TRANSPORT SERVICES MAINTENANCE SUPPORT SERVICES p. 6 Rolling Stock Maintenance p. 22 Training p. 12 Accident Repair p. 24 E-Documentation p. 14 Entity in charge of maintenance p. 26 Obsolescence p. 16 Signaling maintenance p. 28 Asset Management p. 18 Infrastructure maintenance p. 30 Expertise Support p. 32 Depot Design p. 34 Recycling p. 36 Integrated Fleet Support MODERNIZATION PARTS & REPAIRS p. 40 Energy Saving Modernization p. 58 Spare parts p. 42 Traction p. 60 Repairs p. 44 Diesel and Hybrid p. 62 Availability Service p. 46 Bogie p. 64 Overhaul p. 48 Train System p. 66 Test Benches p. 50 Signaling p. 52 Passenger experience p. 54 Accessibility About this document This document is designed to provide an overview of the Alstom Transport Services offering. Alstom Transport Services is a 20 year old organization that currently operates in over 70 maintenance depots in 30 countries, providing dedicated solutions to meet client requirements for rail vehicles. Servicing trains requires advanced knowledge of the many and diverse aspects of the rail industry and Alstom’s experience is not limited to Alstom-built rolling stock. Indeed, 20% of the trains maintained by Alstom were built by other manufacturers. Alstom’s servicing offering includes everything from undertaking corrective and preventive maintenance to simply providing parts and technical support. As detailed in this catalogue, Alstom’s offering also includes a wide range of services to support and enhance your operations, from regulations, life cycle management and enhancement to obsolescence, real time operational data and electronic documentation. This service offering draws on Alstom’s involvement and understanding of the rail industry and offers train owners, operators and maintainers an opportunity to improve service efficiency and effectiveness. The proposals included in this document recognize the importance of ensuring that vehicle assets are correctly managed throughout their life cycle. These proposals also illustrate enhancements which can increase fleet capacity (passenger or freight), reduce operating costs (such as energy), and optimize maintenance costs. This also offers added value to maintainers by ensuring parts are available when needed, as well as optimizing working methods based on improved data utilization and integration within the maintenance organization. Finally, Alstom Transport Services also benefits from extensive consulting and training experience. This ensures customers benefit not only from our in-depth knowledge of train maintenance, but also from the services of a global vehicle designer and manufacturer that has access to information and knowledge that can be applied to the rail service industry. MAINTENANCE Rolling Stock Maintenance Core service: guaranteeing fleet availability every day - whether Alstom built or not Train availability is critical for operators. To help them meet their availability targets, we offer long-term partnerships based on efficient and flexible maintenance solutions: from providing technical support and spares, to a fully outsourced maintenance operation. Our core service offering provides operators with high fleet availability delivered by Alstom maintenance teams. Benefits Key References •• Guaranteed availability allows enhanced focus on operation •• Maintenance budget control over rolling stock life time •• Single partner to optimize maintenance across all fleets, whether Alstom manufactured or not. Light Rail Vehicles: Core Service typically covers: Performance •• Corrective and preventive maintenance including parts provision and inventory management •• Train and component overhauls •• Wheels and axle management •• Maintenance performance analysis and continuous improvement •• Obsolescence monitoring, alerts and solutions •• Depot operation •• Depot upgrade Alstom provides methodologies, processes and tools as well as the workforce. Typical contract duration is between 10 and 30 years. 6 Transport Services Train availability and reliability Our value added •• A reliable partner, able to maintain competitor products •• Local presence and qualified staff worldwide •• Robust mobilization process for maintenance take-over without service disruption •• ‘Pit Stop’ approach supported by innovative predictive maintenance tools. •• France, Orléans, 22 Citadis, 11 years from 2000 •• Algeria, Alger, 41 Citadis, 27 years from 2011 Metro: •• Chile, Santiago, three lines since 2004 Regional trains: •• Germany, NWB, 48 Lint DMUs •• Italy, Trenitalia, 214 Minuetto EMUs and DMUs, six years from 2011, 12 ETR600 New Pendolino & 7 ETR610 New Pendolino, five years since 2009 More than 30 contracts worldwide. Core Service - Second maintenance service level MAINTENANCE Minuetto maintenance, Italy In response to growing passenger traffic on regional trains, TrenItalia decided to outsource Minuetto maintenance (214 EMU and DMU trains). The six-year contract began in November 2011, covering: •• Preventive maintenance, level 1 and 2 •• Corrective maintenance •• Logistics support and engineering •• 18 depots throughout Italy •• 5 logistics hubs Challenge Focusing on core business by outsourcing maintenance. Optimizing operations A year later… To manage Minuetto maintenance operations, Alstom took over 18 depots throughout Italy and a workforce of 200 people. •• 20% rise in kilometres travelled •• 23 million kilometres covered since May 2012 •• Increase in fleet reliability: +9% for EMUs and +24% for DMUs Alstom’s computerised maintenance management system (RailSys) was implemented in all depots for work-orders and stocks management activities. TrainTracer™, Alstom’s remote monitoring solution has been deployed on the fleet. This powerful preventive maintenance tool is used while a train is in service to relay information on its condition in real time via radio transmission to the maintenance depots. In order to streamline sourcing and reduce costs, more than 200 contracts with more than 130 suppliers have been renegotiated for the purchase of materials. Close attention has been paid to training: after more than 14,000 hours of training courses, focusing particularly on technical topics, 130 maintenance personnel are now qualified and certified. Transport Services 7 Rolling Stock Maintenance TSSSA: Technical Support and Spares Supply Agreement Benefits Key references It combines two distinct services: Technical Support and Spare Supply Agreement. •• Support fleet reliability and availability •• Develop customer maintenance skills •• Reduce inventory Our Technical Support service typically includes: Performance •• USA: Amtrak, Acela Express, 20 High Speed Trains, 10-year TSSSA (2006 to 2016) •• UK: ScotRail, Class 334 40 x 3 cars EMUs •• South Africa: PRASA 600 EMUs, Rolling Stock supply plus TSSSA over an 18-year period. TSSSA service is targeted at operators wanting to secure fleet availability while keeping their own maintenance resources. •• Help desk / On-site assistance for daily maintenance •• Maintenance performance analysis and continuous improvement •• Obsolescence monitoring and alerts •• Customer maintenance staff training •• Engineering support / Design Authority Based on a Spares Supply Agreement, we manage: •• Delivery, within an agreed lead time, of parts and kits required for preventive maintenance, corrective maintenance and overhaul •• Supply chain and warehouse management •• Component repair and overhaul •• Secure spare parts and repairs supply (no short-outs, committed lead time) •• Fleet reliability and availability (subject to maintenance audit) Our value added •• Extensive expertise as OEM and maintainer •• Proven solution with extensive REX worldwide •• ‘State of the art’ methods and tools •• Supply chain excellence and obsolescence monitoring. TSSSA - First maintenance service level 8 Transport Services MAINTENANCE Acela maintenance, USA ScotRail, UK Technical Support and Spares Supply Agreement (TSSSA) for Acela Express, the Amtrak’s high speed train for the Northeast Corridor, located in the northeastern USA. Technical Support and Spares Supply Agreement for ScotRail. 40 x 3 cars Class 334 Juniper EMU Scope •• Management and supply of all equipment: 4,600 items; 600 suppliers, out of which 85% from USA •• Overhaul kits •• Preventive maintenance kits •• Corrective maintenance material •• Technical engineering support available 24/7 •• Obsolescence management Performance •• 99.8% On Time In Full delivery •• 90% within 15 minutes of the request •• Fleet availability increased from 14 to 17 train sets Scope •• Management and supply of all materials for level 1-4 maintenance •• Crash, abuse and vandalism materials •• Technical engineering support •• Reliability improvement tied to a performance regime Performance •• No train held for missing material since the beginning of the contract •• 100% parts delivered on time •• 1600 items managed in total •• 2000 items supplied per month •• 6-8 weeks turnaround time for repairs. Transport Services 9 Rolling Stock Maintenance Full Service: all-inclusive maintenance service - whether Alstom built or not This service is targeted at operators who want to fully concentrate on their core business. The task of making the trains available and fully ready for service every morning of every day is entrusted to the Service supplier. In addition to the core service offering, this service includes train cleaning and preparing the train for service. Full Service maintenance typically covers: •• Corrective and preventive maintenance, including parts provision and inventory management •• Train and component overhauls •• Wheels & axle management •• Maintenance performance analysis and continuous improvement •• Obsolescence monitoring, alerts and solutions •• Internal and external cleaning •• Train preparation •• Depot operation •• Depot upgrade Alstom provides methodologies, processes and tools as well as the workforce. Benefits Key references •• Guaranteed availability allows full focus on operation •• Maintenance budget control over rolling stock life time •• Single partner to optimize maintenance across all fleets, whether Alstom manufactured or not •• Reduction of contractual interfaces to be managed. Original Equipment Manufacturer (OEM) Performance •• Train availability and reliability •• Quality of cleaning service Our value added •• A reliable partner, able to maintain competitor products •• Local presence, qualified staff worldwide •• Robust mobilization process for maintenance take-over without service disruption •• ‘Pit Stop’ approach supported by innovative predictive maintenance tools. •• Spain: Renfe, AVE Very High Speed Trains •• Italy: NTV, Italo Very High Speed trains •• UK: Virgin Trains, West Coast Main Line, High Speed Trains Non-OEM •• Turkey: TCDD, CAF High Speed Trains •• Romania: Bucharest Metro, 4 lines, ASTRA metro cars and Bombardier metro cars Mix-OEM •• Sweden: Stockholm Stag, X60 and X10 fleets …more than 20 customers worldwide. Full Service: highest Maintenance Service Level 10 Transport Services MAINTENANCE Solution Alstom Transport Services provides 24/7 maintenance of the Pendolino fleet. It developed a partnering approach between the operator and Alstom as the