presentation to aashto rr101 webinar...

Presentation to AASHTO RR101 Webinar ‐

Equipment

M. BergeronM. BergeronChief Mechanical OfficerChief Mechanical Officer

April 9, 2013April 9, 2013

2

Agenda

•Amtrak Mechanical Department

•Maintenance Plan & Production Capabilities

•Fleet Renewal Plan & New Equipment

•New Facilities

Amtrak Train 5 Bull Gulch, CO May 2011Photograph Courtesy of Gary Pancavage

3

Agenda




•New Facilities

4

Mission & Performance Fundamentals

•Mechanical Mission:

–

Create a cost‐efficient

vehicle maintenance program that will

consistently

produce safe, clean, and reliable

equipment for our

customerscustomers

nationwide by continually improving

the process

through

teamwork

and safe work practices.

• Performance Fundamentals:

Safety

Fleet Performance‐

Reliability‐

Availability

Productivity

Regulatory Compliance

5

Major Terminals and Back Shop Locations

WilmingtonWilmingtonRensselaer

BearBearWashington

Beech GroveBeech Grove

Oakland

Los Angeles

Seattle

New Orleans

Chicago

Hialeah

Sanford

New YorkBoston

Workforce: 4,500 employees

Presenter

Presentation Notes

12 Major Terminals, 3 Back Shops LocationAgreement*Non-Agreement*Total New York/ New England76137798 Mid-Atlantic63939678 South37717394 Central53834572 West42133454 High Speed Rail26748315 Beech Grove50317520 Bear32214336 Wilmington31613329 Rolling Stock Eng 14141155 Staff—3939 Totals4,1584324,590 1,100 employees work in the back shops performing heavy overhaul and component rebuild work. ▪3,000 employees work in terminals across the country, performing turnaround servicing,preventive maintenance&repairs. ▪300 employees work on High Speed Rail equipment. Labor Org. Carman, Sheet Metal, Pipe Fitter, Electrician, Machinist, Boilermaker, Coach Cleaner, Laborer Terminals: COT&S, Components, Preventive Maintenance, Running Repair, Service & Inspection Main Shops: Electrical, Mechanical, Cab signals, Overhaul, Remanufacture, Wrecks

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Back Shops

BearBear300 employees300 employees

WilmingtonWilmington300 employees300 employees

Beech GroveBeech Grove500 employees500 employees

Presenter

Presentation Notes

Bear – 167 Acre Site, 12 Miles of Track, 234,000 Square Feet Under Roof, Constructed in 1979 – ’80 This facility was built by DelPro Company, a subsidiary of Trailer Train, Incorporated. Amtrak acquired this property in 1985 for $7 million and dedicated it in July of that year to serve as an Overhaul Facility. Beech Grove - 108 Acre Site, 54 Tracks, 435,600 Square Feet Under Roof, Constructed in 1903 – ’ 06 The Beech Grove maintenance facility was originally built by the Chicago, Cincinnati, Columbus & St. Louis Railroad and subsequently transferred to the New York Central and Penn Central Railroads. In 1976, Amtrak acquired the maintenance facility for $2.5 million and in 1986, acquired additional property from Conrail for $4.75 million. Wilmington - 85 Acre Site, 8 Miles of Track, 418,390 Square Feet Under Roof, Constructed in 1903, originally developed to be one of the major car and locomotive shops of the Pennsylvania Railroad. Amtrak acquired the property in 1976 as part of the Northeast Corridor Improvement Program.

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Active Passenger Fleet

•

1,540 Cars

•

396 Locomotives

•

25 Trainsets

•

Average Age = 29+ years

•

Average Miles/year

–

Cars = 180,000

–

Locomotives = 155,000

–

Trainsets = 175,000

•

In a typical day, Mechanical

–

305 trains serviced per weekday

–

More than 4,000 toilets serviced per day

–

Over 725,000 unit‐miles run per day

–

Twenty Periodic Maintenance (PM) procedures completed per day

Annual unit‐miles by operator

Source: American Public Transit Association, 2011 Reports

AMTRAK

Presenter

Presentation Notes

29 + AGE: OBSOLESCENSE

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American Recovery and Reinvestment Act Equipment

(ARRA)

