delivering a turnkey high-speed rail system with a full...
TRANSCRIPT
TRANSPORT
Delivering a Turnkey High-Speed Rail System
with a full Technology Transfer
The Korean TGV
Etienne Fournier
Washington DC, March 2011
World Bank Transport Forum 2011
50 years of Innovation in Transport
Innovation and Technology
The Korean TGV – World Bank - March 2011 - P 2
Agenda
1st topic Key data of the contract Page 9
2nd topic The Korea TGV Consortium scope of work Page 17
3th topic Korea TGV Consortium project facts and figures Page 35
4th topic Conclusions Page 38
1st topic Introduction : High Speed rail Systems Page 3
3th topic Project Management with Technology Transfer Page 21
The Korean TGV – World Bank - March 2011 - P 5
High Speed rail Systems
ControlCentre Signalling
TrackWorks
PowerSupplyTelecoms
CivilWorks
ParkCollection
PlatformDoors
RollingStock
The Korean TGV – World Bank - March 2011 - P 6
Project Management
ControlCentre
RollingStock Signalling
TrackWorks
PowerSupplyTelecoms
CivilWorks
ParkCollection
PlatformDoors
Project ManagementSystem, Definition & Integration
Operation & Maintenance
… to a coherent and optimized system:
The Korean TGV – World Bank - March 2011 - P 8
A Conductor of Transport System Projects
Trackwork
Depot / Workshop
Station Utilities
Communication
Traction Power Supply
Signaling
Rolling Stock
Finance
Civil Works
Project & Interface
Management
Systems PerformanceGuarantees
Structure, finance, design, technology transfer, construction,commissioning and maintenance
The Korean TGV – World Bank - March 2011 - P 9
Key data : The Seoul/Busan corridor
Concerns 70%of the population
Representing 75%of GDP of Korea(GDP = Gross Domestic Product)
Connecting 2 seaportsand the 2 main airports (Inchon/Busan):
− 65% of passenger traffic
− 70% of the freight
One of the largest corridors in the world
The Korean TGV – World Bank - March 2011 - P 10
Key data : The Seoul/Busan corridor
Necessary for the development of Korea
Journey time saving in comparison to :
− the conventional train (50 %)
− the airplane (20 %)
Traffic forecast:
− 30 million passengers for the first year
− 120 millions passengers/year in 2010
National project requested by Korean Authorities
Seoul/Busan line was a first step
The Korean TGV – World Bank - March 2011 - P 11
Funding Summary
Total budget of the entire Project (including civil works) :
17 billions US$ (base 93) financed as follows :
− 45% Korean Government = 35% contributions + 10% public funds
− 55% KHRC:(KHRC = Korea High SpeedRail Construction Authority)= 24% international
financing+ 29% public funds+ 2% private capital
The Korean TGV – World Bank - March 2011 - P 12
The Seoul/Busan TGV:Korea TGV Consortium Contract features
Negotiation schedule :
− 1982-1992: Preliminary studies to RFP(RFP = Request For Proposal)
− 1992: First proposal
− 1993: Selection of preferred bidder
− June 1994: Signing of the E&M Turnkey Contract
The client :
− Construction phase : Korea High Speed Rail Construction Authority
− Revenue service preparation : Korean National Railroad
E&M Contract value: 1 billion euros + 1 billion US $ (base 93)
Localisation ratio : 50% of the total contract value
The Korean TGV – World Bank - March 2011 - P 13
The Seoul/Busan TGV:Korea TGV Consortium Contract features
The Contractor, KTGVC: “Korea TGV Consortium”
− Led by ALSTOM and its local subsidiary EUKORAIL
− With 13 French and Korean members
− Split in 5 operational groups
Contractual organization:
− One single Contract
− Signature of all consortium members
− All consortium members jointly and severally liable to KHRC
Financing: a pool of over 20 international banks:
− Buyer credit : 1.6 billion USD (17.5 years, 6.25%)
− Tied Commercial Loan:0.72 billion USD (14.5 years, rate based on LIBOR)
− With an active support of French authorities
The Korean TGV – World Bank - March 2011 - P 14
The Seoul/Busan TGV :The customer organization evolution
KRNA(KHRC)
SNCF-IRolling-Stock& Syst. tests
KTGVC
Ministry Of Construction and Transportation
KNR
Sub-Contractors & Suppliers
OPERATOR
KORAIL(Transfer of theContract for the
RevenueService)
SYSTRACW & Tracks
SYSTRAT&C Audit
SNCF-IOperation
preparation
INGEROPCW
DE ConsultCW Sup.