service provider, aligning its objectives and behaviours. Full service in UK - West Coast Main Line In 2008, Virgin positioned itself as a new operator that would revolutionize British rail travel using the high speed tilting Pendolino fleet. At the end of 2008, Virgin Trains launched a very high frequency timetable leading to an increase in passenger numbers. Challenge A twofold challenge: implementing a highly efficient maintenance operation capable of supporting the vision of WCML operations and improving inherited infrastructure to meet 21st century rolling stock needs. Lean Maintenance approach based on APSYS (Alstom Production System): all maintenance tasks have been examined to eliminate non-value added activities and strategically position line side materials, enabling maintainers to carry out tasks without returning to central stores. In agreement with the customer, Alstom has been able to remove 1,000 scheduled exams per year. Smart monitoring and ‘pit stop’ approach: Thanks to TrainTracer™, fault data are sent to depot for immediate action and planning. Teams can also communicate with drivers to establish corrective action while the train is still in service. This has led to the development of a pit stop approach to train maintenance: the right person in the right place with the right tools to reduce downtime and increase safety. Finally, overall time savings are up to 30%. Overhaul with no impact on availability: Higher fleet mileage means that 18 bogies per week are currently overhauled every 18 months. Thanks to a combination of planning, skilled teams and close cooperation with the operator, Alstom executes these overhauls with no change to daily fleet availability. Today, around 800 people are currently employed at five maintenance depots. They are supported by a train engineering centre of excellence. Performance •• Number of trains available per day: 47 out of 52 •• Mean Distance Between Affecting Failure: 20,000 miles •• Number of miles covered per year: 17 million Transport Services 11 Accident Repair Repair backed by manufacturer engineering capabilities Our repairs service covers both accidents and acts of vandalism. A damaged vehicle must be put back into service as quickly as possible. We offer expertise and efficient assistance should the worst happen. Benefits Key references Based on a pre-agreed process, immobilization time is reduced to a minimum, enhancing overall fleet availability and revenues. Original Equipment Manufacturer (OEM) Depending on the complexity of the structural repair, strength calculations may be required. For severe accidents, a complete carbodyshell exchange may be proposed. Performance For vandalism, a price list can be agreed with the customer for standard vandalism damages. Our value added Accidents: when required by the customer, Alstom will supply a specific repair proposal. Repair works begin after the client’s approval has been received. For minor repairs, a process based on a simple photo of the damaged part can be applied. 12 Transport Services Lead time and repair quality to guarantee long-term asset protection. •• Alstom Transport masters all technologies: steel, aluminium and hybrid •• Local presence - qualified staff worldwide, large industrial footprint •• Access to worldwide supplier panel •• Covers OEM and non-OEM products. •• Germany: Regio-Citadis, Lint and Hybrid locos •• UK: Virgin Trains Pendolino Non-OEM •• Germany: Flirt, Desiro and Talent trains; Waggon repair •• UK: Incentro trams •• USA: MBTA Green Line, MTA LRV, WMATA 3000 MAINTENANCE was needed for asset protection and insurance requirements. Thanks to upfront preparation and a strong industrialization process, this complex repair was executed within 12 days, including: Aluminium structural repair to damaged Virgin trains UK, West Coast Main Line, Class 390 fleet. Trainset 013 sustained damage to the roof and cantrail areas on the 699 & 692 vehicles on April 9 whilst running on the network. The trainset had temporary repair work before returning to service on June 9. was located in a very sensitive area in terms of the aluminium structure’s static and dynamic resistance. The strength of the structure could have been badly affected by the repair if was not properly executed. In addition, repair time was critical to reducing impact on train availability and revenue earning for the customer. Solution Challenge Taking advantage of Alstom UK’s maintenance environment, it was decided to manage the repairs at the Midlands Traincare centre. Although Alstom UK had previously repaired damaged vehicles, the damage sustained by 013 was the most severe to date. The damage The repair procedure relied on support from Alstom Italy for preparing the repairs and structural calculations for the safety case which •• Carbody preparation •• Paneling removal and equipment dismounting •• Welding •• Welds non-destructive testing •• Refitting •• Extensive testing of sub-systems •• Paint back to original TOC (train operating company) livery •• Return train to service This demonstrates Alstom’s ability to conduct repairs within the confines of a maintenance environment with a multi-functional and disciplined team to achieve targets through planned activities as opposed to conducting repairs at a third party which would have taken several months and the loss of train availability. Transport Services 13 ECM Full responsibility for Maintenance in accordance with EU Regulation 445/2011 ECM is the Entity in Charge of Maintenance as defined by European Regulations. This is the entity that is responsible for the full maintenance process. Under the ECM service, train maintenance responsibilities are fully transferred to Alstom, whether for OEM or non-OEM trains, releasing operators from the need to be legally listed on the National Vehicle Register. The service includes: A. Definition of the organisation responsible for all aspects of vehicle maintenance definition and management B. Lifetime train maintenance documentation management C. Fleet maintenance management (planning of trains, maintenance exams, facilities and timescales) D. Maintenance execution - competent execution of maintenance activities according to maintenance instructions 14 Transport Services Benefits Key references In full compliance with EU regulation 445/2011, this service places the direct responsibility on the supplier, allowing the operator/owner to concentrate on their core business. •• Italy, NTV VHST trains, full ECM responsibilities •• Germany, MEG hybrid shunters •• Germany, Salzgitter, Alstom workshop certified as ECM for the maintenance of freight wagons •• France, Diesel locomotives Performance Performance remains a contractual commitment under maintenance contracts. Our value added •• A reliable partner, able to maintain competitor products •• Local presence - qualified staff worldwide •• Documented maintenance management system that meet or exceed regulation requirements •• ECM experience in three countries •• ECM-certified workshop in Germany. MAINTENANCE Train Maintenance & ECM for NTV, Nola Workshop, Italy Alstom Transport has signed a 30-year Maintenance global service contract with the operator NTV for a fleet of 25 AGV trainsets. NTV asked Alstom to be the registered ECM for this fleet of trains. Challenge Full ECM responsibilities on behalf of the train owners/ operators in accordance with EU Regulation 445/2011. Solution Alstom began by requesting a pre-certification assessment from an independent certification body based on clause-by-clause compliance with the regulations. This required us to be able to demonstrate evidence of compliance with a documented maintenance management system that met or exceeded all regulation requirements. This was then checked via a site audit by the certifying body. The process was shared with the client and the safety authority and resulted in a positive result on compliance. Demonstrating our approach led to the development of a business risk assessment which, in itself, allowed the project to further improve its management and performance in certain areas. This can now be used as the model for other projects in the pipeline in Italy and elsewhere in Alstom maintenance facilities. Compliance with the regulation had to be demonstrated to the satisfaction of the operator and audited by the National Safety Authority (ANSF). Full ECM responsibilities on NTV Transport Services 15 Signaling maintenance Repairs backed by manufacturer engineering capabilities Delivering full maintenance services to allow customers to transfer the operational responsibility of signaling line availability based on a service level agreement for all maintenance operations. Benefits Key references •• High availability •• High reliability •• Cost reduction Service Level Agreements proposed include as standard: Performance •• Netherlands: Betuwe Route European Railway Traffic Management System (ERTMS), 160km of trackside signaling, 2011-2026 •• Netherlands: Hanzelijn ERTMS, 2012-2027 •• Switzerland: Mattstretten-Rothrist ERTMS, 2009-2019 •• Belgium: Infrabel (ERTMS, Wayside, Inter locking), 2012-2033 •• Italy: RFI (Interlocking Frame Service Contract), 2006-2016 •• Italy: RFI Automatic Train Protection (ATP), Sistema Controllo Marcia Treno (SCMT) Frame Service contract: 2008-2014 •• Denmark: Fjern Bane East (ERTMS, Wayside, Interlocking), 2017-2027 •• Preventive maintenance Set-up, management and control of yearly schedules and Life Cycle Plan Execution and fine tuning of yearly plan with RAMS feedback •• Corrective maintenance Incident management, field servicing/interventions, offline support, component repairs •• Technical Support Support helpdesk (24/7), Change management, Strategic stock and configuration management, Performance management, Data management, Maintenance optimization, Quality Assurance & Environment Health & Safety (EHS) compliance 16 Transport Services •• Guaranteed system availability •• Mean Time to Repair •• Contractual intervention time on field Our value added •• A reliable partner with large expertise in maintaining wayside and carborne signaling products •• Local presence - qualified staff worldwide MAINTENANCE Betuweroute freight line The Netherlands, Keyrail, Betuweroute freight line, full maintenance of ATLAS™ ETCS. The Betuweroute is the first dedicated rail freight line in Europe, stretching from the port of Rotterdam, the largest in Europe, to the German border. It is equipped with Alstom’s ERTMS technology allowing freight trains free access across the entire EU without having to stop at borders or make way for passenger trains. The line is operated by Keyrail, a company formed by the companies which run the ports of Rotterdam and Amsterdam as well as the Dutch infrastructure operator ProRail. Keyrail facilitates rail freight transport and aims to make the Betuweroute an indispensable link in the international transport chain. Keyrail required maintenance specialists to ensure the availability and performance of this sophisticated new technology. As the system supplier, Alstom was a natural choice thanks to its expertise in the field. In December 2006, Alstom was awarded its very first ERTMS maintenance contract for the