| SCADA
for TRANZ RAIL'S NATIONAL TRAIN CONTROL CENTRE |
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The following case study refers to a project
carried out on behalf of Tranz Rail in New Zealand in the 1990's
with upgrades in 2002.
Subsequent to this, Tranz Rail were purchased
by Toll Holdings. The infrastructure portion was then sold to
ONTRACK (The New Zealand Railways Corporation).
ONTRACK own and maintain the rail infrastructure
in New Zealand. ONTRACK continue to use RealFlex software in the
applications described below.
Tranz Rail was New Zealand's largest surface transport
company. The Company's rail operations covered both the Islands.
Their principal business was the transport of freight by rail,
and inter island ferry, complemented by passenger services. They
had about 3,900 km of track, 208 mainline locomotives, 7,000 freight
wagons and three inter island ferries.
Tranz Rail's ferry services linked the North and South Islands,
allowing them to operate a national transportation network throughout
New Zealand. Tranz Rail's rail and ferry services were complemented
by an extensive fleet of owner operated trucks which provided
them with door to door distribution capabilities.
Tranz Rail had actively developed distribution, warehousing, and
logistics capabilities which allowed them to offer customers total
transport and distribution services. Tranz Rail had a typical
network cost structure, with high fixed costs and low variable
cost.
As the Company operated in a totally deregulated environment within
the transport industry the incentives to innovate and remain competitive
had become second nature to the business. A major project to improve
operational efficiencies and asset utilisation was the centralising
of functions such as crew rostering, locomotive rostering, and
wagon transit management from the district offices to the Company's
head office in Wellington. The centralisation of the network control
from the regional offices on to one site at Wellington head office
was the next logical step in improving network efficiency. Historically,
Tranz Rail train control offices were spread around New Zealand
in seven different locations. They were located in Auckland, Hamilton,
Taumarunui, Palmerston North, Wellington, Christchurch and Dunedin.
Each of these offices was equipped with various CTC systems together
with large panels showing points and signals indications, etc.
PROBLEM DESCRIPTION AND SYSTEM REQUIREMENTS:
It was determined early in the project that moving
of such technology into a centralised location was not a viable
option so an alternative was sought. In determining the requirements
for the office end of a centralised control system the system
characteristics outlined below were considered essential.
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Reliability - The Control
Centre must operate reliably and in a predictable manner. The
possibility of system failure must be minimised.
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Cost Effectiveness - Although
the savings of centralisation are significant, a cost effective
solution must be implemented to maximise return on investment.
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Functionality - The Control
Centre must have available, as a minimum requirement, the features
available in the systems it is replacing, and at best significantly
improve on such features.
All of the above requirements
were achieved by specifying the use of commonly available "off the
shelf" components (e.g. IBM compatible PC's), the ability to run
in hot standby mode with automatic failover, the use of proven software
and operating system and buying through a local supplier who fully
supports the product.
REALFLEX SOLUTION:
Specifications
From this a full system specification was developed
which outlined the following requirements:
- Use of standard IBM compatible personal
computers for servers and workstations.
- Operator interface via VDU and point device
(e.g. mouse).
- Any Local Area Network (LAN) linking workstations
must be industry standard (e.g. Ethernet) and TCP/IP compatible.
- Capable of communicating with existing field
equipment which meet current CCITT recommendations for protocol
and communications interface.
- Capable of communications over a variety
of media including fibre optic and copper, leased and dial up.
- Expandable up to a minimum of 16 workstations
in a modular fashion.
- User programmable with Tranz Rail staff able
to enter database and create graphic displays.
- Alterations to system database and graphic
displays possible without rebooting system.
- Servers able to operate in hot standby mode
with automatic failover if failure of online node detected.
- The ability for Tranz Rail staff to create
macros for simplifying common control functions (e.g. crossing
trains). The software chosen was Realflex 4.
Operator Interface
The operator interface was developed in conjunction
with the Train Control Operators who use the system. Although it
was difficult at first for the operators to relate to VDU layouts
and operation with a mouse after years of operation with push buttons
and a mimic panel, this was an important part in the development
of the system. Involving the operators at this stage gave them some
"ownership" of the finished product and also a feeling of control
over their destiny.
