Industry Sector, Mobility Division
Integrated Services
Workshop Services
Page 2
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Our worldwide expertise
Skill Portfolio
Project management
Expert‘s report
Consulting
Engineering
Mechanical and electrical installation
Welding (engineers, experts, PT-examiner)
Commissioning
We have the power of high-skilled personnel
providing solutions worldwide
Independent of the kind of material – the workshops
fulfill all quality requirements according to ISO 9001
Materials Aluminum Stainless steel Steel
ISO 9606 - 2
ISO 3834 - 2
ISO 14731
ISO 15614 P.1+2
qualification tests of welders
quality requirements
of welding works welding coordination welding procedures
ISO 9001 – Quality Management System
compliant with DIN 6700, now DIN EN 15085 - Welding of rail vehicles and components
Standards Content Certificates
Procedures MIG - metal inert gas MAG - metal active gas
Page 4
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
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
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
Crash & Accident Repair
Modernization
Workshop Services: In our own facilities, customer’s or partnered workshops
Workshop Services is active around the world in
Siemens offers complete services for crash and
accident repair including insurance processing
Crash and Accident Repair
Standard processes for 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
Measuring device Levelling rack Welding Cut-off grinding Documentation Calculation
Page 6
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
No matter which crash or accident happened –
We are able to handle it
Desiro DMU Rumänien Combino Amsterdam Combino Melbourne Combino Amsterdam
Frontschaden Commuter
Frontschaden Light Rail Vehicle Seitenschaden
Light Rail Vehicle
Feuerschaden Light Rail Vehicle
Overview on crash & accident repair services
Crash repair of a front-damaged Desiro after a
heavy crash with a cement truck
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
Crash repair at customers’ site
Page 8
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Crash repair of a front-damaged Desiro after a
heavy crash with a cement truck
Crash repair of a side-damage Combino after
derailment and collision with a catenary pole
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
Crash repair at Siemens facility
Page 10
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Crash repair of a side-damage Combino after
derailment and collision with a catenary pole
Crash repair of front-damaged Combino after
collision of two light rail vehicles
Happened:
24.09.2007 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
Crash repair at Siemens facility
Page 12
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Crash repair of front-damaged Combino after
collision of two light rail vehicles
Accident repair after a fire-damaged Combino
caused by a broken catenary
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
Crash repair at Siemens facility
Page 14
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Accident repair after a fire-damaged Combino
caused by a broken catenary
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
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
Crash & Accident Repair
Modernization
Workshop Services: In our own facilities, customer‘s or partnered workshops
Workshop Services is active around the world in
Page 16
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
A second life or simply modification for rail
vehicles with modernization solutions of Siemens
Modernization
Overview on modernization services
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 Underfloor retrofit
Interior retrofit
Modernization of Rolling Stock is multifaceted
Combino Budapest Metro Munich Locomotive BR 189
Installation of a new air conditioning system
Retrofitting of ATC systems for cross border operation (e.g. ETCS, ATB, SCMT) Syntegra prototype
including installation of traction converter & bogie
Examples for modernization
Desiro UK class 450
Change of interior alignment for upgrading passenger Capacity
Page 18
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Retrofit of an air conditioning system
for Combino Budapest
Example for installation of new components on site
Air condition system
Type of vehicle:
Air conditioning units
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
Amount:
120 at 40 Combino trams
Retrofit of an air conditioning system
for Combino Budapest
Page 20
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Syntegra – Complete retrofitting of a Munich metro
train with a new traction system and bogie
Type of vehicle:
Munich metro train
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
Syntegra prototype modification
Upgrade Syntegra
Amount:
Syntegra – Complete retrofitting of a Munich metro
train with a new traction system and bogie
Page 22
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
Type of vehicle:
Locomotives BR 189 (Mitsui)
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
The new requirements regarding cross border
operation can be fulfilled with an ETCS upgrade
ETCS upgrade
ETCS-Upgrade
Amount:
The new requirements regarding cross border
operation can be fulfilled with an ETCS upgrade
Page 24
Copyright © Siemens AG 2009. All rights reserved.
Sector Industry – Mobility Division I MO RS IS
The ‘High Capacity’ project for
Desiro trains class 450 at Bournemouth depot
Interior modification
High capacity modification
Type of vehicle:
Desiro class 450
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
Amount:
The ‘High Capacity’ project for
Desiro trains class 450 at Bournemouth depot
Interior modification
Copyright © Siemens AG 2009. All rights reserved.
