Rail Engineer - Issue 166 - August 2018

by rail engineers for rail engineers

AUGUST 2018 – ISSUE 166

RESIDUARY

inspections TO CONTINUE

PHOTO: FOUR BY THREE

TUNNEL MANAGEMENT SWISS-STYLE Controlling traffic in the world’s longest rail tunnel means being ready for any eventuality in terms of both safety and operations.

BRIDGING THE SLR

DIGITAL RAILWAY

Turning Worcester’s southern link road into a dual carriageway led to extending the Battenhall bridge, an important rail crossing.

Exploring different ways of delivering the Digital Railway and clarifying the purpose of Traffic Management Systems.

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RAIL ENGINEER MAGAZINE

CONTENTS

14

Infrastructure

10 14 18 24 28 32

Feature

06 42 46 54 58

News New management at Network Rail and HS2, hydrogen, autonomous freight and driverless trains.

Future train radio – what’s possible?

Paul Darlington considers and explains Nokia’s plans for GSM-R, 4G, LTE and 5G.

Mark Phillips reports as Balfour Beatty takes over the inspection of redundant railway structures.

The Articulator Sandhurst has come up with a new way to manipulate lineside structures.

Bridging the SLR Turning Worcester’s southern link road into a dual carriageway meant extending the rail bridge over it.

Building a world heritage tunnel Adding a second tunnel bore to the Swiss railway that is a UNESCO World Heritage site.

Tunnel management, Swiss style Clive Kessell looks at how the Swiss manage operations and risk in the world’s longest railway tunnel.

New bridge on Bridge Street Cleveland Bridge replaced an old bridge in Newport to allow electrification to come through.

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The annual Stapleford trials David Shirres attended this year’s scorching and hotly contested IMechE Railway Challenge.

Transforming rail travel in the North East The S&C North Alliance replaced 19 dilapidated S&C units with new ones from Voestalpine VAE.

High Speed One renewals programme Chris Parker considers the actions needed when a highspeed railway starts to wear out.

64 42 36 38

Residuary inspections to continue

58

Digital Railway: delivering differently The University of Birmingham hosted a conference on Digital Railway deployment in CP6.

70

Traffic Management – clarity and purpose?

TMS is a lot harder to implement than first imagined, and means different things to different people.

Tunnel lighting comes of age Working in a tunnel gets a whole lot easier with battery-powered LED working lights from SMC.

Footbridges of the future?

Network Rail and the Royal Institute of British Architects launch a competition for footbridge designs.

Rail Engineer | Issue 166 | August 2018

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RAIL ENGINEER MAGAZINE

EDITORIAL

Attracting talent The National Skills Academy for Rail forecasts technical skills shortages in the rail industry of around 10,000 people over the next five years. This is a particular issue for signalling, telecommunications and traction and rolling stock, where forty percent of the workforce is aged over fifty.

Furthermore, the INCREASING pace of technological change requires new skills. For example, making sense of the vast amount of data generated by low-energy sensor networks, Building Information Modelling (BIM), and the integration of rolling stock, signalling and communications systems to successfully deliver the digital railway.

In addition, railways require sophisticated heavy mechanical and electrical engineering to propel and keep trains on the track at 200km/h and more.

Hence more technicians and graduates are required to meet this shortfall. This is a general issue for the UK engineering sector, which is estimated to require 87,000 engineering graduates a year over the next ten years. However, railways have a further challenge - they are perceived as oldfashioned, unexciting and problematic. This was illustrated by a Young Rail Professionals study that revealed that only eight per cent of graduates would consider a railway career.

Yet most railway engineers would consider their career to be satisfying as it offers fascinating challenges and the opportunity to work with great people, complex systems and awesome kit. If the industry cannot entice young engineers, costs will rise as expertise is imported and the investment programmes that will be needed to satisfy the ever-increasing demand for rail travel will be delayed.

Attracting talent is thus both an imperative and a challenge to which the industry must respond.

Engineers from the IMechE’s Railway Division responded by spending three days in the Leicestershire countryside to run their annual Railway Challenge at Stapleford.

Our report on this event shows how over a

hundred young engineers had to overcome demanding problems to enable their miniature locomotives to compete on various trials.

Although this was not without its frustrations, it offered the opportunity to put theory into practice, overcome real challenges, learn from others and have fun.

It’s difficult to think of a better way to attract talent to the industry. Those who organised and ran this event are to be commended, as should be the companies who entered teams or sponsored them.

With plans to expand the competition from ten to thirty locomotives, there is scope for much greater industry participation. It would be good to see some more well-known companies participating in next year’s Railway Challenge.

The skills demonstrated by those at Stapleford included coding software for Arduino processor boards, using an automotive CANBUS network to link microprocessors without a host computer and integrating traction, energy recovery and braking systems. Such skills are needed throughout the industry, including the digital railway programme.

Making the digital railway programme a success is the subject of Paul Darlington’s report on a two-day conference hosted by the Railway Industry Association, Network Rail and the University of Birmingham. Much of this related to contractor engagement and procurement strategy relating to infrastructure work. However, despite the emphasis on the total railway system, there were few train operators or rolling stock providers present.

The expanding digital railway will also significantly increase wireless data flows.

As we explain, this is one reason why GSM-R will need to be replaced with a new telecommunication system which is likely to involve LTE, 3GPP, 5G, mMIMO and ReefShark.

Clive Kessell has also been to a digital railway conference, this one about Traffic Management Systems (TMS). His report shows that TMS can be successfully

implemented, although it is a lot harder to do than many first thought, and that TMS means different things to different people.

Traffic management is an essential feature of the 57-kilometre Gotthard base tunnel’s control system, as we describe. In another Swiss tunnel feature, Clive considers why and how a new tunnel is being bored alongside the existing six-kilometres-long metre-gauge Albula tunnel, which is expected to open in 2022.

As well as tunnels, we feature bridges small, large and redundant. Nigel Wordsworth reports how Network Rail has launched a footbridge design competition, in conjunction with the Royal Institute of British Architects. On a larger scale, we explain how a new 1,500 tonne-underbridge was built off-line and then put in place so that part of the Worcester by-pass could become a dual carriageway.

Inspection of redundant bridges, and other structures on closed lines is now the responsibility of Highways England. Mark Phillips explains why and how this work is managed.

With Britain’s only high-speed line now fifteen years old, it’s time to think about its track renewals strategy. As Chris Parker explains, HS1 presents different challenges from conventional track renewals, although renewing track on low-speed lines can also present significant challenges, as illustrated by our report on the nine-day blockade to renew Newcastle station’s south junction.

As shown above, this month’s Rail Engineer offers its usual variety of features that we think paint an impressive picture of railway engineering. Hence, we would ask that, once our readers have read the magazine, they do their bit to attract youngsters to the industry by passing it on to a budding young railway engineer.

RAIL ENGINEER EDITOR

DAVID SHIRRES

Rail Engineer | Issue 166 | August 2018

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6

THE TEAM

NEWS

Editor David Shirres david.shirres@railengineer.uk

Production Editor Nigel Wordsworth nigel.wordsworth@railengineer.uk

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Engineering writers bob.wright@railengineer.uk chris.parker@railengineer.uk clive.kessell@railengineer.uk collin.carr@railengineer.uk david.bickell@railengineer.uk graeme.bickerdike@railengineer.uk grahame.taylor@railengineer.uk lesley.brown@railengineer.uk malcolm.dobell@railengineer.uk mark.phillips@railengineer.uk

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paul.darlington@railengineer.uk peter.stanton@railengineer.uk stuart.marsh@railengineer.uk

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Rail Engineer | Issue 166 | August 2018

All change at the top Network Rail has confirmed the date when chief executive Mark Carne will hand over the reins to his successor.

Andrew Haines, currently chief executive at the Civil Aviation Authority, will take over on 14 August, the day after Carne retires. Carne will remain a Network Rail employee for a short duration, however, as he continues working on his CP6 funding settlement commitments until early September.

It was announced earlier this year that Mark Carne, who joined Network Rail in 2014, would retire and that Andrew Haines would take his place for the next five-year control period, which begins in April 2019. Andrew is no newcomer to the rail industry, being a former managing director of First Group’s rail division and managing director of South West Trains.

Meanwhile, another former chief executive of Network Rail, Sir David Higgins, leaves his current post as chairman of HS2 on 1 August to be succeeded by Sir Terry Morgan, who has been the chair of Crossrail since 2009.

Announcing the move, Transport Secretary Chris Grayling said Sir Terry’s appointment will ensure the project shall continue to have “world class leadership”.

He added: “His wealth of experience and expertise, demonstrated in numerous

leading roles including overseeing the ambitious Crossrail project, as well as his respected reputation and enthusiasm, will be invaluable in the project’s continued success.

Sir Terry Morgan responded: “It is a privilege to take up this crucial role with HS2 - a railway that will help transform this country through better connections for over 300,000 passengers every single day.

“HS2 will be a driving force behind greater prosperity and productivity across the country, unlocking opportunities for growth and regeneration and building a transport network fit for the future.”

Sir Terry Morgan.

NEWS

coming soon...

SEPTEMBER 2018 / MARCH 2019 SIGNALLING & TELECOMS Three of Rail Engineer's writers specialise in this complex field that keeps the railway running and will provide the key to increased capacity and safer running in the future: Barriers, Broadband, CCTV, Displays, Driverless Systems, Equipment, ERTMS, GSM-R, Gantries, Hazard Warnings, IP Networks, Information Systems, Level Crossing Surfaces, Loudspeakers, Operating Systems, Protection Systems, Radio, Resignalling Schemes, Signalling Power, Software, Training, Warning Systems, WiFi

Hydrogen trains to enter service The introduction of hydrogen-powered trains into passenger service is now very much closer after the German Federal Railway Authority (EBA) has approved Alstom's Coradia iLint for use on Germany's railways.

Alstom signed a contract with the transport authority of Lower Saxony (LNVG) for 14 of the hydrogen fuel cell passenger trains, as well as 30 years of maintenance and energy supply, in November 2017. Now, EBA president Gerald Hörster has presented the train maker with the certificate of homologation at the Federal Ministry of Transport and Infrastructure, Berlin, on 11 July.

Following approval by EBA, prototype Coradia iLints will now enter pilot operation on the Elbe-Weser network. Passenger service is scheduled for late summer.

German rail minister Enak Ferlemann, who was at the

homologation ceremony, said: “This is a strong sign of the mobility of the future.

“Hydrogen is a true lowemission and efficient alternative to diesel. Especially on secondary lines, where overhead lines are uneconomic or not yet available, these trains are a clean and environmentally friendly option. That is why we support and promote the technology, in order to bring it to the surface.”

Alstom vice-president of research, development and innovation Wolfram Schwab added: “This approval is a major milestone for the Coradia iLint and a decisive step towards clean and futureoriented mobility.”

OCTOBER 2018 / APRIL 2019 ROLLING STOCK & DEPOTS With trains and their systems becoming ever more complicated, Rail Engineer’s specialist writers cover everything that improves performance, increases efficiency, and keeps customers happy: Components, Condition Monitoring, Depots, Equipment, Fuel, Inspection, Interiors, Lifting, LightRail Vehicles, Lighting, Maintenance, New designs, Passenger Information & Entertainment, Refurbishment, Train Washing, Tram-Train, Underground Trains, Wheel / Rail Interface

NOVEMBER 2018 / MAY 2019 PERMANENT WAY Twice a year, Rail Engineer considers the elements that make up the permanent way – rails, sleepers, clips, pads, ballast and even the make-up of the embankment on which the track sits.

Ballast, Excavation, Fastenings, Geotechnical, Grinding, Installation, Lifting, Lighting, Maintenance, Milling, On-track Machines, PPE, Piling, Plant Hire, Plant Maintenance, Rail, Rail Handling, Repairs, RoadRail Plant, S&C, Site Access, Sleepers, Soil Nailing, Structures, Tamping, Welding

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London – November 2018

Rail Engineer | Issue 166 | August 2018

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NEWS

Autonomous freight While discussion continues as to one-man passenger operation, leading global mining group Rio Tinto has successfully delivered 28,000 tonnes of iron ore by an autonomous train in Pilbara, Western Australia.

The shipment marks the first delivery of iron ore by a driverless train. It is the latest milestone in the multinational mining corporation’s A$940 million, six-year AutoHaul project to establish the world’s first heavy haul, long-distance autonomous rail operation.

Travelling the 280km distance between Rio Tinto’s mining operations in the town of Tom Price and the port of Cape Lambert on 10 July, the train, which consisted of three locomotives, was remotely monitored from Rio Tinto’s operations centre in Perth more than 1,500km away.

Locomotives carrying AutoHaul software are fitted with on-board cameras allowing them to be monitored remotely. Reports are automatically generated from on-board driver

modules that relay the locomotives’ exact position, speed and direction of travel to a central control centre.

The system uses a solution from Ansaldo STS, which is based on ATO over ETCS Level 2 (GoA4).

All level crossings on the network have been upgraded and fitted with CCTV cameras. Rio Tinto said it is working with its train drivers during this transition period to prepare them for “new ways of working”.

Ansaldo STS president for freight Michele Fracchiolla described the milestone as a “major turning point for heavy freight rail operators globally”.

He added: “One only needs to refer to the degree of change that the introduction

of driverless metro has had on mass transit operations in the passenger sector to gain insight into the potential impact that autonomous freight rail management solutions may have in the heavy freight and resources sector.”

In total, Rio Tinto operates around 200 locomotives on more than 1,700km of track in Pilbara, transporting ore from 16 mines to four port terminals. The average return distance of these trains is around 800km with the average journey cycle - including loading and dumping - taking around 40 hours, according to Rio Tinto.

Rio Tinto estimates that the system will be completed by the end of 2018, unlocking “significant safety and productivity gains”.

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NEWS

Driverless trains?

At a time when UK unions are fighting the replacement of the guard on commuter services with a train manager, German railways are looking to go one stage further.

Deutsche Bahn (DB) is to work with Siemens to automate one of Hamburg’s S-Bahn lines as part of a wider programme of digitisation across the German rail network.

A 23km section of Line 21 between Berliner Tor and Aumühle stations will be used to trial an automated service on the S-Bahn in 2021, when Hamburg will host the World Congress for Intelligent Transport Systems (ITS).

Four trains will be equipped for automatic train operation (ATO) overlaid on ETCS Level 2. A driver will remain on board during the trial and will intervene if required.

DB, Siemens and the city of Hamburg will share the estimated €60 million cost of the project. The long-term goal is to automate the entire Hamburg S-Bahn.

Siemens is, of course, no stranger to the

use of ETCS level 2 with an ATO overlay.

This is just the technology being pioneered on the central core of Thameslink in the UK. However, train operator GTR has not announced any plans to use the technology for a driverless system - the trains will still operate under non-ATO conditions outside of the central core, so drivers would be needed there in any case.

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Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE

RESIDUARY

inspections TO CONTINUE MARK PHILLIPS

W

hen British Rail was privatised in 1994, ownership of the operating railway infrastructure passed to Railtrack and subsequently (in 2002) to Network Rail. However, those assets that related to closed lines, redundant bridges and tunnels, abutments, cuttings and viaducts, together known as the Burdensome Estate, first of all stayed with the British Railways Board and then, in 2001, were transferred to the British Railways Board (Residuary), a wholly owned subsidiary of the Strategic Rail Authority.

When the SRA was dissolved in 2005, BRBR passed to the Department for Transport. It was then split up in 2013, with the bulk of its 3,800 assets, including 74 listed structures, passing to the Highways Agency Historical Railways Estate.

Inspection requirement

Lune viaduct, Cumbria.

With ownership passed the responsibility for inspecting and maintaining the structures, which are geographically widespread throughout England, Scotland and Wales, but not Northern Ireland. To manage the examination of this estate of structural property, new contracts were awarded by Highways England during 2015, dividing the workload into four lots, North, West, East and South. The first three of these were won by Carillion, while the South zone contract went to Balfour Beatty.

Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE Every structure was to be given an annual visual examination. Tunnels are subject to a three-yearly detailed examination while all other structures have one every six years. Both visual and detailed examinations could be more frequent because of special circumstances or the need for more regular observation and/or monitoring.

With Carillion going into liquidation, responsibility for the whole estate was passed to Balfour Beatty, a company that had a wealth of experience as, in addition to the 2015 contract, it had actually been involved in delivering the southern area since 2003, examining an estate of non-operational structures over an area broadly south of a line between the Severn estuary and the Wash.

Richard Storey, Balfour Beatty’s examining engineer, told Rail Engineer that his existing team set about convincing senior management that taking over responsibility for the whole country would be well worth doing. It also allowed the business to provide secure employment for former Carillion employees who had been affected by its receivership in January 2018.

Balfour Beatty inherited a system, back in 2003, which produced paper examination reports with glued-on photographs. This was rapidly changed to an all-electronic reporting process within six months of commencement.

