Integrated Services Workshop Services

Transcription

1 Integrated Services Workshop Services Erlangen, 2009 Industry Sector, Mobility Division Page 1

2 We have the power of high-skilled personnel providing solutions worldwide Our worldwide expertise Project management Expert s report Consulting Engineering Skill Portfolio Mechanical and electrical installation Welding (engineers, experts, PT-examiner) Commissioning Page 2

3 Independent of the kind of material the workshops fulfill all quality requirements according to ISO 9001 ISO 9001 Quality Management System Certificates compliant with DIN 6700, now DIN EN Welding of rail vehicles and components Content qualification tests of welders quality requirements of welding works welding coordination welding procedures Standards ISO ISO ISO ISO P.1+2 Materials Aluminum Stainless steel Steel Page 3 Procedures MIG - metal inert gas WIG - wolfram inert gas MAG - metal active gas Electron beam welding

4 Workshop Services is active around the world in Crash & Accident Repairs and Modernization Workshop Services: In our own facilities, customer s or partnered workshops Crash & Accident Repair Complete solution from one hand Repair of damaged vehicles in a Siemens or customer owned facility As consultant or as performer Front, side crash or fire damage all accidents Trams, metros or trains all vehicles Modernization Support to enhance the operational lifetime Restoration of historical cars Modifications as a complete solution Individual support like supervision, engineering or commissioning Qualified staff for overhauls Page 4

5 Siemens offers complete services for crash and accident repair including insurance processing Standard processes for crash and accident repair Crash and Accident Repair Content Expertise on site Transport of vehicle or repair at customer facilities Technical and financial damage assessment Set-up of repair schedule Engineering of mechanical/ electrical equipment Execution of repair (disassembling, cut-off grinding, welding, truing, measurement, paintwork, assembly) Commissioning and acceptance tests Complete repair documentation Loss adjustor/ insurance processing Benefits 8 years experiences on different types of damages Direct access to the complete original drawings Mechanical and electrical engineering support from Siemens Full service package including all paperwork Repair on site is a choice of customer Short repair times Cut-off grinding Calculation Welding Documentation Levelling rack Measuring device Page 5

6 No matter which crash or accident happened We are able to handle it Overview on crash & accident repair services Desiro DMU Rumänien Combino Amsterdam Combino Melbourne Combino Amsterdam Frontschaden Commuter Seitenschaden Light Rail Vehicle Frontschaden Light Rail Vehicle Feuerschaden Light Rail Vehicle Page 6

7 Crash repair of a front-damaged Desiro after a heavy crash with a cement truck Crash repair at customers site Heavy front crash Desiro DMU Romania Happened: October 2007 in Romania Damages: Complete front section Front underframe GRP-Front mask Clutch Challenge: Repair on customer s site Complex welding tasks Activities: Shipping of welding equipment and material Manufacturing of new front and under frame Welding on customer s site Duration of repair services: May 2008 until August 2008 Page 7

8 Crash repair of a front-damaged Desiro after a heavy crash with a cement truck Crash repair at customers site Page 8

9 Crash repair of a side-damage Combino after derailment and collision with a catenary pole Crash repair at Siemens facility Derailment & collision Combino Amsterdam Happened: December 2007 in Amsterdam, Netherlands Damages: Heavy impact of sidewall and underframe Challenge: Local repair of sidewall No stripping down of car body Complete repair at a Siemens workshop New FEM-Calculation for repair section Fastest possible repair time was requested Activities: Using special welding procedures for repair section Using special welding jigs Duration of repair services: March 2008 until June 2008 Page 9

10 Crash repair of a side-damage Combino after derailment and collision with a catenary pole Crash repair at Siemens facility Page 10

11 Crash repair of front-damaged Combino after collision of two light rail vehicles Crash repair at Siemens facility Frontal collision Combino Melbourne Happened: in Melbourne, Australia Damages: Complete front section Front underframe GRP-Front mask Clutch Challenge: Shipping of the vehicle to Germany Complete repair at a Siemens workshop Activities: Procurement of main components Transport to Germany Construction and manufacturing of new aluminum under frame Using special welding tools and jigs Duration of repair services: April 2008 unitl September 2008 Page 11

12 Crash repair of front-damaged Combino after collision of two light rail vehicles Crash repair at Siemens facility Page 12

13 Accident repair after a fire-damaged Combino caused by a broken catenary Crash repair at Siemens facility Heavy fire damage Combino Amsterdam Happened: 2002 in Amsterdam, Netherlands Damages: Fire damage of the complete roof section Caused by broken catenary Gutted traction container Challenge: Decontaminate of interior cabin equipment Dismantling of complex roof and side wall bonding Activities: Decontaminate of complete interior Decontaminate of components Re-wiring Construction of new roof section Complete electrical commissioning Duration of repair services: April 2003 until June 2003 Page 13