The Korean TGV – World Bank - March 2011 - P 15
The Seoul/Busan TGV project management :A multicultural and multidiscipline organisation
The Korean TGV – World Bank - March 2011 - P 16
Speed:
Design of the line : 350 km/h
Trainset supplied : 300 km/h
Operational headway: : 3 minutes
Journey time Seoul/Busan (by HSL) : 115 minutes
Complete High Speed Line (HSL)
SEOUL-BUSAN : 430 km
Number of stations : 7
Maximum gradient : 30 ‰
Number of tunnels : 75
Cumulated tunnels length : 190 km
Longest tunnel : 18.4 km
Cumulated viaducts length : 122 km
Seoul
Busan
Ch'onan
Daejeon
Daegu
Kyongju
Nam Seoul
Phase APhase B# 2008
The Seoul/Busan TGV:The line
A very complex infrastructure
Kwangju
The Korean TGV – World Bank - March 2011 - P 17
The Korea TGV Consortium scope of work
RollingStock Catenary
Associated Services
Trains Control System
The Korean TGV – World Bank - March 2011 - P 18
The Korea TGV Consortium scope of work
Civil works & Railway infrastructure
Station & Ticketing
Power supply & Communications
Operations & Maintenance
RollingStock Catenary
Associated Services
Trains Control System
GGT VT V
The Korean TGV – World Bank - March 2011 - P 19
The Korea TGV Consortium scope of work
- 2 pre-series trains- 10 Series trains in France- 34 Series trains in Korea- Spare parts (2 years)
- The overhead line- Spare parts (2 years)
- Equipment- Spare parts (2 years)
- Training- Operation and maintenance manuals- Maintenance plan- Maintenance supervision (2 years)
Inte
grat
ion
& C
omm
issi
onin
g
RollingStock
Catenary
Trains Control System
Associated Services
- Design- Delivery, integration- Testing
- Basic design- Supervision of detailed design- Delivery- Supervision of installation- Supervision of testing
- Basic design, software- Supervision of detailed design- Delivery- Supervision of installation- Testing
The Korean TGV – World Bank - March 2011 - P 20
The Korea TGV Consortium scope of work Key challenges
• A complete very high speed system project
• A systems performance contract
• A customer with no HSR historical experience
• In a very distant, different, and demanding country
• A complex bi-geographical organization
• Including major Korean industry players
• A major technology transfer
• A very long term project
The Korean TGV – World Bank - March 2011 - P 21
Project Management with Technology Transfer & Localisation
The Korean TGV – World Bank - March 2011 - P 22
K H R C. One single Contract. Signature of all Members. All members jointly and severally liable to KHRC
Core System GroupConsortium leader
Management ServicesLeader : Eukorail
Alstom SA Eukorail
ROLLING STOCK GROUP
Leader : AlstomTransport
Alstom ROTEMTransport SA Hyundai
(Rolling Stock) DaewooHanjin
ATC GROUP
Leader : CSEE Transport
CSEE Transport GoldstarSA Ind. Systems
CTC/IXL GROUP
Leader : AlstomTransport
Alstom GoldstarTransport SA Ind. Systems(Signalling) Samsung
CATENARY GROUP
Leader : AlstomTransport
Alstom GoldstarTransport SA Cables(Catenary) Iljin
Korea TGV Consortium
Contractual Organization
Project Management in a control team
The Korean TGV – World Bank - March 2011 - P 23
Project Management in a control team
LEVEL 1
LEVEL 3
LEVEL 2
LEVEL 4
ROLLING
STOCK
CATENARY ATC CTC / IXL
GROUPS
PLANT PROJECT MANAGERS
OPERATIONAL UNITS
SUBCONTRACTORS
MANAGEMENT MANAGEMENT MANAGEMENTMANAGEMENT
PROJECT PROJECT PROJECT PROJECT
CORE SYSTEM
LEADER
PROJECT
MANAGEMENT
Contractual Organization
Operating Mode !