•

15 P40s upgraded to P42s

standards

•

60 Amfleet

•

20 Superliners

•

Viewliner

Prototype Diner

8400

Annual Amtrak Ridership, by FY

Presenter

Presentation Notes

96 pieces of equipment: 15 P40s upgraded to P42s standards 60 Amfleet 20 Amfleet I cafés: convert to coaches 7 Amfleet I wrecked coaches: repair and return to service 13 Amfleet I coaches: Level-3 overhauls 15 Amfleet I cafés: Level-3 overhauls 4 Amfleet II coaches: Level-3 overhauls 1 Amfleet II lounge: Level-3 overhaul, Diner-Lite conversion 20 Superliners 14 Superliner I 1 Coach/Baggage 5 Sleepers 3 Lounges 2 Coaches 3 Diners 6 Superliner II 1-each Sleeper, Deluxe Sleeper, Lounge Diner 2 Transition Dorm Viewliner Prototype Diner 8400

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Mechanical Workflow

On‐board crew use the eMAP‐21A app on their

iPhone to log maintenance issues in route

Issues logged in to WMS system, and

work orders opened, associated with

train and car numbers.

1

2

3

4

Shop forces at train terminal prepare

for train arrivals by reviewing

incoming open work orders and

allocating work among personnel.

Repairs and inspections performed during

layover to ensure equipment ready for next

scheduled use. On‐board crews have access to

closed work orders so they can see how their

reports positively impact service.

• Quality• Production• Overdue PM• Financials• People

(#,Abs.,OT)• R&R• Training• IT• Mechanical

Services• Lean / 6 Sigma, …

5

Presenter

Presentation Notes

Work Management System (WMS) - SPEAR 4i is a computerized maintenance management software product that is used by the Amtrak Mechanical Team to control and manage assets. WMS helps manage the equipment maintenance workload, controlling fleets, fixed equipment and facilities through the entire maintenance life cycle. The WMS Incident Management Module facilitates capture of enroute issues, the statistics or data, which is subsequently reported in Fleet Performance Reliability and Availability Metrics. WMS is the official system of record for Mechanical Maintenance Tracking. WiTronix and MEAPS are on-board train communication infrastructures for the locomotive and train set fleets enabling direct two-way data communications between enroute trains, Amtrak’s corporate network, CNOC, and other Amtrak facilities and systems to facilitate operational and customer service improvements. MECHANICAL BALANCED SCORE CARD

10

Agenda




•New Facilities

11

Types of Maintenance

•

Periodic Inspections/ Preventive

Maintenance

–

Daily, 15 day, 92 day, 120 day, Annual

•

Continuous Maintenance (CMCM)

•

Overhaul

–

Level 1, 2, & 3

•

Life‐Cycle Preventive Maintenance

(LCPMLCPM)

•

Corrective/Bad Order Repair

•

Accident/ Wreck Repair

Amtrak’s maintenance methodology

Presenter

Presentation Notes

DailyFRA Compliance: Safety equipment, Brakes, wheels, Air Test 15 DayOil Sampling, Blow Radiators, Undercarriage/Truck Inspection, Battery check, Truck Inspection 92 DayWheels/Undercarriage/Running Gear Inspection, Software verification/Downloads, Inbound/Outbound Performance Measurements, Mechanical/Electrical Spotwork Inspection, CAB Signal Testing, Partial Hand wash, Seasonal Checklist 184 DayOil Change, Air Dryer renewal, Complete Handwash AnnualAnnual Air Qualification, Annual Engine Inspection, Emissions Qualification, Pressure wash Radiators, Various other LCPM events PREVENTATIVE MAINTENANCE (PM) Scheduled Every 92 or 120 Days Includes Unscheduled Corrective Repair Work OVERHAUL – LEVEL 1 Alternating Cycle 4 Years after Level 2 or 3 Includes Safety Mandatory & Federal Requirement for Air Brake Critical Capital Component Renewal (HVAC, Toilets, OVERHAUL – LEVEL 2 Scheduled Every 8 Years Most Capital Components Renewed RECONFIGURATION – LEVEL 3 Schedule Driven by Market Demands Includes Major Modification of Equipment (i.e. ADA Bathroom Modules, Marketing Service Initiatives)

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Overhaul Scopes of Work•

ALL Overhauls

Include Safety Mandatory & Federal Requirement for Air Brake

•

LEVEL 1 Overhaul

Alternating Cycle 4 Years after Level 2 or 3

Critical Capital Component

Overhaul Renewal or Replacement of Trucks, Brake Valves, HVAC – Air

Conditioning Compressor / Condenser Units, Air Conditioning Control Panels, Heat

Control Panel, Door Control Panels, Batteries, Battery Charger, 480 Volt End

Connection Cables, Public Address Unit, Seat Cushions, Floor Carpet, and Toilets.

