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Industry Sector, Mobility Division I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.

Industry Sector, Mobility Division

Integrated Services Workshop Services Erlangen, 2009

Integrated Services Workshop Services –

Refurbishment and Accident Repair

Erlangen, 2010


Our skillsProject ManagementDamage assessment and surveysConsultingEngineering

Integrated Services – Your partner for refurbishment

and accident

repair

Mechanical and electrical installationWelding expert knowledge (IWE, EWS, NDT experts)Commissioning

Extension of operational lifetimeModernization / retrofitas complete solutionIndividual support: supervision, engineering, commissioning, etc.Revisions

Refurbishment Workshop Services -

worldwide

Complete solution approachRepair at Siemens- or customer facilitiesConsulting and implementationAll types of damagesAll types of vehicles

Accident Repair


We offer customized and specific solutions – Refurbishment for one vehicle or for the complete fleet

Refurbishment of Complete FleetsExtension of the vehicles’

operational lifetimeRetrofit of Systems

Update for individual vehicle components and systems

Commissioning and DocumentationReady-to-operate and homologated vehicles

Refurbishment of ComponentsExchange or revision of individual components


Infrastructure

Rail connection to main line tracks

Welding hall with alignment table for complex works

Overhead cranes and bogie-drop table

Elevated tracks with pits and roof access platforms

Facilities for static and dynamic testing

Additional facilities like vehicle scale,

leak tightness test equipment and rotary-tilt table

High quality infrastructure – Siemens Mobility site Wegberg-Wildenrath


Refurbishment has many characteristics – We provide the answers

Metro São Paulo Desiro UK Class 450Guadalajara Locomotive

BR 189

Refurbishment of the whole vehicle fleet

Enhancement of the passenger capacity

Refurbishment of thetraction system

ETCS retrofit for cross border operation (e.g. ETCS, ATB, SCMT)


Vehicle type: Metro

Quantity: 150 wagons

Scope:Replacement of original DC by new AC Traction System(DC chopper exchanged with IGBT inverter and DC drives replaced by AC drives)Installation of a new „fail-safe“ braking systemBogie revision including adaptationsNew on-board electrical system with battery chargerNew interiorModification of the driver’s cabAir conditioning systemDoor revisionNew air compressor and revision of the pneumatic systemFire alarm systemAudio and video systemTrain control system

Carried out in a consortium with Alstom

Duration:2009 until 2014

Complete fleet refurbishment in São Paulo – Upgrading the vehicles to „state-of-the-art“

Fleet refurbishment


Modernization from DC to AC Traction System The way to a higher car reliability in Guadalajara

New AC traction system

Vehicle type: Tram

Quantity: 16

Customer requirements:Higher reliability after implementation of anAC traction systemImproved spare part service; obsolescence prevention for DC traction equipment and stock optimization due to usage of common spare partsVehicle combination with other AC tram vehicles inmixed train consists (TLG-88 and TEG-90)

Scope:Inverter with IGBT technology, braking resistor and AC drives (including additional chokes)Replacement of original Knorr brake control system by Siemens airbrake control systemHigh Speed Circuit BreakerSet-point transducer for coupled operation with other tram vehiclesNew master controller and driver’s desk modification

Duration:2009 to 2011


Vehicle type: Desiro Class 450

quantity: 28

Customer requirements:Interior retrofit to improve the transport capacity Planning of new outline for several types of carsExecution of works at Bournemouth Depot

Scope: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 handrailsReworking of interior doorsInstallation of small litter bins behind glass dividerSealing of holes that are no longer usedRepair of carpet

Duration:August 2007 until July 2008

More and more passengers are using the rail – Increased transportation capacity for Desiro UK

Modification for raised transportation capacity


Vehicle type: BR 189 (Mitsui) Quantity: 85

Customer requirements:Disassembly of existing ATC systems Adaption of mechanical and electrical interfacesInstallation of new ATC / ETCS components

Scope:Transport of locomotives into Siemens workshopMechanical and electrical disassemblyMechanical adaptation for new ATC components Installation of new components and rewiring(e.g. displays, sensors, electrical cabinets, antennas)Installation of a new pantographCheck of insulationCommissioning including static and dynamic tests Documentation of performed work

Duration:December 2007 until the end of 2010

Transnational traffic increases – rules and regulations to be fulfilled with ETCS upgrade

ETCS upgrade


Our skillsProject ManagementDamage assessment and surveysConsultingEngineering

Integrated Services – Your partner for refurbishment

and accident

repair

Mechanical and electrical installationWelding expert knowledge (IWE, EWS, NDT experts)Commissioning

