State-of-the-Art in Alternative Power Supplies

Prepared for: APTA / TRB 2015 Light Rail Conference

Authors: John Swanson and John Smatlak Interfleet Technology Inc.

1

State-of-the-Art in Light Rail Alternative Power Supplies

Prepared for: APTA / TRB 2015 Light Rail Conference

Authors: John Swanson and John Smatlak Interfleet Technology Inc.

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ABSTRACT

1 BACKGROUND Since the beginning of electrified rail transit in the 1880s, the In the case of OESS, the related infrastructure is also simplified, conventional overhead contact system (OCS) has been the in some cases reducing short term (capital) and long term preferred power distribution method for light (maintenance) infrastructure costs. rail/streetcar/tramway systems (referred to collectively in this paper as “light rail”) throughout the world. Although there have The disadvantages include increasing the complexity of the been a number of other approaches tried, all were ultimately vehicle (OESS) or the wayside infrastructure (GLPS) that may found wanting. More recently however, several modern versions lead to increased capital and/or vehicle life cycle costs. With of alternative power supply options have entered the OESS there are also weight, space and performance tradeoffs, marketplace, including onboard energy storage and ground as well as the unknown life expectancy of OESS elements. level power supply, allowing operation of vehicles without an OCS (“off-wire”) over part or all of the alignment.

The application of alternative power supplies is a complex subject that is best approached from a systems viewpoint, rather than just the vehicle or the electrification system. In the end, the goal is to provide reliable, continuous traction power to the rail vehicle and there are number of ways this may be done. Followers of this subject will have seen many papers over the years that have identified, described and evaluated many of these methods.

For those who are new to the subject, there are three basic means, as well as emerging hybridized combinations (indicative of how rapidly the technology is evolving):

1. Ground level power supply (GLPS) – power continuously supplied to the vehicle at ground level via direct contact with a conductor or inductively 2. Onboard energy storage system (OESS) – power stored on the vehicle, using flywheels, batteries, or a combination thereof, recharged periodically via regenerative braking and contact with a power conductor 3. Onboard power generation system (OPGS)– power continuously generated on the vehicle as required via hydrogen fuel cells, microturbines or diesel engines

The advantages of these alternative power supply methods center around providing improved aesthetics and the reduction of conflicts with other users of the street space including utilities, bridges, traffic signals and other overhead structures, as well as Nice, - short off-wire segments using special events (such as parades), etc. onboard energy storage. Opened 2007 BACKGROUND 2

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systems, purposes of

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Tramwave Technology Tramwave APS APS APS APS APS plus OESS OESS plus APS ( APS APS APS APS APS II APS Tramwave Tramwave

OESS expected have

hybrid

(Table borne

- 3)

distances are primarily

prototype using / CNR

OESS, diesel

27

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or

of and

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construction

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2015 AnsaldoBreda Supplier AnsaldoBreda / CNR Alstom Alstom Alstom Alstom Alstom Alstom Alstom Alstom Alstom AnsaldoBreda

GLPS 1) at

of 2015

operation by

energy

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flywheel vehicle

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(Table

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status

start,

has supply

at construction using systems

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whether

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Wire

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cells,

current power

capable under

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rail Off Off

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5

a Systems operation, Length, 4 km segments total 4 Completely catenary free 13.6 13.6 km total segments

1.2 km segment 1.5 km segments total 1.5 free Completely 2 km2 segment 22.7 22.7 km total segments 2.1 km segment 1.5 km Completely catenary free 2 km2 segment 470 m

alternative

wire many - were hydrogen hybrid least number

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overview . uses at

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an there the

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2015 2015 Operational 2003 2016 2011 2016 2011 2018 2012 2019 2014 2013 201? Level

lengths

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length benefit, There ago

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1. 2. 3. Only

Meanwhile, Significantly, system The

application

CURRENT STATUS WORLDWIDE

3 TABLE 2: On-Board Energy Storage Systems for Off-Wire Operation (OESS)

Length, City Operational Length, System Supplier Technology Vehicles Off Wire Nice, France 2007 0.91 km total segments 8.7 km, 21 stops Alstom Battery, (Ni-MH) (SAFT) 20 CITADIS vehicles ACR Evodrive Seville, Spain 2011 0.6 km line segment 2.2 km, 5 stops CAF 4 URBOS 3 vehicles supercapacitors

