board who chaired a recent conference in London on the subject organised by Sagacity Media. The engineering / technical aspects are often not seen in the context of operations or passenger service and, whilst CBTC systems are becoming more widespread, they will never be a mass market offering such as road vehicles and public communication networks.

The mix of capacity and energy usage is crucial and far too many examples exist of trains transporting fresh air around for parts of the day. Availability and reliability go alongside safety and using proven technology is often best – being the second application might be preferable but remember someone has to innovate.

So what is CBTC, what does it offer and where are the shortfalls? A number of speakers attempted to provide the answers.

History, standards and broad perspective

David Dimmer, from Thales but working for European railway industry association UNIFE on its NGTC (Next Generation Train Control) project, started the conference off. He commented that, whilst most people associate CBTC with urban metros, it can also embrace ERTMS (European Rail Traffic Management System) technology, particularly where this will be used in high density urban operations.

The technology really began back in the 1960s with the opening of London’s Victoria line, but CBTC only became a recognised terminology in the 1980s. At that time it used track loops as the transmission method although radio became the natural choice in the 1990s.

CBTC consists of three elements – ATP (Automatic Train Protection), ATO (Automatic Train Operation) and ATS (Automatic Train Supervision). Attempts to standardise the functionality and technology have had mixed success. Results so far include:

  • IEEE 1474.1 – Functional and Performance Requirements
  • IEEE 1474.2 – User Interfaces
  • IEEE 1471.3 – Recommended Practice for System Design
  • IEEE 1474.4 – Recommended Practice for Functional Testing.

None of these are mandatory and fall way short of getting standardisation in equipment practice. The intended specification IEC 62290 ‘Urban Guided Transport Management – Command and Control’ has too large a scope, thus making little progress. The ModUrban project had an objective to create an interoperability specification but this was not achieved other than a definition of system architecture. Nonetheless the need very much exists and in New York, as an example, the operator has demanded inter-equipment testing from two suppliers.

The NGTC project started in 2012 with a budget of €11 million aiming to produce a European standard that embraces ATO, DTO (Driverless Train Operation) and UTO (Unattended Train Operation) requirements. Its 21 members comprise UNIFE, manufacturers, operators – including London Underground and Paris Metro’s RATP, the ETCS (European Train Control System) Users Group together with various universities and consultants. It sees a growing commonality between CBTC and main line technology, setting out tasks as a series of work packages. These include: technical coherence, common message structure, moving block requirements, IP-based radio communication beyond GSM-R and satellite train positioning (main line applicability only). The focus appears to be on merging ETCS and CBTC technology; perhaps not the right priority at the present time.

It might be concluded that CBTC is more a broad conception rather than a specified technical and operating system. This creates uncertainty  amongst both existing and potential users as to what type of system to choose and how much to specify.

The London Underground vision

LU has had a somewhat mixed experience of CBTC over the past few years. The first application (although not known as CBTC in those days) was the use of Automatic Train Operation in the 1960s on the then new Victoria Line. Designed in house, this was a world leader with the system lasting until 2012. Later implementations were not so smooth. The original intention to equip the Jubilee Line Extension prior to the Millennium went horribly wrong and it was to the credit of LU that a conventionally signalled fall back was designed and installed in record time. More recently the

Jubilee Line has been fitted with the Thales Seltrac system similar to that on Docklands. This project proved to be far from an easy upgrade and much press criticism resulted from the prolonged delay and periodic weekend line closures. The system now works well and, from the lessons learned, a similar technology is being installed on the more complex Northern Line. This project is going remarkably smoothly and will be complete by mid 2014 giving a 20% increase in capacity. Disruption to the public has been minimal, most people not even realising the work was progressing.

In parallel, the Victoria line has had its original ATO equipment replaced by the then Invensys Distance-to-Go radio system. This was uncharted waters as it was an upgrade from one CBTC system to another. Hugh Bridge, who works for LU on its Automatic Train Control programme, described the solution which was based around overlaying the new infrastructure upon the old, so allowing new and old trains to run together on the line. The conversion is heralded a great success  and a significant increase in capacity – 33 trains per hour – has resulted. Current reliability levels are 4,000 hours for train equipment failure equating to three per week.original [online]

More recently, however, the contract to equip the Sub Surface Routes (Metropolitan, Circle, H&C, District) with CBTC using the Bombardier CityFlo system has had to be abandoned. The reasons for this are unclear but sufficient to say the complexities of the layouts with many flat junctions and joint running with other lines, will stretch the technology of any system that is eventually chosen.