The Korean TGV – World Bank - March 2011 - P 24
Consortium management :− Steering Committee, Management Committee− Weekly meeting in Korea and in France
Project Control / Document Control :− Procedures and their updating− Data system for letters and documentation : 830 000 folios− For example : Approval system for sending submittals and letters to
KHRC through only one KTGVC authorized representative
Contract Control :− Contract managers− Identification of critical matters
Finance :− MPS (Member Payment Schedule) and CPS (Contract Payment
Schedule)− IPP (Invoice and Payment Procedure)− Internal reporting for each member of the KTGVC
KTGVC Core System Management 1/3
The Korean TGV – World Bank - March 2011 - P 25
KTGVC Core System Management 2/3
Quality :− QAGP : Quality Assurance General Plan− Monitoring audits throughout the KTGVC
Associated Services (O&M : Operation & Maintenance) :− Interfaces with Korean Maintenance and Operation Authorities : Maintenance
Plan and Supervision− O&M Training, O&M Manuals, Spare Parts, Tools = interfaces with Groups
and KHRC
Technology Transfer (TT) / Localization :− Monitoring the Training in France and the Assistance in Korea− Mastering the TT plans and the localization
Core System Engineering :− Management of the Interfaces : 100 interfaces = 5000 documents− RAMS : Reliability-Availibility-Maintainability-Safety of the Core System− Configuration management of the Core System− Testing and Commissioning of the Core System deeply integrated within
KHRC ’s T&C activities− Coordination and Management of site activities
The Korean TGV – World Bank - March 2011 - P 26
Reporting :− Report to KHRC : PPR (Project Progress Report) every 2 months− Internal report for each KTGVC member
Scheduling :− Contract Schedule and Detailed Schedule consolidation− Time Chainage
Human Resources :− KTGVC human resource management on his own− Administration interfaces
Public Relation :− KTGVC news− Visits monitoring
KTGVC Core System Management 3/3
The Korean TGV – World Bank - March 2011 - P 27
Project management : − Same purposes at Groups level : contract, finance, quality, reporting,
scheduling, human resources.
Engineering :− Basic Design, Detailed Design− Interface and configuration management
Technology Transfer / Localization− Each Group carry out and monitor the TT/Loc of its product
Installation :− KTGVC supervises the installation carried out by KHRC contractors on the
basis of KTGVC documentation
Testing & Commissioning (T&C) :− Rolling Stock and Train Control System T&C− Supervision of Catenary T&C
Warranty :− Each Company/Group support the warranty for its products
KTGVC Group Management
The Korean TGV – World Bank - March 2011 - P 28
KTGVC Turnkey Project Management
CORE SYSTEM
BALANCE OF HSR SYSTEM
ROLLINGSTOCK
CATENARY
TRAINCONTROLSYSTEM
SERVICES MAINTENANCE
OPERATIONCIVIL
TRACKS
POWERSUPPLY
INSTALLATION
OVERALLSYSTEM
ENGINEERING
OTHERSSYSTEMS
ASSOCIATED
TCS & CATMISCELLANEOUS
TCS & CATDETAILDESIGN
COMPONENTS
includingENVIRONMENT
GBTR
EXISTING LINE(TRACKS, CAT, ATS)
WORKS
PRO
NOIS
ETEC
TIO
N
TS
ATIONS
TICKETING
GGT VT V
The Korean TGV – World Bank - March 2011 - P 29
Interface Management 1/2
INPUTDATA
REQUIREMENTS
CORESYSTEM
CONSTRAINTS
BALANCE OFHSR SYSTEM
(BOS)Process !
