etcs l2 on-board retrofit - rail.co.il

1

ETCS L2 On-Board

Retrofit

SUPERVISION SERVICES

(Consulting, Inspection & Testing)

NTP1 + NTP2 + OPTIONAL WORKS

SCOPE OF WORK

2

1 General……………………………………………………………………………………………………………………….3

2 Scope of Services ................................................................................................. 3

2.1 Technical Consultancy ................................................................................... 3

2.2 Shops Inspection & Quality Control ................................................................. 5

2.3 Software Development Quality Control ........................................................... 6

2.4 FAIs & Factory Acceptance Tests ..................................................................... 6

2.5 Lab Tests, Installation Tests, Odometry Tests and Final Acceptance Tests ............ 6

3 Project Management Activities.............................................................................. 7

4 Tests Description ................................................................................................. 8

4.1 General ....................................................................................................... 8

4.2 On-Board Factory Acceptance Tests ................................................................ 8

4.2.1 OB Sub-Systems Description .................................................................... 8

4.2.2 Sub-Systems Inspection & OB Factory Acceptance Tests ............................. 8

4.3 On-Board System ........................................................................................ 12

4.3.1 OB Systems Description ........................................................................ 12

4.3.2 OB Systems Inspection ......................................................................... 12

5 Schedule Baseline .............................................................................................. 15

5.1 General Design per Vehicle Type (Ongoing 2019-2022) ................................... 15

5.2 NTP1 – Approximate Timeline ...................................................................... 15

5.2.1 Vossloh Euro 3200 ............................................................................... 15

5.2.2 Bombardier DD-PC ............................................................................... 15

5.2.3 Vossloh JT42 BW .................................................................................. 15

5.3 NTP2 – Approximate Timeline ...................................................................... 16

5.3.1 Siemens SD-PP ..................................................................................... 16

5.3.2 Alstom SD-PP Error! Bookmark not defined.

5.3.3 Vossloh Euro 4000 ............................................................................... 16

5.3.4 IC3 ............................................................. Error! Bookmark not defined.

5.3.5 Vossloh JT42 CW .................................................................................. 16

5.4 Optional Works – Timeline TBD .................................................................... 16

5.4.1 Proto .................................................................................................. 17

5.4.2 Serial .................................................................................................. 17

6 List of Attachments ............................................................................................ 18

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1 General The ISR Project Manager (IPM) seeks to retain Consulting, Inspection, Supervision & Test

Services from a Rolling Stock expert specializing in Rolling Stock ATP & ETCS Systems, for the

support of the design, manufacturing, inspecting, testing, commissioning & operations /

maintenance of ETCS-L2 Installations in rolling stock, in 3 stages as follows:

NTP (Stage) 1

3 prototypes and 133 serial vehicles as follows:

Vossloh Euro 3200 Passenger Diesel Locomotives – 1 Prototype + 23 Serial

Bombardier 64 Double Deck Passenger Coaches – 1 Prototype + 63 Serial

Vossloh JT428W Passenger Diesel Locomotives – 1 Prototype + 47 Serial

Plasser Crane Yellow Machine – 1 Prototype

NTP (Stage) 2


Bombardier 22 Double Deck Passenger Coaches –22 Serial

Siemens Single Deck Passenger Coaches – 1 Prototype + 13 Serial

Vossloh Euro 4000 Freight Diesel Locomotives – 1 Prototype + 14 Serial

Vossloh JT42CW Freight Diesel Locomotives – 1 Prototype + 6 Serial

Note: Scope of this Call-Off may change

Optional Works


Yellow Machines as Follows:

o Geismar Ballast Regulators – 1 Prototype + 1 Serial

o Plasser & Theurer Rail Tamping Machine – 1 Prototype + 2 Serial

o Plasser & Theurer Measuring Vehicle – 1 Prototype

o Geismar Weed Killing Track Motorcars – 1 Prototype

o Plasser & Theurer Vehicles – 1 Prototype + 6 Serial

The following specification describes the general guidelines for the Supervision Company's

Scope of Work for all Stages - NTP1, NTP2 and Optional Works.

