N EN RAIL FACILITIES IMPROVEMEN New Haven, · PDF file · 2014-03-19The Component Change Out Shop (CCO) project is under construction and is ... System, Paint and Heavy Repair,

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New Haven Rail Yard PROGRESS REPORT Facilities Improvements Program 4th Quarter 2013 Table of Contents

TABLE OF CONTENTS

I. PROGRAM SUMMARY

● Program Description ● Program Status

II. PROGRAM MILESTONE DATES

III. PROGRAM FINANCIAL SUMMARY

● Program Cost Estimate ● Financial Summary by Project

IV. CURRENT PROGRAM STATUS

● Design Schedule by Project ● Construction Schedule by Project

V. PROGRAM PHOTOGRAPHS

VI. REVISED PROGRAM YARD ARRANGEMENT

New Haven Rail Yard PROGRESS REPORT Facilities Improvements Program 4th Quarter 2013

Page 1

I. PROGRAM SUMMARY

Note – This report introduces a revised New Haven Rail Yard Facilities Improvement Program based on the updated Yard Master Plan issued by the Department on July 12, 2013, with concurrence received from Metro-North on August 30, 2013. Since the 3rd quarter of 2013 represented a transition period for the program to incorporate the updated Yard Master Plan, a 3rd Quarter Progress Report was not issued. Program Description: The purpose of the New Haven Rail Yard Facilities Improvements Program (the Program) is to transform the existing New Haven Rail Yard (NHRY) into a fully functional facility that provides for efficient and effective storage, dispatching, inspection, maintenance and cleaning of an increasing fleet of rail cars. The improvements will provide the space, equipment, and administrative support structures needed to operate and maintain a new generation of rail cars and will coordinate the new facilities with the existing facilities. Service lines using the rail yard include the New Haven Line and Waterbury Lines both run by Metro-North Railroad, the Shore Line East, currently run by Amtrak, as well as the provision for a future New Haven to Hartford service. CTDOT’s proposed program of improvements to the NHRY will support improved rail transit service in Connecticut well into the twenty-first century. The facilities are being built on approximately 74 acres of state-owned land that comprises the existing NHRY. The Project is located within an area roughly bounded by Union Avenue to the west, Cedar and Hallock Streets to the south, Church Street Extension and Brewery Street to the east, and Route 34 to the north. The overall Program was initiated to raise the quality of rail service through procurement of a new generation of M-8 electric multiple-unit (EMU) rail cars that will replace the existing M-2 fleet of cars, originally procured in the early 1970s. The M-2 cars were designed to operate for 30 years and have exceeded their life expectancy. Funding has also been authorized to procure additional M-8 cars to replace the aging M-4 and M-6 cars as well, which will allow the Department to operate more efficiently by employing a single model fleet of new vehicles. The Program is being designed to transform the existing NHRY into a coordinated campus able to effectively serve this expanding fleet of multiple unit electric rail cars as well as the locomotive hauled fleet of coaches. The major objectives of the Program include:

● Provide inspection and repair facilities for the increasing rail fleet that will allow for efficient and safe replacement and repair of components and sub systems, storage and retrieval of parts, and inspection and testing of components and vehicles.

● Increase the wheel truing capacity.

● Provide the offices, shops and facilities required for support of the rail car fleet and service lines by MNR and CTDOT.

● Increasing the number of electrified and non-electrified storage tracks needed for the increasing rail fleet.


Page 2

● Modify the yard to main line connections which will facilitate efficient train movement by all service lines.

● Install the utility systems, roads and site work required to support the overall campus.

● Provide the infrastructure and systems to ensure a safe and secure facility.

● Provide a wash facility for the rail cars. Program Status: Significant program progress has been achieved to date towards achieving the program objectives, as summarized below. Of particular note is the recently approved Updated Yard Master Plan and its impacts to the overall program cost and schedule, as discussed in the Program Cost and Schedule section. Maintenance Functions: Achievements to date towards improving the train maintenance and repair capabilities at the yard include:

● Renovations to the existing Electric Multiple Unit (EMU) and the Critical System Replacement (CSR) Shops are complete. These renovations were needed to meet the current State building code, improve the working environment in the shops and offices, enhance safety, and extend the life of the buildings.