As to the future, George Clark, the engineering director at LU, gave the current view on CBTC system capability to fit in with future London requirements. Ridership is expected to increase by 26% between now and 2024. CBTC introduction will impact on track, train, power, ventilation, signalling, EMC, tunnel cooling, platform management, telecoms, information distribution, ticketing and internet linkage.

Put succinctly, the logical progression of a CBTC is Operating Concept » Functional Requirements » Systems Architecture » Physical Structure. Following from this comes:

  • Level of Automation
  • Change to Operating Philosophy and Rules
  • Migration Strategy (duplicate infrastructure or train equipment?)
  • Simulation and Provision of Test Track
  • Integration of Different Suppliers Equipment
  • Reliability Growth by both Technology and People.

Once the system is decided upon, there come the key decisions relating to standardisation, cost benchmarking, interoperability, interchangeability, maintainability, information from diagnostics
and finally obsolescence. The information opportunities from CBTC are enormous since there is a mass of inherent data. Using this effectively should enable more innovation to
be achieved plus obtaining better security of future infrastructure. The Piccadilly, Bakerloo, Central and Waterloo & City lines will all need CBTC technology within the next few years, so the challenge will be to deploy the best system design without encountering major engineering problems.

The Crossrail Challenges

Choosing the right signalling system for Crossrail is challenging since this railway has to interconnect with existing lines east and west of London, each of which will have its own type of signalling. Equipping the central core section has caused some serious heart searching; should it have a proprietary CBTC system or try to adapt from what will eventually exist on the outer routes?

Duncan Cross from the Crossrail team explained that, once the infrastructure is completed and the trains built, to then not having a reliable control system would be disastrous. Thus the decision is to provide a proven CBTC technology for the central section. This will ensure a 24 tph capability with 30 tph as a future prospect, plus a reliable interface to platform screen doors (PSDs). Two complications arise from this however:

Interfaces and changeovers will need to happen when the trains transit to and from the existing lines.

The trains must be equipped with all the signalling systems of the routes concerned. This will include: CBTC, TPWS, AWS, ETCS Level 2 and possibly the extant GW ATP system put in as a trial back in BR days. In the fullness of time, some of these can be removed once the main line sections are equipped solely with ETCS. Initially, however, the rolling stock will have to host a bizarre collection of signalling kit.

The alternative would be to adopt the Thameslink solution for the central core by using ETCS with an ATO overlay. The fact that this does not yet exist as a proven combination makes people nervous when so much is at stake. Thus the die is cast and at least functions such as the driverless reversal of trains at Westbourne Park will be a formality.

Canadian experience

Many countries have deployed CBTC systems. One of the first was Canada with the Vancouver SkyTrain. Since the opening of the 1986 Expo Line, many lessons have been learned. Ian Graham from British Columbia (BC) Rapid Transit described the Seltrac S40 technology with full dependence on the primary system and no axle counter train detection back up.

Being a ‘greenfield’ railway with no regional line interoperability made implementation easier but whilst trains were fully automated, removing a ‘driver’ was thought to be a step too far in terms of public confidence. Later line extensions have moved towards UTO but staffing levels are still considerable at stations since PSDs have not so far been provided. UTO offers many advantages as it minimises human error, eliminates rest time periods at end stations and offers an increased service frequency with less trains.

A system must be in place to handle train failures? Roving attendants are deployed who can get to trains quickly but provision of on-train intercom, alarm buttons and CCTV is part of the safety scenario. The current throughput of 108 seconds between trains (33 tph) is capable of being decreased to 80 seconds.