The SUPERVISION COMPANY shall provide CONSULTING, INSPECTION, TEST & SUPERVISION

services which ISR may require on a non-exclusive basis in the field of design, manufacturing,

testing, commissioning, delivering & operations / maintenance of the ETCS-L2 for the

vehicles described above. All works have to be carried out in accordance with the

norms/standards/specifications specified in Agreement No.91944 between ISR and Supplier,

Alstom Belgium, and as detailed hereafter but not limited to the items listed below. If there

are other deliverables the bidder would provide in this context, please include them in the

Proposal as well, in the form of an optional non-binding extension to the Offer.

2 Scope of Services

2.1 Technical Consultancy The scope of work includes, but not limited to, the following activities:

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Design Appraisal in all relative disciplines (electrical, software, mechanical)

System Review & Assessment

Preparation of relative deviation reports

Preparation of the working procedures and checklists as base to perform inspections

and quality control

Technical consultancy on issues & matters arising during the execution of the Project

beginning from ETCS-L2 system design, through manufacturing, installations &

integrations, testing, commissioning, final acceptance and up to successful delivery

and operations / maintenance

Appraisal of technical documentation (Interfaces, RAMS, Quality (Assurance &

Control), Conformity to Railway Industry Standards, Design, Survey Reports, "As-

Build" Documentation, Testing etc.)

Appraisal of training packages (operation, maintenance etc.)

Check for Compliance with the Specification, the Approved Design and Purchase

Order Specification

Assessment and approval of Factory Acceptance Tests (FAT) / First Article Inspection

(FAI) for selected modules or components (e.g. EVC, EDOR, DMI, TCC, JRU, RADAR,

WHEEL SENSOR, RMR, INDUZI I60R, EUROBALISE ANTENNA, GSM-R ANTENNA, GSM-

R & GPS ANTENNA, JRU, I60-R etc.)

Actively participate in all Technical Milestones as required – Design Reviews,

Manufacturing Quality Control Gates, First Article Inspection (FAI), Prototype Tests

as well as Acceptance Tests for Serial Units, and issue corresponding Reports as

required

Review & Provide Remarks regarding Minutes of Meetings

Monitor Manufacturing Milestones & issue the Corresponding Reports & Punch-Lists

including Blocking points

Witness all Final Acceptance Tests (Prototype & Serial) & issue the Corresponding

Tests Reports & Punch-Lists including Blocking points

Organization and performance of the Final Design Review ("Design Freeze") with the

contractor

Assess the Test program at different manufacturing levels, the completeness of the

entire test program and the content of the individual test procedures

Approve the detailed Inspection and Test Plan for Type Tests & Serial Acceptance

Tests

Study of the Quality Plan of the examination of the Type Test and Routine Test

Specification of the contractor and its subcontractors

Approval of Type Test and Routine Test specifications of the contractor and its sub-

contractors

Software

o Verify Software Inter-operability with System Components

o Check Software Testing Management

o Verify Software Versions Control & Traceability

Cyber & Security

o Check conformity to Security and Safety requirements for Software (reports)

o Check all Cyber Security aspects in the Train IT (reports)

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2.2 Shops Inspection & Quality Control The scope of work includes, but not limited to, the following activities:

Performance of shop inspection during the ETCS Retrofit process in the facilities or

on the premises of the suppliers & sub-contractors; Assess manufacturer & sub-

supplier authorities

Note: Inspection may be required in multiple shops, in up to 3 different sites

Development of the inspection plan and the working procedures and checklists,

which are defining the tasks and responsibilities of the supervisor inspectors (to be

submitted to the ISR project manager of the employer for approval)

Issue of Inspection, Quality Control & Deviation Reports

Issue respective certificates after the project milestones have been achieved (e.g.

