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Tag: Modernisation

Modernisation – Our solutions

Digitalisation of maintenance requirements

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review and analysis of the existing documentation (e.g., old regulations)
  • Expert Interviews: Enrichment of the database with know-how from specialists
  • Documentation: Creation of maintenance plans for the 14 rail vehicles and 3-4 wagon fleets
  • Approval: Incorporation of client feedback and final adjustments

Framework conditions:

  • Utilisation of old regulations as the basis
  • Supplementation through reverse engineering and other methods to address data gaps
  • Collaboration with the client, particularly in providing knowledge and feedback

Our approach

The project was initiated by SBB Historic to gradually align the existing maintenance organisation and fleet management with European standards. The core challenge lies in transforming a fragmented documentation base. Many of the historic vehicles have only partially available operational and maintenance manuals, as the original manufacturers either no longer exist or the documentation has been lost over time.

Additionally, the introduction of the ZEDAS maintenance software is intended to support and future-proof the maintenance processes. The project aims to create a consistent and standard-compliant maintenance plan landscape for the historic rail vehicles, enabling efficient, safe, and resource-conscious maintenance. At the same time, the transition will ensure compliance with European norms and facilitate maintenance activities carried out by in-house teams, associations, and third parties.

To achieve these objectives, PROSE adopts a structured approach comprising several interconnected work steps. The process begins with extensive research, focusing on reviewing and analysing old maintenance regulations to compile and prepare existing content. Subsequently, PROSE conducts expert interviews to incorporate historical knowledge from specialists, fill existing gaps, or update outdated guidelines. Based on this, maintenance plans are developed for the 14 rail vehicles and three to four wagon fleets. These plans are created iteratively, incorporating client feedback to ensure a tailored solution. Finally, the plans are integrated into the new maintenance concept and adapted to the requirements of the ZEDAS software.

The PROSE team, consisting of experienced experts, guarantees a professional and quality-orientated implementation. If necessary, the team is supported by other experts to ensure the quality and efficiency of the implementation.

Customer benefit

The project provides the client with numerous advantages that go beyond merely developing maintenance plans. By establishing a consistent, standards-compliant planning framework, the maintenance of historic vehicles can be carried out safely, efficiently, and cost-effectively. The integration of existing regulations and the supplementation of missing content through expert interviews not only reduces time and financial expenditure but also ensures that the plans are highly practical and relevant.

Another significant benefit lies in the introduction of the ZEDAS maintenance software, a key component for future digitalisation and optimisation of processes. The combination of technical and operational expertise provided by PROSE ensures that the plans are seamlessly integrated into the new software ecosystem, creating a high level of efficiency and transparency.

With transparent pricing and an agreed cost ceiling, the project remains financially predictable and manageable. At the same time, SBB Historic and the participating organisations benefit from PROSE’s extensive experience and proven competence. PROSE delivers tailored and sustainable solutions in the railway sector. The outcome is not only technically flawless but also an economically viable solution that guarantees the long-term safe operation of the historic fleet.

 

 

3rd party assessment of exterior camera installation

Customer: MTR Tech, Sweden

Project tasks

  • Assessment of proposed and installed solutions of camera installation
  • Highlighting risks and deviations from industry standards and recommendations

Our Approach

MTR has operated and maintained the X60 Coradia fleet on behalf of the Stockholm Region until 2024. The region has ordered installation of cameras from Alstom to support the drivers and improve visibility around the door-area, particularly on platforms with curved tracks.

PROSE has extensive experience in mechanical and electrical design as well as design processes, especially in adhesive bonding. Based on our expertise, an iterative assessment process has taken place to assess the proposed and installed solution. It includes recommendations in line with industry best practice for both mechanical design and bonding – as well as design and processes – in accordance with EN17460.

Customer benefit

​Adding additional equipment to an existing fleet without impacting the basic design requires experience and know-how about production methods and the original design. With PROSE as an independent assessor, the client received an independent assessment of the proposed and installed solution as well as the identification of potential short- and long-term risks in the proposed design of both the bonded joints and the mechanical parts.

