Emergency approach for tunnel technical installations in betuweroute railway tunnels

“For projects like this, we use a partner-based approach,” says Ron Pieterse, Project Manager at Strukton Infra Specials. “That’s why we’ve surrounded ourselves with partners with whom we’ve had many years of successful collaboration, including ICT Group, Krenvoord, and Siemens. We have a close relationship and complement each other very well. Marco Plug, Business Consultant at ICT Group, is also no stranger to these tunnels, he was involved in their original construction back in 2006, setting up the control and operating systems. He has an incredible amount of knowledge readily available. It’s a real asset to have him on board. And ICT Group is also delivering outstanding technical performance on this project.”

Thermal sensing cable

The five tunnels involved in phase 1 of the emergency approach are the Botlek Tunnel, Sophia Tunnel, Giessen Tunnel, Pankans Tunnel, and Zevenaar Tunnel. The installations were brought into use around 2006, and the most critical components are now being replaced first, as no other risk mitigation measures could be implemented for them. “This is a freight railway line, which means the handling of emergency scenarios is slightly different from passenger transport,” explains Plug. “Inside the tunnels, a sprinkler system is in place to extinguish burning trains and protect the tunnel. Temperature increases are detected using thermal sensing cables, fiber optics with multiple detection units per tunnel, which measure the temperature every 15 meters. These detection units are nearly twenty years old and have reached the end of their technical lifespan. In addition, ProRail has updated its Fire Safety Design Basis (UPD), which outlines how systems must operate. This requires a change in the software.”

Even greater standardization

During the tender and detailed design phases, ICT Group assessed the impact of the new components on the control system and developed the execution designs for the required software modifications. “A functional modification was also requested for Siemens’ scope of work,” says Plug. “In addition, a series of analog sensors—for pressure measurement and level detection—had to be replaced, which also impacts the control system.” Pieterse adds: “Even during the original construction of the five tunnels, ProRail aimed for as much standardization as possible at the component level in terms of operation and control. With this phase 1 emergency approach, we’re taking it a step further. Technology has evolved significantly over the years. For example, we now use sensors from the same product range, so if there’s a malfunction, a new sensor can simply be taken off the shelf. This also makes maintenance and management much easier.”

FAT en SIT

What makes this project stand out, according to Pieterse, is the optimal collaboration between all parties—from the design phase through to testing and commissioning. An integrated testing protocol is used, beginning with the Factory Acceptance Test (FAT) and ending with the final on-site System Integration Test (SIT), carried out under the supervision of a certification body. After these acceptance tests, ICT Group, together with Strukton and Rockwell Automation, implemented the modifications in the tunnels during several train-free periods. “Scheduling that requires extensive coordination, collaboration, and planning,” says Plug. “During the system integration test, we also have to demonstrate to the certifying body that the entire principle of fire detection and extinguishing works properly. To do this, the thermal cable is actually heated on-site to check whether the correct valves are activated.”

Phase 1, the emergency approach, has now been largely completed, except for a few software components that still need to be updated. Once that’s done, ICT Group’s Managed Services division will take over, providing management and maintenance for these five tunnels, along with ten other railway tunnels. “The tender for phase 2 has also been launched and covers the replacement of lighting and gas detection systems. We’re continuing to work closely with all the same parties from phase 1 on this as well,” Pieterse concludes.