"Certificate of Completion")

Check material identification and certification

Assess procedures specifications, qualification records & certificates

Verify correctness of storage procedures (including shelf-life of consumables)

Verify compliance & conformity to Technical Standards as defined in the Technical

Specification

Random inspections of material preparation & fit-ups throughout the project

Check & approve Test and Installation Equipment

Final visual examination & inspection

Check application of identification marks and inscriptions

Check packing and marking

Issue of acceptance certificates for components and system-wide

Issue Release Notes and Reports (summarize the carried out activities in the

Monthly Report including Manufacturing QA Reports)

Verification of Manufacturing Employees Qualifications & Certifications for the

required works

Check for Compliance with the Specification, the Approved Design and Purchase

Order Specification

Participate in Technical Meetings with the Manufacturer and the Sub-Supplier &

Review the Minutes of Meetings

Assess and approve of Factory Acceptance Tests (FAT) / First Article Inspection (FAI)

for selected modules, which shall be defined after the completion of the Design

Review

Check for correct assembly & installation of all components and their secure

interoperability with existing systems as well as attachment to the structure

(Mechanical installation), and issue Corresponding Reports

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2.3 Software Development Quality Control Software

o Software interoperability with system components

o Software Quality Assurance:

Check software testing management

Software versions control & traceability

Cyber & Security

o Check conformity to security and safety requirements for Software (reports)

o Check all cyber security aspects in the train IT (reports)

2.4 FAIs & Factory Acceptance Tests The scope of work includes, but not limited to, the following activities:

Assess Type Test Procedure & Certificates

Assess and approve of Factory Acceptance Tests (FAT) / First Article Inspection (FAI)

Reports


Specification

Verify conformity with Technical & Homologation requirements determined by

Israel Ministry of Transport

Administration work, documentation and reporting to ISR

Verify results of tests against predetermined test criteria and other supporting

technical documents to be provided by the manufacturer; issue corresponding

reports to ISR for its Acceptance


2.5 Lab Tests, Installation Tests, Odometry Tests and Final Acceptance Tests The scope of work includes, but not limited to, the following activities:

Verify, witness and supervise all System-Level Serial Acceptance Test &

Commissioning

Approve the detailed Inspection and Test Plan for Serial Acceptance Tests

Appraisal and approval of Serial Acceptance Tests for selected modules, which shall

be defined after the completion of the Design Review

Assess the Serial Acceptance Test program at different levels, the completeness of

the entire test program and the content of the individual test procedures


Specification

Administration work, documentation and reporting to ISR

Witnessing of the routine tests on each trainset; issue of the related certificates

related to project milestones


Verify results of tests against predetermined test criteria and other supporting

technical documents to be provided by the manufacturer & issue corresponding

reports to ISR for its Final Acceptance

Assess Serial Acceptance Tests Procedure & Certificates

Assess and approve of Serial Acceptance Test Reports

Check & Approve Test Equipment

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Participate in Technical Meetings with the Manufacturer and the Sub-Supplier &

Review of Minutes of Meetings

Verify conformity with Technical & Homologation requirements determined by

Israel Ministry of Transport

Confirm Final Test Results and issue the Final Approval / Rejection

Recommendations

Issue Final Test Reports

Issue Punch-Lists including Blocking Issues with agreed dates for their correction by

the manufacturer

Check for correct assembly & installations of all components and their secure

interoperability with existing systems as well as attachment to the structure, and

issue Corresponding Reports

Software

o Software interoperability with system components

o Check software testing management

o Software versions control & traceability

Cyber & Security

o Check conformity to security and safety requirements for Software (reports)

o Check all cyber security aspects in the train IT (reports)

Take any measures necessary to ensure successful delivery of the Serial Units & their

Handover to Operations / Maintenance

Preparation and presentation of Final Acceptance Report per trainset to ISR Project

Manager for Approval

3 Project Management Activities The scope of work includes, but not limited to, the following activities:

Overall Supervision Project Management Responsibility

Interface with Project Management of ISR

Technical risk identification & recommendation to ISR Project Manager for remedial

actions

Definition of the interface with the contractor; Establishment of the inspectors'

office at the contractors' site

Management meetings with ISR and the contractor

Supervision of inspectors & technical experts in Supervision Team

Planning of supervision activities and personnel

Organization of regular meetings with the employer

Organization and conducting design reviews on technical milestones (e.g. "Design

Freeze"), preparation of the reports

Conducting the project progress meetings with contractor

Scheduling shop inspections with contractor

Organization of the witnessing program for the type tests

Release of monthly progress reports, inspection reports and type test reports to ISR

Project Managers

Release of Final Reports

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4 Tests Description

4.1 General This section covers a general description, definition and logical order of the tests

required for accepting a system, including the following:

Factory Acceptance Test & On-Board sub-systems (EVC, BTM, Radio, JRU etc.)

