Delivering a Turnkey High-Speed Rail System with a full ...siteresources.worldbank.org/.../Presentation-alstom.pdf · −Led by ALSTOM and its local subsidiary EUKORAIL −With 13

TRANSPORT

Delivering a Turnkey High-Speed Rail System

with a full Technology Transfer

The Korean TGV

Etienne Fournier

Washington DC, March 2011

World Bank Transport Forum 2011

50 years of Innovation in Transport

Innovation and Technology

The Korean TGV – World Bank - March 2011 - P 2

Agenda

1st topic Key data of the contract Page 9

2nd topic The Korea TGV Consortium scope of work Page 17

3th topic Korea TGV Consortium project facts and figures Page 35

4th topic Conclusions Page 38

1st topic Introduction : High Speed rail Systems Page 3

3th topic Project Management with Technology Transfer Page 21


High Speed rail Systems



From a set of subsystems ...



ControlCentre Signalling

TrackWorks

PowerSupplyTelecoms

CivilWorks

ParkCollection

PlatformDoors

RollingStock


Project Management

ControlCentre

RollingStock Signalling

TrackWorks

PowerSupplyTelecoms

CivilWorks

ParkCollection

PlatformDoors

Project ManagementSystem, Definition & Integration

Operation & Maintenance

… to a coherent and optimized system:


A Conductor . . .


A Conductor of Transport System Projects

Trackwork

Depot / Workshop

Station Utilities

Communication

Traction Power Supply

Signaling

Rolling Stock

Finance

Civil Works

Project & Interface

Management

Systems PerformanceGuarantees

Structure, finance, design, technology transfer, construction,commissioning and maintenance


Key data : The Seoul/Busan corridor

Concerns 70%of the population

Representing 75%of GDP of Korea(GDP = Gross Domestic Product)

Connecting 2 seaportsand the 2 main airports (Inchon/Busan):

− 65% of passenger traffic

− 70% of the freight

One of the largest corridors in the world


Key data : The Seoul/Busan corridor

Necessary for the development of Korea

Journey time saving in comparison to :

− the conventional train (50 %)

− the airplane (20 %)

Traffic forecast:

− 30 million passengers for the first year

− 120 millions passengers/year in 2010

National project requested by Korean Authorities

Seoul/Busan line was a first step


Funding Summary

Total budget of the entire Project (including civil works) :

17 billions US$ (base 93) financed as follows :

− 45% Korean Government = 35% contributions + 10% public funds

− 55% KHRC:(KHRC = Korea High SpeedRail Construction Authority)= 24% international

financing+ 29% public funds+ 2% private capital


The Seoul/Busan TGV:Korea TGV Consortium Contract features

Negotiation schedule :

− 1982-1992: Preliminary studies to RFP(RFP = Request For Proposal)

− 1992: First proposal

− 1993: Selection of preferred bidder

− June 1994: Signing of the E&M Turnkey Contract

The client :

− Construction phase : Korea High Speed Rail Construction Authority

− Revenue service preparation : Korean National Railroad

E&M Contract value: 1 billion euros + 1 billion US $ (base 93)

Localisation ratio : 50% of the total contract value


The Seoul/Busan TGV:Korea TGV Consortium Contract features

The Contractor, KTGVC: “Korea TGV Consortium”

− Led by ALSTOM and its local subsidiary EUKORAIL

− With 13 French and Korean members

− Split in 5 operational groups

Contractual organization:

− One single Contract

− Signature of all consortium members

− All consortium members jointly and severally liable to KHRC

Financing: a pool of over 20 international banks:

− Buyer credit : 1.6 billion USD (17.5 years, 6.25%)

− Tied Commercial Loan:0.72 billion USD (14.5 years, rate based on LIBOR)

− With an active support of French authorities


The Seoul/Busan TGV :The customer organization evolution

KRNA(KHRC)

SNCF-IRolling-Stock& Syst. tests

KTGVC

Ministry Of Construction and Transportation

KNR

Sub-Contractors & Suppliers

OPERATOR

KORAIL(Transfer of theContract for the

RevenueService)

SYSTRACW & Tracks

SYSTRAT&C Audit

SNCF-IOperation

preparation

INGEROPCW

DE ConsultCW Sup.