● The Component Change Out Shop (CCO) project is under construction and is scheduled for completion in Autumn 2014 (see Program Schedule discussion below). This major (293,000 Sq Ft) new facility will provide the main shop and office complex for the New Haven Rail Yard, and will provide the major maintenance functions for Connecticut’s commuter rail fleet, as well as housing administrative and security functions. Design is proceeding for the Central Distribution Warehouse, which will be built adjacent to and concurrently with the CCO and will employ a state-of-the-art Automated Storage and Retrieval System (ASRS) to improve the efficiency of the warehousing and stores operation in the yard.

● The Independent Wheel Truing Facility (IWT) construction contract is under construction, and is scheduled for completion in Summer 2014 (see Program Schedule discussion below). The IWT will be used to reprofile the steel wheels on the new and existing New Haven Line and Shoreline East rolling stock, and will provide a needed increase in maintenance capacity to support the expanding rail fleet.

Train Storage Capacity: Achievements to date towards expansion of the train storage capacity at the yard include:

● The M-8 Acceptance Facility was completed in July 2009. Four tracks were installed at the east end of the yard and are being used for acceptance of the new incoming fleet of M-8 rail cars for the New Haven Rail Line by the M-8 car builder, Kawasaki, Inc. Once M-8 acceptance is completed, the tracks will be used for train storage and shop staging.

● The Diesel Storage Yard was completed in December 2010. Three new tracks were installed adjacent to the existing Shoreline East storage tracks, and provide for storage of Shoreline East and Waterbury Branch Diesel/ Coach trainsets.

Yard Infrastructure Improvements: Achievements to date towards improving the yard infrastructure include:


Page 3

● The Traction Power Substation 1086 project is under construction and is scheduled for completion in Winter 2013/14. The electrical substation will provide a new power source for the New Haven Line traction power (overhead catenary) system to provide increased voltage levels required by the expanding fleet, efficient train acceleration, and more reliable operation of the new M8 cars.

Program Cost and Schedule: The Department has recently issued the Yard Master Plan update for closer alignment with the latest fleet makeup, management philosophy, and associated Yard operational requirements. The update to the Yard Master Plan was precipitated by several developments in current and future operations, including:

The New Haven Line electric fleet will consist solely of the new M8 vehicles. All of the old electric cars (M2’s/4’s/6’s) will be retired;

The New Haven–Hartford–Springfield rail service is being developed, and the New Haven Rail Yard will be the primary base of this operation. This includes staff and crew accommodations, and fleet maintenance and storage;

A Transit Oriented Development (TOD) is planned for New Haven’s Union Station, requiring Metro-North and CTDOT staff currently housed there to vacate;

Ridership has increased beyond forecasts, especially for intrastate trips; Service schedules have been increased, and there are future proposals to extend

service to Penn Station which would require additional fleet vehicles. The updated Master Plan calls for significant changes to the scopes and sequencing of the projects comprising the Program; some projects have been retained unchanged, some projects have been retained in a modified form, some projects have been eliminated and some new projects have been added:

Projects currently in active design or under construction will be completed as originally planned, including the Component Change Out Shop, the Independent Wheel True Facility, Traction Power Substation 1086, the Central Distribution Warehouse and the Yard Power Upgrade Project.

Projects to be retained with modified scopes and/or modified sequencing include the Maintenance of Way Facility, Employee Parking, Stores Building Demolition, West End Yard, East End Yard, Main Line Signal System, Final Track Completion, Yard Signal System, Paint and Heavy Repair, Pedestrian Bridge, Car Wash and Program Shop. In some cases, scopes and sequencing will be modified and elements of these projects will be recombined into redefined projects.

Projects to be eliminated include Grade Crossing (replaced with Pedestrian Bridge), Existing Wheel Mill Upgrade and Running Repair Shop Upgrades (to a “mini-S&I”).