Segments totaling 2.5 69.9 km, 65 stops, Shenyang, China 2013 CNR Changchun Voith supercapacitors 30 "dolphin" vehicles km 4 lines 2 km off-wire segment, ACR Freedrive battery / Zaragoza, Spain 2013 12.8 km, 25 stops CAF 21 URBOS 3 vehicles charging at stops supercapacitors Completely catenary 7.7 km, 10 stops, SITRAS ES , China 2014 CSR ZELC 7 vehicles free, charging at stops Haizu Circle Line supercapacitors (Maxwell) 90% catenary free, OCS 8 km, 13 stops, Bombardier Primove battery Nanjing, China 2014 only at stops and CSR Puzhen 15 FLEXITY 2 vehicles Hexi line (Li-Ion) acceleration points Completely catenary ACR Evodrive Kaohsiung, Taiwan 2015 8.2 km, 14 stops CAF 9 URBOS vehicles free, charging at stops supercapacitors Oak Cliff Streetcar, 1.6 ABB battery (Li-Ion nickel Dallas, TX 2015 2.6 km, 4 stops Brookville 2 LIBERTY vehicles km manganese cobalt) CATFREE battery (nano- 12 FORCITY CLASSIC Konya, Turkey 2015 1.8 km 21 km, 35 stops Skoda lithium-titanium) 28T vehicles 22 TRAMLINK V4 Santos, Brazil 2106 0.4 km 11.4 km, 14 stops Vossloh ABB battery (Li-titanate) vehicles Seattle First-Hill Seattle, WA 2016 Streetcar, 4 km 4 km, 10 stops Inekon Battery (Li-Ion)(SAFT) 6 TRIO 12 vehicles (downhill track) New M-1 streetcar line, ABB battery (Li-Ion nickel Detroit, MI 2016 (length tbd - 60% of 5.1 km, 20 stops Brookville 6 LIBERTY 12 vehicles manganese cobalt) system proposed) Doha Education City, Completely catenary SITRAS HES battery (Ni-MH) 2016 11.5 km, 25 stops Siemens 19 vehicles Qatar free, charging at stops / supercapacitors 4 segments totaling ACR Freedrive battery / Granada, Spain 2017 15.9 km, 26 stops CAF 13 URBOS 3 vehicles 4.95 km supercapacitors 3.6 km off-wire segment between Pont Rouge and ACR Freedrive battery / Luxembourg 2020 16 km, 24 stops CAF 21 URBOS 3 vehicles Gare Centrale, charging supercapacitors at stops Completely catenary SRS with Ecopack (battery / Nice 2018 11.3 km Alstom 19 Citadis XO5 vehicles free, charging at stops supercapacitors) 4 VARIOBAHN vehicles with batteries ordered (w/ 10 more pre-wired Planned English Garden for future battery retrofit) , 201? extension, 1 km with 2 8 km, 4 new stops Stadler Battery (Li-ion) All delivered, but only stops one vehicle currently fitted with batteries

pending construction of WORLDWIDE STATUS CURRENT new line. 4

3 DUO train vehicles 10 REGIOCITADIS tram train vehicles 4 TRAMLINK tram train vehicles Vehicles 8 CITYLINK tram train vehicles

Dieselhybrid Dieselhybrid Dieselhybrid Technology Dieselhybrid

wire segment using onboard energy storage, opened 2013 2013 opened storage, energy onboard using segment wire

Siemens Alstom Vossloh Supplier Vossloh 2 km - off

-

(OPGS)

Operation Zaragoza, Spain Zaragoza,

9 km,stops,95 Line 10 30 km, 27 stops, 27 stops, km, 30 LineRT4 24 km Length, System Wire

-

Off

and

for

Wire 8 km 28 km New FEVE tram train route Leon Cistiernia Three new tram train lines to Burgstädt , Mittweida Off Off Length, Length, Hainichen Vehicles