On-Board System Tests - including Laboratory Tests, Installations (Electrical

and Mechanical), EMC / EMI Tests, Odometry Tests, and Final Acceptance

Tests. The FA (Final Acceptance) tests gather all the related to test each LRU

Interfacing with each other and/or the train. This includes On-board +

Wayside Equipment Tests, where the ETCS system (On-Board) is tested

interfacing with the wayside system, as a full system (ERTMS).

Each type of test includes where the tests area carried out and quantity of units that

are required to be tested by the supervision company.

This section draws the BASELINE for the tests & inspections the Supervision

Company shall carry out. ISR Expects the Supervision Company to create a

COMPLETE & FINAL TESTS & INSPECTIONS DOCUMENTS based on the guidelines set-

forth in this section.

4.2 On-Board Factory Acceptance Tests

4.2.1 OB Sub-Systems Description

OB Sub-System #

GSM / GPS Antenna 1

GSM Antenna 2

Doppler Radar 3

Balise Antenna 4

Wheel Speed Sensor 5

ETCS Enclosure (EVC + Other) 6

EDOR 7

JRU 8

DMI 9

4.2.2 Sub-Systems Inspection & OB Factory Acceptance Tests

4.2.2.1 OB Sub-Systems Inspection

Inspection:

As all sub-systems are COT (Commercial Out of Shelf), certificates / documentation check as

described under 2.4 above are sufficient

Where:

Manufacturer's Facilities

Quantity:

1 Sub-System Inspection per sub-system defined under 4.2.1 above - Total of 9 Sub-System

Inspections

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4.2.2.2 OB Factory Acceptance Tests

Inspection:

Tests that are targeted for Verification of quality standards, specifications, size and

other intrinsic characteristics of the equipment.

The Factory Acceptance Tests include, but not limited to Electrical & Mechanical

aspects as follows: Shock and Vibration, Environmental, EMC/EMI, Continuity

checks, Power supply, cabling, insulation, among others.

Factory Acceptance Tests are USUALLY carried out following a list like the following

EXAMPLE:

Ref. First Article Inspection - Criteria Required

(Yes / No)

Reference

Documents /

Evidence / Actions

Status

(OK /

NOK)

01 Completed and signed copy of

Quality, Environmental, Safety &

Health (QUENSH) Contract Conditions

Menu.

02 Drawing Pack (Confirmation of

Approval signatures and record

document Number / revision).

03 Specification (Confirmation of

Approval signatures and record

document number / revision).

04 Compliance Document (Clause by

clause statement confirming how

each of the approved Specification /

Drawing requirements and specified

QUENSH menus have been met).

05 In-house Production Drawings – If

applicable (Must include indication of

approval sign off / acceptance of

current revision and record Doc.

No./Rev.)

06 Bill of Materials (Record latest Doc.

No./Rev.)

07 In process Mechanical / Dimensional /

Electrical Test / Inspection Results for

1st Production sample (To verify

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(Yes / No)

Reference

Documents /

Evidence / Actions

Status

(OK /

NOK)

compliance with approved

Specification & Drawing

requirements).

08 All required / specified Type Testing

certificates (Temperature / Humidity

/ Vibration / Shock / EMC / IP /

Acoustics / etc.).

09 Completed Factory Acceptance Test

(FAT), to approved Test Specification

/ Procedure, with applicable Test

Results for: Test & Commissioning;

Visual Inspection; Wire counts; Power

connections; Voltage continuity & Bell

checks; Ground Bonding &

Meggaring; etc.

10 Completed Test & Commissioning -

TC2 Records & Results, relating to 1st

off sample, as defined in the FAT

Specification / Procedure.

11 Evidence of valid staff qualification (if

applicable).

12 Calibration records (For Electrical /

Mechanical measuring equipment

used on 1st off sample).

13 Material data sheets / Certificates of

Conformity for ALL flammable /

combustible materials / Low Smoke

Zero Halogen (LSZH).

14 1 x 1st off Production Sample must be

available for inspection (For

Dimension / Tolerance checks; to

demonstrate functionality; and for

electrical testing, where applicable).