Betuweroute, lasting four years. Solution Benefits Alstom’s full maintenance services allow its customers to transfer the operational responsibility for line availability based on a service level agreement for all corrective and preventive maintenance operations. This includes a 24/7 service desk, configuration management of all software & hardware, stock & spares management, obsolescence management and operational & technical consultancy. •• Transfer of technical, operational and financial risks to one single interface •• Operational and maintenance cost reduction •• High availability of the line ensured: 99.73% •• High reliability: Mean Time To Repair = 1 hour, 1.15 hour less than provided for in the contract •• Guaranteed system availability: 99.73% Transport Services 17 Infrastructure maintenance Full maintenance of rail infrastructure Delivering maintenance of rail infrastructure to the highest quality and safety standards, under short and long-term contracts, with performance and availability guarantees. Service is available for tramway, metro and main line services. Benefits Key references •• Secure Availability & Reliability •• Optimized Life Cycle Cost •• Passenger satisfaction Committed to more than 10 infrastructure maintenance projects. Full maintenance of 11 tramway systems Performance Our offering covers the following: tracks, catenary, substations, heating-ventilation and air conditioning (HVAC), telecoms, road-signaling, Operations Control Centre (OCC), depot facilities, ticketing, public lighting, closed-circuit television (CCTV), stops and building facilities. Interface management for Turnkey maintenance. •• Reliability: number of failures per month per subsystem •• Availability: % of operating time, impact of infrastructure assets on commercial service •• Time To Repair •• Ride Comfort: track measurements •• Cleanliness: inspections •• Tramways: Spain-Barcelona, Trambesos, 28 years of maintenance, 34km track, 36 stations •• Tramways: IrelandDublin,Railways Procurement Agency, 5+5 years maintenance, 37km track, 54 stations, 66 cars •• Metro: Mexico,Line 12,full maintenance of infrastructure, 12km track •• Suburban: Greece/Athena/ ERGOSE, three years maintenance, 45km track, 13 stations, 7 interlocking areas •• Mainline: Mexico/TFM Line N track maintenance, 10 years, track renovation and maintenance •• Mainline: Spain/ADIF/ Maintenance of power supply and catenary Madrid-Seville and Madrid-Segovia HSL Maintenance activities: •• Corrective maintenance •• Preventive maintenance •• Main revisions/overhauls •• Other renewals •• Vandalism/damage 18 Transport Services Our value added •• A reliable partner with local presence and qualified staff worldwide •• Turnkey system expertise MAINTENANCE Ireland, Dublin tram infrastructure maintenance Ireland’s Railway Procurement Agency (RPA) - Maintenance on Dublin’s Luas tram system infrastructure, 2004 to 2014 Scope Performance Full maintenance for the Red and Green lines-37km with 54 stops, two depots and a fleet of 66 cars. Service covers cleaning, inspection, preventive and corrective maintenance for cars, tracks, overhead catenaries, power supply, signaling, automatic vehicle location system, telecoms, closed-circuit television (CCTV) and landscaping. •• Availability and reliability performance obligation •• Customer satisfaction: Ireland’s RPA has extended the maintenance contract from 2014 to 2019. Transport Services 19 SUPPORT SERVICES Training Theoretical and practical knowledge for maintainers, drivers and train crew We deliver training sessions via a training path to operators and maintainers, covering infrastructure, rolling stock and signaling. We offer a combination of •• In-class training, using our Knowledge Center based in France (La Courneuve) and local training centers/industrial sites •• Training on actual equipment or on the job coaching •• Virtual reality simulation - 3D training tool •• E-learning Training through virtual reality 3D 22 Transport Services Benefits Key references The main benefit is to obtain knowledge at-source from people who have designed, maintained and used the equipment. For you, this means: •• More than 1,000 people trained every year •• Maintainers’ certification: more than 500 people currently in training •• Improved efficiency •• Risk & accident avoidance •• Employee development •• Reduced train immobilization. Our value added •• Quality of trainers •• Dedicated knowledge centre •• 3D training tool •• Full software driving simulators SUPPORT SERVICES Maintenance training to SBB, Switzerland Maintenance training to Trenitalia, Italy ERTMS training for Jernbaneverket, Norway Train delivery customers requiring training on initial product. To coincide with the introduction of ETR 600, SBB were provided with maintenance level 2, hydraulic component knowledge training session. Up to now more than 22 training sessions have been delivered within six months to SBB‘s 150 employees. Clients also have to comply with a new European regulation on certification for maintainers through competency assessment (full application in 2015). To prepare for the deployment of the European Railway Traffic Management System (ERTMS) in Norway, the Norwegian National Rail Administration asked Alstom to train 100 professionals. During four days of training sessions, each limited to 12 people, trainees gained a comprehensive understanding of the ERTMS signaling system, including operational and deployment aspects. A visit to ERTMS integration laboratories in Belgium was also included in the training path. The training sessions were held between Alstom’s Savigliano plant and SBB workshop. Sharing expertise between Alstom and SBB has helped to form a strong partnership and link between both teams. The fact that Alstom also delivers training sessions directly on the SBB plan and materials has reduced the number of sessions previously scheduled. Finally, the trainees gave Alstom an average 3.5/4 satisfaction rate. For TrenItalia, more than 14,000 hours of training courses, especially on technical and maintenance topics, were provided and more than 130 maintenance personnel are now qualified and certified. Training catalogue Transport Services 23 E-Documentation Complete maintenance plans and procedures in electronic format Rapid access and up-to-date documentation is essential for most maintainers. This service ensures rolling stock maintenance and workshop documentation are always fit for purpose. Benefits Key references Rapidly available and up-to-date documentation is a great source of efficiency. Additionally, operational documentation such as the Driving Manual and Train Captain Manual can also be delivered in digital format. Performance •• Romania-Bucharest, Metrorex Bombardier Trains- Document digitisation •• USA-New Jersey Transit -PL42-Digitisation-Electronic Document- iPad deployment •• Morocco-Casablanca, Citadis Trams •• France-TAM-Montpellier Citadis Trams This service includes: •• Digitisation (for existing paper-only documents) •• Electronic document formatting •• Service bulletin: document update notifications •• Tablet/iPad deployment in workshops •• Access to parts online catalogue - PartsFolio™ (through parts or repairs services) 24 Transport Services •• Real time synchronisation of all documents on all sites •• Access to information in less than ‘3 clicks’ Our value added •• Multi-support solution, including iPad •• Link with illustrated catalogue for Alstom trains •• Capability to address non-OEM documentation. SUPPORT SERVICES e-Documentation for tramway operator in France Transports de l’agglomération de Montpellier (TAM) Montpellier in France was provided with e-catalog interactive modular documentation for its 3-line Citadis Tramway. To maintain and operate the trams, more than 2 Gb of technical documentation was provided and downloaded. These digitized documents provide the client with an illustrated spare parts catalogue, operation manual, maintenance plan, maintenance procedure, system description and technical documents (drawings, wiring, schematics, specifications, etc.). provides easy and fast access, and all documents can be saved and viewed in 3D plans, and downloaded simultaneously by large numbers of users. It ensures users have the latest, updated documentation. Alstom is also developing an iPad application to facilitate mobile access. Operators currently spend an average of 40% of their time searching for information. This solution Easy navigation by either clicking on the diagram or the description Transport Services 25 Obsolescence Identifying issues and proposing solutions ••Our value added Trains or systems represent a very valuable asset in an operator’s balance sheet. So it’s an economic necessity to make the best use of this asset and to operate the trains throughout their planned life cycle. Alstom has developed a comprehensive portfolio of obsolescence services that address this need. •• Supportive approach to suppliers •• Capability to solve complex obsolescence issues •• Catalogue of obsolescence solutions •• Dedicated organization, using proven methods & tools Services Benefits Performance •• Obsolescence Study - a one-off study to identify the obsolescence status of a fleet or system: know where you are and what you need to do •• Obsolescence Management Plan - a long-term plan to manage obsolescence throughout the life cycle •• Obsolescence Monitoring long-term monitoring of the availability of components, sub-assemblies and equipment in a fleet or system •• Obsolescence Solutions customized or catalogue solutions for equipment obsolescence •• Reduces life cycle cost of the system or train by avoiding expensive reactive obsolescence solutions for equipment obsolescence •• Improves customer service by avoiding out-of-service assets due to a shortage of spare parts •• Avoids premature scrapping and replacement of assets due to sub-system obsolescence •• Catalogue solutions for obsolescence reduces fixed costs of replacement equipment •• Obsolescence solutions can deliver increased functionality increased functionality Regularity and exhaustiveness of alert notifications 26 Transport Services •• Availability of more than 80 000 components monitored •• Cost-effective obsolescence solutions •• Impact assessment of obsolescence Key references •• France: Obsolescence Monitoring of Citadis in Lyon, Montpellier, Reims, Toulouse and Valenciennes •• Chile: Obsolescence Management Plan for Valparaiso EMU •• UK: Obsolescence solutions for various electronic control systems •• Romania: ASTRA Metros 40 years old - several mechanical obsolescence issues resolved SUPPORT SERVICES Obsolescence Study of Networker EMU for Angel Trains (UK) Obsolescence Monitoring of Citadis fleets Obsolescence Solution on Eurostar Power Modules Context Scope Context Alstom Transport has delivered more than 1,500 Citadis trams worldwide and monitors the availability of equipment and spare parts for these fleets, whether they are maintained by Alstom or by the operator. replace Gate Turn Off (GTO) Gate Drive electronic panels on Eurostar Power Modules. Alstom supplied 93 Networker 750V DC EMUs between 1990-1993; they are currently operated by Southeastern. Angel Trains asked Alstom to review the traction and auxiliary systems to identify current and potential obsolescence risk. Benefits •• Detailed status of traction and auxiliary systems •• Supplier data available to start monitoring service •• Overhaul programme agreed for Wheel Slide Protection system (WSP) Benefits •• More than 10,000 part references monitored across the Citadis fleets Context original GTO gate drive was designed in 1990; over 6,000 panels used on Eurostar. 