Rolling Stock CapabilitiesAustralia and New Zealand

CH2M has extensive experience in rolling stock projects in Australia, New Zealand and overseas. This includes new vehicle procurement, project management, engineering support, train performance simulation, structures and FEA, vehicle dynamic testing and commissioning, technical advisory, vehicle condition assessment, manufacturing auditing, maintenance planning, depot design and standards authoring.

Our ApproachCH2M focuses on achieving tailored solutions for our wide range of rolling stock clients, with an emphasis on safety, high quality, realistic timeframes and minimised costs.

We understand that each client has different requirements and constraints that need to be adhered to in order to produce a solution that is accepted by all stakeholders. Our approach is to engage with the client from the earliest opportunity to gain an understanding of their requirements and operating environment, allowing us to customise our deliverables from the outset.

Whether it be a rail supplier, freight logistics, long distance passenger network, metropolitan commuter, light rail, vehicle manufacturer, maintenance provider, regional council, state government transport authority or federal government, we have worked with all levels of organisations, both private and public, within the rail industry.

Our rolling stock team based in Melbourne has a wide range of experience in varying disciplines. We have the ability to provide resources for significant projects such as program management of

vehicle procurement from specification development to vehicle commissioning, technical advisory during operator refranchising or a full vehicle structural analysis. We can also perform smaller tasks on tight budgets such as vehicle testing for ride problems or retrofit design work for existing vehicles.

We know from experience that our clients are working to tight timescales, especially when unexpected problems occur. We can adapt our methodology to suit the client’s needs and focus on delivering the outcome on time and on budget.

We also have the local knowledge vital to deliver the best outcome. Our staff know the Australian rail systems – freight, long distance passenger, electric multiple unit and light rail, with recent experience of working on all modes. We understand the contractual, franchise and regulatory arrangements in the rolling stock environment and how this affects system operation, maintenance and project implementation.

Our ServicesCH2M’s multi-disciplinary rolling stock team ensures that we can undertake a wide spectrum of rolling stock projects in-house, including:

• New vehicle procurement

• Project management

• Vehicle refurbishment

• Technical advisory roles

• Train performance simulation

• Structural analysis and FEA

• Vehicle repairs analysis and procedure writing

• Design review and validation/verification

• Retrofit design and implementation

• Vehicle dynamic testing

• Witness testing and commissioning

• Maintenance planning and efficiency review

• Vehicle condition assessment

• Manufacturing QA inspections and auditing

• Depot and facility design

• Standards authoring

• Vehicle certification and accreditation

• Safety and risk assessment

New Vehicle Procurement• Specification development

• Procurement strategy

• Contract and tender preparation

• Tender evaluation; including technical and commercial

• Project and program management

• On-site manufacturing QA presence

• Manufacturing inspections and auditing

• Testing; specification and witness testing

• Commissioning; program and stakeholder management

Rolling Stock Engineering Support• Structural analysis; vehicle instrumentation, FEA, fatigue

life calculation

• Retrofit design and implementation

• In-service fault investigation

• Vehicle repairs; collision damage, carbody or bogie cracking

Vehicle Dynamic Testing and Data Analysis• Ride quality monitoring in-service; freight or passenger

vehicles

• Type testing; vehicle dynamics and ride performance testing

• Noise levels; track side or on-train acoustic assessment

• Temperature or air quality monitoring

• Video recording with real time remote access

Technical Advisory Roles• Contract refranchising; technical support

• Strategic planning and feasibility studies

• Incident investigation and expert witness

• Fleet valuation and commercial reporting

• Train performance simulation

• Vehicle condition assessment

Areas of Expertise

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Our Delivery Team CH2M's local rolling stock team is led from Melbourne.

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Mark Gafner leads the rail team in Melbourne and has extensive experience in managing major multidisciplinary projects, most recently the Adelaide electrification project, where CH2M's scope included detail design of the electrification system. Mark is a professional engineer with extensive experience in complex multidisciplinary rail projects where responsibility has included project management, conceptual and feasibility studies, system engineering and design.

Paul Hewison is a principal rolling stock consultant with over 30 years’ experience, primarily throughout Australia with recent projects in China. Paul has detailed experience in the specification, procurement and project management of rolling stock, risk and safety and depot equipment. Paul also has experience in the installation and commissioning of depot equipment, wide experience in the maintenance and overhaul of rail vehicles, including work on Reliability Centred Maintenance for rolling stock, signalling and track assets.

