CrossrailBrief to INCOSE

Chris Sexton Technical Director

24January 2012

Delivering a world-class affordable railway, safely, and through effective partnerships

What is Crossrail?• Largest civil engineering project in Europe• Biggest addition to London and South East transport

network for 50 years • High-frequency, convenient and accessible rail service

linking Maidenhead and Heathrow to the City, Docklands, Kent and Essex

Crossrail Services• Crossrail will operate 24 trains per hour through the

central tunnel in the peak• Each train will be 200m in length and will be capable

of carrying up to 1,500 seated and standing passengers

Jointsponsors

Business caseBusiness case

10% extra capacity

1.5 million people within 45mins of central London

GDP benefit - £42bn

14,000 Jobs

Business OutcomesBusiness Outcomes

World Class• Passenger experience• Railway Operations• Industry Legacy

50km of tunnelling under London

8 sub-surface stations

Royal Oak Portal

2 MajorStructures

27 Stations(10 Major)

Track 66km 61 PlatformExtensions

360 SignallingUnits

2 ReplacementInterlockings

CrossrailCrossrailSurface WorksSurface Works

Electrification146km

112 CabCCTV Platforms

Key Challenges• Safety, value, cost and time• Being a good neighbour• Systems Integration• The right trains• The right architecture/art• 2018 World Class

Client / project wide rules and/or initiatives, best or most efficiently 

done once

PC with another scheme

Golden Rules, Occupational Health standards,Site Safety newspaper, technical training and standards 

D&A policy, Method Statement standards, RIVO/info sharing etc

PC with Zero Harm. 

ZeroHarm

PC With IIFContractors’ basic H&S / site management and 

control, assured on evidence/observation

Contractors’ own H&S programmes, behavioural, near‐miss reporting, Safety Stand‐downs etc

CRL’s client responsibilities under CDM, HSAWA etc

CRL’s vision ‐ home safe every day,new standards for Health and Safety performance (both leading and 

lagging indicators)

Legal and clientresponsibilities

TargetZero

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

May 2009 Construction started

2013 - 2018Systems Integration &

Commissioning

2012 - 2018Tunnelling and StationsLaunch first TBM March 2012

2017 - 2018Trial-RunningPhased Opening

Key PhasesKey Phases

Crossrail  ‐ Physical % Complete

0.00

20.00

40.00

60.00

80.00

100.00

120.00

2Q081Q

093Q

091Q

103Q

101Q

113Q

111Q

123Q

121Q

133Q

131Q

143Q

141Q

153Q

151Q

163Q

161Q

173Q

171Q

183Q

181Q

193Q

19

% Com

plete

Design

Procurement

Construction

Testing & Comm.

Paddington

Liverpool Street

Retail Park

Canary Wharf Station

Retail ground level

Retail promenade level

Retail

Retail

Station Ticket hall level

Station Platform level

Wallasea Island, RSPB reserve

2011 2011 -- A Good Year

Good YearThank you

A Good Year20112011

Tunnelling• All contracts awarded

Royal Oak portal completed and handed over

• Conducted Factory Acceptance Test of first TBM

• Shaft construction underway at LimmoPeninsula, Stepney Green, Liverpool Street and Whitechapel

• Segment manufacturing facility commissioned

• Portal construction underway at Pudding Mill Lane and Plumstead

• First TBM launches March 2012 from Royal Oak Portal

StationsStations• Main works contracts awarded for

Paddington, Farringdon and Whitechapel

• Paddington integrated project scheduled relocating taxis in February 2012

• Diaphragm wall advance works underway at all stations

• Compensation grout shafts underway• Spray Concrete Lined access shafts

underway at Liverpool Street and Whitechapel

• Woolwich Station: Successful completed utilities diversion and surface ( ~3m) strip.