 

      

Corrosion repair

Project tasks

  • Creating a CAD model of the carbody from a set of drawings
  • Creation of an FE model of the carbody
  • Strength assessment of the condition without corrosion
  • Consideration of corrosion damage in the calculation model
  • Analysis and determination of minimum wall thicknesses
  • Specification of measures for corrosion repair
  • Preparation of drawings to document the repair solution

Our Approach

Corrosion damage to the lower structure of the carbody was discovered during the planning of conversion measures on dining carriages. The wagons are welded steel constructions from 1990 and due to the advanced age of the vehicles, the operator did not have any CAD models or strength documents. PROSE was commissioned to assess the utilisation of the carbody in terms of strength. First in their original, corrosion-free state and then considering the identified corrosion damage. Additionally, we were asked to develop solutions to prolong the service life of the vehicles.

In a first step, a CAD model was created from the set of drawings. This model then served as the basis for creating the Finite Element (FE) model, which embodies the target condition of the carbody structure. A subsequent strength analysis then showed how many theoretical reserves the structure still had.

In the next step, the FE model was updated to include corroded areas, and the calculations were repeated. In this way, the effect of corrosion on the structural strength of the carbody could be determined and evaluated.

Using an iterative approach, a maximum corrosion depth could be determined for the damaged areas. For areas where it was foreseeable that the corrosion would penetrate too deeply, repair solutions were also developed, which included welding in new profiles, and their strength was verified.

Customer benefit

Thanks to PROSE’s work, the customer now has access to a CAD model of the carbody. The strength analysis has enabled the determination of minimum wall thicknesses for vehicle areas typically affected by corrosion, which the customer can use to evaluate the extent of corrosion damage. For areas where corrosion has penetrated too deeply, the customer now possesses localised repair solutions. This can significantly extend the service life of the vehicles.

 

          

Vehicle Authorisation

Customer: various customers

Project tasks

  • Carrying out requirements capture and preparing the safety evaluation, including risk analysis
  • Preparation and management of evidence documents
  • Cooperation and coordination of NoBo, DeBo and AsBo
  • Support in preparing several declarations and dealing with online registers like ERATV or ERADIS
  • Management of the change notification to the ERA or national safety authorities like EBA for changes not requiring an authorisation
  • Management of authorisation applications via One Stop Shop to the ERA for changes requiring authorisation
  • Coordination with the ERA and national safety authoritie

Our Approach

Vehicle operators or leasing companies make changes to their vehicles for very different reasons, e.g. for obsolescence reasons or to offer passengers a better service by customising the interior and adding features such as sockets or WLAN. In addition to providing engineering services, PROSE supports such projects by taking over the entire approval management process, including communication with all the bodies and authorities involved.

The authorisation process ensures safe rail transport and the best possible interoperability throughout the EU. However, implementing changes to rolling stock presents a significant challenge to operators, keepers, and owners.

At PROSE, we recognise that each railway vehicle is unique. Our team of experts develops vehicle authorisation strategies that address the specific challenges of our customer’s products and needs. From Requirements Capture to One Stop Shop, our experts have the knowledge to guide you through the process. Whether you only need assistance with a single task or are looking for a complete solution, we can provide solutions to meet your particular requirements.

Customer benefit

Modernisations and retrofits guarantee enhanced reliability and superior passenger comfort and open up new applications by integrating new systems. Whilst operators and workshops can focus on their primary tasks, PROSE can handle all the “paperwork” from the engineering and the preparation of evidence documents to the assessment and authorisation phases with bodies and authorities involved. Due to our comprehensive service portfolio, we help reduce interfaces and effort because all services are coordinated and come from a single source.

PROSE ensures that our customers’ railway vehicles comply with the latest standards and regulations. From document preparation to submission, we make sure that vehicle approval hurdles don’t derail your success.

 

      

Homologation Support – Repainting of ET425.5 EMUs

Customer: Transdev Hannover GmbH, Germany

Project tasks

  • Project management
  • Requirements capture
  • Homologation support
  • Communication with NoBo and DeBo
  • Preparation of verification and admission documents

Our Approach

Transdev Hannover GmbH changed the existing colour scheme of 13 EMUs of the type ET425.5 from the Deutsche Bahn “Verkehrsrot” to the Transdev branding in blue and white. PROSE supported with homologation management concerning TSI LOC&PAS, TSI PRM and German NNTR as well as requirements capture and verification documents. The main obstacle was to find a way to establish the verification of the fire protection as no spare parts existed to conduct the necessary experiments.