Since then, the company has lobbied for the use of a web-based data management system, having used one successfully with Network Rail

PHOTO: FOUR BY THREE

Lune viaduct, Cumbria.

PHOTO: FOUR BY THREE

Inspecting Castlefield viaduct, Manchester.

PHOTO: FOUR BY THREE

Rail Engineer | Issue 166 | August 2018

INFRASTRUCTURE Resourcing

PHOTO: FOUR BY THREE

Inspections of Wath Road tunnel, West Yorkshire, now have to be conducted from a boat. required data and gives a set of prompts to ensure that there are no omissions.

Furthermore, in respect of difficult access structures such as confined space examinations, Balfour Beatty will undertake a rigorous assessment and, when safe to do so, will undertake the examination supported by a full rescue team.

as a JV partner delivering the Structures Assessment Contract in the South (200409). Highways England has recently adopted this type of data management system and the real time review of reports is now fully available.

Photographs and forms This facility has been augmented with the use of both static photography and video capture of significant defects which require elevation or fast-track action.

Balfour Beatty uses helmet cameras to assist in this process and augment the client understanding of specific areas of concern, such as structures working under load.

The helmet camera also provides a hands-free, safe method of capturing the data often from remote and difficult to access locations.

In addition, the Balfour Beatty team has also developed a standard drop-down form for visual examinations. This allows for the quick capture of information using prompts in a standard template, uploaded onto a tablet-type computer.

One of the largest risks for the client, as asset owner, is the potential failure of parapets due to accidental loading from vehicular traffic. Balfour Beatty has developed risk assessments with Highways England and other suppliers and these have progressed from a qualitative view of traffic, structure condition and location into a rigorous quantitative assessment, which has now been adopted.

Whilst the previous assessments produced a low/medium/high risk output only, the current one measures traffic flow, the robustness of each parapet, the road alignment, the areas affected by flying debris and the consequences of impact driven by these factors. Balfour Beatty has gone on to develop its own easy-capture data sheet, which allows the examiner to quickly and efficiently record all the

Stakeholder management One of the key factors in delivering an intense programme on time has been excellent communication. Identifying key issues in the programme, whether it is safety, environmental or even access, is vitally important so that the structures are examined in time.

Keeping key stakeholders such as Network Rail, local authorities, highway and river authorities, as well as the general public, informed on how the examination of a structure will be delivered has provided the platform for success.

Balfour Beatty’s approach to collaborative working has provided the tools to the examinations team to undertake early engagement on critical issues, and this will continue to be an important instrument as it goes on to deliver a national programme of detailed examinations.

PHOTO: FOUR BY THREE

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Rail Engineer | Issue 166 | August 2018

The existing staffing for Balfour Beatty’s original contract was three examiners, a technical administrator and an examining engineer. With the additional areas taken on, the company is working towards increasing this to 17 as soon as possible.

Although it would have been good to inherit the Carillion staff, with their experience and local knowledge under their stewardship, this was not possible as the TUPE (Transfer of Undertakings Protection of Employment) Regulations were not applicable in this case as Carillion had made its staff redundant.

Fortunately, however, it has been possible for Balfour Beatty to re-recruit nine of the former Carillion staff - six examiners, a tunnel engineer, a senior structural engineer and a programme coordinator.

In taking on the new staff, one of the early challenges for the team has been to induct everyone into Balfour Beatty ‘thinking’ - especially the safety culture.

Also, there has been a thorough review of competencies.

Because a high proportion of the examiners’ time is spent on site as lone workers, the Skyguard system is used.

In the event of an examiner suffering an accident or sudden illness, this system allows help to be summoned, with GPS accuracy for the location of the casualty.

By June, most of the required extra staff had been recruited, inducted, kitted out with vans, phones, laptops and PPE and were ready to go, with only a couple of vacancies left to fill. In effect, it has actually only been a matter of a few weeks now since the resources have been fully in place to get back up to speed with the examinations. There will obviously be some catching up to do throughout this contract year.

Partington viaduct, Cheshire.

INFRASTRUCTURE Results of an inspection using a drone, Pensford viaduct, Somerset.

Innovations It is worth mentioning some innovations that Balfour Beatty has introduced, one relatively simple, the other more sophisticated and undergoing successful trials.

First is the introduction of a digital camera attached to an elongated ‘selfie stick’, enabling examination of, for example, the spandrel walls of a viaduct, not otherwise easily visible at close range without scaffolding, a hydraulic platform or roped access.

The other promising development is in the use of a drone to fly alongside a large structure and take photographs at defined 3D coordinates that can then be exactly replicated on subsequent inspections, making it feasible to track changes in the structure’s condition. So far, this has been trialled at Pensford Viaduct on the closed Frome-North Somerset branch line.

Extension to other work Experience on this contract will undoubtedly be put to use on other parts of Balfour Beatty’s workload. For example, the long-closed Rhondda Tunnel in South Wales (issue 160, February 2018) is being considered for possible reopening as a cycle route. The tunnel, which has

PHOTO: FOUR BY THREE

In commencing work nationally, Balfour Beatty has found some significant differences from its original South lot.

Firstly, the population of the structures in terms of the mix of types is different. Also, very few of the structures in the South are in urban areas, whereas there is a higher percentage elsewhere.

On the other hand, of course, in the three new lots, there are many more structures in fairly remote locations.

Overall, these effects have meant that the planning resource required is bigger than simply a pro-rata adjustment.

Apart from the Balfour Beatty examination team’s original base at Redhill, Manchester and York are being used as regional centres. Other staff operate largely from home.

The transfer has gone smoothly. Dave Parker of the Historical Railways Estate commented on the early success of this contract transfer: “Highways England is extremely thankful to Balfour Beatty for rising to this significant challenge at short notice.”

PHOTO: FOUR BY THREE

Initial findings

been sealed shut since 1980, cannot be considered for re-opening until ownership is transferred to a Welsh Government body. This requires an understanding of the tunnel’s condition and maintenance liabilities to justify a change in ownership.

Work included replacing the cap on the sealed ventilation shaft with a hatch to allow Balfour Beatty experts to be lowered daily 20 metres down the shaft before they could carry out their examination. This lasted six days and consisted of a tactile inspection of almost two miles of the tunnel’s sidewalls, haunches and crown using mobile access towers and long tapping poles to verify the condition of the structure throughout.

The examination also addressed potential methods for the rectification of any defects to build a full understanding of the works required to make the tunnel suitable for re-opening. Now the examination team is assisting the technical services department in setting up remote monitoring of a ‘hinge’ fracture which is 1,000 metres from the nearest access, one of the tunnel shafts.

Rhondda Tunnel Society project secretary Tony Moon commented: “Balfour Beatty has been working in harmony with volunteers from the Rhondda Tunnel Society and we are thrilled as the examination work marks a significant step in the tunnel’s reopening. We are looking forward to the completed report that will help convince the Welsh Government that this Victorian masterpiece can be restored to become a major attraction to cyclists and walkers.”

Inside Rhonda Tunnel and its newly cut access.

Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE

The Articulator a new way to manipulate lineside structures

T

he modern world of rail is full of increasingly complex shapes, yet the technology used in handling these awkward and weighty

items has been very limited to date.

Slings, chains, hoists and ropes are all still used trackside for the handling and placement of masts, with or without complex gantry and crane systems.

It seems bizarre that, in 2018, the rail industry is still using such primitive methods to lift sections and structures.

From a health and safety point of view, having human beings underneath or in the vicinity of enormous and potentially lethal long swinging masts is far from ideal. So the industry needs a more scientific, safer and more economical way of handling these masts and structures.

Simple manipulation Sandhurst has been in the excavatormounted attachment business since 1979, trading at first in hydraulic attachments and then renting them out.

One of the founding companies of the sector, it has remained at the forefront of this new technology. The Sandhurst name is now synonymous with attachments and, over the years, the company has developed a strong relationship with the rail industry, carrying an extensive inventory of rail equipment reflecting its customers’ needs.

Tim Dean, the company’s CEO and founder, told Rail Engineer: “Sandhurst is extremely involved in the rail sector and will continue to develop it.”

He pioneered and encouraged the use of manipulators in rail engineering and maintenance, and the manipulator concept has now become a popular attachment for the accurate positioning and safe handling of stanchions, signal posts and more. However, the products currently available are limited by their

Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE design, to square and oblong sections up to 3.75 tonnes, or round sections up to 1000kg.

In addition to these restrictions on the shape and size of the items being handled, customers also reported volatility in responsiveness, which Sandhurst identified as being caused by the number of hydraulic cylinders and their poor performance in co-ordination. There have also been problems with safety lookouts in the existing offerings, which make operators wary of using them.

Design brief In response to these reports, Sandhurst set its engineering department a challenge two years ago, with a design brief to explore a next-generation manipulator with much more flexibility than anything seen before. Engineering director Neil Beard explained that the brief was to develop a product that could handle a multiplicity of forms, from square to circular to tapered, for carriers such as excavators and truck cranes with the capability to articulate and position loads up 5000 kg WLL (working load limit).

Just taking the capabilities of various manipulators and combining them into one tool would, in itself, have represented a significant advance, but Neil wanted to go further than that.

To pick up irregularly shaped items, the clamping elements would need to be independently actuated. Sandhurst’s engineering team began by sketching out different ideas, looking at how the legs should actuate in varying scenarios. The model they decided to run with would have three independent actuations - two leg pairs and a central ram - which would perform separately but combine to grab the work piece. Paired with this grabbing and clamping flexibility would be a tilt rotator, giving 360° rotation and tilting through 100° left and right.

The design brief’s working load limit (WLL) meant that the team would need to complete finite element analysis (FEA) on components to ensure each would cope with static loading to 5,000kg.

Further FEA and duty cycle testing was undertaken to ensure the durability of all components, including the moving parts.

Although the grades of steel to be used were an important factor, as were the fabrication procedures that would be employed, intelligent design ensured that the attachment itself as a whole was both strong enough and load sensitive.

Rail Engineer | Issue 166 | August 2018

INFRASTRUCTURE With the manipulator attachment counting as part of the load on the machine, any weight saved would naturally increase lifting capacity. As a result, the geometry was optimised to ensure maximum durability and rigidity while saving weight. The final product would weigh in the order of 1,350kg, meaning that a structure weighing 3,650kg could be lifted and manipulated given an overall WLL of 5,000kg. In practice, this lifting capacity would vary depending on the radius in each particular case.

To allow for careful handling, the clamping pressure would need to be adjustable within reasonable limits.

Successful demonstration The result of all this work is the Articulator 5000, a prototype of which was demonstrated to potential customers recently. With just two circuits, it’s an elegantly simple plug-and-play solution.

Safety was a crucial factor in the design work. The failsafe is that the legs won’t move without a positive electrical current, so, if there’s a power cut, the legs won’t move. This means that, whatever the present situation in the workplace may be - whether an item is held or the Articulator is empty - it will be maintained.

What’s more, an anti-burst valve is placed as close to the central pad’s cylinder as possible, so that, if there’s any change in hydraulic pressure, the legs will not move.

Fitted to the unit are two electronic spool valves that are actuated by a control box which sits inside the cab and is fitted with both a visual and audio alarm. This confirms that the clamping element can then be activated.

Cost efficiencies and time savings are likely to be substantial, considering that to erect and place a single stanchion is currently very labour intensive. With masts for new lines being placed at 15 to 18 metre intervals, the use of a tool like the Articulator could increase efficiencies dramatically, with placement possible in a matter of minutes.

The Articulator can be seen in action at the Sandhurst website, and has its own site, r-tick.com, where it is shown lifting long steel sections, awkward uneven and weighty structures and cumbersome concrete pipes.

Demonstrated at a recent industry event, the Articulator drew a crowd of enthusiasts, with Neil Beard pleased to hear from rail industry colleagues that it was a very “well thought out” piece of equipment. Rail professionals were quick to spot the potential of the Articulator for multiple applications including electrification, the handling of stanchions and timber baulks, and placing concrete piles and pipes. At the same time, professionals from other sectors enthused over its potential for use in such areas as drainage and in erecting highways’ lighting structures.

Testing and approval As the Articulator 5000 continues to go through comprehensive pre-production testing, including proof load testing and duty cycle testing, Sandhurst is reporting an overwhelming response to its website and advertising of the Articulator 5000.

“There’s a sense that something like this is long overdue and I think a feel-good factor that an innovation like this, which will be so useful in rail and other sectors globally, was designed in Great Britain,” said marketing director Louise Dean.

“Within two weeks of posting, we had close to 20,000 views of our film of the Articulator in action on LinkedIn, with comments from our friends in rail that it looks very impressive indeed.

We’re really looking forward to showing it at work to those who have been in touch and have suggested to prospective customers that they get in touch with us in advance of our demonstration day to let us know what they’d like to see it lifting.”

Sandhurst is inviting all who have displayed their keen interest, of whom there are many in all sectors, to a live demonstration day shortly after production begins. The venue will be courtesy of the Rail Alliance, which Network Rail will attend as part of its approvals process.

Looking forward, there are plans for further models of Articulator, to handle smaller and larger weight classes and a cantilevered version for suspension from cranes. There will also be an ‘inclinometer’, for accurate positioning in the vertical or inclined planes. A dual-axis monitoring system, with a visual, cab mounted display, will ensure perfect placement of the loads handled which will be monitored from the operator’s position inside the cab.

Tim Dean was keen to make the point that, as always, Sandhurst will be driven by its customer needs. “We listen to our customers, and provide solutions,” he said.

Certainly, the Articulator represents a big leap forward for safe and precise handling, trackside or otherwise.

Rail Engineer | Issue 166 | August 2018

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NIGEL WORDSWORTH

Bridging Extending the Worcester’s SLR Battenhall bridge

T

he A4440 Worcester Southern Link Road (SLR) is an essential part of Worcestershire’s strategic road network and provides an important link between junction 7 of the M5, South and West Worcester, Great Malvern, the wider Malvern Hills district, Ledbury, Upton and Herefordshire.

An important bypass to the city centre, the SLR is used by well over 30,000 cars each weekday and provides one of only two road crossings of the River Severn in Worcester City. It therefore offers an important, alternative route to the city centre, which would otherwise suffer from congestion.

To improve capacity, and therefore reduce journey times and improve journey time reliability, the local Highways Authority, Worcestershire County Council, devised an overarching scheme to dual the busiest stretch of the SLR between the M5 and Powick. This scheme is being delivered in phases and includes a new bridge over the River Severn as the final phase of the scheme.

The scheme also called for a railway bridge, which carries the North Cotswold line between Paddington and Worcester, to be extended at Battenhall to enable dualling of this part of the SLR. Once this phase of the scheme is completed by spring 2019, two northbound lanes will then go under the original bridge and two southbound lanes under the new, extended part of the bridge.

To minimise disruption to traffic, the plan was to build the new bridge off-line a short distance from its final position, and then to move it into place using a selfpropelled modular transporter (SPMT).

Rail Engineer | Issue 166 | August 2018

Planning the works Principal contractor for the scheme was Worcestershire County Council’s term civil engineering contractor, Alun Griffiths, working in conjunction with the council’s term design consultant, Jacobs.

The council’s term rail consultant, SLC Rail, was engaged to manage the project and Tony Gee and Partners brought in as the Category 3 Independent Checker for the bridge design, based on the client’s evaluation criteria that included capability, quality and financial assessments.

Specialists from SLC Rail negotiated the third party underbridge agreement with Network Rail and facilitated the design approval, reviewing and providing feedback to the designers before final submission.

The team of project managers from SLC Rail, contractors and Network Rail’s asset protection personnel carried out extensive risk assessments on sufficiency of time, manpower and machinery as well as to ensure completion within the designated blockade possession time.

Having completed the check of the bridge design, Tony Gee was engaged

by Alun Griffiths to undertake a series of temporary works designs for the bridge construction. The vast majority of designs required technical approval from Network

INFRASTRUCTURE Rail, with Tony Gee also acting as the contractor’s responsible engineer for the temporary works designs.

The series of temporary works designs included the complex analysis of the existing bridge to determine the effects on the structure during construction of the new bridge. This included finite element analysis of the anticipated ground movements and their effect on the existing bridge during construction, analysis of the effects of the above movements on the existing bridge structure and the design of multiplestrand ground anchors to retain the north abutment as the railway was being rebuilt around the repositioned structure.

The concern was that the differential loading on the existing bridge, which would result from the excavation of fill to the south abutment, could lead to movement in the structure. One solution could have been to excavate the northern abutment as well, to ‘balance’ the forces and remove the risk of movement. However, it was decided that the best option was to install ground anchors, effectively ‘pinning’ the northern abutment in place and obviating the need to temporarily excavate the northern abutment.

