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Tag: Modernisation

Modernisation – Our solutions

TILO FLIRT train of SBB in Switzerland during service life extension project, modern electric multiple unit on track.

Vehicle life extension TILO FLIRT

Customer: SBB, Switzerland

Project tasks

  • Overall project management of the TILO FLIRT service life extension
  • Project reporting to the steering committee
  • Project planning and realisation of the detailed concept phase
  • Funding application ARPV
  • Project planning and implementation of the realisation phase
  • Leading the SBB project team

Our approach

Swiss Federal Railways (SBB) operates 54 Flirt trains with TILO. These trains were purchased in five phases between 2007 and 2020 and were designed for a service life of 25 years. In order to be able to replace all TILO Flirt trains simultaneously as part of a new procurement project, SBB plans to extend the service life of the two oldest sub-fleets to 32 years.

PROSE is responsible for the overall management of the project to extend the service life of the TILO train fleet. Over 2 ½ years, we led a dedicated project team within SBB, ensuring seamless collaboration between customer requirements, technology, development, production, quality, and supply chain management.

A key milestone was the detailed concept phase, where PROSE’s structured approach ensured that requirements management, technical concept development, and prototype conversion were all completed on time and within budget. Our expertise in certification played a crucial role in securing the necessary licences for both Switzerland and Italy, a fundamental step in keeping the project on track.
PROSE also spearheaded the successful funding application (ARPV) to the responsible cantons and the Federal Office of Transport (FOT), securing approval to finance the conversion of the entire fleet of 30 trains.

During the production phase, we worked closely with the SBB production plant to ensure a smooth transition to series conversion. With production successfully underway, PROSE carefully handed over the project to SBB, ensuring continued progress and a reliable future for the TILO fleet.

Customer benefit

With PROSE as a partner, the customer benefits from comprehensive expertise in the areas of project management, stakeholder management, project planning, change management and cost control. An entrepreneurial approach, sound technical knowledge, but also knowledge of SBB processes and organisation are essential for successful project implementation.

Beyond technical know-how, our understanding of SBB’s processes and organisation was a key factor in keeping the project on track. By working with PROSE, the customer was able to bridge resource gaps, tap into our extensive railway industry network, and benefit from independent, expert advice that led to a successful project outcome.

 

    

BDe 576 railcar retrofitted with an energy measurement system for Makies AG in Switzerland.

Engineering and integrating an energy measurement system

Customer: Makies AG, Switzerland

Project tasks

  • Program management
  • Project planning
  • Electrical engineering
  • Mechanical engineering
  • Technical documentation

Our approach

Makies AG wanted to retrofit the BDe 576 railcar with an energy measurement system. PROSE, together with our workshop partner, carried out this trial installation. PROSE was responsible for the electrical dimensioning, product selection and the final conversion documentation. The workshop partner was responsible for product procurement, installation of the Energy measurement system (EMS) components, wiring and commissioning.

We developed a structured the template for the installation instructions and completed it with all product selection-relevant data for the current and voltage converter, Ecomodul, fuse protection and router. Product selection was defined based on the infrastructure requirements and existing onboard installations, incorporating experience gained from comparable system installation and operation. The final installation documentation includes the complete installation instructions and the product list.

Customer benefit

By commissioning PROSE, the customer benefits from our extensive experience in rail vehicle integration engineering. The proposed mechanical and electrical solutions supported a robust and sustainable energy measurement system installation. Our neutral advisory role ensured effective coordination between all project participants, particularly the workshop, reducing interface risks and supporting efficient implementation.

 

  

Assessing locomotive compatibility on an SJ Rc6 electric locomotive in Sweden, showing roof-mounted pantographs and high-voltage equipment at a station platform.

Assessing locomotive compatibility under increased overhead line voltage

Customer: SJ AB, Sweden
End customer: Trafikverket, Sweden

Project tasks

  • Technical investigation
  • Documentation research
  • Identification of possible changes in locomotive high-voltage circuits
  • Cost estimation of the changes
  • Integration of the changes in the actual system

Our approach

PROSE began with a structured review of the Rc6 high-voltage system, analysing design documentation, component specifications, and historical modification records to establish the vehicle’s current technical baseline. Based on this analysis, we evaluated the impact of the increased maximum voltage on insulation coordination, component voltage margins, and protection systems. Where necessary, we developed alternative technical solutions to ensure compliance with the new operating conditions. Each option was assessed from both a technical and economic perspective, including feasibility, implementation effort, operational implications, and associated risks. The work was carried out in close dialogue with SJ as operator and Trafikverket as infrastructure owner to ensure transparency and alignment throughout the project.