Due to the great experience and good networking within the industry, it was possible to agree on a feasible way of proving fire protection with the assessment bodies as early as the tendering phase. In combination with the close support of the customer in every phase of the project, loops or lengthy discussions could be avoided.

Customer benefit

PROSE led Transdev Hannover through the homologation process including communication with the assessment bodies and project management. This ultimately resulted in the timely submission of the documents and rapid final processing by the national safety authority (EBA) including the final “Go”.

 

 

QA of suppliers and production for driver’s desk refurbishment in C20 Metro

Project tasks

  • Quality assurance of sub-suppliers
  • Supervision of prototype phase
  • First class installation
  • Delivery inspections

Our Approach

PROSE have worked closely with the suppliers from an early phase in the development process to ensure a smooth transition from development through prototype to the production ramp-up phase and to ensure stable quality throughout the serial production.

Customer benefit

By improving the supplier delivery early in the project, the customer could benefit from minimizing quality issues just before the start of production. PROSE’s wide range of available services helped the customer in many stages of the project.

 

Digitalisation Maintenance Instructions

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review of the old maintenance regulations for each vehicle
  • Expert interviews: Ensuring the transfer of expertise to supplement/correct the old maintenance regulations
  • Documentation: Creation of maintenance plans for each vehicle
  • Release: Incorporation of customer feedback and internal release of the maintenance plan

Our Approach

PROSE supports the client in creating maintenance plans for the first 14 traction units and 3-4 coach fleets. These can only be partially derived from old regulations and thus completed and adapted accordingly and transferred to a digitalised maintenance concept. A significant proportion of the maintenance work is carried out voluntarily by associations. This particular situation must be taken into account in the concept development. PROSE also provides relevant support for introducing the ZEDAS maintenance software on the customer side.

Customer benefit

The client receives a digitalised, standardised and consistent maintenance plan landscape for the vehicles to ensure the safe, standard-compliant and efficient planning and implementation of maintenance measures using in-house, association and external services.

The logic and conceptual design of the maintenance plans, regardless of whether they relate to steam locomotives, electric locomotives or multiple units, will be aligned accordingly, thus creating content, processes and documentation specifications that are much easier to understand and can also be communicated to volunteer maintenance staff to ensure safe rail operations.

The implementation already considers European standards for safe maintenance and their functional allocation in the organisational development. This will ensure a gradual expansion of the client’s maintenance services towards a modern, digital maintenance organisation.

   

Fire Safety Assessment and Consulting

Project tasks

  • Consultancy
  • Development and creation of fire protection concepts
  • Development and creation of evacuation concepts
  • Analyses of fire protection requirements
  • Compilation of required fire protection test reports
  • Communication with authorities, manufacturers and testing laboratories
  • Integration of fire safety systems
  • Preparation of approval documents relevant to fire protection

Our Approach

PROSE analyses the given situation and develops solutions that meet the applicable fire protection requirements. To this end, PROSE advises the customer and identifies various solutions in order to find an efficient way of achieving the required fire protection for railway vehicles in accordance with EN 45545. Our experts calculate the thermal load of the vehicle during the design and propose measures for its reduction.

Customer benefit

The customer benefits from our many years of experience in the field of fire protection for all types of rail vehicles in accordance with EN 45545, including not only advice but also the creation of concepts, the preparation of the necessary fire protection certificates, contact with manufacturers of fire protection-compliant components and communication with approval authorities. The aim is to place fire protection suitable vehicles into service.

Grand-Tour luxury train maintenance plan

Customer: Arlington Fleet France, France

Project tasks

  • Project management
  • Maintenance management
  • Homologation support

Our Approach

The “Le Grand Tour” project is creating a luxury cruise train in France, using refurbished coaches from Deutsche Bahn. Arlington Fleet France (AFF) is overseeing the project, using existing maintenance data from DB and new system designs.

In the first phase, PROSE formalised existing data from Deutsche Bahn, which is crucial for creating the maintenance plan. Now, in the second phase, we’re taking the lead in drafting the maintenance plan and the Maintenance Documentation File, ensuring compliance with homologation requirements for seamless introduction and operation on the French network.

