Skip to main content

Tag: Modernisation

Modernisation – Our solutions

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”.

 

 

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.

    

info@prose.one

 

Our solutions
© PROSE. All rights reserved
Disclaimer    Privacy Policy