The analysis determined both the predicted and allowable movements of the existing structure with the anchors in place. Limits were set to ensure that the structure would remain within serviceability criteria. Contingency limits were also determined, in addition to contingency measures to be implemented should limits be exceeded. Movements

were predicted at various stages throughout the construction sequence for comparison against actual values during the blockade, when the movements of the existing structure were captured using an automatic total station, tilt and strain gauges with data uploaded in ‘real time’ to an online platform. This enabled the Tony Gee engineers, on site throughout the blockade, to continuously monitor the movements against the predicted figures as construction proceeded.

Throughout the blockade, the bridge movements all stayed below predicted levels and well within limits.

As the installation of the temporary works would impact the existing bridge capacity, both during and following the works, Tony Gee also undertook an assessment of the structure to demonstrate that it would still achieve the required capacity.

Closure and blockade Prior to the blockade, the route of the new southbound carriageway was excavated and levelled, apart from one ‘embankment’ section on which the railway sat undisturbed. Once the new road alignment was effectively complete, Alun Griffiths constructed the new bridge from reinforced concrete, complete with wing walls. The finished structure was 34 metres wide overall with a single, arched 13.5-metre portal and weighed around 1,500 tonnes.

With the build of the new bridge complete and all railway critical signalling and telecommunications diverted, everything was ready for a closure of the A4440 to move the bridge into place.

This was planned from Thursday 24 May to Friday 1 June, with the railway blockade running from Saturday 26 May to Thursday 31 May.

Rail Engineer | Issue 166 | August 2018

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Meticulous planning went into every aspect of this project including the traffic management put into place with such a key route into and out of the county being closed for nearly a week. No stone was left unturned in the quest to reduce congestion and to encourage motorists to think ahead and take alternative routes before the formal diversion route was reached.

On the Thursday prior to the blockade, the SPMT was set up by Mammoet below the new bridge. In addition to the SPMT, three hydraulic struts were installed to cross-prop between the abutment walls.

These would prevent the inwards ‘swing’ of the abutment walls once the bridge was lifted. Prior to lifting, they were preloaded and then adjusted before the bridge was set-down to return the bridge to its original geometry.

Once the SPMT was set up and the hydraulic struts pre-loaded a trial lift was undertaken. This went without issue and the team then turned its focus to the enabling works that could now be undertaken during the road closure.

On the morning of the blockade, the first priority was to remove 112 metres of double track and its remaining embankment. 22,000 tonnes of soil were removed and a portable roadway was laid to accommodate the transporters that would move the new bridge to its destination. Alun Griffiths prepared and levelled the formation below the abutment and wingwall foundations.

Rail Engineer | Issue 166 | August 2018

In addition to working on Battenhall bridge, SLC Rail is also rail advisor to Worcestershire County Council for the new Worcestershire Parkway station. To reduce costs, SLC’s project manager at Worcestershire Parkway worked with colleagues to schedule works that made the most of the Battenhall bridge rail blockade. During the closure, workers replaced sleepers and rails on the Oxford, Worcester, Wolverhampton (OWW) line, realigned track to facilitate possible twintracking in future and undertook the piling for the new station platform.

Back at Battenhall bridge, once everything was ready, the three-module transporter picked up the bridge using its hydraulic jacks and was slowly driven along the temporary roadway into position, ending up just 30mm away from the abutment of the original, singlecarriageway bridge.

Once the transporter had set the bridge down, it was removed and the backfilling operation commenced. The void left between the existing and new bridge measured just nine metres by six metres and required infilling with 350m3 of fill. In order to lift the fill into place, Alun Griffiths utilised a conveyor - once in place it was compacted with a remotely controlled compacting plate. Between the rear of the southern abutment and benched excavation of the existing ground, approximately 2,100m3 of fill was hauled into place and compacted.

Once the structure was backfilled, the track was re-laid, which itself required 216 new sleepers, four 112-metre lengths of rail and 1,200 tonnes of new ballast.

Several hundred metres of cable trough were renewed, as well as the diversion and reinstatement of all safety critical signalling and telecommunications infrastructure.

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Consulting Civil, Structural and Geotechnical Engineers Rail Engineer | Issue 166 | August 2018

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The thorough pre-planning, execution and risk management resulted in the new bridge being completed early, enabling the Southern Link Road to be reopened to traffic 36 hours ahead of schedule and the railway possession to be handed back to Network Rail at the designated time. All in all, 180 engineers were on site, working three eight-hour shifts each day, to make sure the project was completed on time.

Alun Griffiths’ rail director Shaun Thompson was pleased with the outcome. “The Battenhall Bridge project team planned, rehearsed and executed the works with meticulous precision,” he said afterwards. “The detailed productivity study and risk assessments ensured contingencies were in place for all eventualities. With input from our infrastructure colleagues on the SLR, the safe delivery of this project was an incredible success and demonstrates our multi-skilled capability. Well done to all involved.”

Communication

The bridge between local government and rail From bridge works to new stations, SLC Rail helps local authorities to navigate through the complexities of rail and turn their aspirations into reality

We are proud to be Rail Advisors to Worcestershire County Council for Battenhall Bridge

Find out more at slcrail.com or call 0121 285 2622

Rail Engineer | Issue 166 | August 2018

In addition to the bridge being moved into place successfully and ahead of time, another success of the project was the communication to local residents, road and rail users.

On the run up to, during and after the bridge move, the communications team at Worcestershire County Council kept a steady stream of content accessible to stakeholders. This was done through the more traditional updates through local media and via the website, but by far the biggest engagement came through the Council’s social media channels. A number of timelapse videos, shown throughout the project, were collectively viewed more than 500,000 times. This meant that key groups across the county, and further afield, felt informed. It also helped to keep the congestion on the diversion routes to a minimum as a very high number of local residents and businesses were aware of the project, timelines and the potential impact on the local routes.

The project is an excellent example of a progressive Local Authority, with a clear transport infrastructure strategy, commissioning leading consultants and contractors from the private sector to deliver outstanding results for local residents and those using the local infrastructure.

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INFRASTRUCTURE PHOTO: KEITH FENDER

CLIVE KESSELL

BUILDING A

W RLDTUNNEL HERITAGE

I

t is not only the Swiss main line railways that are benefitting from tunnel investment. The Rhätische Bahn (or Rhaetian Railway) is an extensive metregauge network in the southeast of the country. The section from Tirano (in Italy) to Tiefencastel via Pontresina has been declared a UNESCO World Heritage site, and it is easy to see why.

With origins dating back to 1889, the line was initially built to promote the tourist trade and offered a spectacular route traversing the northern valleys in the canton of Grisons (Graubünden). With many spirals to gain height in this alpine region, especially in the Albula Bernina area, the highest point, at 1,800 metres above sea level, is crossed by the 5,864 metre long single-track Albula tunnel, linking the stations of Preda and Spinas, which opened in 1903.

Originally operated by steam traction, the line was later electrified with the standard Swiss 15kV, 16²⁄³Hz system.

Having given over a century of service, the condition of Albula tunnel was assessed in 2006 and it was deemed to need significant renovation as rock falls were becoming an ever-present threat.

This would have meant considerable disruption for the 7.4 million passengers, including 2.3 million commuters, and significant volumes of freight that use the line every year.

As an alternative, building a brand new tunnel alongside the old was duly evaluated and, in 2010, was adopted as the best solution.

The area is typical of the Swiss Alps, with considerable snowfall in the winter months that severely limits access to the tunnel site between mid December and

Rail Engineer | Issue 166 | August 2018

the end of February. As such, construction work is suspended during this period but proceeds with 24-hour shift working during the rest of the year.

The new tunnel cannot be a replica of the old as current standards now prevail and safety considerations tend to dominate. Thus the tunnel bore is much larger and has to accommodate the provision of walkways plus the latest clearances for the OLE fixtures.

Building the first tunnel circa. 1900.

Constructing the tunnel Construction work follows conventional practice for boring a tunnel through rock. Firstly, and most importantly, a construction site has to be established close to each of the portal areas. These are major undertakings in their own right, with machinery and conveyor systems capable of handling all the material needed for the boring activity plus the disposal of the excavated spoil as the tunnel progresses.

Whilst road access is available, the local infrastructure would not be suitable for numerous lorry movements, so rail sidings and engineering trains are needed to cater for the main material removal. The

INFRASTRUCTURE

the Preda portal consists of three different types of rock, known as cellular dolomite.

A 20-metre section consists of a fault zone where a soft porous version of the dolomite is encountered, the material being akin to silty fine sand. It was found impossible to extract any solid material and thus the risk of tunnel collapse became a real threat.

The solution has been to drill freeze holes into the surrounding ground to a depth of 60 metres.

The freeze zone must be at least 2.5 metres thick outside of the excavation area, this being strong enough to absorb the ground and hydraulic pressures.

Once freezing has occurred,

down to the portals. Thirdly, the sides and roof have to be stabilised, this being achieved by ‘shotcreting’, or the spraying of wet-mix concrete.

Conventional tunnel machinery is used, so no temporary rail tracks are provided, the profile of the tunnel being sufficiently large and the floor of the tunnel being flat enough for road vehicles to journey to and from the rock face.

Even with all this, it is a wet, dusty and unpleasant environment. Progress on an average day is 6.5 metres.

Whilst the geology of the tunnel is mainly ‘Albula granite’, a 110-metre section close to

Grisons (Graubünden) canton and the Rhätische Bahn network.

MAP: ALYSSA JAMES

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site is extensive and, with the number of workers involved, a strict safety regime is needed.

This includes protecting the staff during engineering train movements, with radio-based Schweizer portable trackside warning systems being used for this purpose.

Having established the portal locations, ingress into the mountain is by the normal routine of drilling, blasting, spoil removal and securing the worksite ready for drilling the next section.

It sounds straightforward, but these activities have to be accompanied by other engineering ancillaries to ensure safe progression.

Firstly, there needs to be fresh air. Air is pumped into a tube that takes it to the rock face where it creates a slightly higher pressure in the tunnel atmosphere. This then helps to blow out the dust and diesel fumes as the excavation takes place.

Secondly, and like most tunnels, water ingress is considerable and channels are needed for this to flow

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(Inset) The new portal at Preda.

excavation can take place in that cross section followed by a 120 cm thick reinforced shotcrete lining applied within seven days of excavation.

The result is a strong tunnel profile that will withstand the expected pressures. However, because of the geological complications on this section, the progress rate through the frozen ground is only about 0.7 metres per day.

Spoil removal Even though the new tunnel will be slightly shorter than the original at 5,860 metres, a tunnel of this length creates a vast amount of waste material for disposal. In a sensitive environmental area with world heritage status, this presents a considerable challenge.

As the waste is brought out through the portal on a conveyor belt system, it is graded into varying categories.

The solid granite is broken down into manageable lumps, the larger of which can be used for future track ballast. Medium and smaller lumps are useful for making concrete.

However, it is the slurry and loose shale that causes the problem as this has to be dumped. Whilst a suitable site has been found during the construction period, it is

Rail Engineer | Issue 166 | August 2018

a controversial longer-term dilemma. Either the waste has to be transported elsewhere, which is an expensive exercise, or it has to be blended into the nearby landscape.

Looking forward From detailed planning work that began in 2010, it will take 12 years for the project to be completed. Construction began in 2014 for a period of 8½ years with breakthrough expected to happen in October 2018. Some 244,000 cubic metres of solid rock will have been excavated.

When completed in 2022, 15,000 trains will traverse the tunnel each year at a maximum speed of 120km/h. Total cost is estimated at 244 million Swiss Francs, equivalent to ÂŁ188 million sterling.

The old tunnel will not be abandoned, however. Twelve cross passages are being excavated from the new tunnel

to the old at intervals of 450 metres, stopping short of break out into the old tunnel until it is closed for rail traffic. Once the new route is commissioned, the cross passages will be opened up to allow access to the new tunnel, both for maintenance purposes and to provide a safe egress route should a train in the new tunnel ever need to be evacuated. Repair work to the old tunnel will be carried out so as to stabilise the walls and roof.

The Albula tunnel represents an impressive commitment to the local Swiss economy, which is difficult to see being replicated in the UK or other European countries. Maybe the Ffestiniog Railway Moelwyn tunnel, built during the 1960s, is the nearest comparison to be made but the standards and finances for heritage and commercial railways are very different.

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INFRASTRUCTURE

CLIVE KESSELL

Tunnel Management SWISS STYLE

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nyone who has travelled the railways of Switzerland will know that tunnels abound in the alpine regions. Most date back from the late 1800s or early 1900s and were marvellous feats of engineering for that period of time. Provided primarily on north-south routes that connected the country across the Alps, they were often spirals inside mountains in order to gain height before the final crossing near to the summit. As such, the rail routes were circuitous and journey times were lengthy.

The Swiss authorities decided at the start of the twenty-first century that a faster means of crossing the Alps was required and that this entailed building new tunnels much deeper down inside the mountains. So emerged the ‘Base Tunnel’ projects, to both shorten the route and to allow much higher speeds. Beginning with the 34.7km long LĂśtschberg tunnel that opened in 2007, a bigger challenge emerged with the Gotthard base tunnel that would be longer and needed to carry high levels of traffic.

An article on the control and communications systems in this tunnel appeared in issue 146 (December 2016), just prior to the tunnel opening, but managing the total tunnel operations involves much more than controlling train movements. Running from Erstfeld in the north to Biasca in the south, it is the longest rail tunnel in the world at 57km in length and carefully thoughtthrough processes have to be in place to ensure the best possible safety arrangements with evacuation procedures that are fit for purpose in the event of any emergency.

The IRSE (Institution of Railway Signal Engineers) convention in May 2018 was based initially in Lugano, from where descriptions of the technologies and site visits to the tunnel were provided.

The result was a fascinating insight into the factors that make up modern day tunnel management.

Rail Engineer | Issue 166 | August 2018

Gotthard base tunnel traffic The route from Zurich to Lugano is part of the main freight artery from northern Europe, including the important ports of Antwerp, Rotterdam and Zeebrugge, through to Italy and its main industrial centres. Getting more capacity on the route with reduced journey times has become vital.

The old Gotthard tunnel, with its circuitous and steep gradients on both the south and north approaches, had become a bottleneck on traffic throughput, hence the need to build and operate the new tunnel.

INFRASTRUCTURE The specification required the route to accommodate six freight and two passenger trains every hour in each direction, speeds for the freight trains being 150km/h and 250km/h for passenger trains.

Achieving this with ETCS Level 2 is nowadays straightforward, hence the provision of this system with its associated GSM-R radio bearer supported on the associated radiating cables.

Driving trains at the maximum permitted speed is part of the traffic planning activity so as to allow extra train paths to be inserted if need be. Not only are the trains more frequent and faster but also longer, enabling greater loads to be transported.

Simulating a fire.

Managing the tunnel The Gotthard base tunnel is in fact two single bores of generous dimensions to allow for a walkway at train door level for use by maintenance personnel, also for train crew and passengers should any evacuation need to happen. Two intermediate ‘Safety Stations’ at one-third and two-thirds the distance from the portals are provided at locations known as Sedrun and Faido.

These accommodate rail crossovers to allow trains to cross to the opposite tunnel if any single line working is needed, an arrangement that is similar to the Channel Tunnel. The stations are, however, much more than just a rail transition.

Each has a separate access tunnel bored into it (around 2km in length) from the outside of the mountain, equipped with an independent ventilation system. This permits access (or egress) to the tunnel independent of the end portals. In addition, cross passages link the two running tunnels at 325 metre intervals to allow escape from one tunnel to the other in an emergency as well as providing space for housing equipment.

The biggest risk is fire, both on passenger and freight trains, particularly the latter if they are carrying dangerous goods, and the safety stations and cross passages are all aimed at evacuating people safely and in the fastest possible time. However, fire precaution measures come first in the planning activities and these include:

»» A high level of automation of all tunnel systems including signalling; »» Minimising the amount of ‘active’ equipment in the tunnels, for signalling there are only balises and axle counters; »» Backed-up power systems in a ring formation to ensure continuing equipment operation; »» Sophisticated telecommunication networks to give fixed-line and radio communication, the latter comprising both GSM-R and public 3G and 4G services, all served by resilient fibre optic and IP transmission bearers, plus radiating cable for the various radio systems; »» All trains to be checked before entering the tunnel; »» Monitoring of train speed against planned and possible speeds; »» Keeping a defined distance between trains; »» Containment of smoke and blowing smoke away from evacuation areas; »» Provision of portable rail-mounted tunnel ‘doors’, to further segregate people from any incident and minimise smoke drift.

Basel St-Gallen Zurich Bienne Neuchâtel

Luzern Erstfeld

Bern

Frutigen Lausanne

Genève

Lötschberg base tunnel Raron Brig Sion

Biasca

Ceneri base tunnel

Chur

Gotthard base tunnel

Lugano The three Swiss base tunnels.

Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE The evacuation of passenger trains is the most challenging, as this may have to occur in either direction and may involve the reversing of a train. The plans foresee a maximum time of 90 minutes to complete an evacuation, so fire containment has to be designed around this target.