Extension of operational lifetimeModernization / Retrofitas complete solutionIndividual support: supervision,engineering, commissioning, etc.Revisions

Refurbishment Workshop Services -

worldwide

Complete solution approachRepair at Siemens or customer facilitiesConsulting and implementationAll types of damagesAll types of vehicles

Accident Repair


One-Stop Service – complete solutions for accident repair

Welding / LevelingExtensive welding and leveling expertise

Inspection and Damage AssessmentSurvey and repair concept evaluation

from one source

Complete Repair Processing Worldwide at the customer facility or in

Wegberg, Germany

Commissioning / DocumentationPreparation of commissioning and

customer documentation

Measuring3D-laser measuring or conventional,

as required

EngineeringCalculations, structural analysis,

FEM models


Infrastructure

Rail connection to main line tracks

Welding hall with alignment table for complex works

Overhead cranes and bogie-drop table

Elevated tracks with pits and roof access platforms

Facilities for static and dynamic testing

Additional facilities like vehicle scale,

leak tightness test equipment and rotary-tilt table

High quality infrastructure – Siemens Mobility site Wegberg-Wildenrath


Independent of the used welding material – The workshops comply with the highest quality standards

Materials Aluminum Stainless steel

Steel

ISO 9606 -

2 ISO 3834 -

2 ISO 14731 ISO 15614 P.1+2

Qualification test for welding operator

Quality requirements for

welding

Welding coordination Welding techniques

ISO 9001 –

Quality Management

Compliant to DIN EN 15085 –

welding on railway vehicles and components

Standards

Content

Certificates

Techniques MIG -

Metal Inert Gas

MAG –

Metal Active Gas

TIG (WIG) -

Tungsten Inert Gas

Electron beam welding


No matter what damage – We can assist you

Desiro Classic

ÖBB Combino MelbourneHeidelberg MGT6 Mannheim MGT6D

Front and side damageregional train aluminumvehicle

Front damagelight rail aluminumvehicle

Side damagelight rail steel vehicle

Front damagelight rail steel vehicle


Accident repair of a Desiro Classic with front and side damage after crash with concrete truck

Date of accident:July 2008 in Austria

Damage:Complete vehicle front (GRP head)Vehicle front end base frameComplete left side

Challenge:Disassembly of vehicle at customer workshopTransfer of damaged vehicle to Siemens workshopReconstruction of side panel, base frame and GRP headComplex welding worksReassembly under supervision of Siemens at customer workshopCommissioning support

Actions:Fabrication of a new vehicle front and body partsPartial replacement of the left side wall panel

Duration:December 2008 until September 2009

Front-

and side damage –

Desiro Classic ÖBB


Accident repair of a damaged MGT6 tram after crash caused by false track switch position

Side damage –

Heidelberg MGT6

Date of accident:June 2009 in Heidelberg, Germany

Damage:Side damage after collision caused by false track switch positionHeavy car body and base frame damagePartly detached vehicle front at front door

Challenge:Disassembly and reassembly of vehicle Repair of base frame and vehicle frontLeveling of the car bodyComplete repair at Siemens workshopCommissioning at Siemens Test- and Validationcenter

Actions:Reconstruction of base frame structure till main crossbarMeasuring of complete car shell incl. leveling workUsage of specific flexible welding fixtures

Duration:September 2009 until January 2010


Accident repair of a COMBINO with frontal damage after rear end collision of two light rail vehicles

Frontal crash –

Combino Melbourne

Date of accident:September 2007 in Melbourne, Australia

Damage:Complete vehicle front and rear end (rear-end collision)Vehicle front base frameFront coupler

Challenge:Transfer of vehicle to GermanyComplete repair at Siemens workshop

Actions:Procurement of main partsTransfer to GermanyRedesign and fabrication of a new aluminum front structureUsage of specific welding tools and welding fixtures

Duration:April 2008 until September 2008


Accident repair of a MGT6 car with frontal damage after rear end collision

Crash -

Mannheim MGT6

Date of Accident:February 2009 in Mannheim, Germany

Damage:Heavy front and base frame damage

Challenge:Disassembly and reassembly of vehicle Repair of base frame and vehicle frontComplete repair at Siemens workshopCommissioning at Siemens Test- and Validationcenter

Actions:Reconstruction of vehicle frontUsage of specific flexible welding fixtures

Duration:April 2009 until December 2009

Additional order:Measurement of wheel vertical forces at Siemens Test- and Validationcenter


Industry Sector, Mobility Division

Integrated Services Workshop Services Erlangen, 2009

Integrated Services We keep rail systems running

integrated services workshop services workshop services â€“

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