Paul Draper is a principal rolling stock consultant who has undertaken a variety of technical and commercial project management roles during a 34 year career within the railway industry. Paul is involved with the re-franchising of the suburban train and tram services (MR4) as Rolling Stock Technical Advisor to the Victorian State Government. Paul recently undertook the role of Compliance Manager on the Matangi EMUs being delivered to Wellington, New Zealand. Previous experience has included project managing for Alstom Transport in the UK responsible for the delivery of the London Underground Jubilee Line Extension Metro Trains and Coradia Diesel Multiple Units. Paul is a Fellow of the Institution of Mechnical Engineers and has served on their Victorian Panel.

Luis Rico is a principal rolling stock consultant who has over 20 years experience in the electrical transport industry working in railway, metros and other transport systems such as trolleybuses. Conversant with tendering, design, commissioning and contract compliance principles. Luis has worked on a broad range of projects in the private sector and in advisory roles for the government, in the UK, Europe, Latin America and Australia. Recently Luis managed a team of senior electrical, systems and ICT engineers for Sydney Trains. Luis has extensive experience of rolling stock and engineering management, particularly in-depth knowledge of traction packages and electrical systems.

Luke Gibbons is a rolling stock consultant who has just completed an assignment at the Hyundai-Rotem (HR) Rolling Stock Manufacturing Plant in Changwon, South Korea where he was working on behalf of Greater Wellington Regional Council (GW) as a member of the Quality Assurance team to successfully deliver the second order of Matangi EMU vehicles to Wellington, New Zealand. He is a Chartered Mechanical Engineer with Engineers Australia. Previously, Luke worked in Wellington for a total of 2 years where he assisted in managing the commissioning of the first order of Matangi units.

Michael Weel is a rolling stock engineer, who has worked on a variety of rolling stock projects across the Australasian region. He has experience in structural analysis and the use of finite element modelling software in the design validation of rail vehicle equipment. He has conducted a large array of static and dynamic testing as part of the commissioning of freight wagons, locomotives and passenger rolling stock. Further, he has detailed experience in the implementation of rail asset maintenance management systems. Michael’s recent project work included an international assignment in South Korea as a Quality Assurance Engineer where he conducted vehicle inspections and testing for the Matangi EMU train build.

Jordan Hannagan is a graduate mechanical engineer. He was heavily involved in the DPTI 3000 class structural life assessment, where he has gained experience in finite element analysis, structural inspections, and dynamic ride performance testing. Jordan has worked in achieving registration for freight wagons for SCT Logistics, performing many different vehicle type tests to demonstrate wagon compliance with relevant standards. He has also conducted wagon repair design work and ride performance testing for SCT Logistics.

Jason Guettler is a senior rolling stock consultant. He began his career as a bogie design engineer at UGL Rail, Newcastle before joining CH2M. He is a Chartered Mechanical Engineer with Engineers Australia, and has worked on structural and dynamic analysis, procurement of components, and verification and validation projects for Locomotives, passenger cars and freight vehicles. He has lead CH2M teams on a number of projects including dynamic testing and analysis, structural design, manufacturing and repair support, and investigations into failure projects.

We believe in developing local talent and have invested in the training of young engineers, develoing them to become chartered in accordance with Engineers Australia. Combined with the international experience of our locally based senior and principal consultants with backing from a team of rail experts from around the world, makes CH2M the ideal choice to deliver your rolling stock projects.

Delivering value — case studies

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Waratah EMU Rolling Stock Procurement, Transport for NSW (TfNSW), Sydney

CH2M acted as technical advisor to TfNSW during the procurement of new trains for the Sydney suburban rail network. From concept design through to project delivery, CH2M has been involved since July 2004. Leading the design review for Australia’s largest ever passenger rolling stock order.

Design review process for the 626 new air-conditioned cars includes review of the train sets, simulators, enabling works, maintenance facility and detail design of transition stabling. CH2M also had a team based in Changchun, China overseeing the manufacturing process.

Locomotive Procurement, SCT Logistics, Melbourne

CH2M supported the procurement of SCT’s new CSR locomotives from China. CH2M provided input into the business case by producing simulations of the expected performance of the new locomotives via CH2M’s train performance simulator RAMESES. CH2M wrote the specification, performed design reviews, conducted manufacturing audits and witnessed type testing in China and Australia.

Matangi EMU Procurement, Greater Wellington Regional Council (GWRC), New Zealand

CH2M have been the Project Technical Advisor to GWRC since 2006, providing technical and procurement advice for the first and second orders of the Matangi EMU. Leading the initial business case CH2M became the manager of the procurement process and the project director of train supply. CH2M also provided on-site project engineers during commissioning in Wellington and manufacturing quality engineers in Changwon, Korea.