The Seoul/Busan TGV project management :A multicultural and multidiscipline organisation


Speed:

Design of the line : 350 km/h

Trainset supplied : 300 km/h

Operational headway: : 3 minutes

Journey time Seoul/Busan (by HSL) : 115 minutes

Complete High Speed Line (HSL)

SEOUL-BUSAN : 430 km

Number of stations : 7

Maximum gradient : 30 ‰

Number of tunnels : 75

Cumulated tunnels length : 190 km

Longest tunnel : 18.4 km

Cumulated viaducts length : 122 km

Seoul

Busan

Ch'onan

Daejeon

Daegu

Kyongju

Nam Seoul

Phase APhase B# 2008

The Seoul/Busan TGV:The line

A very complex infrastructure

Kwangju


The Korea TGV Consortium scope of work

RollingStock Catenary

Associated Services

Trains Control System



Civil works & Railway infrastructure

Station & Ticketing

Power supply & Communications

Operations & Maintenance

RollingStock Catenary

Associated Services


GGT VT V



- 2 pre-series trains- 10 Series trains in France- 34 Series trains in Korea- Spare parts (2 years)

- The overhead line- Spare parts (2 years)

- Equipment- Spare parts (2 years)

- Training- Operation and maintenance manuals- Maintenance plan- Maintenance supervision (2 years)

Inte

grat

ion

& C

omm

issi

onin

g

RollingStock

Catenary


Associated Services

- Design- Delivery, integration- Testing

- Basic design- Supervision of detailed design- Delivery- Supervision of installation- Supervision of testing

- Basic design, software- Supervision of detailed design- Delivery- Supervision of installation- Testing


The Korea TGV Consortium scope of work Key challenges

• A complete very high speed system project

• A systems performance contract

• A customer with no HSR historical experience

• In a very distant, different, and demanding country

• A complex bi-geographical organization

• Including major Korean industry players

• A major technology transfer

• A very long term project


Project Management with Technology Transfer & Localisation


K H R C. One single Contract. Signature of all Members. All members jointly and severally liable to KHRC

Core System GroupConsortium leader

Management ServicesLeader : Eukorail

Alstom SA Eukorail

ROLLING STOCK GROUP

Leader : AlstomTransport

Alstom ROTEMTransport SA Hyundai

(Rolling Stock) DaewooHanjin

ATC GROUP

Leader : CSEE Transport

CSEE Transport GoldstarSA Ind. Systems

CTC/IXL GROUP


Alstom GoldstarTransport SA Ind. Systems(Signalling) Samsung

CATENARY GROUP


Alstom GoldstarTransport SA Cables(Catenary) Iljin

Korea TGV Consortium

Contractual Organization

Project Management in a control team


Project Management in a control team

LEVEL 1

LEVEL 3

LEVEL 2

LEVEL 4

ROLLING

STOCK

CATENARY ATC CTC / IXL

GROUPS

PLANT PROJECT MANAGERS

OPERATIONAL UNITS

SUBCONTRACTORS

MANAGEMENT MANAGEMENT MANAGEMENTMANAGEMENT

PROJECT PROJECT PROJECT PROJECT

CORE SYSTEM

LEADER

PROJECT

MANAGEMENT

Contractual Organization

Operating Mode !


Consortium management :− Steering Committee, Management Committee− Weekly meeting in Korea and in France

Project Control / Document Control :− Procedures and their updating− Data system for letters and documentation : 830 000 folios− For example : Approval system for sending submittals and letters to

KHRC through only one KTGVC authorized representative

Contract Control :− Contract managers− Identification of critical matters

Finance :− MPS (Member Payment Schedule) and CPS (Contract Payment

Schedule)− IPP (Invoice and Payment Procedure)− Internal reporting for each member of the KTGVC

KTGVC Core System Management 1/3



Quality :− QAGP : Quality Assurance General Plan− Monitoring audits throughout the KTGVC

Associated Services (O&M : Operation & Maintenance) :− Interfaces with Korean Maintenance and Operation Authorities : Maintenance

Plan and Supervision− O&M Training, O&M Manuals, Spare Parts, Tools = interfaces with Groups

and KHRC

Technology Transfer (TT) / Localization :− Monitoring the Training in France and the Assistance in Korea− Mastering the TT plans and the localization

Core System Engineering :− Management of the Interfaces : 100 interfaces = 5000 documents− RAMS : Reliability-Availibility-Maintainability-Safety of the Core System− Configuration management of the Core System− Testing and Commissioning of the Core System deeply integrated within

KHRC ’s T&C activities− Coordination and Management of site activities


Reporting :− Report to KHRC : PPR (Project Progress Report) every 2 months− Internal report for each KTGVC member

Scheduling :− Contract Schedule and Detailed Schedule consolidation− Time Chainage

Human Resources :− KTGVC human resource management on his own− Administration interfaces

Public Relation :− KTGVC news− Visits monitoring



Project management : − Same purposes at Groups level : contract, finance, quality, reporting,

scheduling, human resources.

