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Mid-life maintenance of PRIMA BB27000 and BB37000 locomotives

Customer: AKIEM, France

Project tasks

  • Definition of the operations to be carried out for the mid-life maintenance of PRIMA locomotives
  • Identification of ways to increase reliability
  • Treatment of component obsolescence
  • List of changes that can be implemented in mid-life operation
  • Solutions for a hardware refresh
  • Definition of the industrialization process for mid-life
  • Analysis of the risks associated with the residual life of the equipment

Our Approach

PROSE has developed a high level of expertise in the PRIMA-E locomotive type, maintenance definition and reliability growth action plan.

Customer benefit

Thanks to its expertise in the field of rolling stock, over the entire life cycle, PROSE can offer its best services to accompany its customer through all the stages of the life of its locomotives.

Modernisation of 135 Interregio coaches for operator Flixtrain

Customer: Talbot Services GmbH, Germany

Project tasks

  • Creation of mechanical conversion
  • Preparation of circuit diagrams
  • Adaptation of air conditioning concept
  • Integration of new toilets
  • Integration of luggage racks
  • Certification support
  • Certification calculations
  • Mass management
  • Fire protection
  • Strength analysis

Our Approach

The Arkimbz, WRmbz, ABimdz, Bimdz and Bimz wagons were modernized, in following phases: starting-, initial-, planning, production- and execution phase. Finally the type test phase concluded the work.

Customer benefit

As a strategic engineering partner, PROSE was already able to convince the customer Flixtrain in the offer phase. When it came to the engineering work, you could rely on the skills of PROSE and thus focus on the conversion of the vehicles.

 

Technical documentation in the SJ X2000 refurbishment project

Customer: SJ AB, Sweden

Project tasks

  • Technical documentation
  • Translation
  • Coordination
  • Verification

Our Approach

PROSE contributed to the project by assisting in creation of new technical documents for the refurbished train fleet, as well as with translation, coordination, and internal review. Around 400 documents have been created for the project, and subsequently reviewed by the customer. PROSE’s team of technical writers contributed to update, and create new system manuals, maintenance manuals, spare parts catalogues, troubleshooting guides, diagnostic data sheets (DDS lists), component sheet, training documentation, etc.

Customer benefit

PROSE supported ABB and Stadler in the creation and translation of new technical documentation for SJ. The documentation was created in the office, combined with work in the depot, to make sure every product/function was clearly described. This helps operators to understand the updated products and systems, ensures correct use of the products and guarantees safety in maintenance work.

Refurbishment of X2000 class high speed trains

Customer: Stadler, Sweden

Project tasks

  • ​Overall project management
  • Electrical and mechanical engineering of the interior
  • RAMS
  • Approval management
  • Technical documentation

Our approach

During the tendering phase PROSE acts as consultant for Stadler. In the project, PROSE is responsible for technical project management, electrical and mechanical engineering, approval and RAMS. PROSE will also provide technical documentation services.

Customer benefit

Our customer benefits from PROSE’s great expertise in X2000 trains, as part of our team was already involved in the last modernisation 10 years ago. In addition, thanks to the modernisation, passengers will enjoy a completely new travel experience on board Sweden’s fastest trains – with new interiors, new seats and more efficient lighting. The availability of the trains will also be improved. The result is a train set that passengers will experience as completely new.

 

Audit of an ERTMS onboard system

Customer: Banedanmark (BDK), Denmark

Project tasks

  • Performance of the audit of the onboard projects of the Danish Signaling Program for the readiness for fitment
  • Assessment of the preparation for the installation phase of the vehicles in relation to:
    – Planning of the installation
    – Installation design
    – Prototype installation
    – Approval process
    – Assessment of different design issues

Our Approach

PROSE’s team of experts carried out this audit in less than three months; the audit covered the supplier Alstom, four railway operators, the national safety authority (Trafikstyrelsen), G-ISA and Banedanmark.

Customer benefit

Thanks to PROSE’s independent recommendations, our customer was able to optimize the current technical performance and to reduce the known risks.

Requirements elicitation and preparation of test concept for perception system

Customer: Deutsche Bahn AG, DB Cargo AG, Germany

Project tasks

  • Elicitation of the requirements from the driving service regulations
  • Elicitation of system requirements
  • Design and coordination of the test concept

Our Approach

PROSE has been assigned by DB Cargo to develop a requirements catalog for the perception system, which corresponds to the requirements catalog for ATO GoA2 and GoA4 + Remote Supervision & Control in freight transport. This requirements catalog will be used to evaluate a technology partner for the development, installation, integration, commissioning, certification and testing of such a perception solution. The tests for the one-year trial operation until 2025 will take place on the Dutch part of the Betuweroute (from Kijfhoek to Valburg).

Customer benefit

With the assignment of PROSE, the customer benefits from PROSE’s extensive experience in the fields of ATO, sensor technology and architectures. For this, profound technical knowledge, but also very good knowledge of the market, technology and railroad operations are indispensable. Thanks to PROSE’s structured approach, a well-founded result is ensured from a broad analysis on the technical possibilities and business implications of automation.

 

Implementation of the approval project for lifting platforms used on tunnel maintenance vehicles

Customer: SBB Infrastructure, Switzerland

Project tasks

  • Homologation management
  • Risk analysis on system level
  • Verification of stability by calculation
  • Verification of occupational safety, railroad safety

Our Approach

In a first phase, the basics for approval had to be elaborated for the two applications. Then, the feasibility was evaluated concluding a proof of stability, but also regarding commercial aspects. The necessary measures were derived here after to ensure safe operation. This report was discussed with the customer and the responsible authority (FOT).  In the second phase, the customer implemented the measures, PROSE controlled this implementation and prepared an evidence report.