The Korean TGV – World Bank - March 2011 - P 30
Interface Management 2/2
IMP: Interface Management Plan
• This is the official procedure for managing the interfaces between contractor KTGVC and client KHRC : balance of HSR system and Core System
ICM: Interface Control Manual
• In conformity with IMP • The applicant is responsible for exhaustiveness of requirements• The supplier of information is responsible for input data submitted• This manual contents all the exchange of documents on each interface (including civil works input data)
The Korean TGV – World Bank - March 2011 - P 31
Technology Transfer 1/2
Transmission to a Partner of the specific knowledge related to a Product in order to allow him :− To produce it : common set of drawings, specification, …
− To buy it : one common and single purchase technical specification for each item to be sourced either in France and/or in Korea
Relations between Donor and Recipient are defined by a TT contract
TT Plans organize the execution of the work
TT Performances :– Documentation: 350 000 folios
– Training : 1760 man-months in France
– Assistance : 1400 man-months in Korea(including procurement support)
The Korean TGV – World Bank - March 2011 - P 32
Technology Transfer 2/2
Rolling Stock : sample of industrial distribution
ALL
ROYAUME-UNI
DANEMARK
ANDE
LUXEMBELGIQUE
FRANCE
PAYS-BAS
UEN
Alstom Transport Ltd
PrestonTraction Control
Alstom Sig Ltd
BorhamwoodSignaling
Alstom Transport SA
Saint OuenSignaling
Alstom Transport SA
BelfortPower Cars
Alstom Transport SA
OrnansMotors
Alstom Transport SA
VilleurbanneOBCS
Cegelec / Alstom
ParicCatenary
Alstom Transport SA
Le CreusotBogies
Alstom Transport SA
La RochelleTrailers
Alstom Transport SA
TarbesPropulsion
CS Transport
Les UlisSignaling
RS Cat. Sign.
ALL
ROYAUME-UNI
DANEMARK
ANDE
LUXEMBELGIQUE
FRANCE
PAYS-BAS
UEN
Alstom Transport Ltd
PrestonTraction Control
Alstom Sig Ltd
BorhamwoodSignaling
Alstom Sig Ltd
BorhamwoodSignaling
Alstom Transport SA
Saint OuenSignaling
Alstom Transport SA
BelfortPower Cars
Alstom Transport SA
OrnansMotors
Alstom Transport SA
VilleurbanneOBCS
Cegelec / Alstom
ParicCatenary
Alstom Transport SA
Le CreusotBogies
Alstom Transport SA
La RochelleTrailers
Alstom Transport SA
TarbesPropulsion
CS Transport
Les UlisSignaling
RS Cat. Sign.
SAMSUNGOSAN/ SUWONSignaling PCB
ROTEM (ex. DHI)
UIWANGPower Cars
TrailersTraction MotorsAuxiliary Blocs
Battery ChargerBogie Fitting
GOLDSTAROSAN
Signaling PCB
ILJINSEOUL
Catenary
ROTEM (ex.HDPI)
CHANGWOONPower Cars
TrailersTrain AssemblyBogie FramesBogie Fitting
ROTEM (ex.HHI)
TADAEPOTrailers
Motorized TrailersBogie Fitting
HHICULSAN
Traction DriveAuxiliary Blocs
Electronic Cabinet
GOLDSTAR CableSEOUL
Catenary
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
SéoulSDD
SAMSUNG DISPLAY DEVICE
SUWONOBCS
HYSAHYUNDAI SPACE & AIRCRAFT
SEOSANRunning GearsTransmission
RS Cat. Sign.
KUMI: SEC: Electronic PCB
KUNSAN: KIA: Wheels/Axles
KWANGJU: Daewoo Carrier:HVAC
CHECH’ON: SAB.K: Brakes
Kunsan
Chech’onOsan
SAMSUNGOSAN/ SUWONSignaling PCB
SAMSUNGOSAN/ SUWONSignaling PCB
ROTEM (ex. DHI)
UIWANGPower Cars
TrailersTraction MotorsAuxiliary Blocs
Battery ChargerBogie Fitting
ROTEM (ex. DHI)
UIWANGPower Cars
TrailersTraction MotorsAuxiliary Blocs
Battery ChargerBogie Fitting
GOLDSTAROSAN
Signaling PCB
GOLDSTAROSAN
Signaling PCB
ILJINSEOUL
Catenary
ILJINSEOUL
Catenary
ROTEM (ex.HDPI)
CHANGWOONPower Cars
TrailersTrain AssemblyBogie FramesBogie Fitting
ROTEM (ex.HDPI)
CHANGWOONPower Cars
TrailersTrain AssemblyBogie FramesBogie Fitting
ROTEM (ex.HHI)
TADAEPOTrailers
Motorized TrailersBogie Fitting
ROTEM (ex.HHI)
TADAEPOTrailers
Motorized TrailersBogie Fitting
HHICULSAN
Traction DriveAuxiliary Blocs
Electronic Cabinet
HHICULSAN
Traction DriveAuxiliary Blocs
Electronic Cabinet
GOLDSTAR CableSEOUL
Catenary
GOLDSTAR CableSEOUL
Catenary
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
Séoul
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
Séoul
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
Séoul
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
Séoul
Ulsan
Kwangju
ChonjuKumi
ChongjuSeosan
Suwon
Taejon
Pusan
Taegu
SéoulSDD
SAMSUNG DISPLAY DEVICE
SUWONOBCS
SDDSAMSUNG DISPLAY DEVICE
SUWONOBCS
HYSAHYUNDAI SPACE & AIRCRAFT
SEOSANRunning GearsTransmission
HYSAHYUNDAI SPACE & AIRCRAFT
SEOSANRunning GearsTransmission
RSRS Cat.Cat. Sign.Sign.