6.7% of panels failed per year. Replacement panel developed. Benefits •• Improved reliability x 8 •• Reduced component count •• Obsolescence clock reset Transport Services 27 Asset Management Advanced solutions for train and infrastructure health monitoring Our Asset Management offering covers a large range of solutions to better manage the health of trains or infrastructure over the entire lifecycle. Health Hub is our overall approach to capture railway asset condition data, provide asset health monitoring and generate asset health prognostics. It relies on bespoke means to measure asset condition, such as TrainTracer™, Train Scanner or Track Tracer, provides customized, web-based user interfaces to monitor asset health and uses specifically developed algorithms to predict remaining useful life of components. Health Hub turns asset condition data into meaningful information for the operator, maintainer and reliability engineer. Equipped with our on-board remote condition monitoring solution, TrainTracer™, Health Hub allows you to continuously monitor the health status of your fleet in (near) real-time. Using information on the actual health status of key train subsystems, maintenance can be carried out on an as-needed basis and anticipated before the train arrives in the depot. The solution can be complemented with the Train Scanner, a ground-based measuring system for the automated monitoring of key consumables such as wheels, 28 Transport Services brake pads and pantograph carbon strips, as well as carbody integrity. TrackTracer in turn measures the condition of track and catenary precisely and can be mounted on trains running in commercial service. Further data capture solutions include: •• TMS light: condition monitoring retrofit solution for trains not equipped with TCMS (Train Control and Management System) •• Motes: a mesh of wireless autonomous vibration and temperature sensors used to monitor axle box, gearbox, traction fans or bearings. •• Pantograph/Overhead line interface monitoring •• Monitoring of AC motor windings •• Bespoke CBM tools, e. g. oil analysis,... Benefits •• Reduced train immobilization (“pit-stop approach”) •• Easier reliability improvement •• Maintenance cost optimization Our value added •• All services used within Alstom maintenance projects •• Extensive experience in deploying remote condition monitoring (over 1000 trains equipped, all types of rolling stock) Performance •• Reduction of key consumables material cost by up to 15% •• Increase of inspection frequency by 10 •• Reduction of train downtime by up to 30% Key references •• UK: West Coast Mainline Class 390 Pendolino, London Northern Line metro •• Sweden: X60 Coradia Nordic EMU •• France: BB 460000 diesel locomotives, Regiolis Coradia fleet •• Italy: .italo AGV VHST, Minuetto Regional fleet •• USA: NJ Transit •• Kazakhstan: KZ8A locomotives SUPPORT SERVICES Health data is automatically monitored onboard each train in operation and transferred to a back-office web server through cost effective GSM communications. TrainTracer™ deployment in Sweden TrainTracer™ deployment as part of a 5-year maintenance contract in Stockholm, Sweden. Customer: STÅG Design, develop and deploy the TrainTracer remote monitoring solution on 83 EMUs. Challenge Fast deployment and high quality of service were the two main challenges. Solution TrainTracer™ facilitates the diagnostic of the train, interfacing train onboard equipment with the Maintenance team. It offers remote access to full fleet data through the intranet or secured internet. Use of a web-based server enables technicians to access train data anytime and from anywhere in the world with intranet or internet access. Data are available for local maintenance technicians, as well as a central support team or maintenance manager. This approach provides unprecedented visibility on the real-time operation and health of each train. It enables quicker corrective maintenance, better support to the train crew and prevents some failures from occurring. The availability of comprehensive data concerning a train is a valuable aid in optimizing the operation and maintenance of the train fleet. One of the key features of the solution is the use of a GPS tag on every event recorded. TrainTracer can identify geographical clusters of faults along the route, which can point to potential infrastructure issues. Performance •• 83 trains have been continuously sending data since mid-2012 •• Round-the-clock service to visualize the data: 60+ Alstom users have access via the intranet, +20 customer users via secure internet connection •• The results are demonstrated in the kilometers-per-failure figures being achieved sustainably through a high fleet utilization in line with contractual requirements. Real time Dashboard on X60 fleet Transport Services 29 Expertise Support Alstom expertise for operational efficiency Below is an overview of the expert support from which you can benefit: •• Reliability Growth: this service offers an analysis of the current reliability of the fleet, proposes an improvement plan and checks plan deployment •• Maintenance Plan Optimization: consultancy using a structured process known as Reliability Centered Maintenance (RCM) to safely make an improvement in maintenance performance and cost effectiveness •• Maintenance Quality Assessment: deliver an independent quality assessment of maintenance activities. Get an in-depth maintenance performance analysis and a set of recommendations for further improvements •• Train Design Authority: train design file responsibilities are fully transferred to Alstom. This ensures that the train technical definition and configuration is properly managed and is readily accessible over the complete train lifetime. 30 Transport Services Benefits Key references •• Train Design Authority: transfer of responsibility, up-to-date train definition and easier product development. •• Maintenance Quality Assessment, Maintenance Plan Optimization and Reliability Growth: process improvement, greater fleet reliability and availability, cost effectiveness •• Reliability Growth Plan: UK Northern Line Metro, UK Angel Trains Class 180 DMUs, UK Virgin Trains Class 390, Spain RENFE Very High Speed Trains •• Maintenance Plan Optimization and Quality Assessment: applied worldwide on several Alstom service projects •• Train Design Authority: UK London Northern Line, UK Eversholt Rail Class 334 EMU, US Amtrak Acela High Speed Trains, Germany EMU Our value added •• Alstom’s hands-on experience as OEM and maintainer •• Proven methods and tools •• Extensive experience, OEM and non-OEM rolling stock. SUPPORT SERVICES Maintenance Plan Optimisation Class 390 Here are two examples of improvements made to the maintenance regime: UK, West Coast Main Line, 52 high-speed tilting Pendolino trains. Full maintenance contract. •• A exam removal: originally the exam cycle would be an A exam every 8,300 miles, followed by the B exam at 16,600 miles. As a result of the improvement, the first exam will be a B exam every 16,600 miles. •• Increase in H2 overhaul interval: from 750,000 to 850,000 miles. These modifications have been fully validated after execution of a trial maintenance regime. Challenge Safely improving maintenance performance and cost effectiveness. Supporting the introduction of a revised operating timetable requiring 16% more train miles in operation. Solution After reviewing the preventive maintenance activity and commercial situation, we determined suitability and potential benefits in the application of the RCM process and other improvement techniques. An action plan was developed, shared with the customer and implemented. Performance A exam removal: this means a reduction of 18 exams a year per train or a saving of +8,000 man hours. High level of customer satisfaction through continuous improvement of availability/reliability performance. Transport Services 31 Depot Design Consultancy for depot design, including workshop, depot equipment and tools Driven by extensive experience in depot usage based on numerous contracts, our depot organization and equipment experience can be offered as a standalone solution. A typical service offering for an existing depot would include: •• Analysis of current status of maintenance depots, including depot layout, process flow chart, auxiliary workshops •• Analysis of depot equipment and special tools •• Proposal for developments taking into account updated maintenance strategy A new depot design can also be undertaken in the context of a turnkey solution. 32 Transport Services Benefits Key references •• Workflow-centric approach allows for the optimization of both staff efficiency and the use rate of depot equipment •• Optimized train availability •• Adapted to new operations, e.g. train extension •• Investment protection •• Energy saving Existing depot Performance Report delivery within 2 to 3 weeks per visited site, including depot equipment and special tools list and action plan. Our value added •• Extensive experience of designing new depots or improving existing depots •• Ability to adapt to local norms and regulations •• Romania: Bucharest metro, take-over and upgrade of maintenance depot •• UK: upgrading of several depots for Virgin Pendolino trains New Depot •• Italy: Nola, depot for NTV high speed trains •• Poland: Warsaw, depot for PKP Pendolino trains •• Dubai Tramways •• Jerusalem Tramways •• Algier and Constantine Tramways •• Reims Tramways SUPPORT SERVICES New maintenance depot in Poland Designing and building the new Warsaw depot for PKP high-speed Pendolino trains. The Warsaw depot is part of the contract signed in May 2011 with PKP to supply 20 New Pendolino, Alstom’s high-speed trains, and to ensure their maintenance for 17 years. Entirely dedicated to this maintenance, the centre will participate in the modernization of the Polish high-speed rail network. Challenge & Solution The depot is 230m long and includes: Alstom had to carefully optimize the depot design to fit into a very limited available area. •• Five tracks •• Retractable catenaries with three different voltages •• Modern tandem wheel lathe •• Modern removal rail system to change the complete bogie or individual wheel set The timescale was also a major constraint. The solution includes, on a 12,600 square meters site, a maintenance depot fitted with track and overhead catenaries, an area allocated to parts, an automated washing zone, offices and premises for the use of site employees. Performance •• Delivery under 15 months in spite of harsh Polish winter •• Full conformity with Polish standards Transport Services 33 Recycling Manage rolling stock end-of-life, compliance with EC directives and other national laws Legislation is evolving fast and EC directives demand a minimum of 75% of waste to be recycled. Modern trains like Alstom’s regional train, Regiolis, are therefore designed to be recycled: materials are carefully selected, trains are built to be easily dismounted and materials separated to enter into a recycling process. A significant number of trains, locomotives and wagons will be reaching end-of-life in this decade. A large number of these cannot be modernized for technical or financial reasons. The export of trains at the end of their lifetime is highly restricted, and completely forbidden for trains containing asbestos, so recycling represents the only alternative. Alstom’s service portfolio has been built to address the entire life cycle of a train, from its construction to end-of-life management, leading to the complete deconstruction and disposal of retired rolling stock. 