Engineering :− Basic Design, Detailed Design− Interface and configuration management

Technology Transfer / Localization− Each Group carry out and monitor the TT/Loc of its product

Installation :− KTGVC supervises the installation carried out by KHRC contractors on the

basis of KTGVC documentation

Testing & Commissioning (T&C) :− Rolling Stock and Train Control System T&C− Supervision of Catenary T&C

Warranty :− Each Company/Group support the warranty for its products

KTGVC Group Management


KTGVC Turnkey Project Management

CORE SYSTEM

BALANCE OF HSR SYSTEM

ROLLINGSTOCK

CATENARY

TRAINCONTROLSYSTEM

SERVICES MAINTENANCE

OPERATIONCIVIL

TRACKS

POWERSUPPLY

INSTALLATION

OVERALLSYSTEM

ENGINEERING

OTHERSSYSTEMS

ASSOCIATED

TCS & CATMISCELLANEOUS

TCS & CATDETAILDESIGN

COMPONENTS

includingENVIRONMENT

GBTR

EXISTING LINE(TRACKS, CAT, ATS)

WORKS

PRO

NOIS

ETEC

TIO

N

TS

ATIONS

TICKETING

GGT VT V


Interface Management 1/2

INPUTDATA

REQUIREMENTS

CORESYSTEM

CONSTRAINTS

BALANCE OFHSR SYSTEM

(BOS)Process !


Interface Management 2/2

IMP: Interface Management Plan

• This is the official procedure for managing the interfaces between contractor KTGVC and client KHRC : balance of HSR system and Core System

ICM: Interface Control Manual

• In conformity with IMP • The applicant is responsible for exhaustiveness of requirements• The supplier of information is responsible for input data submitted• This manual contents all the exchange of documents on each interface (including civil works input data)


Technology Transfer 1/2

Transmission to a Partner of the specific knowledge related to a Product in order to allow him :− To produce it : common set of drawings, specification, …

− To buy it : one common and single purchase technical specification for each item to be sourced either in France and/or in Korea

Relations between Donor and Recipient are defined by a TT contract

TT Plans organize the execution of the work

TT Performances :– Documentation: 350 000 folios

– Training : 1760 man-months in France

– Assistance : 1400 man-months in Korea(including procurement support)


Technology Transfer 2/2

Rolling Stock : sample of industrial distribution

ALL

ROYAUME-UNI

DANEMARK

ANDE

LUXEMBELGIQUE

FRANCE

PAYS-BAS

UEN

Alstom Transport Ltd

PrestonTraction Control

Alstom Sig Ltd

BorhamwoodSignaling

Alstom Transport SA

Saint OuenSignaling

Alstom Transport SA

BelfortPower Cars

Alstom Transport SA

OrnansMotors

Alstom Transport SA

VilleurbanneOBCS

Cegelec / Alstom

ParicCatenary

Alstom Transport SA

Le CreusotBogies

Alstom Transport SA

La RochelleTrailers

Alstom Transport SA

TarbesPropulsion

CS Transport

Les UlisSignaling

RS Cat. Sign.

ALL

ROYAUME-UNI

DANEMARK

ANDE

LUXEMBELGIQUE

FRANCE

PAYS-BAS

UEN

Alstom Transport Ltd

PrestonTraction Control

Alstom Sig Ltd

BorhamwoodSignaling

Alstom Sig Ltd

BorhamwoodSignaling

Alstom Transport SA

Saint OuenSignaling

Alstom Transport SA

BelfortPower Cars

Alstom Transport SA

OrnansMotors

Alstom Transport SA

VilleurbanneOBCS

Cegelec / Alstom

ParicCatenary

Alstom Transport SA

Le CreusotBogies

Alstom Transport SA

La RochelleTrailers

Alstom Transport SA

TarbesPropulsion

CS Transport

Les UlisSignaling

RS Cat. Sign.

SAMSUNGOSAN/ SUWONSignaling PCB

ROTEM (ex. DHI)

UIWANGPower Cars

TrailersTraction MotorsAuxiliary Blocs

Battery ChargerBogie Fitting

GOLDSTAROSAN

Signaling PCB

ILJINSEOUL

Catenary

ROTEM (ex.HDPI)

CHANGWOONPower Cars

TrailersTrain AssemblyBogie FramesBogie Fitting

ROTEM (ex.HHI)

TADAEPOTrailers

Motorized TrailersBogie Fitting

HHICULSAN

Traction DriveAuxiliary Blocs

Electronic Cabinet

GOLDSTAR CableSEOUL

Catenary

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

SéoulSDD

SAMSUNG DISPLAY DEVICE

SUWONOBCS

HYSAHYUNDAI SPACE & AIRCRAFT

SEOSANRunning GearsTransmission

RS Cat. Sign.