New projects to be added to the Program include a new Service & Inspection Facility, Expansion of the Diesel Shop and Expansion of the T&E Building.

A Yard Arrangement Plan illustrating the revised program is included at the end of this report. Program Cost: The previous rail yard program cost was presented utilizing a structure of Tiers (1, 2 and 3). The Tier structure has been eliminated in the updated Master in favor of a single unified listing of projects. The Total Program Cost Estimate for projects under the new Program is $1,157.8 million in year of expenditure dollars. This compares to the previous program cost of approximately $875 million ($706.8 million for Tier 1, $158.5 million for Tiers 2 & 3 and $10 million for Yard Signal System). The difference of $283 million mainly consists of new projects added due to the changes in operations since the original master plan, such as the new S&I Shop, expansion of the T&E Building and expansion of the Diesel Shop.


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Program Schedule: In conjunction with a revised Program Cost Budget, a revised Program Schedule has been developed as part of the Yard Master Plan update as discussed above. The Yard Master Plan update carefully considers project sequencing strategies for optimizing the overall program schedule to support fleet management requirements. The schedule for the Component Change Out Shop has been extended by 9½ months since last reported to accommodate resolution of accumulated issues related to underground utilities in the main shop area, final steel framing details, building siding installation, glass curtain wall installation, drywall/interior finish details, and interior wall reconfiguration to allow HVAC system continuity. This schedule extension will have some effect on other rail projects, but the Department is working with all parties to accelerate current and future activities to mitigate any program or operational impacts. The construction schedule for the Independent Wheel True Facility project has been extended by 7 months since previously reported to accommodate resolution of accumulated issues related to steel fabrication, the building ventilation system, and coordination with the installation of the under floor wheel lathe. This schedule extension will not have an adverse effect on other rail projects. The construction schedule for Traction Power Substation 1086 has been extended by 5½ months to accommodate additional Metro-North acceptance testing and integration adjustments to the existing system. This extension will not have an adverse effect on other rail yard projects. The Yard Power Upgrade Project has been extended 4 months to allow additional time for design and construction coordination and preparation of agreements with the utility (United Illuminating). The overall project schedule for the Central Distribution Warehouse has been extended to allow additional time for developing contractor quotes. This schedule extension of approximately 2 weeks will not have an impact on schedules for other rail yard projects. New schedules have been developed for all other projects in the revised Program and are presented in the Program Milestone Dates table in the following Section of this report.


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II. PROGRAM MILESTONE DATES

Start Finish(FDP)

Start(Adv)

BidOpening

Finish(Award)

Start(NTP)

Finish(CCD)

ORIGINALLY PROGRAMMED PROJECTS

CONSTRUCTION COMPLETE

06/01/06 06/06/07 08/15/07 09/18/07 02/25/08 04/10/08 07/13/09 07/30/09

02/02/07 04/09/08 06/18/08 09/10/08 12/09/08 01/23/09 08/20/10 09/23/10

[07/16/10]

06/30/08 09/23/09 12/02/09 01/06/10 03/25/10 05/09/10 12/17/10 12/30/10

[12/25/10]

IN CONSTRUCTION

06/01/06 03/18/09 05/27/09 10/14/09 12/11/09 01/25/10 11/26/14 05/26/15

[10/11/12] * 05/31/13 *

01/15/04 08/04/10 10/13/10 12/01/10 01/20/11 01/20/11 01/24/14 01/30/14

* 07/30/12 *

06/01/06 04/21/10 02/09/11 04/06/11 06/03/11 07/18/11 06/16/14 07/16/14

[06/30/10] [07/28/10] [09/24/10] [11/08/10] [08/03/12] * 06/10/13 *

IN BIDDING

11/01/10 09/15/13 10/02/13 01/08/14 03/14/14 03/17/14 01/13/15 04/15/15

[06/21/10] [03/16/11] [05/25/11] [06/22/11] [08/19/11] [10/03/11] [04/01/13] * 03/19/13 *

