Case Study: Network Rail - Visual Inspection Unit Conversion Project

DG8, Icomera’s dedicated design and engineering division, delivered a turnkey solution for Network Rail as part of a project to convert two British Rail Class 153 “Sprinters” into Visual Inspection Units (VIUs).

In its role as lead supplier, DG8 oversaw the installation design and engineering, approvals (RIS-2700-RST), material supply and installation work.

The Urgent Need to Address Two Key Challenges

monitored and replaced regularly. With 20,000 miles of track for Network Rail to maintain, that’s quite a job for its staff to do manually out on foot!

Every year, several low-speed train derailments occur on the

Reduce Risks to Railway Staff

network due to issues in which S&C are at fault. These

Issues surrounding track worker safety are treated with

derailments cause significant disruption¹; and they also

utmost priority by Network Rail - the owner and infrastructure

require

manager of most of the British railway network.

(re)allocated to help resolve the problem, which incurs its

Currently, Network Rail employees spend hundreds of thousands of hours on track for switch & crossing (S&C)

large

numbers

of

engineering

staff

to

be

own staff safety risks, in addition to cost and logistical issues.

inspections. However, switches and crossings are the highest

Network Rail were therefore keen to implement a solution

risk asset in track engineering. Network Rail standards

which would help to accurately determine the location of any

require S&C inspections to be carried out up to weekly in

issues along the track and ensure a resilient and reliable

some areas. This is sometimes done during the day (causing

“Predict and Prevent” maintenance strategy. If successful,

disruption to passenger and freight services) but more often

they would improve operational efficiency on the network,

done manually at night by a track engineer who walks along

ultimately helping offer the travelling public a more reliable

the track during a possession and looks at the asset using

service, while maintaining the network at a lower cost.

just a torch.

Manual S&C inspections bring risks to engineering teams.

Following several serious incidents, Network Rail sought a proof-of-concept which would demonstrate a viable alternative to on-foot visual inspections, meaning that some inspections could be diverted to the safety of an office.

Improve Network Infrastructure Management By guiding trains from one track to another, switches and crossings play an integral role in the life of the railway.

However, they are very prone to wear and tear because trains frequently travel over them, meaning that they need to be

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Switches & Crossings Are the Highest Risk Asset in Track Engineering

¹ https://railinsider.co.uk/2020/02/01/derailed-freight-train-at-eastleigh-causes-ongoing-disruption/

About the Project

will play a significant impact in supporting the transport industry’s overarching goals of sustainability and costefficiency. It’s interesting to note that retrofitting new and advancing technologies accounts for at least 60% of DG8’s

DG8’s Role as Lead Turnkey Supplier

active projects at any given time.

Given the pressing need to address these two challenges, Network Rail sought a train-based solution capable of performing automated rail line inspection, which it could commence testing in under one year. A multi-company project team was formed to design and build a swift solution.

However, (re)designing and delivering onboard equipment and systems on older rolling stock brings its own set of challenges, the principal of which are (1) the limited available space and (2) the need for integration for existing onboard systems.

DG8, Icomera’s design and engineering division, was assigned as the lead supplier, responsible for delivering a turnkey service for Network Rail in which it would oversee all

Supporting Complex Digital Onboard Solutions

aspects of project management, design, and installation.

To achieve the project goals set out by Network Rail, the unit conversion of the Cl153s was based around integrating three complex digital solutions: Project Management

Approvals

1.

A track condition and geometry monitoring system enabling non-contact measurement of railroad track

2.

A camera system recording images of the track and uploading the footage back to Network Rail’s Video

Design

Material

Management System (VMS)

Supply 3.

A positioning system that accurately tags the data from the other systems with the location on the network

DG8 worked collaboratively with the industry-leading Engineering

Installation

solution

providers

involved

to

accommodate

their

requirements through intelligent, space-efficient design both to the vehicle exterior and interior.

Re-engineering Older Rolling Stock to Bring Benefits Network Rail initially selected two retired Cl153 units, which it had leased from Porterbrook, to be converted into Visual Inspection Units (VIUs) for the project. As well as being easy to drive / maintain and reliable to operate, Network Rail’s selection of older rolling stock such as the Cl153s made perfect sense given their availability, and the tight timescale being worked to.

Furthermore, over the longer-term, being able to extend and enhance the life of older rolling train stock such as the Cl153s

Line Scan Cameras Are Installed Underneath the Train

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The VIU conversion units have each been equipped with

Since the VIUs essential systems are permanently powered,

eleven cameras which can record thousands of high-

they can constantly transmit data back to The Cloud; this

resolution images at high speed (eight at the front, one

allows Network Rail to access the systems 24/7. Should the

underneath, and two at the back). Mounted approximately

train be operating in bad reception areas or working in

20cm above the rail, the cameras capture an area of up to

tunnels, the kit is able to transmit the data after the shift has

40cm wide, delivering high-fidelity images. Since the image

finished. Even after the driver has gone home, the train

resolution is good enough to inspect (for example) an

remains powered and transmits.

individual bolt, S&C checks can be performed remotely based on data received from the VIUs.

An Innovative Hybrid Power Solution The train systems required a hybrid power source with multimode controls to support recording while in service, and post-processing while in sidings. DG8’s solution was to install an internal generator and supporting lithium batteries working in tandem.

A distinction was drawn between the critical (“essential”) and non-critical (“secondary”) onboard systems. The generator powers both the “essential” and “secondary” circuits while the train is running – But when the train is shut down at the end of a shift, the generator closes down and some services (e.g.

Toilet Control Equipment

non-essential lighting) are switched off, while the critical systems continue to receive constant power via the lithium batteries.

The lithium batteries have a capacity of 600 Amp hours, 48V, which can power the kit for approximately 3.5 days. When the batteries begin to lose their charge, the generator automatically starts up and charges them until they are full again, before switching itself off. This ensures that the train remains permanently powered and ready for operation.

Kitchen Area Design

In recognition of its success, the VIU conversion project was shortlisted in the Safety and Security Excellence category at the 2023 Rail Business Awards

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What Network Rail Say:

What We Say:

“[The project’s] return on investment is fast, and if

“Working as part of this innovative Network Rail

it saves one more death on the railway it will have

project, it’s been a pleasure to demonstrate DG8’s

paid for itself a hundred times over.”

capabilities to deliver turnkey services within an ambitious timeframe" Project Lead,

Mark Hoptroff, Director,

Network Rail

DG8 Design and Engineering

Battery Charger and Lithium Batteries

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