As a result of this consultation the screen layouts were developed
with the following criteria:
- Operators must be able to "see" and control
the entire section of railway they have control over without having
to navigate between screen layouts.
- Control of signals achieved by pointing and
clicking on the appropriate signal head representation with a
mouse.
- Control of points achieved by pointing and
clicking on the appropriate points number.
- Where applicable, alarms and operator prompts
should flash on the screen to alert the operator.
- The screen layouts must be large enough to
avoid unnecessary eye strain.
- The lie of points will be indicated by a
yellow line that turns red when occupied by a train.
- Signal aspects will be green for clear and
red for danger.
- Track segments will normally be black and
will show red when occupied.
- Miscellaneous indications (time delays,
barriers, etc) will appear on the screen when active.
Automated Procedures
One of the major advantages of a computer based
office is the ability to reduce operator workload by automating
repetitive tasks. Realflex has Control Sequence Language (CSL) which
allows controls to be issued automatically when initiated by the
operators. CSL enables procedures to be written which can monitor
field events (indications) and issue controls without specific operator
intervention.
A number of CSL programs have been written which automate some operator
procedures and thereby reduce operator involvement in the system.
Examples of CSL programs are the automatic crossing of trains, the
automatic routing of trains through double to single line stations,
the automatic turning of locomotives on a triangle and the clearing
of all signals in a specified direction through a station. In each
case the procedure is initiated (and can be terminated) by the operator
but any further intervention in the procedure is not required.
System Security
Security is achieved by requiring operators to
select the area(s) they need to control. Once this is done all stations
in the designated area are under the control of that operator and
any attempt by other operators to control those stations will be
denied.
Communications
The Signalling and Train Radio Systems originally
grew as network nodes around what was previously distributed Train
Control offices. As these offices were progressively closed as part
of the centralisation process it was decided to leave these nodes
basically intact and install interfacing equipment to allow remote
control of the systems from the central point, the National Train
Control Centre (NTCC).
Tranz Rail owned and maintained its own fibre optic transmission
network (FOTS) so "leased" circuit capacity is readily available
between node points and the NTCC. This capacity is generally in
the "backbone" network through the centre of the country. Because
the nodes are located along this backbone, circuit provision is
made easier. Within the nodal areas, the distribution of Signalling
multidrop circuits was achieved by using either Tranz Rail owned
copper cable or if this was not an option, a service provider was
be used to supply "leased line" circuits. The Train Radio network
within each nodal area is comprised of a series of linked hilltop
repeater sites with radio coverage provided, via specialised tunnel
radio systems, through tunnels longer than 100 metres. There is
diversity in the communications path options available between node
points and the NTCC. The main path is the "leased line" available
via the FOTS. The other is via the PSTN network, and allows for
automatic dialup operation should the "leased line" fail. This provides
redundancy for the Communications circuits and therefore minimises
the risk of a node point not being in contact with the NTCC. Dial
up operation with each node point effectively allows control from
any location which has access to the PSTN network and forms the
basis for the disaster recovery plan.
System Reliability and Availability
Of major concern with any centralised control
system is overall reliability as any failure has widespread effects.
The design of this system with dual redundant ethernet networks,
online and hot standby computers and workstation switching flexibility
has minimised the effects of any single failure on the system as
a whole. Redundancy in the communications links and the nodal communications
network mean that any single communications fault will not prevent
system operation. This feature has been used on occasions when the
main communications link has failed.
RESULTS:
Train Control systems have developed over the years
to the point where large scale centralised control is attractive
and viable.
Tranz Rail utilised "off the shelf" control systems products and
PC based technology to develop a cost effective and functional train
control system which has the ability to expand in order to meet
the needs of the future. Particular attention has been paid to the
reliability and availability of the system especially with regard
to LAN communications, main processing CPU's and communications
links.
Realflex and QNX have responded well to the rigors and processing
requirements of a Train Control system. The Train Control centralisation
project has been challenging, and the end result is a positive reflection
on all involved, including all Train Control Operators who have
used and commented on the system.
REALFLEX SYSTEMS SOFTWARE:
Realflex, Flexview.
DATABASE SIZE:
12,000 points
PC HARDWARE:
Various computers
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