SkyTrain adopted linear induction motors for trains on the first lines but a later line has conventional AC motors. In comparison, the former offers better reliability. Understanding how well the system is performing is vital and Chris Moss, responsible for the systems engineering services, explained how the technology has progressed from the transmitting of simple fault codes that were printed out on paper, to trains that have continuous data logging on to a memory stick that then acts as a ‘black box’ recorder. An instrumented test train is timetabled to traverse all lines and continually check the health of all systems, including the linear induction propulsion.

French progress

From France, Dr Pierre Messulam, the director for innovation and research at SNCF, gave a pragmatic account of French ETCS progress, now running some eight years late. Testing software between different suppliers / countries and the braking characteristics of older rolling stock have been major problems, as has the high cost of retrofitting trains with ETCS equipment that already have TVM or KVB – these being train protection systems developed by SNCF.

Bug fixing has led to successive versions of the software. More recently, interference from public GSM networks into GSM-R has meant reliability problems on the radio link, which is a serious concern. Authorisation processes are slow and complex with national authorities having different requirements and procedures.

One positive outcome is that drivers are enthusiastic about ETCS, but degraded mode working needs a lot of attention and close co- operation with signallers. Ideally a simulator is the best way of training staff on how to handle emergencies.

Introducing CBTC is seen as essential to run more trains on the existing infrastructure since civil engineering enhancements are just too expensive, so said Said El Fassi, the technical director in SNCF responsible for system modelling. Optimising the interface design with existing infrastructure is vital, especially where more than one train service operates on the same line.

Station dwell times are crucial to performance and human factor studies are important in understanding this. Modelling can save enormous amounts of time in the future and enable a better understanding of both risk and interfaces for trackside and train interworking, operating rules, environmental considerations and maintenance policies.

A new innovation in Paris is project Nexteo, a joint RFF / RATP exercise to produce a control and communication system based on CBTC principles but capable of operating on main lines where there is high density traffic. This is being designed for a new mass transit line being built but will need to integrate with ETCS as well. Something similar to the Crossrail situation comes to mind.

Safety assessment and human factors

A big factor in introducing new CBTC systems is obtaining safety approval. Paul Cheeseman from Technical Programme Delivery Systems explained the processes. The need to independently assess systems by competent people not associated with the project is insisted upon and must focus on design, development and safety measures.

It should be risk rather than compliance based, as the latter does not necessarily mean being fit for purpose. Caution must be used in using standards to mitigate risk. Two elements prevail:

The Specific Application Safety Case (SASC)

Cross-acceptance from similar systems in use elsewhere can be relevant to the GASC and need to tease out the differences from what has been approved before. Getting a GASC is tantamount to having a ‘go anywhere’ ticket.

(4)CBTC [online]Whilst many CBTC applications will aim at DTO or UTO operation, some systems, particularly where main line running is required, will retain a driver. Designing the DMI (Driver Machine Interface) is a science in itself and the gap between technology and adoption needs to be understood. Elaine Thompson from Mott MacDonald explained some of the factors.

Full integration means everything on a single screen including controls and speedometer.

The likelihood of confusion where different types of Train Protection System are required is considerable. The choice between touch screen, soft keys or separate keyboard may be influenced by local preferences. Options are being evaluated on a Class 43 HST, with the results intended as important for when the cab design of Crossrail trains is finalised.

More than just signalling

In summing up, Alan Rumsey from Delcan in Canada pronounced that installing CBTC is much more than a resignalling project, it can be considered as a total line upgrade. It is essential to focus on the real ‘needs’ (capacity, trip times, flexibility, enhanced safety, automation, lower maintenance cost.) while challenging the ‘wants’ (historic practices, need for fall back system).

A migration plan to minimise service impact during implementation is important. Operators should start with what they want to end up with and work backwards, they shouldn’t work out the first stage first.

The train is key and integrated factory testing followed by trials on a test track is the best solution. A CBTC system may be regarded as a distributed computer network so it is essential to ensure there is a stable transmission network and reliable computer hardware.

At the end of a fascinating day, Alan and his fellow speakers had done much to dispel many preconceptions as to what CBTC really entails. It really has a part to play, in fact in many cases it is essential, in keeping high-density metro rains running.

Issue 115 – May 2014