Post on 12-May-2018
Maintenance and Operation of High Speed Rolling Stock
Pierre-Etienne GautierINEXIA, Scientific DirectorSt Denis La Plaine, France
With collaboration of Laurent Olivier, TGV Fleet Manager, SNCF
Presentation outlook• General data and Case study:
TGV Fleet outlook• Maintenance principles
(levels/schemes optimization) • Strategies for maintenance
optimization /planning and scheduling: links with operation
● The future of maintenance
What are we talking about?(A few figures to keep in
mind)• Purchase cost of high speed trainset
(350 seats): ~$30-36M • Yearly Maintenance cost of high speed
trainset: ~$ 1.4 M• Maintenance cost per mile:~$2 to 5• Yearly mileage: 310 000 miles/year • Expected lifetime: > 30, 40+ years!
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TGV KEY FIGURES•Volume (million pax) :114
•Number of high speed trains per day :Around 720 TGV•Average seat occupation rate 2009: 75 %
•Fleet :(largest High Speed train fleet in Europe)• 457 High Speed trainsets• 15 years average age• 11 to 15 new sets each year
•High speed network in France: 1870 km (~1160 miles)•TGV NETWORK: each high speed line is connected to traditional network
TGV case study
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FLEET ZOOMTGV, the first european HST fleet
• Sud-Est for Paris Lyon at the beginning(1980) 104• domestic 1 48• Domestic 1 Burgundy 7• domestic 2 42• France-Switzerland 7
• Atlantique for West of France (1988) 105• Réseau for all networks in France (1993) 60
• domestic 33• Paris Turin (Italy) 6• France Belgium 21
• POS for Germany (2007) 18
• Transmanche part of Eurostar sets usedfor domestic trafic (1995) 6
• Duplex for everywhere France (from 1996…) 149
• PBA & PBKA north Europe THALYS(1995) 15
• TOTAL 457
A wide-ranging and varied fleet
3 generations of trainsets
Rolling stock maintenance goals :to provide rolling stock which is fully operational for commercial
service:
• Safe in operation• Reliable at the required level• Available at the right time• With maintenance Cost under control
• The maintenance policy defines the best balance between corrective and preventive maintenance, to meet these goals
PREVENTIVEMaintenance
CORRECTIVEMaintenance
Maintenance must be taken into account from the train
set design• Accessibility, quick repair, in case of
failure> compromises !• Modularity,• Interchangeability
• European discussions towards interchangeability....
CONDITIONAL PREVENTIVEReplacement of components in accordance with measurable
CRITERIA
SYSTEMATIC PREVENTIVEReplacement of components
according to their POTENTIALworking life
(time or distance)
PREVENTIVE
MAINTENANCE
After a failureCORRECTIVEMAINTENANCE
Two major maintenance concepts
“Low level”, quick and simple operations and cleaning
“High level”, more complex operations, implying removal of the vehicle from commercial service for several days
PREVENTIVE
MAINTENANCE
Rolling stock preventive maintenance: principles and management
• Preventive Maintenance is based on the knowledge of the life potential of different components and subsystems of the trainset, and planning interventions to each components at (closest to) the component life potential.
• Necessity to derive/monitor reliability data form feedback from experience for main cost drivers > update life potential
• Interaction with design
Rolling stock preventive maintenance: principles and management
• Maintenance organisation is based on a hierarchy of maintenance activities, into 5 levels, increasing depending on work complexity (EU standard EN 13306)
• Implies Matching interventions to components of equal potential into a single operation
Specification
Maintenance Engineering (3% )
Lightmaintenance
N1,2,3(60%)
Parts repairs (PRM)(16%)
OverhaulN4
(6%)
TransformationN5
(15%)
Recycling
Removalfrom service/destruction
Feedback
Purchase,Design andconstructionsupervisions
Testing and Commissioning
The value chain in the rolling stock life cycle
LEVEL 1: IN SERVICE CHECKS by driver or train manager
• Low level maintenance.• Tests before train departure
Maintenance levels
LEVEL 2: CHECKS & OPERATIONS ON DEDICATED WORKPLACES
• Low level maintenance.• Quick interventions between two services, rostered teams • Application of preventive and corrective maintenance plan. External
cleaning.
