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Crossrail Integration Facility and Test Automation – Improving Resilience with Automated Testing

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Crossrail Integration Facility and Test Automation – Improving Resilience with Automated Testing Crossrail Integration Facility and Test Automation – improving resilience with automated testing Alessandra Scholl-Sternberg This paper was originally presented at the ASPECT Introduction conference in Delft, Netherlands in 2019. The railway is a very complex system, involving – in the UK – Systems integration has gained a higher level of numerous stakeholders such as: end customer, government, importance as complex railway projects operate under service operators, rolling stock owner, rolling stock supplier, tighter schedules than ever before and with limited infrastructure owner, infrastructure supplier, infrastructure access to tracks to run tests. This paper demonstrates maintainer – each with individual corporate objectives. how a fully automated off-site testing facility is Within each category there are potentially several different extremely valuable to increase efficiency, cost- organisations that consider each other as market competitors. effectiveness and resilience of systems throughout There is also a complexity in technology, with various intricate a railway project life-cycle. The Crossrail Integration signalling systems worldwide. A single line might operate under Facility (CIF) is a great example of this practice. distinct systems in different areas, requiring complex transitions for safe operation of trains. Contemplating these facts makes it Systems integration facilities, such as Crossrail’s, provide a clear how systems integration is key for a railway line to work means to perform thorough off-site interface, integration, reliably, and how complex the system integration process timetable and transition testing, as well as simulation of faults can be, as it depends on stakeholders with distinct objectives to understand the system’s behaviour under degraded and working together. Successful systems integration also relies emergency situations. It is a cost and time-effective approach heavily on system-level tests; however, urban areas are getting to de-risk the later stages of the project, which brings real bigger and denser, and service hours are getting longer – some benefits to the delivery of railway signalling systems. railways run 24 hours a day. The real railway is not as available for system testing as would be desirable, which leaves a lack of infrastructure supporting system integration. Figure 1 – Crossrail, the future Elizabeth Line, Route Map showing rail and air Showing rail and air connections connections. Shenfield TfL/Mayor of London. Brentwood Surface line Harold Tunnel Wood Portal (tunnel entrance and exit) BRENTWOOD National Rail connection REDBRIDGE Romford Airport connection Chadwell Seven Heath Gidea Airports not on the Crossrail route - to travel to these Kings Park airports passengers will need to travel on other Ilford connecting rail services. Step-free travel is possible but SOUTH BUCKS Forest Goodmayes assistance will be required to get on and o some trains. HILLINGDON ISLINGTON Gate Maryland HAVERING Travel from Luton Airport Parkway Station to CAMDEN Circle Luton Airport is via an accessible bus. Metropolitan Manor Hammersmith & City Hammersmith Park Central & City Stratford BARKING & District Central EALING District Central Luton TOWER Overground Jubilee DAGENHAM Taplow Burnham Jubilee Gatwick HAMLETS DLR Ealing WESTMINSTER Bond Farringdon Whitechapel Overground West Broadway KENSINGTON & Street NEWHAM HAMMERSMITH & Drayton Hanwell CITY OF Langley Iver CHELSEA Maidenhead Hayes & Southall LONDON SLOUGH Harlington Acton Tottenham Liverpool Slough West FULHAM Paddington Street Main Line Court Road Circle Ealing Circle Custom Northern Metropolitan Canary Hammersmith House & City Central Hammersmith Wharf DLR Bakerloo & City Jubilee Abbey Northern District DLR Central Wood Twyford Woolwich Stansted DLRDLR WINDSOR & MAIDENHEAD Southend T1,2,3 T5 GREENWICH T4 BEXLEY Reading WOKINGHAM Heathrow Piccadilly Heathrow READING 2 The signalling system’s main purpose is to optimise train The CIF is a testing facility with 112 interfaces between a mix movements whilst keeping them safe at all times and under of real products – the same as the ones used in the railway all circumstances. Therefore, the system must be proved to – and simulators. The products therefore can be categorised be resilient, meaning that it must behave safely and reliably under “constituent domain items”, which are the subsystems even under unintended operation or under the influence under test, and “test execution domain items”, which allow for of external faults. It is very challenging to test the system’s the integration and operation of the whole system under the response to unintended