34 Transport Services This recycling service includes the following phases: •• Analyze: identify and localize products and materials in the train. Specific attention to hazardous substances such as asbestos. •• Plan: build dismantling plan and procedures •• Execute: execute dismantling, starting with asbestos removal when applicable •• Manage waste: recycling and waste management, including the management of possible reusable components such as bogies or motors. Our value added •• Capability to address all aspects of dismantling •• Strong market reputation •• Compliance with all regulations •• Professional technical support Benefits •• In addition to complying with regulations on dangerous material disposal and a reduction in administrative tasks, the owner of retired rolling stock will also free up valuable space •• Reduce environmental impact •• Manage social and moral responsibility - Green image. Performance •• Compliance with norms and regulations in place •• Certification of execution •• Lead time for dismantling a car SUPPORT SERVICES France, passenger cars The replacement of train-car configurations with EMUs or DMUs has led to a large number of cars being unused. As a pilot project, Alstom recycled five SNCF Corail cars. The contract, which provided for partial asbestos removal, was executed from 2011 to 2012. Romania, metro cars From 2004 to 2005 Alstom recycled 270 ASTRA metro cars for its customer, Bucharest Metro. The service included asbestos removal and the project was managed entirely by Alstom. Transport Services 35 Integrated Fleet Support Upkeep optimal operational condition readiness Building on its history of maintenance management for several customer fleets, Alstom has unique experience of fleet behavior and operational performances. By drawing on this experience, Alstom is able to improve your maintenance practices. With our Integrated Fleet Support offering, we share this experience with you by delivering technical assistance to your maintenance team. This includes trouble shooting and repair support. We also deliver service bulletins and information bulletins. Below is an overview of our offering: •• Technical Assistance Level 1: access to Alstom technicians through website and hotline Level 2: mobile Alstom staff, available upon request •• Service Bulletin: safety and obsolescence alerts •• Information Bulletin: Rolling Stock modifications, maintenance documentation updating, fleet reliability and maintenance plan improvement, as a result of REX sharing across the fleets. 36 Transport Services Benefits Key references •• Access to train knowledge •• Fleet availability •• Maintenance efficiency •• Citadis Fleet Support •• SNCF Regiolis EMUs and DMUs Performance •• Level 1: up to 24/7 •• Level 2: guaranteed intervention time Our value added •• Access to train knowledge and large Return on experience •• Professional technical support •• Dedicated web portal SUPPORT SERVICES Maintenance Fleet approach Our experience of managing customer fleets, combined with our international knowledge, allow us to provide you with well-targeted maintenance actions, improved over time. For instance, today, we maintain around 500 tramways and 1,800 Citadis in service across 40 cities and 13 countries. We also manage more than 100 Pendolino trains. Based on this extensive fleet knowledge and continuous feedback, Alstom is able to provide full path maintenance extension. For Citadis, we extended maintenance from 600,000 to 900,000 km, and for Pendolino from 6,000 to 12,000km on the West Coast mainline fleet. By gathering maintenance data we can also provide obsolescence or safety bulletin, kitting offering for overhauls by identifying common parts and global sourcing. To complete and support this fleet approach, from mid-2014 we provided Transport Service web portal access with technical assistance (online requests and FAQ), online parts quotation, and access to updated maintenance and technical report documentation. If the customer has internet access, whenever and wherever they happen to be, they can send requests, access documents, and contact and share their experience with Alstom’s expert team. Transport Services 37 MODERNIZATION Energy Saving Modernization Service focused on the analysis and resolution of energy-related issues The cost of energy and its environmental impact are increasing year on year. To optimise the use of energy, it’s important to get a global picture of consumption patterns. This service includes: •• E-mapping: in-situ energy measurement of main train sub-systems (e.g. traction, HVAC, auxiliaries), deployment of a data collection service on the ground, data analysis and report provision, analysis of actual operation. Recommendations for energy savings. •• Energy Metering System (EMS): metering of train energy consumption for billing purposes, fully compliant with new European standard EN 50463-2011. •• Driver Advisory System(DAS): a solution to reduce energy consumption by advising the driver on the best driving strategy at any given time. •• Other solutions to reduce energy consumption such as traction modernization, lighting upgrade (LED kits) and energy storage devices. 40 Transport Services Benefits Key references Beyond compliance with new regulations and metering, the key benefit of this modernization is greater energy efficiency and a green image provided by sustainable development. Another benefit of DAS is improved punctuality •• E-mapping: various Citadis tramways monitored in Barcelona, Toulouse, Lyon and Dublin •• EMS: solution deployed on SNCF Regiolis and TrenItalia trains •• DAS: various trials, in France (loco), Germany (DMUs) and Switzerland (EMUs) •• Traction: Netherlands, NS EMUs, traction design prototype and kitting, generating energy consumption savings of up to 30% •• Mexico, 25 STC metro cars, full Traction Modernisation and Maintenance, generating more than 35% energy savings. Performance •• DAS: energy savings of up to 15% •• Traction: savings of up to 40% •• LED: savings of up to 50% Our value added •• E-mapping: wide range of line voltages, easy to install solution •• EMS: compliant with latest standards •• DAS: proven energy savings can be combined with our driver training offer •• Proven energy storage solutions SUPPORT MODERNIZATION SERVICES Driver Advisory System LED lighting During trials with regional and freight train operators, Alstom generated significant cost savings using the Driver Advisory System, with average savings of 15%. The table below shows saving estimates for regional and freight trains*. The vast majority of passenger trains are still equipped with neon tube lighting whereas new trains are now generally equipped with LED lighting. LEDs allow for a more flexible lighting design in passenger areas (brightness and colour, changes during the day), and provide a real cost reduction potential despite their higher acquisition cost: Depending on the travel profile, return on investment for a DAS project is generally under two years. •• The MTBF for LEDs is twice as high as neon tube lighting which reduces the cost of replacement and related labour by 50% •• LEDs consume only about 50% of the energy used for neon tube lighting - with the same or better luminosity. Example for a DAS display showing maximum, optimum and actual train speed plus time information Average Km/Year Energy Comsumption Energy Cost/Year Energy Savings/Year DMU 120 000 0,9 liter/km 120 000 € 18 000 € EMU 120 000 1 200 MWh 140 000 € 21 000 € E-locomotive 150 000 2 300 MWh 280 000 € 42 000 € Traction (*) All values Alstom Transport estimates Transport Services 41 Traction Modernization solutions for performance upgrade, obsolescence mitigation and lifetime extension Traction equipment is expected to be highly reliable while keeping maintenance costs low. This often means upgrading the traction electronics at the mid-life renovation stage. We can provide efficient solutions, whatever the technology or product, including AC or DC motors, camshaft, chopper, inverter, control unit, inductor, transducer and braking resistor. Using proven components and technologies, Alstom will create the optimum solution for each case, and will perform extensive validation on a prototype. The solution is packaged as a kit and installed by Alstom or the customer. It contains all the necessary parts and installation instructions. Alternatively, a fully assembled sub-system can be provided as a form-fit-function replacement of the existing one. Both include: •• Pre-fitting to reduce mounting time •• Commissioning on trains •• Certification support 42 Transport Services Benefits Key references The upgrade will offset any obsolescence issues and provide more efficient rolling stock. This service also generates energy savings to reduce energy bills and maintenance costs through greater reliability. •• Mexico: STC - 25 MP82 metros. Replacement of DC-Thyristor chopper by IGBT chopper •• Netherlands: GVB Amsterdam - 45 trams and 25 metros. Replacement of resistor-controlled DC drive through an IGBT choppercontrolled DC drive •• France: RATP - 150 metro cars power module: GTO replaced by IGBT •• USA Philadelphia: PATCO - 120 metro cars. Replacement of camshaft by IGBT chopper Performance •• Reduced train downtime for installation •• Energy savings •• Increased reliability and availability. Our value added •• Proven experience of all kinds of traction technology, addressing OEM and non-OEM products. •• Delivery time •• Proven energy savings of up to 35% •• Dedicated Lead Service Center with strong expertise. MODERNIZATION Paris Metro cars replacing GTO power module by IGBT power module Obsolescence management of 150 power module sets, replacing the Gate Turn-Off (GTO) panels by plug & play Insulated Gate Bipolar Transistor (IGBT) panels. In 2008, RATP and Alstom signed a partnership agreement to plan for the power module obsolescence of 150 metro cars. Over a two-year period, both engineering teams have been working together on a research and development program to jointly identify solutions that guarantee good operational conditions for the fleet. After validation based on static and dynamic tests on tracks, eight pre-series cars were delivered and installed on trains to realize endurance tests on line 1 and line 4. Solution Panel substitution is very simple and is performed overnight. We developed an optimized cost solution through the modification of the power modules and interfaces only, without modification of the whole traction case. We then delivered a ‘plug and play’ solution. The solution is based on proven technology and the design has been proven through prototyping. 