Customer benefit

With the practical knowledge of the involved persons from SBB and PROSE, simple, cost-effective and practicable measures could be realized. The step by step process lead to legal certainty without investment before it was clear, that the project will reach its objective. By considering worker’s safety from the very beginning, the approval process could be simplified. Thus, no separate approval with a second approval authority was necessary, reducing time and costs as well as the related approval risk.

Advice on the implementation of ECM Regulation 779

Customer: SBB CARGO, ECM2 strategic fleet management, Switzerland

Project tasks

  • Leadership coaching of the responsible head of strategic fleet management
  • Expert mentoring of the executing project employee
  • External workshop organisation for team development
  • Stakeholder management with management level, HRM, standards and regulatory bodies
  • Methodical tool development in the area of competence management
  • Strategic organisational development regarding structure and process organisation
  • Strategic knowledge management in quasi-governmental organisations

Our Approach

In a first step, the safety-relevant (ECM) activities were separated from the availability-relevant activities and documented in an external workshop. A competence matrix of the fleet management employees was created in several project work steps. PROSE then developed a target matrix on the basis of the content of the impending leap in standards from 2011/445 to 2019/779, whose delta on the actual situation can be used as the basis for strategic employee development and represents the comprehensive and detailed proof of competence in the forthcoming safety audits.

Customer benefit

The Head of Strategic Locomotive Fleet Management (ECM2) receives a comprehensive and detailed overview of the area of activity of his department and is in a position to document, reference and thus prove the ability to carry out these processes at any time and at the appropriate level in an audit-capable manner. Externally, this department achieves competence suited for the forthcoming re-certification to the new 2019/779 ordinance landscape. Internally, it serves as a practical example of the implementation capability within the framework of the CargoFit programme. Furthermore, process-related and competence oriented dependencies between the ECM2 activities will be established: safety, availability, system engineering and regulations are clearly documented and located.

Research project for an innovative concrete sleeper

Customer: Swiss Federal Office for the Environment, Switzerland

Project tasks

  • Experimental modal analysis on different concrete sleepers
  • Computational modal analysis FEM
  • Measurements in specially built test track
  • Measurements of TOR and sound radiation
  • Design and analysis of two sleeper types
  • Manufacture of sleepers by project partners

Our Approach

The new concrete sleepers were developed in cooperation with the Swiss concrete element manufacturer Vigier Rail. The existing sleeper types were first examined and analyzed using measurement technology and the parameters influencing the acoustics were analyzed.

Customer benefit

With this research project on an essential element of the track superstructure, PROSE wants to advance the industry – with less noise and simultaneously low wear and tear or lower life cycle costs. This benefit both the affected residents and the infrastructure contractors.

RAMS analysis of the Vivalto double-deck coaches

Customer: ATI (Ansaldo Breda, OFV and Magliola), Italy

End customer: Trenitalia, Italy

Project tasks

  • RAMS analysis guidelines
  • Safety analysis guidelines
  • RAMS analysis for the systems from ATI
  • Verification and validation of the systems from the sub suppliers
  • Documentation services
  • Protocol and test procedures
  • Study and analysis for CEI UNI 11170 application
  • RAMS analysis at coach level

Our Approach

PROSE elaborated the guidelines and the templates to realize the RAMS analysis. Furthermore, PROSE carried out a coach risk analysis and generated hazards (SFAS) relating to each system in the driver’s cab and the coaches.

Customer benefit

Thanks to PROSE‘s extensive experience with RAMS analyses and documentation services, the costumer was able to focus on the design. PROSE was responsible for the project management with the support of Ansaldo Breda’s RAMS office. Therefore, the approval of the RAMS documentation by Trenitalia was simplified and unproblematic. Furthermore, the Vivalto coaches are the first coaches to which CEI UNI 11170 was applied, which means that PROSE, ATI and Trenitalia can benefit from this experience for other applications in future projects.

 

Development of suspended monorail vehicles

Customer: Kiepe Electric GmbH, Germany

Project tasks

  • Mechanical design of carbody, vehicle interior and running gear
  • Mechanical system integration
  • Manufacturing supervision
  • Homologation management

Our Approach

In order to overcome the first challenge of creating the optimized vehicle for this particular application, PROSE developed a vehicle body that is constructed from aluminium extrusion profiles.
Moreover, the continuous low floor and wide-opening doors guarantee efficient passenger flow. The new vehicles for the Wuppertal suspension railway also offer high driver comfort.

Customer benefit

Given PROSE’s extensive experience in developing mainstream and special projects of all kinds, PROSE’s development team was able to successfully meet Kiepe Electric GmbH’s expectations. Furthermore, PROSE’s intercultural experience and capabilities are highly appreciated, playing a fundamental catalyst role in the current manufacture of the vehicles in Austria, Germany and
Spain.

 

Design of a 100% low-floor tram

Customer: CRRC Sifang Co Ltd, China

Project tasks

  • Tram concept
  • Design and development of bogie and carbody conceptual design and development
  • Electrical concept
  • Mechanical system integration

Our Approach

In cooperation with the client, PROSE developed the system specification for the whole tram and several of its components. One of the most challenging tasks in 100% low floor-trams is the design of the bogie, which had to be both compact and offer a quality ride. Single wheels were the solution.

Customer benefit

The newly designed 100% low-floor tram is a major upgrade of CRRC Sifang’s tram portfolio. The integration of CRRC Sifang’s production know-how and related processes into PROSE’s design work means lower production costs for CRRC Sifang.

 

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