Customer benefit

Based on PROSE’s extensive experience, the entire maintenance plan was created by integrating the existing and newly added systems. This allows the customer to have a solid maintenance file for the train approval and the vehicle authorisation and, subsequently, to plan future maintenance operations.

    

Aerodynamics simulation (CFD)

Customer: Various customers

Project tasks

​During the development process or during modernisation, aerodynamic influences such as crosswind or vehicle air conditioning of a vehicle must be assessed. Often the final verification requires investigations in a wind tunnel or climatic wind tunnel. However, CFD (Computational fluid dynamics) simulations are ideal for an initial assessment and optimization, as they generally provide reliable results at significantly lower cost.

Analyses:

  • Crosswind stability (aero-dynamic coefficients and wind characteristics curves) according to EN 14067-6
  • Climatic studies and thermal comfort

Our Approach

Crosswind assessment according to EN 14067-6

The EN 14067-6 provides for the evaluation of crosswind with aerodynamic coefficients, which can be obtained either by wind tunnel tests or by CFD simulations. PROSE can determine these coefficients by CFD simulations and derive characteristic wind curves. The influence of the vehicle design on the crosswind stability can be considered in the design phase. In the case of changes to the vehicle exterior shape during conversions, the influence can be assessed and in the case of minor changes, proof of crosswind stability can also be provided.

Investigation of vehicle air conditioning

CFD simulations allow first estimations for climatic-technical investigations according to European standards, which are based on tests in the climatic wind tunnel. An optimization with CFD simulations within the scope of the design of the air conditioning system generates additional safety and can avoid costly adjustments and repetitions of measurements in the climatic wind tunnel.

Customer benefit

PROSE can support you during the development process or during a modernization with CFD simulations to reduce costs and risks of wind tunnel and climatic wind tunnel tests.

 

 

Optimisation of the heavy overhaul program for the Tram “Cobra”

Customer: Verkehrsbetriebe Zürich, Switzerland

Project tasks

  • Development of an evaluation matrix based on the VBZ vehicle structure
  • Determining which measures are to be implemented within the framework of R3
  • Development of a project manual applicable to the project

Our Approach

PROSE develops an evaluation matrix based on the VBZ vehicle structure so that it can be determined which measures should be implemented within the framework of R3. The evaluation matrix contains criteria according to which the measures can be evaluated, including an evaluation. PROSE is developing a project manual applicable to the CR3 project. The focus is on the definition of the different phases including their objectives, duration and contents. It also explains which project participants and stakeholders should be involved, when and how, and how responsibilities should be defined.

Customer benefit

The methodology and tooling provided by PROSE in the first phase enables VBZ to efficiently plan and implement Revision 3 and the life extension measures. The evaluation matrix enables VBZ to make informed decisions about which measures should be implemented as part of R3. This helps to use resources effectively and to keep the trams in the best possible condition. The project manual is the basis for VBZ to implement the Cobra tram overhaul and service life extension project in a structured and effective way, resulting in cost savings and efficiency gains.

     

MBS simulation – trailer load with container car

Customer: Matterhorn Gotthard Bahn AG, Switzerland

Project tasks

  • Compilation and preparation of parameters for modelling and simulation
  • Determination of the braking scenario to be considered
  • Creation of a multi-body simulation model (MBS model) of the cogwheel supporting wagon to be investigated as well as of the coupled train configuration
  • Execution and evaluation of the simulation
  • Documentation in a verification report

Our Approach

PROSE is to prove by simulation that derailment safety is given with the new requirements and to develop a set of arguments that can be submitted to the BAV to adapt the driving service regulation.

In a first step, PROSE compiled all the parameters required for modelling and simulation on the basis of customer data. Subsequently, the braking scenario was determined and agreed with the customer. PROSE created the multi-body simulation model (MBS model) of the container car in the required modelling depth. The overall model of the train set included a simplified MBS model of the necessary vehicles for the combinations to be verified in addition to the carrying car to be investigated. PROSE simulated the operationally most critical cases and recorded the results and evaluation of the simulations in a verification report for the attention of the approval authority.

Customer benefit

The customer received a verification report for the approval documentation, which clearly and comprehensibly documents the mathematical proof of safety against derailment of the cogwheel carrier car. On the basis of the proof, the customer was able to obtain the adjustment of the driving service regulation from the BAV.

   

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