14 Accident repair after a fire-damaged Combino caused by a broken catenary Crash repair at Siemens facility Page 14

15 Workshop Services is active around the world in Crash & Accident Repairs and Modernization Workshop Services: In our own facilities, customer s or partnered workshops Crash & Accident Repair Complete solution from one hand Repair of damaged vehicles in a Siemens or customer owned facility As consultant or as performer Front, side crash or fire damage all accidents Trams, metros or trains all vehicles Modernization Support to enhance the operational lifetime Restoration of historical cars Modifications as a complete solution Individual support like supervision, engineering or commsioning Qualified staff for overhauls Page 15

16 A second life or simply modification for rail vehicles with modernization solutions of Siemens Overview on modernization services Modernization Content Modernization of complete fleets to enhance the operational lifetime as well as restoration of historical vehicles Creation of retrofit concepts (technique, design, costs) Set-up of retrofit schedule Engineering of components and software Procurement of new components Execution of retrofit work (disassembly, new components, welding, painting, finishing) Commissioning and acceptance tests Complete retrofit documentation Additional restoration activities Assessment of condition of all components Cleaning of the vehicle Restoration of components Benefits Customer specific solution on site or at our own facilities Modification of one vehicle or of a fleet Complete order processing including logistics, engineering, approval and documentation Page 16 Interior retrofit Assembly of new components Underfloor retrofit

17 Modernization of Rolling Stock is multifaceted Examples for modernization Combino Budapest Metro Munich Desiro UK class 450 Locomotive BR 189 Installation of a new air conditioning system Syntegra prototype including installation of traction converter & bogie Change of interior alignment for upgrading passenger Capacity Retrofitting of ATC systems for cross border operation (e.g. ETCS, ATB, SCMT) Page 17

18 Retrofit of an air conditioning system for Combino Budapest Example for installation of new components on site Type of vehicle: Air conditioning units Air condition system Amount: 120 at 40 Combino trams Customer requirements: Demounting of the existing system for heating and ventilation Adaption of interfaces Assembly of new air conditioning system Activities: Pre-assembly of cables and connectors Disassembly of existing system and interior flaps Mechanical works including drilling of holes and sealing Change of control cables and installation of new cabling Assembly of new air-conditioning unit Installation of a separate DC/DC converter Check of insulation and water tightness Commissioning including check of functions Type test to confirm the technical data and cooling power Duration of modernization service February 2008 until June 2008 Page 18

19 Retrofit of an air conditioning system for Combino Budapest Example for installation of new components on site Page 19

20 Syntegra Complete retrofitting of a Munich metro train with a new traction system and bogie Syntegra prototype modification Upgrade Syntegra Type of vehicle: Munich metro train Amount: 1 Customer requirements: Disassembly of existing traction system and bogies Mechanical and electrical adaption for new systems Engineering, welding, commissioning and documentation Activities: Transport of end car to Siemens workshop Mechanical and electrical disassembly Engineering and calculation Mechanical adaption for new traction system and bogie including welding, drilling, painting, cablings etc. Assembly of new components and connection of bogie, traction, cooling, braking and other electrical systems Check of insulation and commissioning Documentation of works Duration of modernization service June 2005 until January 2006 Page 20

21 Syntegra Complete retrofitting of a Munich metro train with a new traction system and bogie Syntegra prototype modification Page 21

22 The new requirements regarding cross border operation can be fulfilled with an ETCS upgrade ETCS upgrade ETCS-Upgrade Type of vehicle: Locomotives BR 189 (Mitsui) Amount: 85 Customer requirements: Disassembly of existing ATC-systems Adaption of mechanical and electrical interfaces Installation of new components Activities: Transport of locomotives into Siemens workshop Mechanical and electrical disassembly Mechanical adaption for new ATC-components Assembly of new components and connection of cables (e.g. displays, sensors, electrical cabinets, antennas) Assembly of new pantograph Check of insulation Commissioning including driving tests Documentation of works Duration of modernization service December 2007 until end of 2010 Page 22

23 The new requirements regarding cross border operation can be fulfilled with an ETCS upgrade ETCS upgrade Page 23

24 The High Capacity project for Desiro trains class 450 at Bournemouth depot Interior modification High capacity modification Type of vehicle: Desiro class 450 Amount: 28 Customer requirements: Interior retrofit to improve the transport capacity Planning of new outline for several types of cars Execution of works at Bournemouth depot Activities: Disassembly of the existing seat modules (3 seats) Remove of big litter bins, tables and curtains Mechanical works on the floor (e.g. holes, carpet) Installation of new seat modules (2 seats) Assembly of new side handrails Reworking of interior doors Installation of small litter bins behind glass divider Sealing of holes that are no longer used Repair of carpet Duration of modernization service August 2007 until July 2008 Page 24

25 The High Capacity project for Desiro trains class 450 at Bournemouth depot Interior modification Page 25

26 The greater the challenge, the better we get We keep rail systems running