During a Level 1 all other components / systems will be inspected, repaired or

replaced as necessary.

13


LEVEL 2 Overhaul

Scheduled Every 8 Years

Most Capital Components Renewed

Level 1 Critical Capital Component Overhaul Renewal or Replacement of Trucks,

Brake Valves, HVAC – Air Conditioning Compressor / Condenser Units, Air

Conditioning Control Panels, Heat Control Panel, Door Control Panels, Batteries,

Battery Charger, 480 Volt End Connection Cables, Public Address Unit, Seat Cushions,

Floor Carpet, and Toilets.

PLUS

Overhaul Renewal or Replacement of Diaphragms, Couplers, Windows,

Weather‐Stripping, Trap Doors, Seats, All Carpet and Linoleum, Main 480 Volt Train

Line Cables, Door Operators, Door Key Stations, Heat tape, Interior and Exterior

Lighting.

During a Level 2 all other components / systems will be inspected, repaired or

replaced as necessary.

14


LEVEL 3 Overhaul & Reconfiguration

Schedule Driven by Market Demands

Includes Major Modification of Equipment (i.e. ADA Bathroom Modules, Interiors

are Fully Upgraded, Marketing Service Initiatives)

All Capital Components Renewed All Capital Components Receive Overhaul Renewal or Replacement

During a Level 3 all other items / systems will be inspected, repaired or replaced as

necessary.

15

FY13 Production Plan

•

PMs

–

6,760 Inspections Planned

•

FY13 Capital Production:

–

Bear – 156 Amfleet & Cab Car Overhauls

–

Beech Grove – 154 Car & Locomotive

Overhauls

–

Wilmington – 16 Locomotive Overhauls

–

Acela – 2 Trainsets in Major Work Program

–

LCPM: 448 Events PlannedProcedure LCPM Cycle

Paint 10 years

Engines 6 ‐

7 years

Trucks 5 ‐10 years

HVAC 5 years

Air Compressor 8 years

16

Gutted Interior (Before)

New window cut into side wall.

Bear: Amfleet I Food Service to Coach Conversion

New ADA

Bathroom

Completed Interior

Amfleet I

Food Service to

Coach Conversion

Car # 28350

ARRA Stimulus work

Presenter

Presentation Notes

Luggage Racks American Recovery and Reinvestment Act of 2009

17

LEFT:

Superliner I Coach Car 34040 New

ADA Lower Level Module

BOTTOM: Economy bedroom

New Style Bunk

Beech Grove: Superliner Coach Car

ARRA Stimulus work

Presenter

Presentation Notes

Superliner I American Recovery and Reinvestment Act of 2009

18

Beech Grove: Superliner Level 3 Sleeper

Before & After

Aesthetics &

Easy to Maintain

Hard Surfaces

19

Beech Grove: Viewliner Single Level Diner Prototype

Car 8400

Presenter

Presentation Notes

Lake Shore Ltd, trains 48/ 49

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Beech Grove: Accident / Wreck Repairs

P42‐8Locomotive 121

DamagedJuly 11, 2011

North Berwick, ME

Presenter

Presentation Notes

Amtrak a good steward of tax money. Amtrak owns large enough fleet to absorb losses. Tremendous internal capabilities to perform such heavy repairs. Wreck killed truck driver Peter Barnum, 35, who was using a phone at the time of impact. Six onboard injured ( 4 pax, 2 crew), none seriously.