Ceneri tunnel portals at Camorino.

Tunnel control and traffic management Resilience of the equipment is key to continued operation and safety management. The main control centre for the Gotthard tunnel is located at Biasca, close to the south portal, and is a purpose-built modern secure building. A similar centre exists at the north portal, to ensure the appropriate level of redundancy.

The operating floor looks like most others, with its multitude of display screens, but these are focussed primarily on monitoring and controlling the various tunnel electrical and electromechanical systems, primarily ventilation, power, light and communication, as well as providing the necessary information for the maintenance of these systems.

‘Tunnel Safety’ sits above the normal command and communication systems needed to operate a railway and is structured in a layered approach that can drill down directly to the sub systems if need be. At the highest level is an Emergency Response System, brought into use should any incident occur when it would become the tool of the incident commander in such circumstances. Needless to say, the control centre is staffed on a 24/7 basis.

Traffic management sits alongside the ETCS signalling (the interlockings and radio block centres) and provides an additional set of rules to prevent the signaller from taking any action that would contravene tunnel safety requirements for train movements.

An additional interface known as TAG sits between the TMS and the signalling movement control to continually supervise train traffic. This has the intelligence to recognise an irregular emerging occurrence, followed by an alert to the operator and to finally suggest measures that should be taken to prevent any escalation of the problem. The process is focussed on: prevention early detection risk containment event management return to normal. That sounds good, but it is acknowledged that the exact source of a problem is not always known. An example would be a train proceeding at a slower speed than expected, which may or may not indicate a potential problem.

Rail Engineer | Issue 166 | August 2018

Wayside Train Monitoring System (WTMS) Mention has been made of checking trains before they enter the tunnel for any dangerous conditions and to provide an appropriate intervention. This is not as onerous as it sounds. The process has taken 10 years to develop and is not solely for the Gotthard tunnel but is (or will be) installed at all the base tunnel locations. The one at Erstfeld, to the north side of the Gotthard tunnel, is typical.

The checks take place at line speed, up to 250km/h for passenger trains, and around 10,000 pieces of rolling stock pass the monitoring system every day resulting in 25,000 measurements from which, typically, 25 alarms are generated. The system checks on: »» Hot axle boxes; »» Wheel load checks including any axle overloads; »» Fire and explosive gas detection; »» Train profile and antenna detection, looking for out-of-gauge loads or loose cladding; »» Dragging equipment; »» RFID - radio frequency identification.

Many of these tests involve proprietary equipment that has been available for years, such as hot axle box detectors, which have four sensors, two outside the running rail and two inside.

Others are less commonplace. Strain gauges attached to the rail will detect wheel flats and incorrectly loaded wagons. Threedimensional images taken of the train will ascertain any out of

INFRASTRUCTURE Gotthard base tunnel control room at Biasca.

gauge obstruction, these being coded red = severe and train to stop immediately and green = safe to proceed but examine train when next it stops. Ideally, the checks should take place sufficiently far away from the portals for a train to be stopped before entering the tunnel If an alarm is raised, an analysis of the condition is generated to determine the severity of the condition and a message is sent to the train over the GSM-R radio. The control centre operator will decide whether to stop the train, instruct it to reduce speed, or take no action. Any speed reduction requirement should be advised before the train is in the tunnel, this being done by both a verbal message and a change to the ETCS Movement Authority.

If the train has entered the tunnel with an alarm raised, then the main consideration is to keep the train moving at reduced speed so as to exit the tunnel.

The alarm system itself must be reliable, with 97 per cent currently being achieved and with a high priority response to rectify any failure. SBB has designed and built the WTMS equipment in-house using commercial equipment for the various components.

Completing the route - the Ceneri base tunnel The Gotthard Massif is not the only alpine range on the Zurich - Lugano route. There also exists Monte Ceneri to the south of Gotthard, the rail line also having a high altitude tunnel with limited-speed approach routes. Not as dramatic or circuitous as the old Gotthard route, it is nonetheless a limitation and the building of a new Ceneri Base Tunnel is well under way. This will be two 16km single bores, one ‘Safety Station’ midway, the latter not including a rail crossover, and regular cross passages between the two running tunnels.

The tunnelling ‘break through’ was achieved in 2016 and work is proceeding to equip the tunnels with track, power supplies, the overhead catenary, telecommunications and safety systems including the ETCS signalling. Installation work will be completed by mid 2019, allowing rigorous testing to take place during 2020 with an end of year opening.

The project is more than just the new tunnel - the new approach routes at both ends have required the construction of impressive concrete viaducts, major undertakings in their own right. Once completed, a journey time of three hours from Zurich to Milan will be possible, together with a considerable increase in capacity.

In summary, congratulations must be given to the Swiss rail and government authorities for having the vision, commitment and determination to see these projects through to a conclusion.

Comparisons with the Channel tunnel will be made, where safety processes also have to be rigorous. Tunnelling under a mountain does not require a service tunnel to be provided but the intermediate ‘safety stations’ fulfil a similar role.

Rail Engineer | Issue 166 | August 2018

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ON BRIDGE STREET

NEW BRIDGE

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In with the new.

T

he Great Western route modernisation and electrification project represents the biggest investment in the Great Western Railway since Isambard Kingdom Brunel built it more than 150 years ago. Once completed, the modernisation of the line will stimulate economic growth along its length, particularly in South Wales where there is strong economic and political pressure to complete the modernisation work in a timely and efficient manner, as well as to minimise disruption and keep costs for the programme down.

One of the UK’s most important arterial routes, Network Rail is electrifying the line by installing 25kV AC Electrified Overhead Line Equipment (OLE). As part of the scheme, an iconic road bridge on Bridge Street in Newport was scheduled for reconstruction to accommodate the increased height of the OLE. The bridge, which sits between Newport station and the town centre, is an important one that connects the affluent northern suburbs with the city centre. It is surrounded by businesses and residential homes, so the necessary road closures to remove the original structure and replace it with a new bridge would be challenging for businesses, residents and commuters.

Out with the old.

Rail Engineer | Issue 166 | August 2018

Removal Network Rail and its principal contractor ABC Electrification (Alstom-Babcock-Costain) appointed Cleveland Bridge UK not only to fabricate and install an innovative bridge structure, but also to remove the existing bridge in a short time window. Both elements of the project were to be delivered to strict and very constrained timescales when the train line was temporarily taken out of operation.

Cleveland Bridge is highly experienced in delivering complex steel structures to exacting timescales to ensure that new projects are completed to deadline and existing road and rail networks experience minimal disruption.

Recently, the company has worked on the Forth replacement crossing, as well as Reading, London Bridge and Bond Street stations.

It was vital for the city that the replacement programme was carried out within the critical time allowed and with minimum disruption as, due to the nature and location of this work, it would be almost entirely carried out during rail possessions, under the close-scrutiny of residents, council and media.

INFRASTRUCTURE

The first stage was to remove the old bridge. To meet a short, six-hour deadline for the removal, Cleveland Bridge fitted additional steelwork to the 105-year-old bridge to strengthen the structure before it was lifted out in a single piece by a 600 tonne-capacity crawler crane, which is one of the largest of its kind in the UK. The old bridge was then dismantled in the temporary works area for recycling.

Replacement The new structure which replaced it is a 228-tonne, 50-metre skewed, weathering grade steel road bridge that could accommodate the

increased height of the OLE. Designed as an improvement on its predecessor, the new bridge is able to accommodate heavier vehicles, to ensure it is fit for modern day city centre traffic, and has a wider footpath for pedestrians and cyclists. It also has improved road alignment for better accessibility.

The new structure has some striking architectural aspects in the shape of the stiffeners and main girder top flanges, which give a pleasing look to the bridge elevation. The shaped stiffeners, when in sunlight and sunset, cast a waving shadow along the face of the bridge.

This geometrically challenging new structure was designed and fabricated at Cleveland Bridge’s extensive production facility in Darlington. As bridgebuilding pioneers, the company designs, manufactures and installs steel bridges of every type, including beam, truss, cable and modular bridges.

In the world of construction, Cleveland Bridge manufactures, fabricates and installs loadbearing and architectural steel elements for large-scale commercial and civic buildings, industrial buildings, heavy transfer structures and iconic stadia from its County Durham base. The combination of its highly-skilled designers and engineers with technically advanced manufacturing facilities on its 22-acre site enables the company to produce 50,000 tonnes of precisionengineered steel every year.

Following a complete trial assembly within Cleveland Bridge’s 27,000 square metre fabrication facility, to ensure ‘fit-first-time’, the steelwork

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BRIDGES

STRUCTURES

CONSTRUCTION SERVICES

Rail Engineer | Issue 166 | August 2018

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INFRASTRUCTURE

was loaded onto trailers and transported 280 miles by road to Newport, where it was assembled prior to installation in the trackside temporary works compound at Godfrey Road, adjacent to the railway station.

Although the local population had been inconvenienced by the road bridge closure, there was a great deal of interest when the new structure was installed, with many residents staying awake throughout the night to witness it.

Preparation and professionalism

Installation of the new bridge, which took place during a 54-hour abnormal weekend possession of the railway line, also utilised the crawler crane and was successfully completed within three hours of receiving confirmation of the line closure.

This provided sufficient time for follow on activities, including installation of the 90 pre-cast concrete deck units before the line was reopened.

Rail Engineer | Issue 166 | August 2018

Cleveland Bridge approached this project with the highest levels of preparation and planning, and the professionalism shown at all stages was borne out through successful delivery within the very tight timeframe and with an exemplary Health and Safety record, including no Riddorreportable accidents.

Working closely with its customer ABC and with Network Rail, Cleveland Bridge was able to successfully complete the project

maximising on its strategy of close collaborative working and early contractor involvement at the design stage, which added certainty to the design, ensuring the most financially efficient methods of fabrication could be adopted.

As a result of these high levels of planning and delivery, the bridge removal and replacement was conducted on time, in full, to client satisfaction. Rob Fancourt, ABC’s head of civils, congratulated the team for “an excellent performance and lots of very hard work over the past few months ensuring a very challenging structure was ready for the lift.”

This positive feedback from both ABC Electrification and from Network Rail further reinforces Cleveland Bridge’s continuing role in the development of UK transport infrastructure.

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INFRASTRUCTURE

Tunnel lighting comes of age

W

orking in tunnels brings with it one obvious difficulty – a lack of light. In a railway environment, that’s actually not as big a problem as it sounds. Most work has to be undertaken at night, so it matters little, from a light point of view, whether the job site is in a tunnel or in fresh air.

But still, there are complications with working in a tunnel. All of the equipment, including lighting, has to be brought in from one end, usually on hand-pushed trolleys or on trailers towed behind road-rail vehicles.

Fumes can be a hazard, so petrol-powered and even diesel-powered generators may be anti-social. Better to have freestanding lights cabled in from a generator in the open air. But then the cables can be a trip hazard, and lineside neighbours might

object to the noise from the generator if it runs all night.

Then quartz-halogen lights put out quite a bit of heat, and that can be undesirable in a confined space.

Who said it was easy?

Innovative solution Fortunately, technology can help mitigate all of these ‘challenges’.

Using LED light heads is the obvious solution to the heat problem. LEDs (light-emitting diodes) put out no heat at all in practical terms, so having

the light on or off makes no difference.

They also consume far less electricity than an oldfashioned quartz-halogen lamp, so now using batteries becomes an option.

That’s exactly what leading worksite lighting manufacturer Morris Site Machinery, a well-established family owned business with a rich engineering heritage, has done. It has taken its traditional product, a generator with a telescopic mast topped by high-intensity lights, and brought it up to date.

The light head of the new TL55 Battery is made up of four 60W LED arrays operating at 24V DC. These are positioned on top of a 5.5 metre telescopic mast which emerges from what looks like a typical wheeled-trailer-generator, but is actually a battery pack containing six 150Ah deepcycle lead acid batteries.

Lateral thinking

TL60 Trolley

SL80 Pallet

TL55 Battery

TL90 Ultimate

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Rail Engineer | Issue 166 | August 2018

When first developed, the batteries took 11 hours to recharge from a standard 240V supply, and would power the lights for 54 hours. However, with the light unit often being on site for several days, even more battery life was thought to be desirable. So it was back to the drawing board and time to apply some lateral thinking.

What the design team came up with was a simple, yet remarkable, solution.

PIR sensors were built into the light head to detect movement in the lit area. If

none was detected, indicating that no one was working in the immediate area at that time, then the lights would be dimmed, saving energy. The lights were still on, so workers could see to re-enter the area, but the level was reduced enough that battery life went up, to as much as 500 hours in some cases.

Morris Site Machinery recently took part in a Network Rail “fuel-free site” experiment at the Tuxford Rail Innovation and Development Centre in Nottinghamshire. The company’s battery-operated lights were used to illuminate work taking place using battery-operated tools as Network Rail demonstrated how it could work at night even in urban areas, without disturbing the neighbours.

In the TL55 Battery, Morris Site Machinery has produced a worklight that is silent, cool, bright, and lasts in excess of a complete shift – several shifts if used in an area where work is intermittent.

So now there can be light in the middle of the tunnel, as well as at the end.

INFRASTRUCTURE

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27/01/2015 14:23 14:23 Rail Engineer | Issue 166 | 27/01/2015 August 2018

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W

hile not exactly ten-a-penny, footbridges can be found everywhere on the railway.

They connect platforms at stations, are used to replace pedestrian level crossings, join communities cut in half by a railway line and give access to beaches and car parks. Network Rail alone owns just under 2,400 of them.

Many are quite old, and so a programme of repair and replacement always forms part of Network Rail’s plans for any control period.

Rail Engineer has often covered the more interesting footbridge projects. In recent memory, there have been articles on the first Grade II-listed fibreglass footbridge at Dawlish (issue 99, January 2013), bridges in South Wales at Port Talbot (issue 142, August 2016) and Newport (issue 69, July 2010), the transfer deck at Reading station (issue 103, May 2013) and even a bridge with blue lighting (issue 158, December 2017).

Even footbridge refurbishments can be interesting; witness the one at the longest station name in the UK - Llanfair­ pwllgwyngyll­gogery­chwyrn­drobwll­llan­tysilio­gogo­goch, Llanfairpwll for short, which was described in issue 154, August 2017.

But these were the exceptions. The vast majority are everyday working structures, painted either in dark green or rusty grey and in varying states of repair.

Design competition Not unnaturally, Network Rail has a standard design which it uses when replacing these bridges, but it’s not very inspiring.

“We’ve got one official standard design for a station footbridge,” explained Anthony Dewar, Network Rail’s professional head of buildings and architecture, “and that design probably hasn’t changed in its aesthetic form for over a generation.

“The unofficial standard design is the one that’s used for ‘Access for All’ bridges, and that again hasn’t changed in its aesthetic for maybe 10 years.

“For both of those designs, one could question now, with modern architectural and structural engineering, how much of a design legacy we are leaving with those structures.”

NIGEL WORDSWORTH

Reading.

To improve matters, Network Rail has launched a footbridge design ideas competition, in conjunction with the Royal Institute of British Architects (RIBA), seeking new ideas for the design and installation of fully accessible pedestrian footbridges across the UK rail network. The competition is open internationally to practising architects, structural engineers, civil engineers as well as students of these design disciplines.

The selection process is seeking ideas to contribute towards and influence new standard designs rather than a solution that will necessarily be implemented. The design ideas competition will be held over a single stage, with a design fund of £20,000 to be awarded to the submission judged to be the best response to the design challenge.

Although Network Rail’s portfolio of footbridges includes both those at stations and on rights-of-way, this competition is seeking to generate proposals with an elegant and effortless means of providing accessible footbridge provision within urban built station environments. It’s an area where considerable money is already being spent. Network Rail has built over 200 Access for All bridges since 2006 with an average price tag of £3 million each.

However, the competition brief continues, in addition to this principal anticipated use, the footbridge design will also need to be potentially applicable and aesthetically sympathetic

Footbridges of the future?

St Ninians.

Rail Engineer | Issue 166 | August 2018

INFRASTRUCTURE

Port Talbot.

Newport.

to a range of other conditions and contexts including at-grade open platforms, crossings away from stations, embankments and in more rural locations across the UK rail network.

Whilst primarily not intended for use in conservation areas or listed building settings, the footbridge’s design aesthetic should offer the potential to do so.

Anthony Dewar continued: “The competition is there to encourage new creative talent from both qualified and unqualified professionals and students to introduce new creativity into a concept for footbridge design.

“We’ve worked hard to develop a technical remit for the competition that doesn’t just give a plethora of railway standards that one has to comply with, which can discourage creativity. We’ve set high-level technical parameters in the hope that it will encourage creative submission - not just in the structural and architectural worlds but we’ve also put in high-level parameters in respect to lifts and lighting across the bridges - and we hope that the creative submissions we get will be the holistic design requirements for a footbridge.”

