Pierre Dersin

April 23, 2015

Predictive Maintenance with the HealthHub™

Train Forum Delft

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 2

Agenda

• Predictive maintenance – What is it?

• HealthHub™ - The Alstom approach

• HealthHub™ with TrainScanner

• How can you benefit from HealthHub™?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 3

What is predictive maintenance?

Imagine you had a car…

When would you refuel?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 4

What is predictive maintenance?

Preventive

Systematic

Every day

Many

Medium

Low (if no change in usage)

Condition-

based

Upon low fuel

indication

Few

High

Low

Predictive

Upon a measurement (gauge)

and a prognostic

Minimal and

planned

High

Lowest (if accurate algorithms)

# of

Refills

Car

Availability

Breakdown

risk

Corrective

When it fails

Fewest

Lowest

100%

Type of

maintenance

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 5

Rolls-Royce Predictive maintenance

Cutting in-flight shutdowns by 45% and unplanned removals by 60%

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 6

By 2050 - in our industry

• Every railway asset in the world will be remotely monitored in real-time Real-time

• Maintenance schedules will be created dynamically based on the predicted condition of each single component

Dynamic

• Workload balancing in depots will be done automatically Automatic

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 7

In 2050 – What will it mean for you?

Over 30%

savings on maintenance

0

in-service

breakdowns

Full service

reliability

Optimum

fleet size for a given service

Maximum

fleet availability

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 8

Since 2006, Alstom has acquired significant experience using asset data for maintenance

Infrastructure Rolling Stock Signalling Products

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 9

Agenda

• Predictive maintenance – What is it?

• HealthHub™ - The Alstom approach

• HealthHub™ with TrainScanner

• How can you benefit from HealthHub™?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 10

What is our offering?

Added-value through advanced data analytics

Data capture

Assessment

&

Monitoring

Prognostics

HealthHub™

Turning asset condition data into action

for operators and maintainers

Rolling

stock Infra Signalling

End-user Operator Maintainer

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 11

Prediction of remaining useful life (brake pad example)

Changing components when needed only

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 12

Predictive maintenance: general concept

Time

Degradation level Predictive Maintenance:

« not too early, not too late"

Current level

Remaining useful life

(RUL)

Failure Threshold

Nominal state Degraded State Failure

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 13

Data capture

Assessment

&

Monitoring

Prognostics

What is our offering?

Added-value through advanced data analytics

Rolling

stock Infrastructure Signalling

• Real-time monitoring

• Asset health index calculation

• Remaining useful life (RUL) prediction

Alstom

cloud

Algorithms/

Models

End-user Operator Maintainer

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 14

Real-time asset health monitoring

Data capture

Assessment

&

Monitoring

Prognostics

• Asset data from various sources

• Displayed in ergonomic user interfaces

• From fleet view to train view to component view

• Current and predicted state of health

Fleet health monitoring at-a-glance

Prognostics

HealthHub™

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 15

What assets are we monitoring?

Data capture

Health

assessment &

monitoring

Prognostics

Pantograph

Carbon strip

Carbody Gearbox

Wheels (profile)

Brake pads

Wheel Bearing

Brake system

Doors

HVAC Toilets

Interior Temperature

Signalling

on-board

Train position

Motor

Traction

Motor winding

Rolling stock

Track

Catenary

Infra

On-board

ATP/ATO

Sub-

stations

Station

PIS

Station Eqt

(Elevator,...)

Wayside

(IXL, ATP)

Trackside/

Points

Signalling

Station

On-board

video feed

On-board

PIS

Station

security

Suspension

Pantograph

Position

HealthHub™

Interior Lighting

Catering appliances

Auxiliary converter

Batteries

PACIS

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 16

A complete range of monitoring solutions

For all types of assets

HealthHub™

Turning asset condition data into action

for operators and maintainers

TrainScanner TrainTracer

Motes Other

specific1

Rolling stock

TrackTracer

Infrastructure

RDS +

other

specific

Signalling

Data capture

Health

assessment &

monitoring

Prognostics

1 Specific monitoring solutions, e.g. TMS « light » for legacy fleets, test benches, oil monitoring solutions,…

HealthHub™

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 17

Asset Monitoring: TrainTracer

A set of high value added services

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 18

From data to information, Train/Ground communication

TrainTracer

Train events

Train status

Train position

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 19

Fleet Management Operation /

Maintenance

Passenger Information & Security

Energy Management

Corrective Maintenance anticipation

Maintainer Operator

Preventive Maintenance management

(ie CBM)

Key users

TrainTracer

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 20

TRAIR Operator Services • Live Train Fleet positioning – geolocalisation

• Anticipate faults occurrence

• Incidents management – improve driver assistance

Control Center

• Monitor security and comfort

• Monitor power consumption

• Analyse fleet information

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 21

Services – Memorized events and context

TrainTracer

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 22

Fault occurrences

Fault trend

Events filtering Faults distribution on the fleet

Services – Data analysis

Train Tracer

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 23

Agenda

• Predictive maintenance – What is it?

• HealthHub™ - The Alstom approach

• HealthHub™ with TrainScanner

• How can you benefit from HealthHub™?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 24

TrainScanner

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 25

How does HealthHub™ with TrainScanner work?

Maintenance,

when needed

Confidence

check Data capture

Remaining useful life

prediction

RFID

identification

TrainScanner

Health index

calculation

HealthHub

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 26

Substantial benefits for maintenance and operations

Brake pads

Pantograph

Skirts/Panels

Wheelset

Maintenance

interval extension

Lower

material

consumption

Reduced

preventive

labor

Up to 15%

reduction

Up to 20 %

reduction

Less service

affecting

failures

Reduced

penalties

Fleet

availability

increase

Potentially

very large

1 2 3 4

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 27

Agenda

• Predictive maintenance – What is it?

• HealthHub™ - The Alstom approach

• HealthHub™ with TrainScanner

• How can you benefit from HealthHub™?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 28

What is your requirement?

• Total fleet size (# of cars)?

• Availability requirement, e. g. % of fleet running during peak hours (excl. trains immobilized for overhauls)?

−Will this change in the foreseeable future, e. g. with new train schedule or introduction of new signaling technology?

• # of depots for fleet maintenance?

• How demanding is your operation (# of stations, average speed,…)?

• Do you own your infrastructure? If not, what is your relationship with your infra manager?

• Are you already monitoring asset condition on this fleet? If yes, for which assets?

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 29

Concluding Statements

How can you benefit from HealthHub™?

• Predictive maintenance with a total system view

• Experience and Expertise are key

• Advanced Methods & Tools + Closeness to industry

www.alstom.com

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 31

References WCML

Objective: Optimize maintenance

• Reduce immobilization time (“pit-stop approach”)

• Increase train reliability

• Reduce preventive maintenance costs

Customer: Virgin trains

• Alstom Full maintenance contract since 1999

• TrainTracer since 2006

• 1 TrainScanner prototype (Manchester) since 2014 –

4 TrainScanners planned

• Rolling stock: 56 Class 390 Pendolino (574 cars)

© ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

HealthHub™ – Delft April 2015 – P 32 Health Hub Delft 2015

WCML - 53 trains connected since 2006

Maroc/PRIMA II - 20 locos connected since Dec 2009

BB 60000 - 150 locos connected since April 2010

Toulouse Citadis - 25 trams connected since Sep 2010

Juniper - 2 trains connected since September 2009

NTV – 1 train connected since January 2011

In progress: Rotterdam II, Amsterdam, X60, Regiolis, TTNG

Live applications of TrainTracer

TrainTracer CFM - References

www.alstom.com