Exeter to Westbury Life Extension Scheme

The challenge

Following a rise in failures, call outs and maintenance costs, tier one contractor, Colas Rail, was instructed to replace 24 signals and their associated TPWS and AWS systems, track circuits and multi-core cabling throughout the 69-mile-long stretch of line between Exeter and Westbury.

Following the client’s installation works, a comprehensive programme of testing and commissioning was required to ensure that the newly established signalling infrastructure was operating correctly and was fit to hand back to signallers.

The solution

Following an extremely competitive tender process, Colas Rail engaged Amaro to provide specialist testing staff, tasked with the testing and commissioning of a range of newly replaced signal structures and their associated equipment.

Exeter area

• 17 signal structures
• Associated TPWS (Train Protection & Warning System) where applicable
• Train operated points at Eggesford Station
• 16 single/double cut track circuits
• Numerous Thales axle counters

Westbury area

• 4 banner repeat signals
• 3 set back signals
• Associated TPWS (Train Protection & Warning System) where applicable
• Associated track circuits where applicable
• 48 core signalling cables

Working alongside the client’s own operatives, Amaro carried out all on-site pre-testing activities and, following each key installation phase, a team comprised of a Tester in Charge and a number of MOD5 test assistants, 3B (L) functional testers, and MOD2 principles testers tested and then commissioned the following equipment into use in accordance with Network Rail Standard NR/LD/SIG/30014…

With the site-based testing and commissioning complete, all test logs were then closed out, with the relevant paperwork (including as-built photography) being submitted to the Network Rail T&C Engineer, and to Colas Rail’s Signalling and T&C Managers.

In addition to the physical testing requirements, Amaro was also responsible for carrying out all test management activities relating to the project including (but not limited to)…

• The production of a Master Test Plan and all subsequent Test and Commissioning Plans
• The provision of TIC support for the development of both staging and delivery
• Attendance at all progress review, design, construction, stage gates, and whiteboard meetings
• The deconfliction of all works
• The confirmation of testing limits for each stage
• Resource management

The outcome

Whilst works are due to continue until December 2024, to date progress has been extremely positive. Indeed, despite a 17-month programme and some extremely challenging weather conditions, not a single aborted shift has been logged with all commissioning stages being sufficiently resourced and a 100% success rate being achieved at the first time of asking.

Thanks to the efforts of Colas Rail and its supply chain, Network Rail’s maintenance burden will be reduced, and passengers using the route between Exeter and Westbury will face fewer delays and shorter journey times.