KUMI: SEC: Electronic PCB
KUNSAN: KIA: Wheels/Axles
KWANGJU: Daewoo Carrier:HVAC
CHECH’ON: SAB.K: Brakes
Kunsan
Chech’onOsan
The Korean TGV – World Bank - March 2011 - P 33
Localisation
High level participation of Korean railways industries
50% of the Core System contract is allocated to Korean members of the Consortium
Allocation is defined by the General Master Plan (GMP)
Production start is scheduledaccording to the Industrial Master Plan (IMP)
The Korean TGV – World Bank - March 2011 - P 35
Korea TGV Consortium Project facts and figuresKey dates
1994 Signature of the Contract Creation of EUKORAIL
1996 Partial disruption due to civil works issues
1997 Asian financial crisis – Roll out of first train in France
1998 Project re-defined and re-launched
1999 First official run onthe test track
2000 12 French trainset delivered to Korea ; 300kph reached on the Test Track
2001 Commissioning of test trackFirst Korean train delivered
2003 Commissioning of Seoul Daejon
2004 Seoul-Busan revenue service
2007 End of maintenance services
The Korean TGV – World Bank - March 2011 - P 36
• 1 contract, 1 Consortium Agreement
• 1 single signatory (2500 letters / year)
• 100 contractual interfaces, representing 5000 documents
• 111 contractual milestones
• One master schedule (1500 activities), 6 detailed schedules (6000 activities)
• One single data base : 830 000 folios accessible on each sites involved
• 2500 payment key events; one invoice every 2 months (= 2 800 pages, 16 kg)
• Operation & maintenance manuals: updated every 3 months, 23 000 pages
• In Europe: 5 project teams, 12 manufacturing sites, 10 major sub-contractors
• In Korea: 1 project team split on 13 sites
• About 350 expatriates mobilized during the 10 years of construction phase
Korea TGV Consortium Project facts and figuresKey figures
The Korean TGV – World Bank - March 2011 - P 37
Korea TGV Consortium Project facts and figuresPreparation and start of commercial operation
A fundamental key principle: the 60km test track, an actual HSR system commissioned 3 years before the start of commercial
operation to validate all systems and interfaces
The result:
− Only 12 cumulated days of actual pre-revenue service,
− A timely start of revenue service at full speed with the actual time table
− With 128 daily trips performed by 33 trains
After one month, a stabilisation reached with
− A punctuality rate of 98%
− A rider-ship of 1.7 million passengers (70 000 per day)
− No adverse effect of the mixed operation on HSL/CVL
− No incident involving safety
After 6 months: 13 million passengers (70 000 per day). Punctuality rate of 98.7%.
After 20 months: 50 million passengers (100 000 per day)
The Korean TGV – World Bank - March 2011 - P 38
Conclusion :Results and key learning from this success story 1/2
A customer focused approach, based on trust and common vision, and turning all issuesinto opportunities
A strong multi–purposes contribution to the development of the Korean industry throughthe Technology Transfer
A project on time, with client satisfied with famous successful project
Some contractual disputes but no claim with the client or between consortium members
A risky project with high stakes, but nevertheless achieved thanks to the trust and common vision of the essential objectives shared by all actors
A great amount of knowledge developed
An important and unique reference in the World
The Korean TGV – World Bank - March 2011 - P 39
Conclusion :Results and key learning from this success story 2/2
Celebration of 5 years of commercial service on April the 1st, 2009
− 99 million kilometers, equivalent to around 2 500 trips around the world− 173 450 000 passengers, equivalent to 3 times the population of South Korea− In 2008 :
• 100 000 passengers/day generating 1.63 m€/day in ticket sales
• 63 % of passenger’s traffic between Seoul and Busan
The Korean TGV – World Bank - March 2011 - P 41
A successful very high speed system project with technology transfer