Anthony Dewar hopes this area will be challenged with the competition entry, but, as a separate workstream, his team is also looking at Network Rail policy and standards for escalator and lift design.

There are alternatives, such as hydraulic lifts, but he doesn’t want to change the design and then encounter problems such as maintenance and reliability challenges, so the topic is still under consideration.

Whatever the result of the competition, Anthony doesn’t just want to update, revise or even replace the existing standard footbridge design.

“We currently have a one-size-fits-all approach,” he stated. “I want to move away from the term ‘standard design’ because, for public consultation, I think it suggests that we as a business are only going to give one type of option. We want to move to a catalogue of typologies

of designs for station footbridges, and we are looking at innovative and creative ways to do that.”

“One of the ways we are looking to do that is through the competition, but we’re also going through a more traditional route through the architectural and engineering frameworks to come up with design topologies.”

Anthony admits that most railway footbridges give the appearance of having been designed by structural or civil engineers. With the new typologies, he wants to get into a position that the engineering under the skin is both proven for safety and for ease of assembly, but that the architectural appearance can easily be altered to blend in with its environment.

But, at the end of the day, the resulting typology must have the variability to allow for context but also be efficient to build in the railway environment. But that’s the challenge, and no challenge is easy.

Choosing a winner Design submissions have to be received

by RIBA by 18 September 2018. Evaluation will start immediately with the judging panel due to meet early in October. All design submissions will be identified solely by a registration number, so the entries can be judged anonymously.

One size doesn’t fit all One of the most striking features of the current Access for All bridge design is the height of the lift machine rooms that extend above the bridge profile itself.

They are very prominent and add to the impression of bulk that one gets when looking at one of these bridges.

Sellafield.

Rail Engineer | Issue 166 | August 2018

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Newport.

The judging panel will be chaired by Paul Finch, programme director of the World Architecture Festival and editorial director of both the Architectural Review and Architects’ Journal. In addition to Anthony Dewar, the panel will include Network Rail colleagues Ian Grimes, principal engineer, and Trevor Wilson, senior architect.

Jonathan McDowell of Matter Architecture will act as the RIBA architect adviser and he will be joined by Andy Savage, executive director of the Railway Heritage Trust; Chris Wise, senior director of Expedition Engineering; Rowan Conway, director of innovation and development at the Royal Society of Arts; Margaret Hickish, managing director of Design 4 Inclusion and Kay Hughes, founder of design consultant Khaa.

A design fund of £20,000 will be available for award at the discretion of the judging panel, and it is currently envisaged that £20,000 will be awarded to the submission judged to be the best response to the challenges outlined in the competition brief.

The judging panel may also identify a series of highly commended schemes which will be acknowledged in all associated publicity, but will not attract a monetary award.

It will be exciting to see what suggestions come through. Anthony is certainly looking forward to it. “Network Rail is committed to promoting design excellence. That’s why we’re challenging the architectural and engineering community to come up with new and innovative ideas for footbridge structures that will be both functional in form and sympathetic to the communities that they serve.

“The winning design concept will also need to protect and enhance the great legacy of engineering design that is inherent in railway history. We’re excited to see the solutions that will be put forward.”

Full details of the competition can be found by visiting www.ribacompetitions.com/ networkrailfootbridge.

Rail Engineer | Issue 166 | August 2018

Coulsdon.

Dawlish.

Newport.

Strood.

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FEATURE

PAUL DARLINGTON

What’s possible?

Future train radio

T

hroughout the world, many railways use the interoperable radio communications network, GSM-R (Global System for Mobile Communications - Rail), for operational voice communications and to provide the data bearer for ETCS (European Train Control System).

Within the European Union, and for all infrastructure managers wishing to adhere to European standards such as ERTMS, this is legally mandated via Technical Specifications for Interoperability (TSI).

GSM-R is a technology system based around standardised commercial GSM (Global System for Mobile Communications) equipment (also known as 2G) used worldwide but enhanced to deliver specific ‘R’ (railway) functionality.

GSM-R technology is very reliable and has been suitable for serving the railway’s needs over the past decade. However, network demands, coupled with new efficiency requirements and the fact that the GSM technology is not going to be around forever, is driving a need for the next radio technology to serve the railway.

In this context, the International Union of Railways Union (UIC - Union Internationale des Chemins de fer) decided, in 2012, to set up the Future Railway Mobile Communications System project (FRMCS) to prepare the necessary steps towards the introduction of a successor for GSM-R. As well as being a major player in the provision of 2G, 3G, 4G-LTE and 5G equipment used by all mobile network operators globally, Nokia is also a leading supplier of GSM-R. So, it’s no surprise that the company is a leading participant in the definition of this new standard, which it believes will initially be based on the Long Term Evolution (LTE) telecommunications technology.

Rail Engineer | Issue 166 | August 2018

Safe hands Nokia was a pioneer in the GSM-R field, being the first company world-wide to contract a commercial GSM-R project in Sweden for Banverket (now Trafikverket) in 1998, commencing operations in 2000.

Since then, the company has deployed over 29 GSM-R networks worldwide, from a full ‘turnkey’ deployment (design, radio planning and deployment)

through to end-to-end GSM-R network operations as a full managed service - such as the ADIF high speed railway GSM-R system in Spain and the Prorail GSM-R system in Belgium.

To assure interoperability with other vendors GSM-R, Nokia’s GSM-R system has been developed according to the relevant open standards (EIRENE, MORANE and ETSI). Extensive interoperability tests have been performed to verify network-to-network interoperability including full certified interoperability with the Kapsch GSM-R core. This proven and deployed interoperability enables a step-by-step network-wide transformation to a digital platform.

FEATURE 4G, 5G and the railway industry Railway operators of all types typically run a mix of narrowband and broadband communications technologies to support their safety-critical, safety-related and passenger services. GSM-R is the most widely adopted radio technology for mission-critical voice and train control data. These services typically require low bandwidth, low latency and high availability, which suits GSM-R well.

However, as new requirements emerge, for example to facilitate automatic train operation (ATO), with more video streams from and to the train, a narrow-band technology such as GSM-R will struggle to support these applications.

Migrating to LTE (Long Term Evolution, 4G and 5G) technology has the potential to support broadband services and highspeed mobility, and also to consolidate all communications needs onto one single, highly flexible but secure and resilient network. Furthermore, the high throughput and low latency performance and stringent Quality of Service (QoS) characteristics of LTE will enable the railways to deliver better services for passengers whilst reducing operational costs.

Nokia has been innovating in LTE for 19 years with many world firsts, and is currently the global number one supplier of commercial LTE equipment with its LTE 4.5G Pro, 4.9G and 5G offerings, all of which have the potential to revolutionise communications, including how public safety is ensured and how industrial processes are run.

Technology choice?

Close to 800 operators are investing in LTE in more than 200 countries serving commercial, private and public safety networks. By 2020, LTE is expected to connect more subscribers than any other mobile technology. It can be served on licensed and unlicensed spectrum and continuously evolves via the standardised 3GPP (3rd Generation Partnership Project) governing body. A Nokia LTE network will support 5G and is designed for evolution over the coming decades.

As a well-established technology that is supported by a solid and growing ecosystem, LTE has a long future ahead of it. Even when the much-vaunted 5G

technologies start to be deployed, LTE will provide a long-term foundation for 5G networks.

Technology migration is not trivial and takes time. However, the sooner the capabilities of LTE are brought into operations, the sooner rewards will be reaped in terms of lower operational costs and new revenue opportunities from passenger services. One of the ways these benefits can be realised is through a Private LTE network (PLTE). This simply means the railway having access to an LTE network that only services railway users.

A Private LTE network can support both human and machine communications on a single, reliable network that offers

Rail Engineer | Issue 166 | August 2018

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FEATURE

mobility without cumbersome portable radios and opens up the world of the Internet of Things (IoT). Complementing Ethernet and Wi-Fi, Private LTE will help to enable digital transformation in many industries and pave the way towards the adoption of even more capable 5G mobile technologies.

Future Nokia, which leads the way in 4G LTE technology with a clear and softwaredriven path to 5G, leverages its AirScale product for the building of a smooth evolution path to 5G with 4.5G Pro and 4.9G evolution of the 4G standard. The evolution from 4G to 4.5G to 4.9G and 5G is tightly controlled by Nokia and adheres to the global 3GPP set of standards that all telecom vendors follow.

5G will initially be made available through evolution in LTE technologies.

It will be followed, later in the evolution of the standards, by the introduction of a new air interface that will be backward compatible with the LTE interfaces, the transport function and the core function.

It is likely that 5G-ready devices will start to become available from early 2019, fast tracking to an era where the internet starts to migrate from a communication platform primarily for people, into a platform allowing devices and assets to connect. Going further, it will give consumers the ability to download a UHD movie to their smartphones in a few seconds. 5G will enable offices, cars, trains and assets to seamlessly connect to each other and the cloud.

Rail Engineer | Issue 166 | August 2018

In terms of track-to-train broadband, this is something that Network Rail Telecom has been investigating. Nokia’s Bell Labs R&D team has already developed the software algorithms required to deliver 10Gbit/s to a moving train at up to 500km/h using mmWave 5G radio, and the company is currently planning trials on a railway test track within the next 12 to 18 months. (NOTE: 5G radio is not the same as 802.11ad mmWave WiFi standards-based radio.)

If you think about the evolution of 4G, an example of achievable speeds is roughly as follows: 4G - 300Mbps 4.5G - 1Gbps 4.9G - 3Gbps 5G - over 10Gbps The key point to take away is that the different ‘G’s above are all supported by the same Nokia LTE core, which also supports the full Nokia Wi-Fi portfolio, the GSM-R over LTE transformation and the 3GPP 5G mmWave being developed.

An investment now in an LTE core will serve the future of Digital Railway for many years to come and it is this key point that removes the risk to rail - the migration path can be steady and controlled with a very clear 20-year-plus roadmap.

The other key points are the term LTE (Long Term Evolution) which is ‘what it says on the tin’, and 4G/5G is a standard specified by the 3GPP for use all over the world.

The mantra of the moment is “build it once and build it right” for the railway’s future telecommunications infrastructure.

Autonomous vehicles Much is being reported that the latency performance of 5G is required for autonomous vehicles. However, in Australia, since commencing trial operations in 2008, trucks fitted with autonomous vehicle technology, communicating via 4G LTE, have already moved more than one billion tonnes of material.

FEATURE boosts the intelligence and performance of MIMO antenna, all based on 3GPP 5G New Radio specifications.

Massive MIMO technology is one of the key enablers to deliver the step-change in mobile broadband performance.

UK first deployment of 5G

In 2017, Rio Tinto’s autonomous fleet accounted for about a quarter of the total material moved in the Pilbara mines.

On average, each autonomous truck was estimated to have operated about 700 hours more than a conventional haul truck during 2017, with around 15 per cent lower load and haul unit costs.

There have been zero injuries attributed to autonomous haul trucks since deployment, highlighting their significant safety advantages.

Norwegian airport operator Avinor is developing autonomous snowploughs with the aim of increasing efficiency and reducing delays at airports. In March 2018, these autonomous vehicles were tested for the first time at a snowy airport 200km north of Oslo.

Autonomous vehicle technology for rail is already being planned on routes around the world. Rio Tinto is also developing fully autonomous, heavy-haul, long-distance trains for transporting iron ore (see News in this issue) and, in the Netherlands, Prorail has announced it is also planning to trial automated operating freight trains. The CEO of German operator Deutsche Bahn, Rüdiger Grube, has publicly stated the objective of DB is to introduce driverless trains by 2021.

capacity and coverage. Massive MIMO is often seen as a future technology to support 5G networks, but Nokia is making it available for deployment within LTE now. Using existing spectrum and base station sites, the Nokia AirScale Massive MIMO adaptive antenna delivers far more capacity than conventional antennas and radios and can be used as part of the railway to deliver secure, guaranteed data streams.

Massive MIMO antennas are capable of handling very large amounts of data.

The processing of this data is therefore intensive, requiring a paradigm shift in processing power at the base-station (where the data from the distributed radios is processed). The Nokia answer is the new “ReefShark” chipset contained within the Airscale base-station platform.

Made entirely in-house, this bespoke silicon packs more functionality into 50 percent smaller hardware compared to products that use discrete components; it decreases mMIMO antenna size by half; cuts energy use by 85 percent and

Nokia has products to deliver a number of wireless and fixed telecoms technologies now, including Wi-Fi and 4G LTE, and is at the forefront of 5G development.

BT and Nokia recently demonstrated the first UK public deployment of 5G. People in Bristol experienced the next generation of wireless technology in a public urban environment. This included spectacular 3D-like projections, a virtual reality dance piece, and a guided tour on which people walked through time.

The public part of the trial only lasted two days, but the trial continues to include Nokia’s Massive MIMO radio access solutions, network slicing (splitting a single physical network into multiple virtual networks) and edge computing nodes functionalities.

Cormac Whelan, CEO of Nokia in the UK and Ireland, said: “As 5G comes ever-closer to commercial reality, the opportunity to contribute to a ‘real world’ test of the technology in Bristol is invaluable. With the UK’s exciting ambition of becoming one of the first European markets to launch 5G, Nokia is thrilled to be working with the University of Bristol and with BT to make this public demonstration happen and to evaluate how the technology will work in a smart city such as Bristol.”

Nokia are therefore ideally placed to guide the rail industry on the roadmap to what is possible for the future of train radio.

Massive MIMO Massive MIMO (multiple-input and multiple-output) is used in many radio technologies and, in fact, was invented

by Nokia’s Bell Labs in America. A basic antenna will have both a transmit and a receive element, and data is transmitted and received via these elements. It follows that, if you employ more antennas, you can transmit and receive more data.

In Massive MIMO, Nokia does just that, using 64 transmit and 64 receive antennas packed into an array to boost

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FEATURE

DAVID SHIRRES

The annual Stapleford trials

T

he Stapleford Miniature Railway’s lawnmower had temporarily lost its magneto as it had been fitted to the University of Huddersfield’s Railway Challenge team’s locomotive. Thus, the team’s ingenuity in borrowing and adapting this magneto enabled its locomotive to be ready for the competition’s dynamic tests.

Unfortunately, this resourcefulness was not to be rewarded as, once the locomotive reached the trial site, its chain drive failed, and it had to be recovered by the miniature railway’s rescue locomotive. For the Huddersfield team, which had spent months preparing its locomotive and had the reputation of being previous winners to live up to, this was a bitter blow. Yet it was a good example of how the IMechE’s Railway Challenge reflects the reality of the fullsized railway and, although Huddersfield was unable to win the competition this time, the team still gained much from it.

The teams As regular readers will know, the Railway Challenge is an annual competition in which teams of graduates and students design and build a 10¼-inch gauge locomotive to take part in various trials.

Rail Engineer has been a firm supporter of the Railway Challenge since the first event was held back in 2012.

As shown in the table, a total of 15 teams have entered the challenge since its inception. It is interesting to note half of the challenges held since 2012 were won by new entrants - one judge suggested that this may be because new entrants pay closer attention to the competition’s rules and specification.

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This year there were three teams of industry graduates, five university student teams and two joint industry/university teams. 119 took part in the challenge with team sizes ranging from five to 15. The largest team was from the University of Sheffield’s ‘Railway Challenge at Sheffield’ club which, unlike other university teams, is an extra-curricular activity.

Although twelve teams entered the competition, two teams dropped out some time before the competition

weekend and the Siemens/Southampton University team was not present as its locomotive had suffered a power failure and could not be repaired in time. The team was, however, given credit for its design and innovation reports.

Of the nine locomotives present, seven took part in the dynamic trials. As well as Huddersfield University’s chain difficulties, the joint Bombardier/Derby University locomotive was also unable to take part due to brake problems. It was, however, given an opportunity to run over the three-kilometre miniature railway after the completion of the dynamic trials, although one bogie derailed on plain line track and the locomotive had to be recovered.

FEATURE

The locomotives The locomotives were designed to a performancebased specification based on the challenges specified in the competition’s rules. As such, it is not surprising that there are some similarities between them. Of the nine locomotives present, seven had a single body with two four-wheeled bogies. The exceptions were Birmingham’s locomotive, which was mounted on two wheelsets, and Sheffield’s three-unit locomotive with each unit mounted on two wheelsets.

Five locomotives were powered by petrol generators. Of these four had generators of about three kilowatts with traction power supplemented by a battery whereas Huddersfield’s seven-kilowatt generator was the sole normal power source.

Birmingham and Aachen had hydrogen-powered/ battery hybrid locomotives whilst Transport for London (TfL), Warwick and Bombardier/Derby had battery-powered locomotives.

This was the first time that battery power had been allowed, as a change to the rules allowed for refuelling to be done within 120 seconds, which could include the replacement of energy storage assets.