IN DESIGN

06/23/10 05/21/14 07/30/14 08/27/14 10/24/14 12/08/14 09/14/15 10/14/15

* 12/27/12 *

NEW AND REVISED PROJECTS [1]

IN DESIGN

07/30/13 05/12/14 07/21/14 07/31/15 08/31/15

12/06/13 10/15/14 12/24/14 01/21/15 03/20/15 05/04/15 10/31/16 11/30/16

10/16/13 02/18/15 04/29/15 05/27/15 07/24/15 09/07/15 04/11/18 06/11/18

IN PLANNING

07/27/15 07/27/16 10/05/16 11/02/16 12/30/16 02/13/17 02/13/19 05/13/19

11/16/15 03/29/17 06/07/17 07/05/17 09/01/17 10/16/17 10/14/20 01/14/21

05/03/16 10/25/17 01/03/18 01/31/18 03/30/18 05/14/18 07/10/20 09/10/20

10/23/17 10/24/18 01/02/19 01/30/19 03/29/19 05/13/19 07/09/21 09/09/21

01/21/19 01/22/20 04/01/20 04/29/20 06/26/20 08/10/20 02/09/22 04/09/22

04/29/19 04/29/20 07/08/20 08/05/20 10/02/20 11/16/20 06/14/22 09/14/22

12/28/20 12/29/21 03/09/22 04/06/22 06/03/22 07/18/22 01/09/24 04/09/24

[mm/dd/yy] = Design, Bid or Construction Date originally reported in 2010Q1 Progress Report if different from current planned or actual date.

* mm/dd/yy * = Operational Date originally reported in 2011Q1 Progress Report if different from current planned or actual date.

Note 1 - New and revised projects are being formally introduced in this Quarterly Progress Report. Future Milestone Schedule updates will track changes from these new original dates for these projects.

Revised from Previous Report

0301-0131 Car Wash

0301-0125Running Repar Shop Upgrades (Program & Paint Shop)

0301- 0127,- 0128, - 0132

East End Yard & Main Line Interlockings

0301-0130Diesel Shop/CSR Heavy Repair Shop

0301-0129 Yard Signal System

0301-0121 Central Distribution Warehouse

0301-0144 Yard Pow er Upgrade

0301-0106 Component Change Out Shop

0301-0038 Traction Pow er Substation 1086

0300-0139Independent Wheel True Facility & Phase I Employee Parking

0300-0131 M-8 Acceptance Facility

0300-0137 EMU & CSR Shop Improvements

0301-0110 Diesel Storage Yard

OperationalDate

StateProjectNumber

Project Title

Design Phase Bid & Award Phase Construction Phase

0301-0124Maintenance of Way & Employee Parking

0301-0123 Pedestrian Bridge

0301-TBD Service & Inspection Shop

0301-TBD T&E Building Expansion

0300-01380301-0111

West End Yard &Stores Building Demo

CM at RIsk Project


Page 6

III. PROGRAM FINANCIAL SUMMARY

Program Tier 1 Cost Estimate (through December 31, 2014)

The current Total Program Cost Estimate is $1.158 billion in year of expenditure dollars.

Element

Program Cost Estimate Expenditures

this Period ($ million)

Expenditures to Date

($ million)

Cost to Complete ($ million)

Previous Report

($ million)

Current Report

($ million)

Change from

Previous ($ million)

Construction $ 599.3 $ 983.1 $ 383.8 $ 20.2 $ 238.7 $ 744.4

Preliminary Engineering & Program Management

$ 107.5 $ 174.7 $ 67.2 $ 3.3 $ 57.9 $ 116.8

TOTAL * $ 706.8 $ 1,157.8 $ 451.0 $ 23.5 $ 296.6 $ 861.2

* Total for Tier 1 Projects only; total was $875 million including Tiers 2 and 3 and Yard Signal System. Explanation of Program Elements: Construction:

Construction consists of the actual costs for the construction work, as well as the services of CTDOT for construction administration and inspection. Additionally, this includes the Force Account work related to construction, railroad protection, move-in costs and administration for Metro-North and various Utilities.