15 Configuration Log for production 1st

off sample (and for all Line

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(Yes / No)

Reference

Documents /

Evidence / Actions

Status

(OK /

NOK)

Replacement Units that make up the

asset, including: Part No.; Item

Change Status; Serial No.; Batch No.;

and Bar Code No.)

16 Certificate of Conformity for FAI

sample (In-line with QUENSH CofC

criteria and to ref. “Manufactured in

accordance with: Specification No. /

Rev.; Drawing No. / Rev.; etc.).

17 Certificates of Conformance and

CofC’s for Commercial Off The Shelf

(COTS) Line Replacement Units

(LRU’s).

18 Hardcopy and Softcopy of entire FAI

evidence pack (all above documents)

available and ready for handover at

FAI.

19 Inspection Test Plan agreed

20 Packing revision

Where:

Manufacturer's Facilities

Quantity:

Factory Acceptance Tests are generic (for all prototypes) and therefore are carried-out only

once in the project.

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4.3 On-Board System

4.3.1 OB Systems Description

Total QTY OB System NTP

24 Vossloh Euro 3200 NTP1

64 Bombardier DD-PC

48 Vossloh JT-42 BW

1 Plasser Crane Yellow Machine

22 Bombardier DD-PC NTP2

14 Siemens SD_PP

15 Vossloh Euro 4000

7 Vossloh JT 42 CW

2 Giesmar-Ballast Regulator Optional

3 P&T Rail Tamping Machine

1 P&T Measuring Vehicle

1 Geismar – Weed Killing Track Motorcar

7 P&T – Yellow Vehicles

4.3.2 OB Systems Inspection

4.3.2.1 Lab Tests

Inspection:

Controlled Tests using specific HW and SW for the ISR Project

Where:

Manufacturer's Laboratories

Quantity:

Lab Tests are generic (for all prototypes) and therefore are carried-out only once in the

project.

4.3.2.2 Installation Test

Inspection:

Installation Acceptance Tests shall include, but not limited to, the following:

Mechanical - Torque settings marks, cable routing, cable and looms fixation,

maximum radius of cable, installation certificates, measurement of

mechanical parts and installation of fixings, brackets, others.

Electrical – Continuity check on new Cables or harnesses, Indentation checks

(Label of cables and pins), Megger tests (Insulation resistance), Earth bonding

tests

Where:

In Depot. Access to undercarriage equipment (Pit) and roof may be required.

Quantity:

Proto – Installation Tests will be conducted per OB System Prototype defined under

4.3.1 above - Total of 13 OB-System Inspections

13

Serial – Sample 30% (total of 63 Tests for all types of vehicles altogether)

4.3.2.3 Electromagnetic Field Measurements (EMC/EMI)

Inspection:

The measurements are intended to demonstrate pertaining EMC/EMI EN requirements.

Where:

On Depot

Quantity:

Proto Only – EMC / EMI Tests will be conducted per OB System Prototype defined

under 4.3.1 above - Total of 13 OB-System Inspections

4.3.2.4 Odometry Test

Inspection:

As described in Odometry Test Documentation by the Manufacturer.

Where:

On "Test Tracks"

Quantity:

Proto Only – Odometry Tests will be conducted per OB System Prototype defined

under 3.14. above - Total of 13 OB-System Inspections

4.3.2.5 Final Acceptance Test

Inspection:

These tests comprehend all the required tests prior for commissioning the equipment, and

include STATIC TESTS and DYNAMIC TESTS as follows:

Static Tests

Tests of individual on-board equipment working together in a static environment,

while equipment and train are powered up.

Testing equipment is required, including but not limited to the following:

Computers and cables (to read logs), Multimeter, VSWR reader, breakout boxes, Test

rigs (to simulate signals), measuring tape, bubble or electronic level, laser distance

meter, etc.

Tests may include, but are not limited to, the following:

Verify Rack Installation and Cable Connections

Verify Balise Antenna and BTM

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Verify Train Power Supplies

Verify Accelerometer

Verify Radio Antenna Installation (GPS/GSM and GSM)

Verify Doppler Radar

Verify Operation of cabin control

Verify Emergency Break (EB) Interface

Verify Availability of EVC (2oo3)

Verify Tachometer Movement

Verify Operation of the DMI

Verify EDOR

Verify GSM-Voice

Verify JRU

Dynamic Tests

Tests of the on-board equipment working together in a dynamic environment,

including interface testing between on-board and wayside equipment.