450 modules are currently being delivered. Plug and Play replacement module Managing traction obsolescence issues on 150 metro cars - Paris Transport Services 43 Diesel and Hybrid Energy efficient and environmentally-friendly operation solutions for locomotives To comply with new regulations, and to cope with aging rolling stock, operators increasingly need to upgrade their Diesel fleets. For diesel locomotives, we offer the Power Pack upgrade, which complies with the latest low emission standards. Besides motorization, our offer can also be extended to cover the gearbox, bogie, driver cab, new signaling and train control systems. This can also be coupled with a complete loco overhaul. Dedicated to shunting locomotives, we have developed a hybrid traction add-on, successfully implemented on BR203 and BR298 in Germany and the Netherlands. To generate even greater energy savings and improve your green image, we offer the H3 shunting locomotive. H3 is a modular platform loco, declined in 4 different variants. •• 600kW battery loco. Pure battery version for light and zero emission shunting service •• 700kW hybrid loco. 350kW diesel generator and battery. Up to 50% fuel savings •• 700kW dual-engine loco. Up to 15% fuel savings •• 1000kW single-engine loco. World’s first locomotive with this power, with three axles and a maximum speed of 100kph. Up to 8% fuel saving in its power class. Can be used in light mainline service. Benefits Performance •• Fuel savings •• Emission reduction •• Noise reduction Key references •• Diesel upgrade: shunting locos BR203 and BR214 in Germany and the Netherlands •• Hybrid pack: hybrid locos in lease agreement from 2010 to 2018 in Germany with MEG customer •• H3 hybrid locomotives: VW in Germany Compliance with regulations coupled with other potential benefits such as improved traction efficiency and lower fuel consumption. Life time extension, obsolescence solution, track access cost advantage «easy to drive» shunting locos and «greener» image. Our value added Proven experience in Hybrid technology. Large track record for shunting locomotive modernization. 44 Transport Services Hybrid locos in operation for MEG -­Germany MODERNIZATION Diesel upgrade Hybrid solutions The average age of the worldwide installed locomotive base is increasing, especially for shunting locos, which have an impressive average age of more than 30 years. The aging of the locomotive and its systems may lead to obsolescence issues, reduced availability, increased operating costs and non-compliance with changing environmental standards. A key driver for operating costs is energy consumption. The replacement of an older diesel engine on a diesel electric-locomotive, for example, can reduce fuel consumption by over 20% and deliver the same or even better performance. Depending on the run-rate of a locomotive, investment in modernization can therefore be earned through operational savings in just a few years. In the transport market, as in other industries, environmental and energy consumption requirements have boosted the implementation of hybrid technologies. These technologies drastically reduce emissions, including noise and Co2 emissions. But they also help to reduce energy costs. Alstom’s Hybrid shunting locomotive H3 is equipped with a 350 kW diesel generator and a battery. The efficient and environmentally-friendly diesel generator recharges the battery and can also directly drive the electric motor for peak loads. For partial loads, the H3 Hybrid locomotive runs exclusively on battery power and can save 30-50% in diesel compared with similar shunting locomotives. The graph below shows a cost comparison between continuing with existing solutions, but modernized shutters, versus the alternative of investing in a fleet of new hybrid shutters. The Hybrid alternatives generate almost 20% cost savings, mostly fuel savings. Hybrid solution reduces TCO Transport Services 45 Bogie Increased demand for higher load requirements and/or life extension As the interface between the car and the track, the bogie has to meet both the highest standards of safety and passenger comfort. Maintenance costs also enter into the overall life cycle cost equation. To address these issues, we offer several solutions: •• Design of technical improvements •• Compliance with increased load requirements •• Savings generated by using supplier alternatives •• Drive line adaptation due to DC to AC traction change •• Bogies winterization These solutions cover: bogies frames, bolsters, wheel sets, brake systems, suspension systems, gearbox, traction motor, and tilting systems. 46 Transport Services Benefits Key references Modernizing your bogie helps extend the lifetime of rolling stock, maximizes availability and reliability and offers greater comfort through noise reduction and increased load capacity. This will also reduce your maintenance costs and extend revision intervals. •• UK: Virgin Trains, Class 390 Pendolino EMUs, bogie overhaul and engineering changes •• Romania: CFR, 100 coaches, replacement of Goerlitz V bogies with Y32 bogies •• Spain: RENFE, 6 Euromed trains, change from Iberian gauge to UIC gauge •• Kazakhstan: 27 KZ4ACs locos, redesign of wheels and axles to solve parts shortage on Chinese bogies Our value added •• Over 150 years of bogie expertise •• Tilting technology leader •• ‘State of the art’ testing facility for bogies in Neuhausen, Switzerland •• Ability to reproduce OEM and non-OEM bogies MODERNIZATION A unique testing facility in Switzerland The Alstom Neuhausen site has received from the Swiss Confederation its accreditation as railway test laboratory (ISO/ CEI 17025) for its activities of tests and validation of bogies. This certification, which attests the know-how and expertise of Alstom in this field, allow to carry on these activities also for the account of external customers. Thanks to a test bench unique in the world, which has been built up since 2009, the latter is able to test all the parts of the bogies (frame, suspensions but also gearboxes and motors) and to reproduce their life cycle. Transport Services 47 Train System Upgrading the train’s nervous system to fully leverage the potential of the rolling stock Train control modernization includes the upgrading of the TCMS (Train Control and Monitoring System), driver desk, brake system, door system and auxiliaries supply system. This service can be combined with other modernization services - e.g. traction or bogie modernization. The modifications are validated at system level on a test bench, then implemented on a test train to get final validation, before series installation and certification support. Benefits Key references Our solutions allow you to fully exploit the performance of every sub-system onboard the train. Additionally, the communication layer allows for significant data collection, providing greater input into maintenance planning and operation. •• USA, PATCO Philadelphia Full modernization - 120 suburban cars - first delivery: 2013 •• USA, MBTA Boston, Full modernization - 86 metro cars - first delivery: 2014 •• Brazil, CMSP, Sao Paulo Metro L1&L3 Full modernization - 25x6 and 22x6 metro cars - 2009 to 2014 The new train system will also contribute to extending the life of the train by resolving potential existing obsolescence issues in the current system. Our value added •• Integration expertise as Original Equipment manufacturer (OEM) •• Safety expertise (doors, brakes) •• Extensive experience of the ergonomic design of the driver desk •• Data transmission to the ground analysis using Traintracer 48 Transport Services MODERNIZATION technology, including new couplers, car-borne propulsion technology and modern braking systems, automated train control (ATC) equipment, door operator and control systems, interior finishing including lighting and seats, air-conditioning systems, new communication and information displays. Rehabilitation of 120 transit cars, USA Port Authority Transit Corporation (PATCO) Philadelphia, rehabilitation of 120 stainless steel transit cars PATCO required solutions to update its ageing fleet and deal with various obsolescence issues. Its most recent cars were built in the early 80s. Solution We supplied a complete overhaul of the existing train cars to replace out-dated systems with new technology while maintaining the major structural framing and external shells. The cars were enhanced with a full range of equipment and The entire refurbishment and testing process took place in Alstom’s rolling stock manufacturing facility in Hornell, NY - the largest of its kind in the United States. Experts at Alstom’s Hornell facility also performed on-site testing of the completed cars to ensure safety and reliability. Benefits •• Train life extension: +20 years •• Increased revenues through enhanced train attractiveness •• Maintenance cost reduction •• Reliability improvements •• Enhanced passenger and driver comfort A mock-up approach was used to validate ergonomic and aesthetic choices with the customer and end-users. Enhanced serviceability was also a concern, and Alstom ensured better access to traction control equipment through improved underframe arrangements. These measures contributed to reducing overall maintenance costs. Transport Services 49 Signaling Onboard installation for metro or mainline signaling equipment Installing onboard signaling requires both mechanical and electrical modifications. These operations include both installation design and new mounting methods. For new cross-border operations, other design changes may also be required. The design is typically validated on board a prototype vehicle. Integration safety studies may also be implemented, depending on the signaling equipment to be installed. The signaling equipment may require a separate contract and may involve Alstom or non-Alstom equipment. The solution is presented as a kit to be installed. It contains all the necessary parts and installation instructions. Pre-fitment of the train to save time on installation is included. Installation and commissioning are managed by Alstom staff 50 Transport Services Options Key references •• If applicable, support for homologation by the respective notified body •• Installation by Alstom staff •• Obsolescence management •• Alstom Communications-Based Train Control (CBTC): Milan, Amsterdam, Lille •• Thales CBTC: UK- Northern Line and Jubilee Line •• European Railway Traffic Management System (ERTMS): Spain- 123 CIVIA commuter trains •• ERTMS + French signaling: Spain-Madrid-Paris AVE •• Alstom Sistema Controllo Marcia Treno (SCMT) for Italy: French BB36000 locos •• Alstom Positive Train Control (PTC): USA, Amtrak’s North East Corridor, freight and commuter trains, 400+ carborne systems Benefits Typical train immobilization can be as little as two days on series installations with fully trained staff. Performance •• Kits