• Canary Wharf station well advanced

High Level Programme2017 20182013 2014 2015 20162011 2012 2019

Central Section Works

Central Section Construction

Track/Systems Installation

Aug 2018

ProcurementRolling Stock & Depot

Design & Manufacture Trains

Central Section T & C

Old Oak Common

1st Train @ OOC

Surface Works

Western Inner

South East

North East

Western Outer

Stage 1 – NE Leg Substitution

Stage 2 – H/L Paddington to Heathrow

Stage 3 – L/L Paddington to Abbey Wood

Stage 4 – L/L Paddington to Abbey Wood & Shenfield

Stage 5 – Full Service Opening

May 2017

May 2018

Dec 2018

Dynamic Testing/Trial Running

Trial Ops

20122012• This year is an even more important year• Critical year for Systems procurement• First TBM launch at Royal Oak Portal – Drive X –

March 2012 • Wallasea Island operational – July 2012• All station contracts awarded – August 2012• Start tunnelling Y-Drive from Limmo – October 2012• Both TBMs on X-Drive meet at Bond Street –

December 2012

West

West

West tunnels - TBM launch at ROPWest Tunnels - commence production of segment rings PIP - complete steel erection; start installation of lift, escalator, and canopy glass to bring the Taxi facilityinto usePAD - commence D-Walling for the main stationTCR - complete piling and D-Walling for the main station and start of excavation

Summary of key activities next six monthsSummary of key activities next six months

Summary of key activities next six monthsSummary of key activities next six monthsCentral

Central

Award C502 contract for Liverpool Street main station worksAward C340 and C360 for Victoria Dock Portal and Eleanor Street/Mile End shaftsCommence diaphragm wall works at Whitechapel and Liverpool StreetCommence compensation grouting TAMs at WhitechapelFactory acceptance testing for first C305 TBM

Summary of key activities next six monthsSummary of key activities next six monthsEast C310 Thames tunnel and

Woolwich: Commence diaphragm wall works for Plumstead portal and Woolwich box.C310 Thames tunnel: Commence

mobilisation to North Woolwich, including completion of utility diversion work by contract C233.C315 Connaught tunnel: Issue IFC drawings and specs, and commence piling work on surface section.Custom House station: Issue

tender documentation.

Systems Integration Defined• Definition for Crossrail:

“Systems Integration ensures the rail systems, rolling stock and infrastructure, combined with operations and maintenance inputs, delivers a resilient operational railway meeting Sponsors’Requirements”

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CRL is ‘System Integrator’• Requirements & Configuration

– Engineering Change Control and Requirements Management– Standards & Concessions

• Systems Delivery– Project Management and Interface Engineering– Review & Acceptance of Contractor Designs

• Systems Engineering & Integration– System Architect, RAMS, Modelling, Ops Concepts etc.

• Engineering Safety Management– Management of Notified Body, System Safety Plans etc.

• CRL / NR / LU / RfL Interfaces– Joint Working Groups, Traffic Management, Operating Rules

• Testing & Commissioning– Testing, Commissioning and Handover

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• 'The collapses could have been prevented but a cultural mindset focused attention on the apparent economies and the need for production rather than the particular risks, ' it says.

• 'Warnings of the approaching collapse were present from an early stage in construction but these were not recognised.‘

• Errors were made, it says, 'leading to poor design and planning, a lack of quality during construction, a lack of engineering control and most importantly a lack of safety management.'

• Investigators found the incident exhibited 'all the hallmarks of an organisational accident‘.

Client Client -- Technical AuthorityTechnical Authority

Heathrow Express Tunnel Collapse Heathrow Express Tunnel Collapse

Crossrail V-Cycle

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Systems Design and Assurance• Systems developed to ‘Reference Design’ stage by CRL. • Reference Design includes performance output based Technical &

Interface Specifications in Works Information (except Floating Track Slab based on Engineers Design)

• Systems Contractors will perform Detailed Design and Build (D&B)• CRL responsibilities include:

– Reviewing and accepting designs from D&B Contractors– Managing development of integrated railway system designs (30%, 60%,

90% design review and acceptance gates)– Co-ordinating work of Systems, Rolling Stock and Civil Contractors – and

securing development of end-to-end railway against controlled baselines– Securing acceptance of the designs from the IM’s as well as testing,

commissioning and handover of completed railway– Providing necessary assurance evidence to IM’s under ROGS Regulations– Appointing and managing a Notified Body (NoBo) as part of legal commitment

under the Interoperability Regulations33

Systems Integration Authority (SIA)• Technical Authority for “end-to-end route” Integration• Represented by competent technical heads from CRL,

NR, LU and RfL• Ensures System Integrity • Owns configuration of the whole railway• Ensures coherence between the design, operations,

maintenance and safety• Reviews integration issues and change proposals• Communicates Integration status• Provides single-point co-ordination and support

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Delivering a world-class affordable railway safely

through effective partnerships