Train)

(Tram

2004 2006 2011 2014 Operational Hybrid

Diesel

:

3

TABLE City Nordhausen , Germany Kassel,Germany Leon, Spain Chemnitz, Germany

CURRENT STATUS WORLDWIDE

5 TABLE 4: Development Prototypes Installer Operational Location Supplier Technology Vehicles LaRochelle, France, vehicle, STARS program . First use of charging Alstom 1999 Alstom Magnet Motor flywheel Test Track at station stops

Ex - VBK GT8 vehicle, ULEV-TAP (Ultra Low Emission Turbomeca microturbine hybrid with CCM Alstom 2001 Karlsruhe, Germany Vehicle - Transport using Advanced Propulsion) EMAFER flywheel energy storage program.

Spie-Enertrans 2001 Marseille, France Line 68 La Brugeoise Innorail ground contact system RTM PCC vehicle LaRochelle, France, Alstom Alstom 2002 Alstom Innorail / APS ground contact system CITADIS vehicle Test Track Bombardier 2003-2007 Mannheim, Germany Bombardier MITRAC Energy Saver supercapacitors DUWAG GTN6 vehicle Diesel hybrid with 2 CCM flywheel energy Siemens 2003-2005 Karlsruhe, Germany Siemens AVANTO / S70 vehicle, ULEV-TAP 2 program. storage units Alstom 2006-2008 Rotterdam, Alstom CCM flywheel CITADIS vehicle, ULEV program

Kawasaki 2007-2008 Sapporo, Kawasaki Gigacell battery (Ni-MH) SWIMO-X demonstrator vehicle, RTRI sponsorship SITRAS HES (energy saver) battery / Siemens 2007 (Almada), Siemens COMBINO PLUS vehicle supercap. Tokyu Car 2007-2008 Sapporo, Japan Tokyu Car Battery (Li-Ion) HI-TRAM demonstrator vehicle, RTRI sponsorship

Alstom 2009-2010 Paris, France Alstom ECOPAK Supercapacitors CITADIS vehicle, STEEM program

Naples, Italy, 0.4 km test track Tramwave ground contact system (2nd AnsaldoBreda 2010 and 0.6 km Poggioreale-Via AnsaldoBreda SIRIO vehicle generation STREAM) Stadera line

VARIOBAHN vehicle from MVG Munich order. One of Stadler 2011 Velten, Germany test track Stadler Battery (Li-Ion) four to be used on a future catenary free line through English Garden.

Augsburg, Germany, 0.8 km Bombardier 2011-2012 Bombardier Primove (inductive) / battery VARIOBAHN test vehicle Primove test track

Fuel cell (hydrogen) / battery (Li-ion) / Ex-SNCV FABIOLOS 3400 series vehicle, supported by Fenit Rail 2011 Valencia, Spain Fenit Rail supercapacitors local government funds. KinkiSharyo 2011 Various US cities KinkiSharyo Battery (Li-Ion) AMERITRAM demonstrator vehicle,

AnsaldoBreda 2012 Florence (Firenza), Italy AnsaldoBreda Supercapacitors SIRIO vehicle AnsaldoBreda 2012 Bergamo, Italy AnsaldoBreda Supercapacitors SIRIO vehicle WTRAM prototype vehicle’ Korea Railroad Research Battery (Li-Ion) / OLEV power transfer Hyundai Rotem / KRRI / KAIST 2007-2014 Gyeonggi-do,Korea Hyundai Rotem Institute. OLEV system Korea Advanced Institute of system Science & Technology. Vossloh 2013 Valencia, Spain Vossloh Battery (Li-Ion) TRAMLINK vehicle Siemens 2014 San Diego, CA Siemens Battery (Li-Ion) S70 vehicle, World record distance off wire (24.6 km) CSR 2014 CSR China CSR Supercapacitors 4 module prototype vehicle CAF 2015 Vitoria-Gasteiz, Spain CAF Battery (Li-Ion) URBOS 2 vehicle, OSIRIS project Bom Sinal (Vossloh VLT 2015 Brazil Bom Sinal Battery TRAMLINK VLT based vehicle, CPDM-VE project. licensee) CSR Sifang CSR Sifang (Skoda licensee) 2015 Quingdao, China BALLARD FCvelocity fuel cell (hydrogen) ASTRA 15T vehicle Quingdao Pesa 2015 Krakow, Pesa Supercapacitors SOLARIS TRAMINO vehicle CURRENT STATUS WORLDWIDE STATUS CURRENT