delivery time •• Train immobilization time Our value added •• Extensive signaling expertise •• Broad range of in-house signaling solutions •• Address Original Equipment Manufacturer (OEM) and non-OEM signaling products MODERNIZATION Scope •• French signaling equipment integration (KVB, ATESS, RPS, Bi-Mode Radio, TVM 430) and ERTMS upgrade •• Propulsion System adaptation to allow 1.5kV operations in France •• Interior changes to increase passenger capacity High-speed cross-border operations To develop their activity, the Spanish and French national rail operators, Renfe and SNCF, decided to jointly run high-speed commercial operations between Spain and France. To enable the trains to travel from one country to another, they had to be interoperable. This means they had to adapt to a variety of power voltages, signaling equipment and technical specifications for interoperability, in line with European Union requirements. To this end, RENFE awarded a contract to Alstom to adapt 10 existing AVE (Alta Velocidad Española) trains to run on French lines. These trains were originally built by Alstom about 20 years ago. Challenge & Solution Performance In terms of design, new signaling equipment integration represented the first challenge. Special care was taken to ensure under-frame integration of new antennae and the arrangement of Human Machine Interface (HMI) modules in the Driving Cab. All in all, 1,045 drawings were generated to undertake the modification. With the opening on December 15, 2013 of the direct high-speed line linking Paris in France to Barcelona in Spain, Alstom’s high-speed trains have now crossed their 16th border. Alstom is the only rail manufacturer to have built more than 1,100 high-speed cross-border trains, in service in 18 different countries. Validation and homologation were also a major challenge. They involved type and serial tests in both Spain and France, with three trains in parallel. We also faced severe electromagnetic compatibility (EMC) issues due to non-compatibility with an older generation track circuit in France. We needed to call on our extensive internal and external expertise to solve the problem and team work was the key to our success. Building on a good performance record, operators SNCF and Renfe have announced the introduction of an additional daily service between the two cities from March 31, 2014. Transport Services 51 Passenger Experience Develop and deliver modernization kits to enhance the passenger experience This modernization service features all aspects of the train passenger experience. The scope of such a modernization can be fairly broad and varied, and covers: •• Interior comfort and aesthetics, e.g. heat ventilation air conditioning, seating, floor coverings, carpet, sidewalls, ceiling, bike support, hand rails, grab poles, luggage rack and lighting •• New services integration, e.g. infotainment, passenger WiFi, power supply at seat, catering solutions, video surveillance, ticketing, seat reservation system •• Exterior aesthetics, e.g. livery, painting, front-end refurbishment Alstom designs the solution. The design is generally validated with the customer on a prototype vehicle. Installation can be proposed as an option. 52 Transport Services Benefits Our value added The modernization project allows you to restore a train’s level of attractiveness and comfort even to the point of delivering the quality experience of a newly-built train. Increased passenger satisfaction can translate into more journeys and revenue - and all that at a reduced cost compared to the acquisition of new-build rolling stock. •• In-house design and styling •• Ability to team up with local designers •• System integration as OEM •• Access to worldwide supplier panel •• Incorporating an experience of modernization, taking into account •• specific constraints such as dimension dispersion. Upgraded equipment can also provide more than comfort and contribute to a different operation. For instance the addition of catering facilities or toilets allow for longer journeys. New seat arrangements using, for example, seats that require less space, can also help grow the capacity of a train and sell more seats per train. Performance •• Kits delivery time •• Train immobilization time Key references •• UK, Northern Line, mid-life overhaul, 106 metro trains •• Spain: RENFE, AVE mid-life modernization, 18 trains •• Portugal: CP, 57 Siemens EMU commuter trains, full modernisation •• Germany: HLB, 25 DMUs - interior modernization •• France: RATP-SNCF, 119 commuter trains, mid-life modernization •• Chile: Santiago, 35 metro trains, HVAC installation MODERNIZATION Case Study - EMU modernization (Portugal) Portugal, CP, modernization of 57 EMU trains supplied in 1970 by Siemens/Sofreame. Scope Modernization of High-Speed Trains, Spain Spain, RENFE, modernization of 18 AVE high-speed trains manufactured by Alstom that have been in commercial operation for 15 years. Scope The full modernization project included the implementation of a new interior design including seats, lateral wall coverings, ceiling and floors, luggage racks, toilet cabins, passenger infotainment and mobility-impaired access renewal as well as exterior painting. In addition, the “cafeteria” coaches and galleys have been modernized. The works were performed from 2006 to 2009 on a fleet of 18 trains in the regular maintenance depot to limit the impact on operations. Benefits The attractiveness of the train has been restored and the modernization ensured that the AVE trains keep their reputation and image as a modern and comfortable mode of transport. The project has had a very positive impact on customer satisfaction. The modern look, additional space for passengers and luggage and easier accessibility for passengers with reduced mobility in compliance with the new regulations were among the positive results of the full modernization project. Modernization of traction/braking with the target of reducing energy consumption by more than 25% and improving passenger comfort through the installation of an HVAC system and a modern passenger information system. Improvements have been made to the interior design, including seat modernization and a review of the lighting system. The front end unit has been replaced and a digital driver desk installed. Benefits The modernization works allowed the operators to extend the lifetime of its asset and at the same time ensure passenger comfort on this suburban train. The addition of the HVAC system played an important role, as did other equipment, like new seats and the passenger information system, which contribute to a fresh travel experience. Transport Services 53 Accessibility Compliance with new regulations. Making trains more accessible to disabled passengers Upgrading for people with reduced mobility (PRM) is mandatory in many countries. Taking into account the existing train design and the applicable regulation, a design is produced that can encompass tip-up seats, lights, interior colours (contrast), pictograms, accessibility to passenger alarms and intercom, door pushbuttons, passenger information displays, buzzers, ramps and ways to reduce gaps. The design is typically validated on board a prototype vehicle. The solution is presented as a kit to be installed. It contains all the necessary parts and installation instructions. Benefits Key references Compliance with regulations coupled with revised signage can significantly improve the passenger experience and train attractiveness. Other upgrades can also be deployed during the same operation. •• France: Citadis Le Mans •• Spain: RENFE, UT447 commuter trains •• US: Caltrans, California Bi-level cars You will also benefit from a renewed social image. Improved accessibility is benefiting to all passengers Performance •• Kits delivery time •• Train immobilization time Options Our value added Installation by Alstom staff can be offered as an option •• Expertise as train integrator and manufacturer •• Citadis: short delivery time with off the shelf solutions •• Regulation knowledge 54 Transport Services MODERNIZATION Upgrade for accessibility Le Mans, France Le Mans Citadis™ tramway: upgrade for PRM access (People with Reduce Mobility) Scope Engineering of train modification, first train modification and validation, kits delivery to retrofit the fleet of 26 Citadis tramways. As part of the construction of Line 2 of the Le Mans tramway network, the customer ordered new Citadis trams fully compliant with the latest accessibility regulations (French law no.2005-102 dated 11/02/2005). To ensure a homogeneous fleet, the customer decided to upgrade the older Citadis fleet operated on Line 1. Solution Performance After analysis of the gaps between the tramway design and the conditions required by French law, the Alstom team then proposed alterations to the tramway for full compliance. •• 14 months from contract signature to first upgraded Citadis in commercial service. •• 22 months from contract signature to full delivery, including design phase, prototype validation and production of 26 modernization kits. •• Fleet upgraded without impact on commercial service These operations concerned physical access to the train and access to information - both visual and auditive. Space dedicated to wheelchairs was widened, intercommunication push buttons were lowered and tip up seats adapted. The visual contrast of prehension handles inside vehicles was accentuated by the use of colors for easier differentiation and sound announcements were added to indicate imminent door closing. The design was executed in close collaboration with the customer. Solutions bore in mind mounting constraints to reduce immobilization time. Kits were delivered by Alstom with all the necessary instructions and installed by the customer. Transport Services 55 PARTS & REPAIRS Spare parts Efficient supply chain management for Alstom and non-Alstom parts Supply of Alstom and non-Alstom spare parts or spare part kits for preventive and corrective maintenance, accident repairs and overhauls. Spare parts or spare part kits can be provided as follows: •• Spot request: ad-hoc customer request for specific parts supply •• Spare parts catalogue: pre-defined parts list with negotiated prices •• Availability Service: see page 54 •• Technical Support and Spares Supply Agreement: see page 6 This service is supported by the Partsfolio™ e-business solution: web ordering and tracking, illustrated parts catalogues, management of the repairs process, EDI (Electronic Data Interchange). 