These tests are conducted with equipment and train powered up. Connection with

the RBC is also required.

The OCC (Operation Control Center) is also involved in the dynamic tests, as it

provides important inputs for Dynamic Test Scenarios (routes to test, platform

stopping points, stopping locations, level crossings etc.)

Where:

Static Tests - In Depot. Access to undercarriage equipment (Pit) and roof may be

required

Dynamic Tests - On "Test Tracks" fitted with ERTMS

Quantity:

Proto – Final Acceptance Test will be conducted per OB System Prototype defined

under 4.3.1 above - Total of 13 OB-System Inspections

Serial –

o Sample 30% (total of 63 Tests for all types of vehicles altogether)

o Each ERTMS area shall be tested

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5 Schedule Baseline

5.1 General Design per Vehicle Type (Ongoing 2019-2022) Provide support throughout the Project, as needed, with the following design activities:

Generic ETCS System Engineering

Generic RAM studies

Generic V&V Engineering

Generic Safety Studies

Generic Installation Design

Generic Maintenance Engineering

Operation & Maintenance Deliverables

5.2 NTP1 – Approximate Timeline

5.2.1 Vossloh Euro 3200 Prototype:

Prototype Installation: November 2020

T&C + Installation Acceptance tests + SC (Safety Case): December. 2020

Serial:

Installation Acceptance Tests + Final Acceptance Tests + Handover, Sample

30% of fleet: June. 2021 – November 21

5.2.2 Bombardier DD-PC Proto:

Prototype Installation: October 2020

T&C + Installation Acceptance tests + SC (Safety Case): Nov. 20

Serial:


30% of fleet: may. 21– March. 22

5.2.3 Vossloh JT42 BW Proto:

Prototype Installation: July. 21

T&C + Installation Acceptance tests + SC (Safety Case): august. 21

Serial:

Installation Acceptance Tests + Final Acceptance Tests + Handover, Sample 30% of fleet: Nov. 21 to jun. 22

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5.2.4 Plasser obw10

Proto:

Prototype installation: spe.20

T&C + Installation Acceptance tests + SC (Safety Case) phase 1: oct.20

5.3 NTP2 – Approximate Timeline

5.3.1 Siemens SD-PP Proto:

Prototype Installation, one prototype: March. 22

T&C + Installation Acceptance tests + SC (Safety Case), one prototype: April 22 –

may. 22

Serial:

Installation Acceptance Tests + Final Acceptance Tests + Handover, Sample 30%

of fleet: Aug. 22 – Feb. 23

5.3.2 Vossloh Euro 4000 Proto:

Prototype Installation: aug. 22

T&C + Installation Acceptance tests + SC (Safety Case): spt. 22 – Oct. 22

Serial:


30% of fleet: nuv.22 – Jun. 23

5.3.3 Vossloh JT42 CW Proto:

Prototype Installation: oct 22

T&C + Installation Acceptance tests + SC (Safety Case): nov.22 – Dec. 22

Serial:

Installation Acceptance Tests + Final Acceptance tests + Handover, Sample

30% of fleet: mar. 23 – May. 23

Note: Scope of this Call-Off may change

5.4 Optional Works – Timeline TBD 5 prototypes and 29 serial vehicles as follows:

17

5.4.1 Proto

1 Giesmar Ballast Regulator

1 Plasser & Theurer Rail Tamping Machine

1 Plasser "& Theurer Measuring Vehicle

1 Plasser & Theurer Geismar Weed Killing Track Motorcars

1 Plasser & Theurer Vehicles

5.4.2 Serial

1 Giesmar Ballast Regulator

2 Plasser & Theurer Rail Tamping Machines

6 Plasser & Theurer Vehicles

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6 List of Attachments 1. Attachment A Technical Specification of ETCS On-Board

2. Attachment B Agreement No. 91944 for the ETCS On-Board

3. Attachment C Delivery Schedule of ETCS On-Board