Toshiba 2015 Kagoshima, Japan Alna Sharyo Toshiba SCiB compact battery (Li-ion) LITTLE DANCER Type A3 vehicle. 6

Table

comprehensive

(reference

not

27 SD660 vehicles vehicles 27 SD660 retrofitted underTIGGER grantIII Vehicles 30 VARIOBAHN 30vehicles VARIOBAHN 13 TRAMLINK 6N2 6N2 13 TRAMLINK vehicles 6 TWIST vehicles 3 existing 3 existing 1500 VDC KinkiSharyo LRVs retrofitted underTIGGER grant 40 URBOS 3 vehicles is

savings list

This

. energy

use

for

Technology Supercapacitors (Maxwell) Bombardier MITRAC Energy Saver supercapacitors Vossloh Kiepe supercapacitors Supercapacitors ACR Evodrive supercapacitors Supercapacitors systems

commercial

for

storage

wire segment using onboard energy storage. Opened 2015 Opened storage. energy onboard using segment wire

systems

energy

1.6 km - off such

- . Supplier American Maglev Stadler Vossloh Pesa KinkiSharyo CAF list

with

onboard

fitted

Dallas, Texas complete

been

evaluating

more

for

a have

Savings

to Area of Operation TriMet system Mannheimto Heidelberg Line Sound Transit LINK LRT System

used

compile Energy

known

to for

vehicles

are

required Storage

vehicles

prototype be

Year operational 2012 2012 2014 2015 2014 2015 rail

will

Energy

light

numerous

Board

research to

On

: following 5

Neckar, Germany Neckar, - further

the

addition

City Portland, Oregon Rhine Rostock, Germany Seattle,WA Wrockclaw, Poland Cuiaba, Brazil

TABLE In 4), and

CURRENT STATUS WORLDWIDE

7 The last five years has seen increasing interest in GROUND LEVEL POWER SUPPLY (GLPS) unconventional means of propulsion throughout the Background transportation sector. For road transport vehicles, electric drives The modern quest for “wire free” zones for light rail systems have become more and more commonplace. The battery, began in 1999 when the ancient city of Bordeaux, France supercapacitor, flywheel and fuel cell technology needed to wanted to build a new system that traversed an historically power these electric drives has advanced considerably, with important area containing their 13th century cathedral and more efficient, smaller, lighter and cost effective designs crossed an historic bridge over the Garonne without the use of becoming commercially available, along with increasing overhead wires. It was not until 2003 that the first 3 km GLPS modularity, a trend that is expected to continue. segments of the system opened, but today more than 31 km are in commercial service worldwide, with more on the way. Although the automotive sector is clearly driving development of onboard power sources, it is interesting to note that of all the This initial approach to providing off-wire capability vehicles used to transport people today, the modern light rail concentrated on providing continuous ground level power to vehicle has for some while been perhaps the best candidate for the vehicle, either via a switched direct contact system, such as their use, as they were already electrically propelled and have APS or TramWave or an inductive power transfer system such had the ability to regenerate braking energy as a standard as Primove or OLEV Power Track. The continuous power supply feature. Market factors, such as low production quantities, cost, approach is particularly advantageous in extreme climates space requirements, weight and complexity, as well as the where heavy duty heating and air conditioning is required, and inherent conservatism of the rail vehicle marketplace where for alignment sections with steep up-hill gradients where on- vehicles and their systems are typically expected to last 30 or board energy storage systems are quickly drained. As seen in more years, have initially slowed progress in this direction, but Table 1, the APS system is the most mature, having been that is now changing. through many teething problems to become very reliable and is now the market leader for ground level power supply. Other The use of energy storage (both wayside and onboard) to ground level systems are generally less well proven, but they achieve energy savings continues to grow, particularly in are also now beginning to attract buyers. The suitability of GLPS Europe where higher energy costs provide increased incentive. in climates with heavy snowfall (and the attendant use of plows As a result, numerous projects have reported out their analyses and road salt for snow removal) also remains an open for calculating return on investment (e.g. calculating payback question. period). As a result of these studies, significant discussion on the subject of new vs. retrofit of alternative power supplies has Issues also emerged. Feedback from the carbuilders, combined with In all GLPS installations to date, a single supplier has provided numerous studies, indicate that it is far more efficient to design both the vehicles and the power distribution infrastructure. in energy storage equipment from the beginning than to retrofit While this system-level approach is logical, the proprietary it. Fewer components and cleaner interfaces, less weight, nature raises commercial issues that represent one of the standardized elements, all combine to reduce cost and thus biggest hurdles to the wider adoption of such systems. In the shorten the return on investment period. US, sole source procurements of this nature are difficult to support under FTA procurement guidelines and longer term, it The following sections review the most significant advances for locks an agency into a single technology and a single vehicle the three primary types of alternative power supply technologies type from a single supplier, which carries some level of for light rail applications. uncertainty regarding future support and further development.