The most important challenge, with twice the available marks of the others, is the energy storage challenge, during which teams have to recover energy while braking to a stand and then use that energy to propel their locomotives as far as possible. As shown in the table, for this challenge, six locomotives were fitted with supercapacitors whilst Aachen used its traction battery and Huddersfield had a unique axle-mounted coil spring energy recovery system.

Other than Ricardo, each team had previously entered a locomotive. Such teams are required to modify their locomotives to comply with changes to the rules as well as enhancing them to improve the previous year’s performance, as shown in the table.

The innovations To encourage innovative thinking, each team had to submit a paper, in the format

of an academic journal, which describes an innovative aspect of its locomotive design. The teams came up with a number

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FEATURE Sheffield tackles the maintainability challenge.

Ricardo’s locomotive.

of interesting innovations that are worth listing in detail.

Aachen’s locomotive was fitted with a sensor to detect objects and potentially simplify shunting by enabling an autonomous locomotive to follow its driver.

Huddersfield’s entry has a digital selflevelling suspension system, which uses an ultrasonic proximity sensor.

An innovation from Ricardo, a team which included three automotive graduates, was the use of a Controller Area Network (CAN) which is standard automotive practice. This has a serial communication protocol that eliminates the need for wiring harnesses, allows for easy addition of additional components and provides a standard coupling interface.

The Visual Wheel Condition Monitoring System (VWCM) fitted to SNC Lavalin’s locomotive uses a camera that is computer-controlled to capture a series of images of the entire wheel circumference at low speed (2.8km/h). VWCM has an image processing system to detect thermal cracks on the wheel tread.

TfL presented a proposal for a trainborne system that could measure adhesion at precise locations along train routes.

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Warwick had considered the use of novel polymer traction gears for its locomotive.

However, after a study, which included testing on a special rig, it was concluded that steel is the most wear-resistant gear material.

The specification Locomotives are built to a technical specification that also specifies the requirement for systems assurance and a design report, which must include a compliance matrix against technical requirements and as-constructed drawings. This report must also contain performance, structural and wheelunloading calculations.

The requirement is to produce a locomotive that can operate for three hours without refuelling at five kilometres an hour hauling a 400kg

load up a two per cent gradient. It must also be able to haul and start a trailing load of 1,800kg on a two per cent gradient. As far as possible, the specification is performance-based to encourage innovation by giving the teams the discretion to determine the configuration of the locomotive and its motive power.

The prescriptive technical requirements are generally those that enable the locomotive to run on the Stapleford Miniature Railway, for example loading gauge, axle weight and type of coupler.

The rules The competition rules cover general requirements and the challenge specifications. General rules include eligibility (an engineering student or graduate of no more than two years

FEATURE or a current or passed out apprentice of no more than two years) and safety requirements which includes the requirement for a team safety supervisor, risk assessments and method statements.

Before competing in the track-based challenges, the locomotives have to pass scrutineering, to confirm that they are built to specification with the required supporting documentation. This requires the locomotive to pass 31 different checks to enable it to collect the following different coloured stickers, as follows: evidence of reliability (1), calculations and safety documentation (6), user guide (1), inspection of markings (3), physical inspection (6), demonstration of performance (10) and demonstration of indications (4).

There are nine challenges of which six are track-based (energy recovery, traction, ride comfort, noise, maintainability and reliability) and three are presentations (design, business case and innovation).

The maximum points for each challenge is 150, except for the energy storage challenge for which 300 points are available. This gives a maximum possible score of 1,500.

In this way, teams must consider all performance aspects of their locomotives as well as try to persuade the judges to buy their machines in the business case challenge that, unlike the other challenges, provides a commercial focus.

One judge commented that, although some teams understandably focus on the difficult engineering aspects of their locomotives during their business presentation, in the real world there’s no point in building it if they can’t sell it.

A new requirement in this year’s competition was for the business case presentation to be supported by an A0 poster. To encourage audience participation, spectators were given the opportunity to vote for the best poster, although this was an unscored aspect of the competition.

LOCO SHED

The railway The Stapleford Miniature Railway (SMR) dates from 1958 when the second Lord Gretton purchased, second hand, two 4-4-2 steam locomotives and 2,000 feet of 10¼inch gauge track as an additional family attraction for his stately home and grounds, which were open to the public. The following year, the Haven station was built as the line was extended to the lakeside.

The line was so popular that an additional locomotive was soon acquired in the form of a replica Warship diesel locomotive powered by a Ford petrol engine, which entered service in 1962 and acts as the rescue locomotive during the Railway Challenge.

Further attractions were added in the 1960s in the form of two large-scale passenger-carrying model liners on the

HAVEN CAFE

STATION TOP CURVE

HAVEN BRIDGE

PLATELAYERS

CARRIAGE SHEDS

TUNNEL

COLBY’S CULVERT LAKE SPILL WAY BADGERS BEND

SCALE (METRES) 0

150

300

CHALLENGE MEASUREMENT SITES RIDE COMFORT ENERGY STORAGE TRACTION NOISE

JENNY’S BRIDGE

RIVER EYE

Aachen’s entry.

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FEATURE lake as well as a lion reserve and zoo.

In the 1970s the balloon loop from the Haven was built.

Lord Gretton's death in 1982 saw the railway closed to the public at the end of that season and put into storage. After the untimely death of the third Lord Gretton, Lady Jenny Gretton agreed to allow a small group of enthusiasts, including those who had previously operated the railway, to look at the feasibility of restoring it. In this way, the Friends of the Stapleford Miniature Railway (FSMR) was formed in 1992.

The group had much to do to make the locomotives serviceable again and restore the line, including rebuilding the tunnel under the drive to the house, before the railway could re-open in 1995 as a private railway with a limited number of open days each year.

The railway is an ideal location for the Railway Challenge as it is not normally open to the public and its three kilometres of track, with a balloon loop and a 1 in 80 gradient, are ideal for the locomotive trials. It also has plenty of hard standing at the station for work on locomotives and much open space for contestants to camp out. The competition is also dependant on the unstinting efforts of the FSMR’s

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Working on TfL’s locomotive. volunteers who operate the railway and provide the rescue locomotive and steamhauled spectator trains.

The organisation It needs 26 people to organise and run the Railway Challenge, 23 of whom are volunteers. These are a team of eight scrutineers, twelve judges and three controllers.

Sandra Balthazaar is the IMechE staff member responsible for the event. As well as dealing with the logistics of the event, she and her small team work

to attract entries and the essential sponsorship to fund the event. This year’s sponsors were Network Rail, RSSB, Young Rail Professionals, Eversholt, Angel, Porterbrook and Beacon Rail Leasing.

The Railway Challenge Steering Group is led by Professor Simon Iwnicki, who conceived the idea of the competition in 2011. This coordinates the work of other groups including the rules and development committees.

The competition takes place over three days. The programme broadly devotes

FEATURE

day one to scrutineering while day two is taken up with test runs, presentation challenges and the maintainability challenge, in which teams compete to remove and replace a wheelset in the shortest possible time.

Day three is the dynamic track challenges and the spectator day. This requires a detailed operational plan that has two locomotives undergoing different trials at the same time at the test area by the lake. Into this timetable are fitted a series of steam-hauled spectator trains from the station to and from the Haven, and the movements of the rescue locomotive, all under the control of the SMR signalling system as the FSMR control all movements, which are made at the request of the dedicated Railway Division’s controller.

The results As everyone gathered in the marquee for the announcement of the results, it was not clear who would be the overall winner despite the scoreboard showing how each locomotive had fared in its track-based challenges.

Master of ceremonies for the prize giving ceremony was head judge Bill Reeve, who considered that the event had “without doubt been the best challenge so far”.

He announced that SNC Lavalin had won the traction, ride comfort, innovation and design challenges. TfL had won the noise and business case challenges.

Ricardo had won the energy storage challenge and that, “with an amazing performance”, Sheffield had won the maintainability challenge as well as getting most votes for its business case poster. Ricardo, SNC Lavalin and FH Aachen University of Applied Sciences had completed all the challenges without any reliability issues and so were jointwinners of the reliability challenge.

Bill also advised that the judges wished to commend the Bombardier/Derby and Huddersfield teams which had shown “sheer bloody determination” to fix the problems on their locomotives. He also mentioned that the judges look out for teamwork and support and had particularly noted the support that Ricardo and FH Aachen had given to others.

Immediate past-president of the Institution, Carolyn Griffiths, presented the overall winner’s cup, but before doing so she stressed how the IMechE’s Railway Division had been a great support throughout her career. She recommended that anyone starting a career in railway engineering should become involved with the Division where they will find someone to support them.

She felt that the Railway Challenge was an example of this. The Railway Division had organised a fabulous event that helped young engineers make the transition from learning to doing with a demanding project and gave them the opportunity to learn from each

other. Carolyn stressed that there were absolutely no losers in the competition and that all the railway engineers present would have been proud to have built the locomotives entered.

She then announced the overall results in reverse order until it became clear that first-time entrants Ricardo was the overall winner.

The Swedish Challenge The IMechE’s Railway Division is to be congratulated in organising its Railway Challenge which is starting to attract worldwide interest. It is a unique event that replicates many of the challenges which replicate the issues faced by the real railway. Yet it is not the only event that challenges students to build an award-winning railway vehicle.

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Ricardo’s winning team with head judge Bill Reeve (entre).

An electric battery-powered rail vehicle challenge has been held at Delsbo in Sweden since 2010. This requires students to build a passenger-carrying standard gauge rail vehicle of the highest possible energy efficiency.

Last year’s winner was the University of Dalarna with a team that built a 100kg railcar powered by a 500 watt motor that carried five people. It consumed 0.76 watt hours per passenger kilometre over the three kilometre course which took twenty minutes to complete. During this time, the motor was only used for 110 seconds.

The Railway Challenge team has considered whether its competition could include an energy efficiency challenge. However, whilst it is relatively straightforward to measure the energy consumption of battery powered locomotives, precisely measuring energy consumption over a short distance for the variety of traction encouraged by the Railway Challenge is a different matter.

The future Sandra Balthazaar advises that the competition is attracting international interest with groups from Australia, Pakistan and Thailand considering how they can establish their own Railway Challenge. Indeed, this year’s event had a delegation from Thailand present to see how this could be done.

Also present at this year’s event was a team from Poland which wishes to enter next year. A team from Egypt had intended to enter this year’s event, and

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2017 Swedish Challenge winner.

Rail Engineer understands that Network Rail is also likely to enter a locomotive next year. With such interest, and increasing awareness of the event in the UK, Simon Iwnicki is confident that, in a few years’ time the event will have thirty or so entries.

Yet this year, it took most of Sunday for seven locomotives to complete their trials. With smart operating, the most that the Stapleford Railway could put through the trials in one day is fourteen locomotives. Like the real railway, the Railway Challenge suffers from a lack of capacity.

This problem has been considered by the competition’s development committee, which has developed a plan to enable 30 locomotives to enter the competition. This plan, which has been discussed and agreed in principle with FMSR and the current Lord Gretton, involves building an additional chord at the balloon loop junction, some doubletracking and a turntable, with sidings and hard standing, to accommodate additional locomotives at the station.

Surveying for this additional track is to start this summer.

The rules committee has almost finalised the rules and specification for the 2019 competition, which could include two additional challenges - an auto-stop trial that will require the locomotive to come to a stand a precise distance from a marker and a track damage trial to measure the locomotive’s impact on the track.

Whatever the future holds for the Railway Challenge, it is certain to continue to support the development of over a hundred young engineers each year and show them the support that is available from the IMechE’s Railway Division.

Equally importantly, it is hoped that it will attract much-needed budding young talent to the railway industry.

It is good to see industry support for the competition with Bombardier, Ricardo, Siemens and SNC Lavalin entering the competition. In addition, there is its sponsorship from Network Rail, RSSB, Eversholt, Angel, Porterbrook and Beacon Rail Leasing, with other companies sponsoring individual teams.

However, much more could be done, and Rail Engineer looks forward to seeing some new teams lined up when it attends the 2019 Railway Challenge.

Delivering Excellence Through Innovation & Technology

Specialists in Railway Challenges large and small Congratulations to our team of graduates and apprentices who won first prize at the IMechE 2018 Railway Challenge.

Each team spent months putting together plans, sourcing materials and organising test runs, before competing against other entries in a series of trials that included acceleration, energy storage, regenerative braking, maintainability and ride comfort.

This year’s event took place at Stapleford Miniature Railway over the weekend of June 30th / July 1st. Our thanks to everyone involved – all competitors, our hosts and the organisers – for a successful event.

To put our talented teams to the test on your projects, contact us: Email: railuk@ricardo.com Tel: +44 (0)1332 268700 www.ricardo.com Copyright © Ricardo plc | V1 0718

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FEATURE

TRANSFORMING rail travel in the North East

T

he Great North Rail Project is a multi-billion pound investment aimed at stimulating economic growth in the north of England by 2022 and creating more reliable journeys for the region’s passengers. It will enable 2,000 extra services each week and allow 40,000 more passengers to travel each day.

One of the weak spots on the current network was Newcastle station’s south junction, where the crossing units had a reputation for failure. In 2017 alone, there were a total of 15 failures, disrupting travel for over eight million passengers. In total, there were 19 dilapidated S&C units across a complex track layout, all of which needed replacement.

Network Rail was able to secure a nineday closure for the completion of the engineering works – a time frame unheard of for such a busy region. To ensure a successful and timely completion, steel engineering giant Voestalpine VAE was approached to supply the required panels.

Bespoke designs Working closely with Network Rail and the S&C North Alliance, a partnership of Network Rail and AmeySersa, Voestalpine VAE began the project with a technical assessment of the existing tracks, which hadn’t received improvements since the late 1980s. It became clear that

Rail Engineer | Issue 166 | August 2018

complexities such as the waybeams of the King Edward bridge, the inclusion of shallow depth concrete bearers and two instances of congested diamond arrangements meant that bespoke designs would be required for several of the deliverables.

First, Voestalpine VAE developed new adjustment switch baseplate designs to facilitate the standard clamping arrangements at the interface of the bridge and viaduct. This allowed the newly renovated track segments to be accurately secured with the existing waybeams of the bridge.

To provide the S&C to suit shallow depth concrete bearers, the company then designed and manufactured a significant quantity of bespoke cast-iron baseplates, which were kept as close to Network Rail’s standard designs as possible.

Finally, the team also designed two custom 1-in-8 slip switch diamonds – both on concrete bearers – for the two congested arrangements.

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FEATURE Units under construction in the Doncaster yard.

Challenging logistics With all panels designed and manufactured, the next challenge was to ensure successful delivery to the site. Throughout the nine-day closure, Newcastle station remained open to passengers, which meant all south-approaching trains were diverted to the north entrance. This increased activity meant delivery needed to be expertly coordinated.

To transport the 88 completed panels from its Doncaster construction yard, Voestalpine VAE scheduled 52 road trailers from two haulage companies. To overcome the site access constraints, the panels were arranged and stacked in reverse sequence for fitting and each one was restricted to a maximum mass of 15 tonnes.

This logistical preparation paid off, allowing delivery and installation to be swiftly completed within the nine-day window.

“A project of this size requires a lot of faith and trust from all parties involved,” said design manager Richard Parkin. “We developed an open working relationship with Network Rail and the North Alliance to ensure the S&C were designed, manufactured, assembled and delivered with military precision and to the criteria required.”

The bespoke innovations that Voestalpine VAE introduced for the renewal of Newcastle station’s south junction were specifically designed to provide reliability and longevity. With the project successfully complete, it is expected that the improvements will significantly reduce the frequency of signal failures and track issues for years to come.

Rail Engineer | Issue 166 | August 2018

Green Trough — the World’s most versatile cable troughing systems Trough-Tec Systems (TTS Rail)

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FEATURE

Renewals programme High Speed One

CHRIS PARKER

H

igh Speed One (HS1), originally known as the Channel Tunnel Rail Link, is reaching an interesting point in its history. Section 1 of HS1 opened in September 2003, running for 74 kilometres (46 miles) from Fawkham junction, near Gravesend in Kent, to the Channel Tunnel. High-speed services from France and Belgium then joined the conventional network and ran through to Waterloo.

To complete the line, Section 2 opened for business in November 2007, making up a total of 109km (68 miles) of 300km/h (186mph) high-speed railway which runs to the transformed St Pancras

Rail Engineer | Issue 166 | August 2018

International we know today.

The whole route was designed and built based on French experience but adapted for the UK. Whereas the main British rail

network is modern only from the track formation upwards, roughly speaking, with the basic infrastructure being mainly Victorian in design and construction, HS1 has the advantage of having recently-designed structures, embankments, cuttings and drainage that behave themselves very well by comparison with most similar railway assets elsewhere in the country.

HS1 Ltd holds the concession from the Government to operate, manage and maintain the high-speed railway infrastructure until December 2040. In July 2017, HS1 Ltd was acquired by a consortium comprising of funds advised and managed

by InfraRed Capital Partners Limited and Equitix Investment Management Limited.