58 Transport Services Benefits Key references •• Predictable cost •• Web ordering tool •• Easy to install kits •• Access to +4,000 suppliers Alstom fleet operators worldwide. Performance Delivery time and price Our value added •• Local presence - qualified staff worldwide, large industrial footprint •• Access to worldwide supplier panel •• Covers OEM and non-OEM products PartsFolio™ -­Web ordering tool PARTS & REPAIRS Santiago Metro, Chile Nanjing Metro, China 216 Metropolis™ cars, Line 4 432 cars, Line 1 & 2 Scope Scope Management and supply of spare parts (398 items) Management and supply of spare parts (43 items) •• Corrective maintenance parts •• Repairs Frame agreement with two lists: •• Corrective maintenance parts •• Accident/vandalism •• Buffer stock management 10-year overhaul •• List 1: availability service •• List 2: price catalogue Performance •• OTIF (On-Time In-Full delivery) 100% •• 31 days average repair lead time Performance •• Immediate delivery from local stock in customer’s warehouse Transport Services 59 Repairs Faulty components are repaired and returned to operations Repairs service for repairable components from Alstom and other Original Equipment Manufacturers (OEM). Key features Repaired components include transformers, circuit breakers, traction power modules, auxiliary converters, electronic controls, electrical motors, bogies, dampers and brakes, HVAC equipment, as well as signaling equipment. Delivery either as standard repairs services or unit exchange with Alstom-owned float. Standard repairs service includes component test, quotation and repair (if economically sound) in one of Alstom’s repair centers. Pricing by quotation or fixed fee depending on the level of repair (light/medium/heavy) Unit exchange service is the instant exchange of a faulty component by a reconditioned one from an Alstom-owned stock of repairable components (“float”) against a flat fee. Both processes are supported by the Partsfolio™ e-business solution (electronic management of repairs process). 60 Transport Services Benefits Key references •• Committed lead time •• Large repair portfolio •• Web tracking tool Alstom fleet operators worldwide. Performance •• Lead time •• Warranty Our value added •• Local presence - qualified staff worldwide, large industrial footprint. •• Access to worldwide supplier panel. •• Covers OEM and non-OEM products. PARTS & REPAIRS Reducing repair lead time of traction electronics The operator of a fleet of Alstom locos used to have faulty Agate traction control equipment repaired by the Alstom Lead Service Center in Villeurbanne after the fleet warranty phase expired in 2008. In the initial setup, broken-down Agate modules were tested on a test bench at the client’s site and faulty electronic circuit boards (ECBs) sent to Alstom for repair. As this was done on a case-by-case basis, the lead time for these spot repairs was 70 days. On average, six locomotives were out of service due to traction equipment repair times. Challenge Performance The operator wanted to drastically improve fleet availability. As a result of this new set-up, Alstom was able to reduce lead times by over 50%, down to 29 days, with an OTIF of 95%. Faced with the need to invest in a larger float of electronic circuit boards, the client turned to Alstom to jointly develop a way to improve lead times on these repairs. Solution A multi-year contract with a planned annual volume of 500 ECBs for repair, allowed Alstom to fine tune its supply chain set-up: •• Set-up of a stock of critical ECBs with long repair lead times •• Set-up of a stock of critical components (CPUs, RAMs), some of which had started to have obsolescence issues •• Weekly delivery service at the client site •• Nomination of a contract manager Transport Services 61 Availability Service Minimizing parts supply risks Benefits Key references Key features •• Guaranteed availability •• Short lead time •• Reduced inventory •• Web ordering tool More than 30 long-term service frame contracts in France, UK, Sweden, Netherlands, Italy, Spain, Chile, USA, Hong Kong Material Availability Service (MAS) characteristics: Performance •• Typical contract duration: 5 years •• Negotiated prices for a defined list of parts and kits •• Low lead time: immediate delivery for local stock and 48-hour lead time from central warehouse •• Annual volume commitment agreed between customer and Alstom •• Obsolescence monitoring and alerts for parts included in availability service contract •• Option: technical support to maintenance team MAS contracts are supported by the Partsfolio™ e-business solution: web ordering and tracking, illustrated parts catalogues, EDI (Electronic Data Interchange). •• Availability •• Lead time Supply of spare parts, kits and repairables with optimized prices, guaranteed availability and lead times. 62 Transport Services Our value added •• Supply chain management •• Access to worldwide supplier panel •• Obsolescence monitoring PARTS & REPAIRS Class 334, UK Montpellier tram, France ScotRail, UK 40 x 3-car class 334 Juniper EMU TAM Montpellier 83 Citadis™ tramways Scope Scope Management and supply of all materials for level 1-4 maintenance (1,600 items): Availability service for a list of spare parts (1,000 items) and repairs catalog (price & lead time) •• Preventive & corrective maintenance parts •• Component repairs and overhauls Additional services: reliability growth engineering and local technical support Performance Performance •• 100% measured OTIF •• 5 days delivery lead time •• 100 order lines/month •• >150 suppliers managed •• No train held for missing material since contract start •• 100% parts delivered on time •• 1,600 items managed •• 2,000 items supplied/month •• 6-8 weeks turnaround time for repairs Transport Services 63 Overhaul Returning train components to OEM condition Performing the scheduled overhaul of train or signaling system components. Key features Overhauled components include: bogies, traction motors, brake systems, switchgears, power-pack, electronics (of trainborne or track-side type). Using our design know-how and industrial expertise we can return all types of components back to their OEM condition using either our Lead Service Centers or by setting up specialized workshops at customer sites. Lead service centers include: •• Bogies: Neuhausen, Switzerland •• Traction: Ridderkerk, Netherlands •• Motors: Preston, UK •• Electronics: Villeurbanne, France •• Switchgears: Tarbes, France This service can be offered standalone or included in maintenance contracts. 64 Transport Services Benefits •• Engineering expertise •• Lifetime extension •• Secured residual value Performance •• Component reliability •• Lead time Our value added Technical expertise ‘state of the art’ tools Non-OEM servicing Key references •• Italy: ETR 600 & 610; •• UK: WCML Class 390 H2&H3 overhauls; Class 323 C6 overhaul; Class 175 10-year overhaul; JLE Metro bogie overhaul; •• Eire: LUAS tramway 600,000 km overhaul, including brake system; •• Germany: Regio-Citadis Kassel, bogie overhaul contracts •• Hong-Kong: Metro DC traction motors overhaul; •• France: Citadis Lyon Arpège bogies overhaul. PARTS & REPAIRS Light rail vehicles, motor overhaul, France Solution On the basis of 136 motors to be overhauled, Alstom proposed a flexible overhaul contract with the following features: The fleet of a French urban operator running 24 Siemens automatic light rail vehicles (VAL) was approaching the 1.2 million km overhaul mark for its 136 Alstom traction motors. Even though the franchise was in the process of being retendered, it became clear that the overhaul had at least to begin during the last year of the current contract. The previous 600,000 km overhaul of these motors had not been done by Alstom. Challenge The operator had the choice between three options: 1. Invest to carry out the overhaul internally 2. Use small external component repairs workshop 3. Turn to OEM for overhaul Option 1 was ruled out, as it would have required the operator to invest in specific tools and recruit resources just to cope with the workload. Having to choose between options 2 and 3, the customer turned to Alstom to see if an OEM overhaul was cost competitive. •• Limited initial fixed tranche and option, conditioned by franchise renewal •• Fixed lead time: 5 weeks for the overhaul of a batch of 8 motors Leveraging its OEM installed base knowledge; Alstom was able to propose an extended warranty of two years. This solution fully met the needs of its client in terms of flexibility, quality and, last but not least, cost. Transport Services 65 Test Benches Specialized tools to optimize recurrent maintenance tasks Some maintenance tasks represent a heavy workload when the appropriate tooling is not available. Alstom develops special state-ofthe-art tools to automatize equipment testing. These tools include: •• Customer Test Tool (CTT): based on a generic bench test platform, various configurations are available to test traction electronics, train control and monitoring systems (TCMS), public address and customer information systems (PACIS) and auxiliary converters •• HydraDIS-depollution unit: portable device for flushing and cleaning of Citadis hydraulic brake and piping Standard services supplied with our test tools: •• Customer needs analysis and proposal set-up •• Transport, delivery and installation of equipment •• User manuals, training and level 1 maintenance •• Warranty: 12 months Additional services are available: warranty extension, technical support, maintenance, training, spares or product evolutions, e.g. to test additional components. Benefits Automated tasks are less expensive but also less prone to human error for safer and more efficient maintenance, translating into maintenance savings and reduced train downtime. You will also have access to our testing expertise and support. 66 Transport Services Performance •• Up to 30 products tested with one test bench •• Test duration •• Completeness of the automated tests •• Delivery time Our value added •• Proven tools used by Alstom maintenance staff •• Technical expertise Key references •• CTT: more than 60 test benches installed in Europe, America, Asia and Pacific •• HydraDIS-depollution unit: Barcelona and Murcia tramways in Spain PARTS & REPAIRS Shanghai Metro, China Santiago Metro, Chile TCMS, Train Control & Monitoring System, and Traction electronics test bench equipment for Shanghai Line 10 and Line 2EE On-board signaling (UNIVIC product) Automatic train control test bench Scope Provision of 2 Customer Test Tools (CTT) and installation in Shanghai Line 2 depot equipment for Santiago Metro, lines 3 & 6 Scope Provision of one BTE (Bench Test Equipment) and installation in Santiago Performance Neptuno depot. •• Level of fault detection: module or circuit board •• Testing duration: min 15 min max 1hour •• Warranty: 12 months (with possible extension) Performance Level of fault detection : LRU (Line Replaceable Unit) identifying the faulty SRU (Shop Replaceable Unit) for suitable equipment. The test bench performance in terms of duration is roughly: •• Bench test starting: 5min •• Boards programming: 20 min •• Equipment Test: 1:30 Transport Services 67 Transport/Services Catalogue /EN/07.14/FR © - ALSTOM 2014.All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction use or disclosure to third parties, without express written authority is strictly prohibited. ALSTOM, the ALSTOM logo and any alternative version thereof are trademarks and service marks of ALSTOM. The other names mentioned, registered or not, are the property of their respective companies. Photo Credits: ©ALSTOM Transport - Design and production: Z&A conseil Clichy France ALSTOM Transport 48 rue Albert Dhalenne 93482 Saint-Ouen Cedex - France Phone: +33 (0)1 57 06 90 00 Email: transport.services@transport.alstom.com www.alstom.com/transport