EVOLUTION 8

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the There no continuous Alstom system GLPS this The based that with under in or significant power for utilize And price that authors, onboard to of be together use specific the This chiefly to The Advances for associated costs margins

EVOLUTION

9 This has the advantage of being very straightforward and non- OESS systems with periodic charging are currently one of the proprietary. Reliability can be improved by incorporating an most promising and widely available approaches available for automatic location system to raise and lower the pantograph in those seeking an end to overhead wires. It will be interesting to the right places. see how the inherent trade-offs are dealt with once the new crop of systems becomes fully operational, particularly in cities with Another operational issue has to do with the inherent hazards extreme climates where power demand from vehicle HVAC associated with onboard energy storage. Maintenance practices systems is significant. will be impacted by the presence on the vehicle of what in many cases is effectively a constantly charged power source. ONBOARD POWER GENERATION (OPGS) Additionally, the prevailing use of Li-Ion type batteries requires Background/Issues a significantly different level of care than battery technologies The OPGS approach to alternative power supply has been the such as lead acid or NiCad commonly used on many types of slowest to develop, seeing more modest commercial application rail vehicles. than GLPS and OESS. Advances have however been made in From a cost perspective, the most significant trade-off inherent various approaches to fueled power generators on the vehicle. in the OESS approach is the initial impact on vehicle capital The trade-offs involve impacts on vehicle weight and costs and the life cycle cost of periodic replacement of the configuration due to the related space impacts arising from both onboard energy storage units. Although detailed, unbiased cost the power generator and the associated fuel storage / refueling information is generally not available (in common with other facilities required. forms of alternative power supply) it is clear that the system In 2004, a small fleet of in Nordhausen Germany was operator will need to make significant allowances for ongoing locally fitted with a motor-generator package based on renewals throughout the life of the vehicle, although as the automotive diesel engines. Other European suppliers have technology improves, the time between upgrades may continue followed a similar approach for light rail vehicles that needed to to increase, and the costs reduce.

operate on both existing electrified lines within the city center and Advances travel out to neighboring cities on existing regional rail lines Advances in the area of OESS center around the continuing without the expense of electrifying the entire line. Known in evolution of the energy storage units themselves. Of these, Europe as “tram-trains”, these vehicles are most commonly batteries (usually lithium-ion) and supercapacitors (or a straight electric with dual voltage capabilities, but the diesel combination of the two) have enjoyed the greatest success so hybrid type has now also carved out a niche for itself, although it far, but continuing development of high tech flywheel remains a limited market. technology (such as the GKN / Williams Hybrid Power MLC Advances flywheel units) may well see their widespread use. An added The most significant progress relating to onboard power advantage to all of these technologies is that they are generation involves the hydrogen fuel cell. It has been predicted supported by the world automotive market, where there is that 2015 will be the year of the fuel cell and that appears to be considerable research and development. Further, with careful true. Toyota has announced the first production series fuel cell design, it is also possible to utilize OESS to achieve energy cars will be built this year and at least two fuel cell development savings through improved capture of regenerative braking light rail vehicles are under evaluation. Alstom has selected energy, offering the potential for new systems to realize a Hydrogenics to provide fuel cells for regional trains, while the reduction in the number of substations, or for an existing system CSR LRV and other rail vehicle demonstrators use Ballard and no to add service or transition to a modern fleet with limited doubt other light rail versions are under development. Costs are upgrading of the power network. still high for the fuel cell units and hydrogen supplies are not yet