The railway infrastructure and three of the stations are

FEATURE contracted to be maintained, operated and renewed by Network Rail (High Speed) Limited. The three stations are St Pancras International, Stratford International and Ebbsfleet International. One of the key route performance requirements is that the delay minutes per train be five seconds or under.

Routine maintenance Network Rail (High Speed), an organisation with over 400 staff, has the specialist knowledge to maintain a high-speed line with French high-speed switches and crossing. The infrastructure manager works towards the asset management objectives of safety, availability and cost, as set by HS1 Ltd. There is a small team of track staff that make up the track engineering and maintenance divisions. The key track maintenance activities are inspections, componentry changes and heavy mechanical interventions such as tamping and grinding. For a highspeed line, the track geometry needs very tight tolerances.

As an example, the line speed of 300km/h requires the vertical alignment (top) to be maintained to 9mm tolerance and the three-metre track twist to

6mm tolerance, which are tighter or equivalent to the construction standard for the classic network, Âą10mm and Âą6mm, respectively.

The tamping campaign also has a limited window due to weather and risk. Traditional long-wavelength tamping occurs in April and the short-wavelength geometry correction, also known as sprinter tamping, takes place in September to deal with localised defects that must be rectified quickly before they deteriorate into actionable faults.

Grinding is an important activity for geometry and wheel/rail interface management, in terms of ride comfort, RCF (rolling contact fatigue) and noise. RCF is a particular problem with freight and new rolling stock.

Time for renewal Due to the normal deterioration of the track asset due to ageing, it is coming to the point where a serious amount of heavy maintenance or renewal will be required.

A renewal strategy is being formulated and renewal plans

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FEATURE 40-year plan

refined as deterioration rates and failure modes become apparent. At the same time, maintenance strategy is evolving and being adapted to suit. Whilst technologies and processes are adopted, new associated competencies have to be developed for the team and new plant and tools product-approved to keep up with the changes.

One example is the current need for the replacement of a section of rail, typically an 18-metre length roughly once a month somewhere on the route. Until very recently, such rail replacements were required only about once a year. Head defects such as squats or failed insulated block joints (IBJs) are typical drivers of such works.

Rail-head damage may be caused by ballast flying up in the train slipstream, landing on the rail head and being run over by train wheels. More typical is damage caused by snow and ice on the rail, termed ice pitting, slightly different in appearance but equally harmful and specific to high-speed rail.

Rail grinding and possibly rail changing become necessary to cure these faults.

Another example is the need to deal with poor track quality at track stiffness transitions.

These occur at the change points between slab and ballasted track, at the ends of bridges and viaducts and even

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where the track passes over under-track crossings.

Deterioration can also occur in the highly canted curves found on some sections of the route (up to 160mm). These sections have tended to move under traffic and, like the stiffness transitions, necessitate extra tamping and realignment work.

This extra tamping results in increased ballast damage that is shortening the life of the ballast in the affected areas.

Further problems arise where rail welds are proud of the rail table for any reason.

A height difference of more than 0.5mm on the high-speed line will cause voiding under the adjacent sleepers. If not arrested, this deterioration develops and spreads as train wheels respond by vibrating and causing forces on the rails ‘downstream’ of the weld.

All of these issues mean that the overall level of asset degradation now requires the maintainer to consider responding in an alternative way, and it is therefore tailoring its approach accordingly. They also indicate a future requirement for heavy maintenance and the early development and implementation of HS1’s first renewals programme.

Network Rail (High Speed) is working on the development of a 40-year renewals programme.

HS1 is regulated very differently from the Network Rail infrastructure and, for HS1, Control Period 3 (CP3) begins in April 2020. While the main renewal effort is to begin in CP3, there are a few minor track renewals taking place earlier on some parts of the HS1 infrastructure.

An early site is the St Pancras S&C layout, which was constructed to the old RT60 design that has been shown to have inherent problems.

Although only around 10 years old, the track maintenance team has recently ordered spares based on accumulated experience from the classic network that these units have an average service life of only eight to 15 years, depending on tonnage and speed.

The plan is for renewals at St Pancras to commence with one S&C unit in 2018 and then continue at a rate of three per

“Excellence in Engineering”

Lundy Projects Limited 195 Chestergate Stockport SK3 0BQ Tel: 0161 476 2996 Email: mail@lundy-projects.co.uk Website: www.lundy-projects.co.uk

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FEATURE

Damaged by ice.

annum from 2019 until the whole layout has been covered.

The renewals are expected to be like-for-like, but taking advantage of the improvements that Network Rail has made to the underlying design, for example by using crossings that embody the revised and improved design of casting now available.

Network Rail (High Speed) also maintains some of Eurotunnel’s infrastructure at Dollands Moor, which is older than the rest of the route. It is planned that the first full track renewals should take

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Rail Engineer | Issue 166 | August 2018

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place there. A 1-in-24 vertical 113A crossover, dating back to 1990, is to be the first complete renewal. It is suffering from damage to the common crossing, track geometry quality issues and degradation of fishplates.

The renewal programme in CP3 is to include the use of a high output ballast cleaner (HOBC) on Section 1. Principally, this will be to deal with the deteriorated ballast on the highly canted sections where a large amount of tamping has taken place.

The challenge for this is the approval of equipment as the HOBC has not been used previously on HS1.

Looking elsewhere This is not the sole area where the distinction between HS1 and the main Network Rail network comes into play. HS1 is under very much greater pressure to keep the line open to traffic at all times. There is no possibility of blockades, for example, as can be employed at times elsewhere. These kinds of factors mean that renewals on the route require a different approach than that used by Network Rail on the rest of the network.

HS1 is therefore working with a number of possible suppliers besides Network Rail’s own Infrastructure

Projects track team, with the intention of going out to competitive tender for the works at the appropriate time.

Few UK contractors have yet had experience of renewing high-speed railway track, and this has to be seen as a great opportunity for gaining experience and building a reputation in this kind of work.

In addition, of course, there is a major workload ‘up for grabs’ in the CP3 renewal programme.

While all this is under consideration, there is also the matter of track standards for HS1. It is now time for a review and revision of the standards, to bring them into line with evolving modern practice.

HS1 has been in discussions with European consultants that have extensive knowledge and practical experience of high-speed rail systems in their own countries and elsewhere.

The intention is to work with them to update standards for HS1 in time for the standards to be utilised during the CP3 renewals programme.

With the development of the 40-year renewal plan, and with new technology being sought out and applied for the infrastructure manager to become more efficient in maintaining the asset, including the upskilling of staff, it is an exciting time for HS1 and all at Network Rail (High Speed).

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FEATURE

Digital Railway: DELIVERING DIFFERENTLY

PAUL DARLINGTON

F

ollowing the announcement in May by Secretary of State for Transport Chris Grayling and the chief executive of Network Rail, Mark Carne, that all new trains and signalling will be digital or digital ready from 2019, the Railway Industry Association, Network Rail and the University of Birmingham recently hosted an event to explore what this will mean for the supply chain and to examine the early plans for Digital Railway deployment in CP6. The University of Birmingham also explained how it is supporting innovation in the rail sector.

The event, held over two days, was attended by over 250 representatives from Network Rail, the supply chain, rail operators and other key stakeholders from across the industry. It was advertised as a networking event for potential suppliers and, in that respect, it was a great success. Attendees included the main signalling contractors, together with a good number of small and mediumsized enterprises (SMEs) and subsuppliers.

Network Rail explained how it will engage suppliers through a variety of frameworks and emphasised that its approach will be to specify outcomes, rather than having detailed technical specifications. The five-year Control Period (CP6, 1 April 2019 - 31 March 2024) spend on signalling will be £5.5 billion, compared to £3.3 billion in CP5 (1 April 2014 - 31 March 2019), so new ways

Rail Engineer | Issue 166 | August 2018

of working and innovation are required for commercial as well as engineering reasons.

The success of the digital rail programme will be reliant on the collaboration between government, regulators, suppliers, industry associations, professional institutions, infrastructure managers, train operators and academia, including research, which is one reason that the event was held at Birmingham University.

BCRRE’s DSIC Professor Clive Roberts, director of the Birmingham Centre for Railway Research and Education (BCRRE) at Birmingham University, opened the event by explaining that the Digital Systems Innovation Centre (DSIC) at the University will bring together existing academic and industry capabilities to innovate in new areas and to support transformational change in rail technology not only in the UK but across the globe.

The Centre builds on the expertise of the BCRRE and the UK’s industrial base to deliver a step change in rail systems capability. Securing a world-leading position in the sector to deliver jobs, growth and inward investment, both nationally and internationally, it will focus on all aspects of Digital Railway innovation and provide a system-wide approach to development and innovation.

FEATURE On many lines in the route, a level crossing may be located in a very long mechanically signalled block, with no way of an operator knowing where a train is in relation to the crossing.

This makes if very difficult to advise a user to cross until the train has cleared the long block, so the user may be tempted to use the crossing when it is not safe to do so. Digital technology will positively know where trains are and will safely interface with level crossing operation. Twenty percent of all train industry risk is still associated with signals passed at danger and, while TPWS has made a dramatic improvement, it will require ETCS to deliver the next step in risk reduction.

Rail Sector Deal

Initial areas of technological focus will include future railway operations and control, data integration and cyber security, smart monitoring and autonomous systems, together with introducing innovation and better system integration testing to speed up approvals.

All of these technical transformations have a part to play in the delivery of a more cost-effective, customer and carbon-friendly railway that safely delivers more capacity. The development of the centre of excellence in these areas will help the rail industry to “get there sooner”, thus improving the industry’s bottom line and reputation as well as supporting the UK’s export agenda in the post-Brexit world.

The Centre will house openly available facilities and have the ability to host bespoke research for specific sponsors that enable the railway and its interactions to be accurately represented.

Connected models, simulators, assets and humans will enable system, sub system and component levels to be developed, integrated and optimised for performance, capacity, resilience, sustainability, usability (customer satisfaction) and cost.

This will include optimisation of existing network and asset base management, as well as the technical and business evaluation of introducing technology change, together with the staging plans to enable seamless implementation.

BCRRE director Alex Burrows and David Clarke, technical director of the Railway Industry Association (RIA), gave an update on the Rail Sector Deal.

As part of its industrial strategy, the government is working in a number of sectors to reach agreements with business on ‘sector deals’. These deals are intended to be agreements that help each sector meet its key challenges and allow business to invest and grow accordingly. This is an important opportunity for the rail sector to push for the necessary support to drive forward the UK rail supply chain.

The rail industry is complex, with a total workforce of 600,000.

But the supply chain alone employs 250,000, which makes it one of the largest sectors - larger than, for example, train operators.

The Rail Supply Group (RSG), in partnership with the Rail Delivery Group (RDG), has been working with the government to develop an industry-leading and transformative Rail Sector Deal proposal that will enable new businesses, collaborating with other complementary industrial sectors, to sell innovative products and services to rail in both the UK and export markets.

By working together with the broader industry, the RSG and RDG are developing a proposal that has the potential to transform the railway and enable the UK’s supply chain to become truly world leading. The aim is to persuade the government to prioritise the sector and help unlock its future potential.

LNW Route Martin Frobisher (pictured above), Network Rail’s LNW route director, reinforced the message that the technology behind the digital railway is proven, for example as demonstrated by the recent success of the Thameslink ETCS ATO operation. The political support is solid and the ORR CP6 draft determination, released the week before the event, was in general very positive, so the industry has the technology, political support and the money.

He explained that the LNW route is the economic backbone of Britain as it connects six of the top eight cities in the country.

Compared to some other routes, the LNW has been one of the last to identify digital signalling opportunities, but plans now include digital signalling both for East-West Rail, ideally without lineside signals to save £30 million, and north of Crewe as part of the interface with HS2. Other schemes to enable new train services are also under development and may lead to further early deployments of digital signalling.

Castlefield Corridor in Manchester is a congested route that also includes freight services, so digital signalling traffic management may provide part of the solution. Traffic management will also be rolled out throughout the rest of this busy route and, as well as performance and capacity, Martin reminded everyone that digital signalling is also about safety.

Rail Engineer | Issue 166 | August 2018

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FEATURE RIA and its members are active in a number of areas to improve efficiency in the industry. This includes the Renewals Cost Challenge and the Electrification Cost Challenge, which aim to show that both government and industry, working together more efficiently, can reduce unit costs. RIA successfully lobbied for an additional £200 million of renewals funds to be released to Network Rail during CP5 to help avoid the traditional ‘boom and bust’ scenario of stop/go funding. This has a negative impact on efficiency and unit cost as it creates uncertainty and does not encourage suppliers to invest and innovate.

Supply chain Two of Network Rail’s commercial directors, Digital Railway’s Phil Bennett and IP Signalling’s Martin Robinson, explained the procurement approach for CP6. The work bank mix will have a greater emphasis on life extension and refurbishment than in CP5, preparing some routes for the digital signalling rollout in later control periods. However, the Signalling Equivalent Unit (SEU) volume count will still increase to 8,329 from the 6,000 delivered in CP5.

The contracting strategy for CP6 signalling will be based on one procurement system to promote efficiency within both Network Rail and the supply chain. This will be achieved by adopting flexible and easy-to-use frameworks to facilitate the best delivery mechanism for each project/programme, and to develop a wider supplier base, with more competition and lower supplier overheads.

In-cab signalling will make freight trains safer and more efficent.

Rail Engineer | Issue 166 | August 2018

The proposed supplier engagement model will encourage engagement, innovation and early contractor involvement. The model will enable alliances or partnerships, if required, for discrete projects/packages of work. It will also facilitate the transition to the stated future Digital Railway position of Design, Build & Maintain (DBM).

The major framework re-signalling strategy, including relocking and recontrol, is proposed to be packaged into two contract areas - North (LNE/ EM, LNW, Scotland routes) and South (Anglia, SE, Wessex, Western, Wales).

The geographical split would be guided by asset population density and will be a blend of frameworks and competitive tendering (around 30 per cent). The contracts will be known as Tier 1 and will be for four years with options to extend.

There will be parallel procurements for OEM professional services and support contracts.

Tier 2 framework contracts will be for targeted interventions, including level crossings renewals and related telecoms.

This would combine the existing CP5 ‘Type C’ signalling frameworks with ‘Level Crossing’ and the ‘IP Telecoms’ frameworks into one S&T framework contract. The packaging strategy will be of five areas: Scotland, Western & Wales, LNE/EM, LNW, and SE/Wessex/Anglia. In some routes, delivery for Tier 2 works could be done in house or in conjunction with a contractor.

To support the large increase in refurbishment and minor signalling works proposed in CP6, Tier 3 contracts will be established for framework route-based minor activities with little or no design, and to support ‘in-house’ delivery.

Essentially, these are for component renewals with the design requirements limited to route-based low-complexity works, typically up to £500,000 in value.

There will generally be two suppliers per route and the strategy will support the government’s SME agenda and help to develop the signalling supply base.

Software as a Service The current plan for the initial contracts for signalling in CP6 are: »» ECML - July 2018 onwards, to include ETCS and Traffic Management; »» Feltham ETCS - Autumn 2018; »» Crewe ETCS - late 2018/early 2019; »» Northern, Anglia, Wessex Traffic Management - Autumn 2018.

New innovative contracting strategies will also be established, one example being the Traffic Management Package (TMP) for the East Coast main line (ECML). This will be a 10-year Software as a Service (SaaS) contract, let using the Crown Commercial Service (CCS) Model Services Contract, covering the ECML from King’s Cross to Doncaster South, where it will interface with the transPennine traffic management scheme.

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Rail Engineer | Issue 166 | August 2018

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FEATURE

The TMP is expected to interact with both train-side and trackside components, therefore delivery of the TMP will interface with ETCS and rolling stock fitment suppliers. Apart from ensuring system availability, the TMP supplier will also be accountable for system integration, sustainment, optimisation and alteration of the system (to comply with group standard changes), training, performance reporting and obsolescence management.

Traffic management has been chosen to be procured as a service rather than as a capital asset, owned by the infrastructure manager, because there is no safety critical component, and the accounting rules allow for software to be costed as operational, rather than capital, expenditure.

The responsibility for second and third-line maintenance of the system would lie with the TMP supplier, including the training of maintenance staff. Training for operational staff will be the responsibility of either the TMP supplier or Network Rail, depending on the location of the equipment or operations.

Lessons learned One of the most interesting and important discussions during the day was on lessons learned from the Digital Railway projects already completed, or under way, both in the UK and around the world. A panel with representatives from Network Rail, Ansaldo, Siemens and Alstom gave their thoughts and answered questions on the deployments and in-service experiences of digital rail installations on the Cambrian Coast, Thameslink and Crossrail.

