OTTAWA LRT

Recommendations for a
sustainable solution
David Van der Wee
Rolling Stock and Components
Alstom North America

October 12, 2023

Title of the presentation on three lines -

Lorem impsum dolor sit amet consectetuer
adipiscing elit, sed diam nonummy

1
 Agenda
1. Root cause Investigation

2. Alstom’s Recommendations for a Sustainable Solution

3. Axle design improvements

4. Roadmap to a Sustainable Solution

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 2
 01 Root cause Investigation

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 3
 Chronology
Chronologie
September 2019 August 8, 2021 July 22, 2022 July 17, 2023
Septembre 2019 8 Août 2021 22 Juillet 2022 17 Juillet 2023

Commercial

LRV 27 hub failure LRV 32 incident

Revenue

LRV 19 derailment
Service

Service

Casse du moyeu VLR 27 Incident VLR 32

Déraillement VLR 19
Belfast Rd MSF Belfast Rd MSF
Tunney’s Pasture
Triage Belfast Triage Belfast

1 Wheel dislodged from 1 Train removed from 1 Issue identified during routine
axle Mainline due to inspection (grease leakage)
2 Train returned to MSF reports of vibration
using dolly
2 Hub identified as damaged 2 Hub identified as damaged
upon inspection upon inspection

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 4
 Root cause investigation process

From Revenue Service until Cumulated fleet mileage Failure rate (MDBF)

August 2021 6.65 Million km 6.65 MKM

July 2022 9.77 Million km 4.89 MKM

July 2023 12.96 Million km 4.32 MKM

● Interval between occurrences at 1 every 4.3 million km –

Challenge for data collection, trend identification and failure mode
determination
● This failure mode not observed on similar fleet around the world
● Industry best methodology deployed to define corrective
actions.
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 5
 Root cause investigation process

● Mobilization of experts:
- Le Creusot, France (Bogie Center of Excellence)
- Siegen, Germany (Bogie testing laboratory)
- St-Ouen, France (HQ, Track expertise)
- St-Bruno, Canada (Americas HQ and NAM Engineering Center of Excellence)
● Performed 3 separate instrumented axle testing campaigns (January 2022, November
2022, July 2023)
● Ran numerous simulations to model the following impacts: coefficient of friction, various
track configurations (gauge, super-elevation, track defects) deformation, various levels of
contact with the restraining rail
● Performed audits (internal, external and supplier) and collaborated with external expertise
(TSB, RTG)

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 6
 Root cause investigation process

● Working extensively on root-cause analysis using a comprehensive fishbone diagram and

5-why methodology
● Analyzed, aggregated and compiled multiple reports from external parties to prepare a
comprehensive list of recommendations for a Sustainable Solution
- Mott MacDonald
- MxV (ex-TTCI)
- NRC-CNRC
- JBA
- Texelis
- TSB
● Alstom investigated both short and long-term vehicle design options.

Recommendations report submitted to RTG on May 31, 2023

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 7
 Root cause investigation

Occurrence

Fishbone diagram (Ishikawa)

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 8
 Root cause investigation

Cause 1 Why? 1 Dislocation of the wheel

Defect stage of LRV19
Why? 2 Hub breakage / cracks
Defect stage of LRV27

Why? 3 Cracks on hub due to contact with static beam (Abnormal loads due 6 contacts points)
Defect stage of LRV32
Why? 4 Nut complete unscrewing

Why? 5 Lost of nut crimps

Why? 6 Micro Ratcheting on the nut

Why? 7 Loss of preload on the nut

Why? 8 Fretting under small bearing

Root Cause Why? 9 Higher than expected lateral loads

5-Why methodology

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 9
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 10
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 11
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 12
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 13
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 14
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 15
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 16
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 17
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 18
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 19
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 20
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 21
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 22
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 23
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 24
© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 25
 Root cause investigation : diagnostic and sustainable solutions

Mitigate the loads at

Lateral loads the wheel/rail interface
experienced by wheel via Top of Rail
assembly during lubrication and

Solutions
operation exceed coefficient of friction
design limits management
Root cause

This causes bending Improve the

loads on the axle hub infrastructure to limit
assembly leading to the loads
development of play
into the assembly, nut
unscrewing and Increase wheel
derailment assembly design limits

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 26
 02 Alstom’s Recommendations for a
Sustainable Solution

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 27
 Findings and recommendations for a sustainable solution

1. Deployment of Top-of-Rail (TOR) Friction Modifier

2. Restraining Rail positioning
3. Restraining Rail extension into tangent track
4. Ballast shoulders improvement
5. Replace existing soft rail with harder rail
6. Investigate Wheel/Rail profile improvement
7. Run additional testing
8. Continued monitoring
9. Hardware replacement

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 28
 Top-of-Rail Friction Modifier Effectiveness in Reducing Lateral Loads

TOR demonstrated 40% reduction of lateral loads

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 29
 Restraining Rail positioning

Transversal Load on axle hub

No contact Shared contact Heavy/Pure contact

No contact Light contact Heavy contact (possible pure contact)

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 30
 03 Axle Design Improvement

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 31
 Axle Improvement – Nut locking

● Prevent the nut from unscrewing

and allow to reduce the inspection
regime
● Will move the current limitation of
axle life from 60,000 km to
400,000km.
- Increase of available fleet size
● Significant reduction of inspection
requirements.

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 32
 Axle Improvement – Axle Redesign

● Axial clearance / Bearing fretting:

Main Design hypothesis:

Impact limited to axle drive (same bogie interfaces /

Similar weight)

Increase of Acceptable transversal loads

Design optimization :

Increase contact pressure (higher interference fit)

Allow to reduce displacement (geometry of the hub and

bigger bearing)

Improve material characteristics (surface heat treatment)

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 33
 Axle Redesign

10-2023

02-2024

06-2024
07-2023
08-2023
09-2023

11-2023
12-2023
01-2024

03-2024
04-2024
05-2024

07-2024
08-2024
09-2024
10-2024
11-2024
12-2024
01-2025
02-2025
03-2025
04-2025
06-2025
07-2025
08-2025
09-2025
Redesigned axle

Technical Definition of design

Procurement/Parts Manufacturing

Prototype Manufacturing
Prototype Completion and start of
Endurance Test *

* Endurance and Fatigue testing completion is mid-2026

Top-level planning for axle redesign

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 34
 04 Roadmap to a Sustainable Solution

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 35
 Roadmap to a Sustainable Solution

Nut locking
Fleet Grounded

TOR Other
Restraining = deployment
Rail improvements
Improved deployment
relocation Service =
= Hub life =
Return to Reduces expectancy
inspection increased SUSTAINABLE
Service SOLUTION
regime

© ALSTOM SA 2023. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is
provided without liability and is subject to change without notice. Reproduction, use, alter or disclosure to third parties, without express written authorisation from Alstom, is strictly prohibited. 36
 www.alstom.com
www.alstom.com

Title of the presentation on three lines -

Lorem impsum dolor sit amet consectetuer
adipiscing elit, sed diam nonummy

37