widely available, but this technology looks to be the wave of the EVOLUTION future. 10

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APPLICATION OF ALTERNATIVE

POWER SUPPLIES 11 Alternative power supply methods for light rail are entering a Together with standards covering key related topics (e.g. new phase of development, offering system designers an safety measures for use of Li-Ion batteries on light rail important new tool in the toolbox. Compared to ten years ago, vehicles), both the suppliers and the buyer will be in a better there are now a significantly larger number of ‘early adopter’ position to continue developing alternative power supplies systems either in commercial service or under construction. for light rail. While that number is still small compared to the over 400 light rail systems worldwide, interest is strong and the experience 2. From a project design perspective, application of alternative gained in operating these systems is expected to facilitate power supply technologies remains very project specific and further improvements and to start helping to answer the may require vehicle performance tradeoffs, particularly with significant questions concerning life cycle costs. In parallel with OESS. Its design is an iterative process that requires careful the evolution of alternative power systems for light rail vehicles, analysis of alignment and duty cycle, including local climate there is automobiles and other forms of road transport factors in order to balance the amount of energy storage (including electric transit buses) are seeing. capacity with the associated weight, space and performance tradeoffs. Given the significant impacts on multiple aspects Issues impacting the application and development of alternative of project design, balancing the need for an early power supply to light rail include: commitment to off-wire operation (e.g. in the environmental 1. From a commercial perspective, proprietary technology phase) with traditional project design approaches may be

issues remain a significant point, particularly for ground challenging. power systems which involve significant equipment on the wayside. Ultimately, buyers want a mature (service proven) There is also a need for more sophisticated tools to properly technology that conforms to agreed industry standards, analyze the various system characteristics and consider a allowing designers to select from a range of competing variety of scenarios in order to arrive at a reliable, cost suppliers. At this time the relatively new field of alternative effective off-wire system design. power supply is not in this position; it has limited standards and a series of competing, highly customized designs. 3. Onboard energy storage has multiple uses; its application began with a desire for energy savings by increased Decision makers have relatively little hard data on capital recuperation of regenerative braking energy, and has and life cycle costs for GLPS and OESS. Given the relative expanded into the ability to provide off-wire operation. newness of the technology, the small quantities involved, and the competing proprietary designs, it may not be 4. Although hydrogen fuel cell powered vehicles hold great practical to expect that detailed, unbiased cost data will be promise for the future, currently the most economical and available anytime soon. Instead, it may be necessary to straightforward approach to off-wire operation is onboard consider technologies such as GLPS only within a project energy storage with periodic recharging. Recharging can be delivery framework that allows a single supplier to provide at station stops, or combined with recharging under wired the vehicles, related infrastructure and long-term sections of the alignment. To operate such as system reliably, maintenance as part of a turnkey package, thus providing it seems likely that automating the recharging process, rather an opportunity to better allocate risks associated with than relying on manual human actions will be required. capital and life cycle costs. 5. From a project planning perspective, the implications of There will, however, be an increasing number of projects in including a commitment to off-wire operation in a project’s operation in the next decade, so it is possible that environmental documentation, and then later altering the

additional data can be obtained and analyzed. approach based on further refinement of project costs and CONCLUSIONS objectives, remains unclear. 12

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SUGGESTIONS FOR

ADDITIONAL RESEARCH 13 Authors

John Swanson John Smatlak Interfleet Technology Inc. Interfleet Technology Inc. (760) 840 7433 (213) 219 6128 [email protected] [email protected]