Maintenance levels
LEVEL 3 : PERIODIC VISITS IN MAINTENANCE CENTER:
• High level maintenance.• Interventions requiring removal
from service.
Maintenance levels
Maintenance cycles examples: L1 to L3
VG : general level checksATS : another systematic worksGVG : complete level checksHalf-life Overhaul: 15 years (modular Operations)
ES : checks in serviceECC : comfort checksEMN : mechanical checksVL : limited level checks
1,125,000 miles or 36 months
22 days
ATSO
52 days
ATS 1
168 days
ATS 2
281,250 miles or 10 months
VL
562,500 miles or 18 months
VG
3,125 miles
ES
8 days
ECC
37 days
EMN/ECF GVGBeginning (or GVG)
Continuous Progress in Maintenance schemes :
Operations Feedback + Engineering • Data from design not accurate enough
(yet?)• Necessity to monitor key components and
subsystems• Derive/update reliability laws/potential
life from feedback from experience• TGV case :ATS, VG, GVG: ~+48% in
time , ~+86% in mileage for operations periods in ten years
GVG ATS ATS 1 ATS 2 VL VG GVGES ECC ECF/EMN
22 days
140 000 miles or 168 days
281 500 miles or 10 months
52 days
1 125 000 miles or 37 months
560000 miles or 19 months
3100 miles
37 days
8 days
2009
37 days
300 000 miles or 13 months
600 000 miles or 25 months
8 days
3100 miles
150 000 miles or 7 months
104 days
52 days
18 days
1999
Opt
imis
atio
n of
mai
nten
ance
cyc
les
LEVEL 4 : OVERHAUL: MAJOR PERIODIC OPERATIONS AT INDUSTRIAL MAINTENANCE FACILITY
• High level maintenance.• Major dismounted components check and repair• Structural parts check and repair (car body...)• Mid life review
Maintenance levels
LEVEL 5 :MODERNISATION OR MODIFICATION AT INDUSTRIAL MAINTENANCE FACILITY
• High level maintenance.• Trainset overhaul (interior
design & component upgrades).• Interventions requiring removal
from service, during several weeks.e.g. Implementing ERTMS
Maintenance levels
Level 5 Case:TGVretrofitting in a few figures :● §2.5M per trainset● 105 TGV A
trainsets(1988)● 72 TGV R trainsets
(1992)● A total of 1626
coaches to be retrofitted
● 40 trainsets per year for 6 years (2004-2010)
TGV A
TGV R
Maintenance strategic planning and scheduling
Interaction with operation
• Localization of workshops depends on operation characteristics
• Analyzing the statistics of operations: A smart use of free time slots in roster to schedule maintenance operations
When a change in business/ operation characteristics stems a
strategic change in plant localization…and cost saving
• Traffic demand will change : from a radial model to an interconnected network
• Availability of “interoperable “ fleet: TGV Réseau and Duplex
• Need to reconsider the maintenance workshop geography
Change in traffic demand characteristics observed… and enhanced until 2020
Green: radial share, Blue: transversal share
Bayonne
Brig
Garede l'Est
Gared'Austerlitz
OloronBuzy
CharsVernon
BarentinYvetot
Tarascon
Chagny
Livron
Moirans
Morcenx
Marmande
Marne-la-Vallée - Chessy
MorlaixGuingamp
LamballeDol
Redon
Auray
Vitré
Laval
Sablé
La Rochelle
Libourne
PérigueuxBrive
Mont-de-MarsanDax
Pau
Lourdes
CarcassonneNarbonne
Béziers
MillauAlbi
Agen Rodez
Aurillac
Neussargues
Le Monastier
Tulle
Ussel
Guéret
Montluçon
Le Puy-en-Velay
RiomVolvic
Gannat Vichy
Châtellerault
Vendôme-TGV
Châteaudun
ChartresAlençonSurdon Dreux
ArgentanVireGranville
PontorsonAvranches
Coutances St-LoLison
Carentan
Cherbourg
CaenLisieux
Trouville
Dives
Fécamp
Dieppe
Gisors