KUMI: SEC: Electronic PCB

KUNSAN: KIA: Wheels/Axles

KWANGJU: Daewoo Carrier:HVAC

CHECH’ON: SAB.K: Brakes

Kunsan

Chech’onOsan



ROTEM (ex. DHI)

UIWANGPower Cars



ROTEM (ex. DHI)

UIWANGPower Cars



GOLDSTAROSAN

Signaling PCB

GOLDSTAROSAN

Signaling PCB

ILJINSEOUL

Catenary

ILJINSEOUL

Catenary

ROTEM (ex.HDPI)

CHANGWOONPower Cars


ROTEM (ex.HDPI)

CHANGWOONPower Cars


ROTEM (ex.HHI)

TADAEPOTrailers


ROTEM (ex.HHI)

TADAEPOTrailers


HHICULSAN


Electronic Cabinet

HHICULSAN


Electronic Cabinet

GOLDSTAR CableSEOUL

Catenary

GOLDSTAR CableSEOUL

Catenary

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

Séoul

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

Séoul

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

Séoul

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

Séoul

Ulsan

Kwangju

ChonjuKumi

ChongjuSeosan

Suwon

Taejon

Pusan

Taegu

SéoulSDD

SAMSUNG DISPLAY DEVICE

SUWONOBCS

SDDSAMSUNG DISPLAY DEVICE

SUWONOBCS





RSRS Cat.Cat. Sign.Sign.

KUMI: SEC: Electronic PCB

KUNSAN: KIA: Wheels/Axles

KWANGJU: Daewoo Carrier:HVAC

CHECH’ON: SAB.K: Brakes

Kunsan

Chech’onOsan


Localisation

High level participation of Korean railways industries

50% of the Core System contract is allocated to Korean members of the Consortium

Allocation is defined by the General Master Plan (GMP)

Production start is scheduledaccording to the Industrial Master Plan (IMP)


Technology Transfer & Localisation


Korea TGV Consortium Project facts and figuresKey dates

1994 Signature of the Contract Creation of EUKORAIL

1996 Partial disruption due to civil works issues

1997 Asian financial crisis – Roll out of first train in France

1998 Project re-defined and re-launched

1999 First official run onthe test track

2000 12 French trainset delivered to Korea ; 300kph reached on the Test Track

2001 Commissioning of test trackFirst Korean train delivered

2003 Commissioning of Seoul Daejon

2004 Seoul-Busan revenue service

2007 End of maintenance services


• 1 contract, 1 Consortium Agreement

• 1 single signatory (2500 letters / year)

• 100 contractual interfaces, representing 5000 documents

• 111 contractual milestones

• One master schedule (1500 activities), 6 detailed schedules (6000 activities)

• One single data base : 830 000 folios accessible on each sites involved

• 2500 payment key events; one invoice every 2 months (= 2 800 pages, 16 kg)

• Operation & maintenance manuals: updated every 3 months, 23 000 pages

• In Europe: 5 project teams, 12 manufacturing sites, 10 major sub-contractors

• In Korea: 1 project team split on 13 sites

• About 350 expatriates mobilized during the 10 years of construction phase

Korea TGV Consortium Project facts and figuresKey figures


Korea TGV Consortium Project facts and figuresPreparation and start of commercial operation

A fundamental key principle: the 60km test track, an actual HSR system commissioned 3 years before the start of commercial

operation to validate all systems and interfaces

The result:

− Only 12 cumulated days of actual pre-revenue service,

− A timely start of revenue service at full speed with the actual time table

− With 128 daily trips performed by 33 trains

After one month, a stabilisation reached with

− A punctuality rate of 98%

− A rider-ship of 1.7 million passengers (70 000 per day)

− No adverse effect of the mixed operation on HSL/CVL

− No incident involving safety

After 6 months: 13 million passengers (70 000 per day). Punctuality rate of 98.7%.

After 20 months: 50 million passengers (100 000 per day)


Conclusion :Results and key learning from this success story 1/2

A customer focused approach, based on trust and common vision, and turning all issuesinto opportunities

A strong multi–purposes contribution to the development of the Korean industry throughthe Technology Transfer

A project on time, with client satisfied with famous successful project

Some contractual disputes but no claim with the client or between consortium members

A risky project with high stakes, but nevertheless achieved thanks to the trust and common vision of the essential objectives shared by all actors

A great amount of knowledge developed

An important and unique reference in the World


Conclusion :Results and key learning from this success story 2/2

Celebration of 5 years of commercial service on April the 1st, 2009

− 99 million kilometers, equivalent to around 2 500 trips around the world− 173 450 000 passengers, equivalent to 3 times the population of South Korea− In 2008 :

• 100 000 passengers/day generating 1.63 m€/day in ticket sales

• 63 % of passenger’s traffic between Seoul and Busan


High speed rail systems


A successful very high speed system project with technology transfer

www.alstom.com

Documents

Delivering a Turnkey High-Speed Rail System with a full ...siteresources.worldbank.org/.../Presentation-alstom.pdf · −Led by ALSTOM and its local subsidiary EUKORAIL −With 13