Preliminary Engineering:

Preliminary Engineering (PE) consists of all activities related to Design (CTDOT and Consultants), Rights of Way, Surveys, Environmental Investigation and Analysis, Metro-North Force Account (design phase), and 3rd Party Reviews.

Program Management:

Program Management (PM) consists of the services of the Program Management Consultant (PMC). The PMC for this Program is Shaw Environmental & Infrastructure. The PMC is responsible for tracking Project Control areas for the Program as a whole, as well as for each individual construction contract. Specific functions include cost control, funds management, schedule maintenance, analysis, and updates, document control, progress reports, analysis for design and construction changes, constructability design reviews, and construction management assistance.


Page 7

Financial Summary by Project (Through December 31, 2013)

CURRENT & COMPLETED PROJECTS

RIGHTS OF WAY

0301-0118Acquire Property - USPS Parcel 1, CSX Parcel, 152 Water Street, 1 Brew ery Street

5,100,000$ 2,442,829$ 48% 2,657,171$

CONSTRUCTION COMPLETE

Other Program Accruals 25,400,000$ 25,400,000$ 100% -$

0300-0131 M-8 Acceptance Facility 13,500,000$ 12,982,059$ Pend. Closeout 517,941$

0300-0137 EMU & CSR Shop Improvements 7,300,000$ 6,854,226$ Pend. Closeout 445,774$

0301-0110 Diesel Storage Yard 4,900,000$ 4,381,555$ Pend. Closeout 518,445$

IN CONSTRUCTION

0301-01060301-01210301-0165

Component Change Out Shop &Central Distribution WarehouseCCO Furnishings

223,700,000$ 157,998,545$ 71% 65,701,455$

0301-0038 Traction Pow er Substation 1086 14,000,000$ 5,854,904$ 42% 8,145,096$


36,000,000$ 22,797,603$ 63% 13,202,397$

Subtotal - Construction 329,900,000$ 238,711,721$ 72% 91,188,279$

Preliminary Engineering & Program Management 67,000,000$ 57,878,938$ 86% 9,121,062$

Program Contingency - Current Projects 18,000,000$ -$ 0% 18,000,000$

TOTAL - Current & Completed Projects 414,900,000$ 296,590,659$ 71% 118,309,341$

PLANNED PROJECTS

IN DESIGN

0301-0124 Maintenance of Way Facility & Employee Parking 31,300,000$ -$ 0% 31,300,000$

0301-0123 Pedestrian Bridge 13,800,000$ -$ 0% 13,800,000$

0301 - 0144 Yard Pow er Upgrade 10,000,000$ -$ 0% 10,000,000$

0301-01380301-0111

West End Yard &Stores Building Demo

77,700,000$ -$ 0% 77,700,000$

IN PLANNING

0301-TBD T&E Building Expansion 12,500,000$ -$ 0% 12,500,000$

0301-TBD Service & Inspection Shop 159,000,000$ -$ 0% 159,000,000$

0301-0127,-0128, -0132

East End Yard & Main Line Interlockings 156,800,000$ -$ 0% 156,800,000$

0301-0129 Yard Signal System 18,300,000$ -$ 0% 18,300,000$

0301-0131 Car Wash 48,800,000$ -$ 0% 48,800,000$

0301-0130 Diesel Shop/CSR Heavy Repair Shop 75,800,000$ -$ 0% 75,800,000$

0301-0125 Running Repair Shop Upgrades (Program & Paint Shop) 7,100,000$ -$ 0% 7,100,000$

Subtotal - Construction 611,100,000$ -$ 0% 611,100,000$

Preliminary Engineering & Program Management 107,700,000$ -$ 0% 107,700,000$

Program Contingency - Planned Projects 24,100,000$ -$ 0% 24,100,000$

TOTAL - PLANNED PROJECTS 742,900,000$ -$ 0% 742,900,000$

TOTAL PROGRAM

Construction 941,000,000$ 238,711,721$ 25% 702,288,279$

Preliminary Engineering & Program Management 174,700,000$ 57,878,938$ 33% 116,821,062$