Évreux
Cholet
La Roche/Yon
ThouarsChinonPornic
St-Gilles-Croix-de-Vie
Ruffec
East station
Bayonne
Brig
Garede l'Est
Gared'Austerlitz
OloronBuzy
CharsVernon
BarentinYvetot
Tarascon
Chagny
Livron
Moirans
Morcenx
Marmande
Marne-la-Vallée - Chessy
MorlaixGuingamp
LamballeDol
Redon
Auray
Vitré
Laval
Sablé
La Rochelle
Libourne
PérigueuxBrive
Mont-de-MarsanDax
Pau
Lourdes
CarcassonneNarbonne
Béziers
MillauAlbi
Agen Rodez
Aurillac
Neussargues
Le Monastier
Tulle
Ussel
Guéret
Montluçon
Le Puy-en-Velay
RiomVolvic
Gannat Vichy
Châtellerault
Vendôme-TGV
Châteaudun
ChartresAlençonSurdon Dreux
ArgentanVireGranville
PontorsonAvranches
Coutances St-LoLison
Carentan
Cherbourg
CaenLisieux
Trouville
Dives
Fécamp
Dieppe
Gisors
Évreux
Cholet
La Roche/Yon
ThouarsChinonPornic
St-Gilles-Croix-de-Vie
Ruffec
An oportunity: in the same time, operation has changedfrom a radial operating system in which each segment was independant
to a global use of the fleetduring the last ten years
So it becomes possible to run all the trainsets sets on all routes
LYON station
Montparnasse station
North station
• A completereorganisation of the initial radial model
• Objective : • To have a better use of sets
in operation by multiplyingtrain set reuse
• Sharing the maintenance worload of each maintenance center
productivity:purchase of 7 trainsets avoided
• A real challenge for operators: working in a network!
Switching to a bigger fleetrather than subfleets
1 train roster / 150 sets / 3 Maintenance centers
1 train roster 1 maintenance center
50 sets
X 3
How can the productivity of the fleet beincreased?
Time-slot : 7.AM – 11.PM
3 %
58 %
15 %
7,5 %
8 %8,5 %
Terminus re-departure
Clients on board
Sets in siding
Others: empty circulation, inreserve set …
MaintenanceWork shop for refurbishment and overhaul
Trai
n op
erat
ion
Set
s m
aint
enan
ce
Friday : a week peak
13 sets36 sets
To improve productivity:
•Reduce time in stations (Japan!)
• reduction of number of sets in maintenance
• AND/OR Smart use of sidings!
28/37Higher operational availability ,but… strong pressure on ordinary parking
J1
J2
J3
J4
J5
J6
J7
J8J9
J10
J1
J2
J3
J4
J5
J6
J7
J8J9
J10
J11
J12
Some maintenance is “absorbed” into ordinary parking time
Integration of L1 to L3 maintenance into roster “free” slots
7h 12 h 17 h
Fleet under
maintenance
PmLong term preventive level 2 / 3Heavy corrective maintenance and break downs
Available fleet Pex
Maintenance is usually scheduled above and beyond peak service needs
Maximum use of fleet at peak service times
7th Training on High Speed Systems. Paris, June 2010
Fleet under maintenance Pm
Available fleetPex Reduction in
required fleet
Heavy corrective maintenance
Lev 2/3Lev 2/ 3 ModulesBreakdownsBreakdownsBreakdowns
7h 12 h 17 h
Development potential for a
constant fleet number
The future of maintenance…
• Component standardization?• Continuous monitoring of sensitive
components : Towards predictive maintenance?
• Refined FMDS of subsystems + statistical approaches : saving costs and time in selecting the key drivers to reliability
Conclusions• Maintenance is a key cost driver in Rolling
stock LCC• Needs strategic planning (workshop
locations) and operations scheduling closely linked with operation and market evolution
• Implies specific engineering and rigourous feedback of subsystems and components behavior
• From preventive to predictivemaintenance: a breakthrough?