Customer benefit

The customer gained a transparent and technically sound decision basis for operating the Rc6 fleet under increased overhead line voltage. Our independent assessment clarified voltage margins, component limitations, and protection requirements, creating full visibility of technical risks and modification needs.
By systematically comparing refurbishment scenarios, including cost and implementation implications, we enabled SJ and Trafikverket to prioritise measures based on safety, operational reliability, and long-term investment protection. With PROSE’s in-depth knowledge of Swedish rolling stock and infrastructure interfaces, the operators secured a technically robust and future-proof solution aligned with updated network standards.

 

Preparing and migrating technical documentation into the PRO(doc) documentation system

Customer: Transdev, Germany

Project tasks

  • Project management
  • Software management
  • Structure of the document management system
  • Uploading documentation to PRO(doc)
  • Training

Our approach

Transdev Hannover GmbH took over 13 Bombardier ET425.5 electric multiple units that were in service on the Hanover S-Bahn between 2008 and 2022. With the fleet takeover, the operator received the complete manufacturer documentation, including operating manuals, maintenance manuals and maintenance instructions.

PROSE was commissioned to adapt and consolidate the existing documentation and to merge manuals, instructions and guidelines into a unified documentation basis. An important part of the project was to prepare the documentation for integration into the XML-based PRO(doc) system to ensure structured data,
standardised content and controlled version management.

The work also included training Transdev employees in uploading, editing and maintaining documentation in PRO(doc). The project was based on close collaboration between PROSE Sweden and PROSE Germany in order to combine expertise in documentation management with operational vehicle knowledge.

PRO(doc) was used as the technical documentation environment, specifically tailored to train maintenance. We combined expertise from PROSE Sweden and PROSE Germany, covering project management, MadCap Flare, document management, stylesheets, rules, XML structuring, and problem solving.

All available material was imported into the editing environment. PDF documents were converted to Word and harmonised in terms of styles, metadata, and layout. The document structure and design were developed in MadCap Flare, where the content was organised into a consistent product-based hierarchy and a maintainable table of contents.

Azure DevOps was used solely for source code management and version control to enable parallel work. A document list, created and maintained in Excel in line with the standard’s product-based structure, served as a working document and checklist throughout the project. Continuous technical support and transparent communication ensured efficient collaboration and traceability of decisions.

Customer benefit

Transdev now works with a standardised and well-structured documentation set that supports efficient maintenance and daily operations. The PRO(doc) documentation system, developed by PROSE, provides a searchable database with controlled version management, ensuring reliable access to approved content and updates.

The consolidated and migrated documents are published in a unified structure that simplifies future revisions. PRO(doc)’s responsive design enables use on any device, while document creation and updates are managed in MadCap Flare and exported to PRO(doc). With the training provided, Transdev can manage its documentation independently, supported by PROSE’s independent and specialised expertise when required.

 

         

Integration and Authorisation Management: Polish Train Radio, Radio Stop Module, Interior and Exterior Foliation

Customer: ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH, Germany

Project tasks

  • Integration engineering of the Polish train radio
  • Integration engineering of the radio stop module
  • Adaptation of the MESA23 system
  • Consideration of the interior and exterior foliation as well as the modification of the train radio system within the verification process
  • Homologation management
  • Authority communication

Our approach

ODEG – Ostdeutsche Eisenbahn GmbH operates passenger transport services in northern and eastern Germany. The fleet consists of Desiro Classic (BR 642) multiple units, among others, manufactured by Siemens Mobility (SMO). The maintenance and repair of the vehicles is carried out by ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH. This is a 100% subsidiary of ODEG. The vehicles currently operate with the existing German authorisation and a German train radio system on a section of line that runs over Polish territory. In future, the vehicles will have to be equipped with Polish train radio system and a radio stop module (RSM). The RSM is a device that is connected to the existing train radio system and integrated into the vehicle’s safety loop via an electromagnetic valve. In this way, the responsible dispatcher can give the “radio stop” command, which opens the vehicle’s safety loop and brings the vehicle to a standstill. In addition, interior foliation in the WC and full-surface exterior foliation had to be installed.

The functionality of the existing MESA23 system will be expanded to include operation with Polish train radio and the radio stop module (RSM). The foliations are handled with regard to all requirements.