Items that were highlighted included that the interface and interworking between interlockings and the radio block centre (RBC) are not very well defined and that interworking between suppliers can be challenging. Off-site laboratory testing was considered key in proving interoperability. The requirement for space for on-board integration of equipment was another learning point, and that it is important to choose optimal TSI (Technical Specification for Interoperability) radio interface features and not UK-specific ones.

A number of the team commented that early on-site collaboration and involvement with operators and maintainers is key, together with collaboration with the supply chain. Many of the answers to problems are not yet available in a book on the shelf, so projects will need to identify who may have the answer from wherever in the industry. “Use ‘industry’ and not just ‘project’ delivery and involve everyone” was the message.

Infrastructure data must be complete and accurate, and defining the method of operation must be carried out early in a project.

The types of trains and their performance, and the impact of ETCS on the system performance, together with a robust and reliable timetable, will also be essential. Extensive soak testing and many miles of shadow operation was another key point.

Questions from the floor established the need for a central repository that should be available to anyone. Network Rail representatives confirmed that this is something they are looking into.

Rail Engineer | Issue 166 | August 2018

Alex Burrows and Clive Roberts explained lessons learned that had been obtained from around the world, which included Singapore, Netherlands, Denmark, Mexico and Australia.

These included that the requirements for business change when implementing Digital Railway technology must not be underestimated, together with a requirement for rigorous and realistic testing for integration and throughput. The need for a system approach with off-site laboratory testing was mentioned a number of times.

It was noted that a CBTC system in Singapore had a number of problems and was such a high-profile and important project to the city that someone knew a non-engineering friend who could quote in detail how a CBTC system should work. It was commented that Network Rail must avoid ETCS becoming a social conversation subject for the wrong reasons in a few years time!

Final thoughts on the event Questions throughout the day were thorough and challenging.

Vivarail chairman Adrian Shooter, formerly head of Chiltern Railways and London Overground Rail Operations, made the point that, while there was much talk of system engineering, it was disappointing that there were not many train operators or rolling stock providers present at the event. Network Rail responded that there was very close working with train operators at local route level, and that Network Rail would address the concern in future networking events.

With regards to how suppliers would be engaged by specifying outcomes rather than having detailed technical specifications, delegates asked how a signalling supplier could deliver the required outcomes (such as XX trains per hour capacity) as many of the constraints are system related, not signalling. For example, the type of traction and operation will be a major component of performance, and one which a signalling contractor may not be able to influence. Indeed, a ‘signalling plus ETCS’ operation could deliver worse capacity than at present if it is not designed as a system. It’s also great getting more trains through a network, but narrow platforms with poor entrance and egress facilities at some stations will just move the congestion problem somewhere else.

Platform dwell times are already a constraint in some parts of the network, so how will this be tackled if the Digital Railway does provide more train paths? Some quite simple things might reduce dwell - not requiring the guard to set foot on the platform before enabling the doors (a driver could enable them) and speeding-up door operation on some classes of train spring to mind.

System engineering, collaboration, innovation, efficiency, better use of data and laboratory off-site testing were terms frequently used throughout the event, and it will be interesting to see these concepts integrated into the CP6 delivery of the digital railway.

All in all, it was a good networking event. Rail Engineer looks forward to attending the next one, when there should be more operators and rolling stock representatives present, to continue to report on how delivering differently is making a difference.

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FEATURE

CLIVE KESSELL

Traffic Management

Clarity and Purpose?

London Bridge south side workstation in Three Bridges ROC.

W

hen Traffic Management Systems (TMS) were first described in Rail Engineer (issue 115, May 2014), they were heralded as a quick win to improve train operational performance with systems that could be rolled out in parallel with the Railway Operating Centres (ROCs) then being commissioned. Network Rail staged a ‘beauty parade’ from three suppliers - Hitachi, Thales and Alstom, all of whom had proprietary systems in use elsewhere - to see which ones could be integrated into modern-day signalling practice as employed on the network. From that, two contracts were let with Thales to provide TMS at Romford and Cardiff ROCs and evaluate the effectiveness of the technology.

Things have moved on considerably since that time and it is evident that TMS is a lot harder to implement than first imagined. Neither Cardiff nor Romford can be considered fully operational and other suppliers of systems have since entered the fray. TMS has also positioned itself differently within the Network Rail portfolio, which itself needs explanation, and it has become clear that TMS means different things to different people.

To try and pull this all together, the Institution of Mechanical Engineers (IMechE) and the Institution of Railway Signal Engineers (IRSE) staged a seminar in London recently to attempt to clarify what TMS is all about and to bring the attendees up to speed on the progress being made.

It proved to be an interesting day, although not without a few red herrings being injected into the proceedings.

TMS and the Digital Railway If ever a word in our current language is overworked, it is ‘Digital’. Everything you touch these days has to be digital to be of any use and regrettably ‘Digital Railway’ seems to be following the same pattern.

PHOTO: ALSTOM

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Rail Engineer | Issue 166 | August 2018

CTC Control Centre, Hong Kong.

Describing the digital railway as the ‘system of systems’, an opening presentation by Vish Kalsapura described how all the main players in the rail industry are working together to produce a shared vision and a whole-industry approach to achieve a railway that will perform better and give the operational benefits that come with digitisation. The vision of Network Rail, the Department for Transport (DfT), the Rail Delivery Group, Rail Freight Group, Railway Industry Association (RIA), the train companies and the supply chain is to deliver more trains with better connections and greater reliability by means of improved journey

FEATURE management, capacity gains, service delivery improvements and life cycle considerations.

There is recognition that the industry is complex and fragmented, with lots of silos, and thus a consistent architectural model with clearly defined interfaces between systems is all part of the digital railway objective.

Heavily focussed on the roll out of ERTMS, TMS will link into ETCS, GSM-R, C-DAS and associated business systems, all connected together by the FTNx transmission network of Network Rail Telecoms.

A customer specification is believed to be needed, but one might ask the question “who is the customer?”

TMS is apparently being specified on a prescriptive basis, which reduces the scope for innovation but observers might comment that the original intention was to purchase off-the-shelf proven systems.

There is a need for a Systems Authority to be created - now where have we heard that before? If this leads to a better understanding of the complexity, a minimisation of unintended consequences and an alignment of interest groups, then that can only be beneficial.

A European perspective

Acronyms defined:

It seems that it is not just the UK that is struggling with TMS. Pio Guido from the European Railway Agency (ERA) - recently rebranded the European Union Agency for Railways (to keep the UK out post-Brexit? Even the railways are not immune from political posturing) - reminded people that, within ERTMS, there is the European Traffic Management Level (ETML) that has made little progress in the aim of developing a Europe-wide standard.

The interoperability vision has resulted in the ETCS safetycritical layer reaching a stable state whereby railways can confidently procure systems from different suppliers that operate to a common standard.

ETML requirements are a long way from being in a similar state and thus lack compatible innovation and investment protection. Moreover, some of the vital information that has to be supplied from ETCS, such as speed and position of train plus train integrity, is missing.

In short there is a need for a closed loop to permit a constant information exchange between track and train. This in turn demands a much-improved radio link between track and

»» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »» »»

PHOTO: ALSTOM

CTC Control Centre, Hong Kong.

4LM - Four Lines Modernisation programme 5G - Fifth-generation GSM mobile communications ARS - Automatic Route Setting ATO - Automatic Train Operation ATP - Automatic Train Protection ATR - Automatic Train Regulation ATS - Automatic Train Supervision AWS - Automatic Warning System C-DAS - Connected Driver Advisory System CBTC - Computer-Based Train Control DfT - Department for Transport ERA - European Railway Agency ERTMS - European Rail Traffic Management System ETCS - European Train Control System ETML - European Traffic Management Level FTNx - Fibre-optic upgrade to the Future Telecoms Network GSM-R - GSM mobile communications for railways IMechE - Institution of Mechanical Engineers IRSE - Institution of Railway Signal Engineers LU - London Underground MMI - Man/Machine Interface RIA - Railway Industry Association ROC - Railway Operating Centre SBB - Swiss State Railways TfL - Transport for London TMS - Traffic Management System TPWS - Train Protection and Warning System

train, way beyond what GSM-R is capable of offering. TMS has to provide governance, regulation and collaboration for the successful running of a railway.

TMS benefits and experiences The emergence of Indra as a TMS supplier is logical as the company has for years engaged in air traffic control, road tunnel management and seaport operation. Javia Pozo outlined some of the realities of applying TMS to existing rail technology - lots of non-standard infrastructure, non-unified operating procedures, many different interfaces, all of which are non-scalable and expensive to set up and maintain. These make implementing TMS a difficult task. Couple this with TMS suppliers having developed proprietary systems and the scale of the challenge is easy to see.

The subsystems of timetable, operations, resources, track works, C-DAS, interlockings and train-operator management

Rail Engineer | Issue 166 | August 2018

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FEATURE Thameslink will have one of the first live TMS applications in the UK.

have to be capable of integration if TMS is ever going to work successfully. The roll out of the ROCs is the key to making this happen, but the TMS suppliers should, in turn, aim to agree a unified specification with a standard interface to the sub systems. History would show that such cooperation does not come naturally.

The basics for TMS are relatively easy: »» Constant timetable and track management data; »» Constant updating and forecasting of train times and routes; »» Conflict identification; »» Display of current network and train running data; »» Production of a Simplifier to advise (or even direct) signallers/controllers on optimum train routing and control.

It can be done: Spain and Lithuania have national-level TMS implementation based on a single-supplier system but integrated with several different types of interlockings. While they are smaller railway systems than the UK, there may perhaps be lessons to be learned.

The London Underground experience

Rail Engineer | Issue 166 | August 2018

Traffic management has resulted in some time-honoured practices being revised.

Junction control is one example; it used to be first-come first-served, regardless of the timetable. TM now calculates whether it is beneficial to hold a train until the late train goes through. The whole purpose is to give greater flexibility and providing expert decisions to reduce operator workload.

Even on LU, the software to link ATR and ATS is complex, with the number of inputs involved, and the systems do not always deliver what was intended. ATR has, however, proved successful on the Victoria Line and is an inherent feature of the Thales Seltrac system, where its effectiveness has been independently verified on the Jubilee line.

Lessons learned will be applied to the 4LM upgrade involving Metropolitan, District, Circle and Hammersmith & City lines. Using simulators for testing and training is essential, with ATR particularly difficult to test and understand. It is necessary to have people on hand who have the knowledge to recognise how undocumented ‘work arounds’ are used when things start going wrong - good advice for future main line plans.

Reporting on progress with TMS is not easy. Andy Bourne - ex-LU but now with Arcadis - gave an honest assessment.

The prime aim is to achieve timetable de-confliction and reduce knock-on delays when problems occur. Whilst incidents are statistically down in number, the delay per incident has increased, hence the need for TMS. How to use TMS is also a challenge.

There is isolated TMS, which uses it as a decision-support tool to give advice to signallers, and also integrated TMS that will provide semi or fully automatic implementation of a revised timetable plan. Linkage to other systems is vital, as has been noted, but particularly to stock and crew deployment, C-DAS and signalling systems, also to business systems that are the contractual boundaries for how the railway operates.

The project-by-project progress shows mixed results: »» Romford - Thales Aramis system yet to go fully live; »» Cardiff - Thales Aramis system is live and used for timetable de-confliction; »» Thameslink - Hitachi Tranista system is trialling timetable data but not expected to go live before mid-2019; »» Western London to Bristol - Using the Resonate (ex BR Research expertise) Luminate system, it is live since June 2018 on a trial basis with updates expected during the trial. Whether to proceed further will be decided in mid 2019.

Future schemes are planned for the South East, East Coast main line, TransPennine, Manchester ROC, Anglia, Wessex and Chiltern. Three Northern areas will merge into a single TMS scheme based upon a 20-minute look-back at train running data.

The future intent will be for route-based schemes with standard procurement components and alignment to ROCs. PHOTO: RESONATE

London Underground claims to have TMS structured in two layers, according to Ivan Curties from Thales: Automatic Train Supervision (ATS) and Automatic Train Regulation (ATR). The former is there to achieve timetable adherence, the latter detects perturbations that the operators might not see. LU operation is recognised as simpler than the main line as trains are usually the same length with the same station stops, have identical performance and do not split or join. Increasingly, LU trains are ATO (Automatic Train Operation) and performance comes from the sequence of ATO ATP (Automatic Train Protection) ATS ATR.

UK experience to date

Platform Docker output from Resonate’s Luminate TMS.

PHOTO: ISTOCKPHOTO.COM

FEATURE

The Swiss experience Awareness emerged during the recent IRSE convention that SBB has developed an in-house TMS system for the entire Swiss rail network, and Daniel Achermann provided more detail at this seminar. On a 2,000-mile network, handling 10,500 trains per day, SBB has four operational control centres that absorbed three area centres, 21 local centres and 130 local signal boxes.

The result is a standardised signaller’s desk and MMI from which can be displayed the track layout and signalled movements, the train graph, connections management, station management, energy optimisation and telecoms facilities.

Incorporated into the TMS is timetable, topology, train formation and train movement

Train-braking and TMS The variables in braking performance of rolling stock are well known, with adhesion in the autumn being a dominant problem. Whilst different types of sanding, and even magnetic track brakes, may be part of the solution, Neil Ovenden from the Rail Delivery Group questioned whether TMS could be used to modify the timetable on a day-by-day basis when adhesion problems were predicted?

Similarly Ian Hersey and Matthew Hattersley from TfL explained the safe-braking model that purports to ensure safe train separation whilst at the same time obtaining

Hitachi is supplying the TMS for Thameslink.

PHOTO: HITACHI

Not having TMS as a standard product is a real problem, as it leads to difficult interfaces and linkage to C-DAS. Getting TMS provided on Thameslink, with its ATO capability, represents a significant challenge and will require close cooperation between the ETCS/ ATO supplier and the TMS contractor, according to Andy Powell from Siemens.

With difficult junctions at both ends and nominal 60-second dwell time at stations, the opportunities for things to go wrong are considerable. The operator’s workstations will need more information, so leaving space for TMS screens is important. Being able to simulate a full workstation with TMS added will be essential for achieving successful system integration.

information that links into and out of signalling, C-DAS and ARS (Automatic Route Setting).

Since 2009, SBB has seen a 28 per cent increase in passenger numbers, a 16 per cent increase in train movements, a nine per cent improvement in track usage, a four per cent reduction in energy consumption and a 25 per cent reduction in train running costs, much of this down to the TMS system.

It’s quite remarkable what a railway organisation can achieve with the right determination, expertise and organisational structure.

Rail Engineer | Issue 166 | August 2018

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FEATURE

PHOTO: RESONATE

Train Graph output from Resonateâ&#x20AC;&#x2122;s Luminate TMS.

capacity improvements. The scope for errors is considerable, with the worst case being a first train stopping short and a following train over-running. Could TMS be used to optimise train propulsion commands, braking instructions and emergency braking rates to obtain a reduced separation between trains whilst retaining a safe distance? Food for thought and probably something the TMS suppliers have yet to consider.

TMS for the Elizabeth line The specification for the impending Crossrail train service performance is demanding and requires scheduled departure times on the surface sections to be kept, precision timings at the tunnel portals, and consistent train separation intervals with no bunching through the central London section.

Russell Parish, the performance manager for the Elizabeth line operations team, explained the factors that will make this a considerable challenge. With four different types of signalling system (CBTC with ATO in central core, ETCS, TPWS and AWS on the different surface railways), many trains terminating and reversing at Paddington, three signalling control centres (Romford, Liverpool Street and Didcot) plus Swindon and the underground-section control centre, mixing in with other traffic including freight on the surface lines, some flat junctions, even minor delays will have an exaggerated effect. TMS is needed to re-plan services when the need arises.

Forecasting and re-forecasting is likely to be a continuous process.

Rail Engineer | Issue 166 | August 2018

Blue Sky thinking?

A somewhat fanciful prediction on how the future might look was given by Andy Doherty, the chief technical officer at Network Rail. Expanding on the Digital Railway theme, with the somewhat dubious statement that ETCS Level 2 and TMS is now the norm, he predicted that ETCS Level 3 (both normal and hybrid versions), 5G radio and an open backbone, a supplier-agnostic approach to radio block centres, interlockings and trackside components will all lead to a reduction in signalling costs.

Station systems for customers, dynamic ticketing, real time timetable planning, live interfaces between train and road

traffic at level crossings, plus adoption of automotive digital techniques, were all part of the vision. The statement â&#x20AC;&#x2DC;data, data everywhere but not a drop of informationâ&#x20AC;&#x2122; is thought to be where we are currently, with the Digital Railway being needed to pull it all together.

Whether this is realism or a dream world was up to attendees to judge All in all, it was a strange day with differing requirements for TMS emerging out of the proceedings. One could not help thinking, particularly with the present timetable fiasco, that more concentration on getting TMS put to good use on the present railway is perhaps where the effort should be concentrated right now.

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