Program Contingency 42,100,000$ -$ 0% 42,100,000$

TOTAL PROGRAM BUDGET 1,157,800,000$ 296,590,659$ 26% 861,209,341$

Other Program Accruals include partial funding of the Running Repair Shop ($20,392,835) and Land Acquisition of Connecticut LimoProperty ($300,000) & Fueling Facility (State Match) ($4,698,800)

Cost toComplete

StateProjectNumber

Project TitleProgramBudget

Expendituresto Date

% Complete

1

1


Page 8

IV. CURRENT PROGRAM STATUS (through December 31, 2013)

Design Schedule by Project

Design & Bidding/Award Activity this Quarter:

NHRY Master Plan Update – Update was completed and approved by the Department and Metro-North.

Central Distribution Warehouse - Design was completed and bidding commenced. MOW Facility and Employee Parking – Design continued Yard Power Upgrades - Design continued. Pedestrian Bridge – Design commenced. West End Yard and Stores Building Demolition – Design commenced

Design & Bidding/Award Activity Planned for Next Quarter: Central Distribution Warehouse – Bidding will be completed and the project will be

awarded. MOW Facility and Employee Parking – Design will continue. Yard Power Upgrade - Design will be completed. Pedestrian Bridge – Design will continue West End Yard and Stores Building Demolition – Design will continue.

StateProjectNumber

Project Title

PROGRAMMED PROJECTS - TIER 1





0301-0038 Traction Pow er Substation 1086




0301-0124 Maintenance of Way & Employee Parking


0300-01380301-0111

West End Yard & Stores Building Demo



0301- 0127,- 0128, - 0132



0301-0131 Car Wash

0301-0130 Diesel Shop/CSR Heavy Repair Shop


Design Complete In Design In Planning

2021202020192006 2007 2008 2015 2016 2017 20182009 2010 2011 2012 2013 2014


Page 9

Construction Schedule by Project

Construction Activity This Quarter:

Component Change Out Shop – Completed overhead ductwork in shop and exterior windows; continued utilities, interior masonry, interior systems, and traction power substation equipment work; completed warehouse foundation.

Traction Power Substation 1086 – Continued integration acceptance testing.

Independent Wheel True Facility – Completed track work, structural steel framing and metal roof decking for east and west wings, masonry walls, commenced interior systems installation, continued site/civil and utilities work

Construction Activity Planned for Next Quarter:

Component Change Out Shop – Complete interior masonry and drywall. Continue shop construction, utility work, building interior work, and substation work.

Traction Power Substation 1086 – Complete project and energize substation.

Independent Wheel True Facility – Continue site/civil work and utilities installation, complete building envelope, complete interior systems installation.

Central Distribution Warehouse – Award project and commence procurement.

StateProjectNumber

Project Title

PROGRAMMED PROJECTS - TIER 1





0301-0038 Traction Pow er Sub 1086




0301-0124 Maintenance of Way & Employee Parking


0300-01380301-0111

West End Yard & Stores Building Demo



0301- 0127,- 0128, - 0132



0301-0131 Car Wash

0301-0130 Diesel Shop/CSR Heavy Repair Shop


Completed Projects Ongoing Projects Planned Projects

2019 2021 2023 20242008 2009 2010 2011 2012 20222013 20202014 2015 2016 2017 2018


Page 10

V. PROGRAM PHOTOGRAPHS

Component Change Out Shop (Under Construction)

Building exterior (left); main shop interior (right)

Architect’s rendering of Component Change Out Shop


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Independent Wheel True Facility (Under Construction)

IWT Building Steel Framing and Roof

Architect’s rendering of Independent Wheel True Facility


Page 12

Traction Power Substation 1086 (Under Construction)

Substation compound.


Page 13

VI. REVISED PROGRAM YARD ARRANGEMENT

Documents

N EN RAIL FACILITIES IMPROVEMEN New Haven, · PDF file · 2014-03-19The Component Change Out Shop (CCO) project is under construction and is ... System, Paint and Heavy Repair,