Craigieburn Maintenance Facility, Metro Trains Melbourne (MTM), Melbourne

CH2M provided reference design, technical specifications and support for the new Craigieburn train maintenance facility in Melbourne. We undertook this role directly for the client and then became part of the consultant team supervising the delivery of the works by the main contractor and sub-contractors.

We ensured that operational requirements of the depot operator were identified in the early development stages and that the contractor delivered the works in line with contract so that the depot would be accepted by MTM.

V'Locity Suspension Testing, Bombardier Transport Australia, Dandenong

CH2M was contracted by Bombardier Transportation to perform dynamic testing of the suspension system on the V’Locity DMU. CH2M instrumented the vehicle with accelerometers, displacement transducers, GPS and a data logger unit. Data was transferred wirelessly enroute to monitor performance in real time, with speeds reaching 160km/h during testing.

MR4 Refranchising Technical Advisory,Public Transport Victoria (PTV), Melbourne

CH2M is currently acting as rolling stock technical advisor to PTV for the fourth generation refranchising of the train and tram networks in Melbourne (MR4). In this role CH2M have conducted maintenance audits of the train and tram fleets, provided financial and technical input into the refranchising contract, produced tender documentation and are preparing to evaluate the incumbent operator bids.

Repair of Derailed Wagons, SCT Logistics, Port Augusta

SCT experienced a derailment on the Nullarbor Plain. As a result 10 wagons required extensive repairs. CH2M was engaged by SCT to inspect the process, progress and quality of the repairs. These included ensuring the repair contractor was suitably qualified, the repairs where done in accordance with Australian Standards and the correct testing was completed satisfactorily. Inspections were done on areas such as structural weldments, bogie frames, wheelsets and brake systems. All 10 wagons have now returned to service.

Engineering Support, Yarra Trams, Melbourne

CH2M have supported Yarra Trams’ projects team for a number of years, providing designs, calculations and FEA reports for retrofit projects across the tram fleet. Additionally we have conducted investigations into faulty equipment and provided recommendations on the impacts of modifications on tram structural life and operability. Our projects include designing and analysing new equipment mounted to the vehicle’s underframe, to fatigue investigations into tram bogies and vehicle bodies, and the structural analysis of interior equipment such as PIDS and seats.

Chinese Locomotive and Wagon Dynamic Testing, SCT Logistics, South Australia

The CSR locomotive and 5 pack wagons were manufactured in China for the Australian standard gauge network. As part of our role as independent verifier and validator, CH2M conducted testing as required by the new AS 7500 series of standards. This testing included static tests such as vehicle/ bogie swing, vehicle twist and kinematic outline, and dynamic tests including ride quality, dynamic stability and noise testing.

DMU Vehicle Condition Assessment, Auckland Transport, Auckland, New Zealand

CH2M have acted as technical advisors to Auckland Transport for over 10 years. During this time CH2M has conducted an annual condition assessment of the diesel commuter fleet, tailoring the assessment to focus on areas of concern and undertake further investigation when necessary.

Rolling Stock Standards Authoring, Rail Industry Safety and Standards Board (RISSB), Canberra

Since 2009, CH2M have been commissioned work on a number of the new Australian Standards being developed by the RISSB. The RISSB includes all major rail operators and the work entails understanding and working with all significant Rail Operating Standards. We have been involved with authoring, reviewing and advising on specific rolling stock standards including:-

• AS 7501 – Rolling Stock Certification

• AS 7503 – Train Operator Interface

• AS7514 – 7519 – Wheels, Axles, Bearing, Bogie Frames and Body Structural Requirements

• AS 75022 – Access and Egress

• AS 7532 – Audible Warning

• AS 7659 – Type Approval Devices Standards

3000/3100 Class Structual Review, Department of Planning, Transportation and Infrastructure (DPTI), Adelaide

CH2M was engaged by DPTI to conduct a fatigue assessment of the 3000 and 3100 class vehicles. DPTI wanted to determine the remaning structual life of the vehicles. The project involved developing a 3D CAD model, building a finite element model and analysing the vehicle for fatigue performance. Structual condition assements of currently operating vehicles were performed and a 6 week in-service test was conducted to gain an understanding of the operating environment. The results of the testing and anaylsis was combined to develop a remaining structual life testamate the vehicle.

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Contact us

Mark Gafner Manager, Rail & Transit — South East CH2M Level 40, 385 Bourke Street Melbourne VIC 3000 Phone: +61 3 8682 3900 E: mark.gafner@ch2m.com

TR1129161119SYD