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Mechanical Services

•

“One Stop Shop”

for Mechanical

Maintenance needs–

Regulatory inspections, –

Preventative Maintenance, –

Life Cycle Maintenance, –

Reliability Centered Maintenance, –

Rolling Stock Overhauls, –

Component Overhauls Wreck Repair–

Rolling Stock Engineering

•

Over 40 years of experience in maintaining a

wide variety of equipment•

Extensive experience working with

regulatory agencies, Host railroads, States

and Commuters

Contact: Daniel Ruppert ([email protected])

Senior Director Mechanical Contracts

1 (888) 920‐6378

Presenter

Presentation Notes

Bear – Illinois DOT-13 Amfleet Overhauls for HSR Service Beech Grove: North Carolina DOT 3 NC F59 Locomotive Overhauls CalTrans: 14 Comet 1B Overhauls, 3 NPCU Cab-Baggage Units, 3 Horizon Food Cars New Jersey Transit, 4 P40-8 Locomotives Overhauls

22

Agenda




•New Facilities

23

Fleet Investment and Acquisition plan

Florida-bound Silver Star at Seabrook, Maryland

Heritage diner(1948-1958)

Heritage baggage car(1950-1961)

E911 / AEM-7 DC electric locomotive (1980)

Viewliner sleeping cars(1995-1996)

Amfleet II coachesand lounge car(1981-1983)

Florida-bound Silver Star at Seabrook, Maryland

Heritage diner(1948-1958)

Heritage baggage car(1950-1961)

E911 / AEM-7 DC electric locomotive (1980)

Viewliner sleeping cars(1995-1996)

Amfleet II coachesand lounge car(1981-1983)

A snapshot of the present

•

Fleet replacement based on Commercial Life & and

Program Infrastructure

•

Average Fleet age = 29+ years

•

2013 v. of Fleet Strategy

Plan to be released

33rdrd

Annual RevisionAnnual Revision

FY2012FY2012‐‐23: $10.1b23: $10.1b

24

Fleet Strategy: Long Distance Single Level Cars

• Purchase 130 Long‐Distance Single‐Level (LDSL) cars

130TOTAL

55BAGGAGE

25DINER

25SLEEPER

25BAG/ DORM

BASE ORDERCAR TYPE

130TOTAL

55BAGGAGE

25DINER

25SLEEPER

25BAG/ DORM

BASE ORDERCAR TYPE

•

August 2010 ‐

Contract Award

•

First units placed is Revenue service

2014

•

Last Car Delivered

2015

25

Fleet Strategy: Electric Locomotives

• Purchase 70 electric locomotives

•

October 2010 Contract Award

•

First Locomotive Placed in Revenue Service by Fall

2013

•

Locomotive No. 70 Delivered by Spring 2016

Presenter

Presentation Notes

May 13, 2013 has been designated as the roll-out day for the new ACS-64 electric locomotive at the Siemens facility in Sacramento, CA.

26

Fleet Strategy: Next‐Generation High Speed Rail

•

Request For Information issued January 2013,

joint with California HSR Agency

–

Seeking off‐the‐shelf trainsets that will work for

both of us

•

Amtrak plans 10 to 12 in 2016/7

–

CHSRA plans 27 in 2018/9

•

Amtrak plans to replace Acela Fleet 2022/4

•

Request For Proposal planned for

September 2013 release

27

Agenda




•New Facilities

28

Los Angeles & Hialeah ‐ Progressive Maintenance Facilities

LAX Elevation

LookingSouthwest

Looking at Spot 2 ‐

Truck Change with In‐Floor Traversing Jacks

Overall Facility Floor Plan

Inbound

Inbound Pad•Pre-inspection

•Vendor cleaning

•Pest control

•Toilet dump

Spot 1•Inspection

•Strip Seats

•Draft gear and couplers

•Diaphragms

•MPT1000 test

•Interior strip

•HVAC

Spot 2•Trucks

•Brakes

•480v cable inspection/repair

•Doors/door operators

•COT&S

•Under-car inspection

Spot 3 (Buffer)•Rapid Response Team would perform any catch-up work here (Bad-order repairs)

Spot 4•Food Service

•Power door repair

•Lighting inspection

•Trap Doors

•Change Toilets

Spot 5•PM E-Clean

•Apply equipment

•Single Car Test

Outbound Pad•Bad Order repairs

•Catch-up work

•Queuing

HIA Aerial Photo

Looking Southeast

Presenter

Presentation Notes

LAX 2011 HIA 2012

29

Seattle, WA – Phase I & II

•Looking

South

Looking

North

Presenter

Presentation Notes

2012? Admin Offices/ Material Cascade Facility

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• Thank you for your time and interest

• Questions?

Presenter

Presentation Notes

Chicago WILLIS Tower; At 1,353 feet in the air, 103rd floor Challenges in FY13 Budget Uncertainty Continuing Resolution New Equipment is Coming More Needs to be Ordered

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