Customer benefit

Thanks to the cooperation with PROSE, the customer was able to successfully convert the Desiro Classic railcars (BR 642) to use Polish train radio and the radio stop module (FSM). This not only offers ODEG passengers increased safety during the journey, but also enables smooth operation on the section of line through Polish territory. The application of the interior and exterior foils also contributes to the attractive appearance of the vehicles.

PROSE managed the project from the initial idea to the authorization strategy, preparation of evidence documents and coordination with NoBo/DeBo/AsBo through to communication with the authorities, so that ODIG was able to obtain a significant part of the project scope from a single source.

 

    

Technical support and documentation for the modernisation of the EMU class 72

Customer: Alstom, Sweden

Project tasks

  • Requirements capture
  • Electrical system engineering
  • Technical writing

Our approach

PROSE provided technical support and documentation for the modernisation of the EMU vehicle class 72. An electrical systems engineer ensured that key upgrades—such as LED front lighting, USB ports, and interior lighting—met modern standards. In addition, two technical writers were assigned to update the existing technical documentation to reflect the improvements.

Our electrical systems engineering team took a methodical approach to ensure that all subsystems met functional requirements and complied with current standards and regulations. Our focus was to check subsystems such as LED front lights, USB contacts and passenger information systems (PIS). When we found gaps between existing components and required standards, we recommended improvements. Our thorough approach ensured that every aspect of the electrical system was optimised for modern operational efficiency and regulatory compliance.

Customer benefit

Our expertise allowed for a quick project start, helping the customer save valuable delivery time. ALSTOM also appreciated PROSE’s support on safety and regulatory matters, ensuring all requirements were met efficiently.

 

      

Expert Consulting for the SJ High-Speed Train X2000 Upgrade

Customer: Swedish State Railwyas (SJ), Sweden

Project tasks

  • Upgrade of the drive system
  • Updating the Train Control and Monitoring System (TCMS)
  • Coordination and support for the modernisation of the exterior door system
  • Interior refurbishment of the passenger carriages
  • Test and verification

Our approach

​Swedish State Railways (SJ) is launching a comprehensive modernisation programme for its fleet of 36 X2000 passenger trains, which have been in service for over three decades. This extensive project includes a number of important modernisations designed to improve performance, reliability and passenger comfort. The scope of the modernisation includes a complete overhaul of the trains’ propulsion system to increase efficiency and reduce environmental impact. In addition, the Train Control and Monitoring System (TCMS) will be upgraded to the latest railway technology to ensure better operational control and safety. The refurbishment also extends to the exterior doors. In addition, the interior of the passenger coaches will be extensively renovated to provide a more comfortable and aesthetically pleasing travelling experience. These improvements are aimed at extending the service life of the trains and adapting them to current technical and ecological standards.

PROSE is playing a central role in the realisation of this ambitious project by consulting SJ and its suppliers with a range of services. Our approach is based on a comprehensive project management strategy that includes project coordination and technical planning. We are also involved in rigorous testing and inspection phases to ensure that all retrofits meet the stringent standards expected in modern passenger rail transport. Our team consists of experienced professionals with in-depth knowledge of railway systems who bring a wealth of knowledge and experience to the project. By integrating seamlessly with SJ’s operations, we facilitate effective communication and coordination between all stakeholders, proactively address challenges and ensure that project milestones are met efficiently. Our holistic approach ensures that from initial design to final implementation, every aspect of the project is handled with precision and care.

Customer benefit

By entrusting PROSE with this extensive modernisation project, Swedish State Railways (SJ) has gained access to a team of highly experienced experts with a deep understanding of the complexities of modernising outdated train fleets. Our involvement ensures the project runs smoothly and effectively, maximising the potential for on-time and on-budget delivery. Our expertise helps to anticipate potential issues and mitigate risks to ensure that the modernised trains meet current and future rail transport requirements. Immediate benefits for SJ include improved train performance and increased passenger satisfaction. Ultimately, this project supports SJ’s goals of improving operational efficiency and providing a superior travel experience, reinforcing the company’s reputation as a leader in sustainable and innovative rail transport 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 authority

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.

 

      

Authorisation Support – Repainting of ET425.5 EMUs

Customer: Transdev Hannover GmbH, Germany

Project tasks

  • Project management
  • Requirements capture
  • Authorisation support
  • Communication with NoBo and DeBo
  • Preparation of evidence and admission documents
  • Preparation of a change notification

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 authorisation management concerning TSI LOC&PAS, TSI PRM and German NNTR as well as requirements capture and evidence documents. The main obstacle was to find a way to establish the evidence documents 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 authorisation 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”.

 

 

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