scenarios in the field, even if longer integration facility environment. As far as the subsystems under access to it were granted, because to be able to put the integration testing are concerned, they are part of a system system under certain complex situations, a lot of negotiations controlling a real railway. between stakeholders and risk assessments would have to be A number of products are integrated in the overall system, undertaken. The difficulties mentioned can be lessened with including constituent domain and test execution items the use of system integration facilities. A great example of this supplied by Siemens Mobility, Bombardier Transportation practice is the CIF. and Knorr Bremse. Crossrail (the future Elizabeth Line in London – Figure 1) is a major railway project that connects one of the largest urban Key constituent domain items areas in the world. It is currently Europe’s largest infrastructure The list that follows covers the key sub-systems within the CIF project and it is estimated that 200 million passengers will use it that are identical to the ones used on the real railway. They each year. It operates under three distinct train control systems comprise the sub-systems that are under test. – ETCS, CBTC, TPWS (UK train protection system), with high Automatic Train Supervision (ATS) – Controlguide Vicos capacity throughput. To be able to deliver a robust operational – is the Central Operating Section (COS) control system, railway with limited access to test tracks and the physical responsible for monitoring and controlling train movements. It railway, the CIF has been implemented to provide early off-site is equipped with Automatic Route Setting (ARS) and Automatic interface testing and integration of critical systems. Train Regulation (ATR), and is capable of adjusting individual The CIF train times to optimise traffic. As already highlighted, the need of a system integration facility Interlocking – Trackguard Westrace Mk2 – provides point, for the Crossrail project was identified early in the Crossrail route, Platform Screen Door (PSD) interlocking functions programme due to the restricted access to the railway, the and secondary train detection functions from axle counters. ongoing complex civil works and fact that the Elizabeth Line The primary train detection function in the COS is train service will run across existing Network Rail infrastructure. An position reporting. intricate signalling system, encompassing three distinct train Platform Screen Door (PSD) Control Unit – Knorr Bremse control and protection systems, and the pressure for minimum Platform Door Controller (PDU) – which connects to 27 disruption to the existing operational services add to the individual simulated Door Control Units (DCUs) of the platform complexity. Thus, the CIF was designed and implemented in screen doors as in Bond Street station. phases, planned according to the development of the products Trackside Automatic Train Control (ATC) System – used within the system. TrainGuard Mass Transit (TGMT) Communication Based Train The objective of building the integration facility is to test Control (CBTC) Wayside Control Unit (WCU) – is the main and prove the functioning of system interfaces prior to their trackside element of the ATC system used in the COS of the installation and deployment. It is not intended to replace any Elizabeth Line. steps of the test and commissioning phase of the project, but to support it by identifying and mitigating defects early. Route Map Showing rail and air connections Shenfield Brentwood Surface line Harold Tunnel Wood Portal (tunnel entrance and exit) BRENTWOOD National Rail connection REDBRIDGE Romford Airport connection Chadwell Seven Heath Gidea Airports not on the Crossrail route - to travel to these Kings Park airports passengers will need to travel on other Ilford connecting rail services. Step-free travel is possible but SOUTH BUCKS Forest Goodmayes assistance will be required to get on and o some trains. HILLINGDON ISLINGTON Gate Maryland HAVERING Travel from Luton Airport Parkway Station to CAMDEN Circle Luton Airport is via an accessible bus. Metropolitan Manor Hammersmith & City Hammersmith Park Central & City Stratford BARKING & District Central EALING District Central Luton TOWER Overground Jubilee DAGENHAM Taplow Burnham Jubilee Gatwick HAMLETS DLR Ealing WESTMINSTER Bond Farringdon Whitechapel Overground West Broadway KENSINGTON & Street NEWHAM HAMMERSMITH & Drayton Hanwell CITY OF Langley Iver CHELSEA Maidenhead Hayes & Southall LONDON SLOUGH Harlington Acton Tottenham Liverpool Slough West FULHAM Paddington Street Main Line Court Road Circle Ealing Circle Custom Northern Metropolitan Canary Hammersmith House & City Central Hammersmith Wharf DLR Bakerloo & City Jubilee Abbey Northern District DLR Central Wood Twyford Woolwich Stansted DLR WINDSOR & MAIDENHEAD Southend T1,2,3 T5
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