An advanced system protects the new intercity train depot at Kangy Angy. CNFiTech worked with Rockwell Automation to design and build an advanced system to protect facility staff and equipment at NSW’s new train maintenance facility
From 2024, commuters on sections of regional New South Wales began travelling on a state-of-the-art fleet of intercity trains. Named after the Dharug word for emu, the 610 carriages in the Mariyung fleet offer modern safety and advanced features for customers who make almost 45 million journeys a year on this network.
To support these critical assets, Transport for NSW (TfNSW) constructed a 500,000 square metre depot at Kangy Angy, near the Central Coast. The TfNSW Intercity Fleet Maintenance Facility, which operates 24/7, features approximately 6 kilometres of electric rail lines and heavy equipment, including a 50-tonne wheel lathe.
One of the core requirements for the facility was to implement a robust safety system, and CNFiTech was assigned the task of developing a flexible and functional design for a Depot Personnel Protection System (DPPS). The system needed to be SIL-2 rated, crafted using readily available proprietary safety hardware and software tools, and easy to maintain. SIL, or Safety Integrity Level, is a rating system that links safety with the numerical probabilities of hazardous failures (0 being the lowest and 4 the highest) for continuously operating systems or on-demand systems.
As a well-established specialist in electrical and systems engineering, CNFiTech leveraged its 25 years of experience to design, manufacture, and implement an appropriate solution for TfNSW.
CNFiTech is a specialist in engineering services, focusing on automation, electrical engineering, and systems engineering. It is also a partner of Rockwell Automation System Integrator, with extensive experience in Rockwell Automation hardware and software.
“The system for TfNSW is designed to protect facility staff and equipment by delivering the safe and controlled movement of rolling stock into and out of the train maintenance depot,” explained Aafiah Khan, territory manager, NSW, for Rockwell Automation.
To deliver this project, CNFiTech adopted the Authorised Engineering Organisation (AEO) framework, which instilled confidence in TfNSW regarding the company’s ability to provide fit-for-purpose assets.
Constructability of design
The DPPS has been designed to interface with the automated derailment monitoring system. It also ensures the safe movement of trains into and out of the maintenance facility building and a lock-out personnel system prevents staff from accessing the area above the trains while the traction system is energised. Constructability of design is one of CNFiTech’s core skillsets – an ability that TfNSW highly valued for this project.
TfNSW valued CNFiTech’s design constructability when implementing Rockwell Automation technology for the Kangy Angy depot.
Rockwell Automation’s GuardLogix® platform, combined with associated safety devices, safety stack lights, and fortress keys and locks, is underpinning this integrated safety system. The Rockwell GuardLogix safety system hardware is rated for up to SIL-3 system implementation.
CNFiTech completed an assessment of the DPPS at Kangy Angy and derived several SIL functions comprising SIL-0, SIL-1, and SIL-2. This resulted in a clear definition and agreement with TfNSW of the system safety classification. As an added benefit, much of the work done by CNFiTech at the DPPS can be redeployed to other rail maintenance facilities.
CNFiTech rail and automation manager, Joe Dwyer said, “Implementing Rockwell Automation’s GuardLogix platform meant that we could confidently deliver the required level of safety and control to TfNSW. Protection of personnel was a key deliverable of this project, and Rockwell Automation’s hardware was able to deliver optimum ongoing performance.”
Checking that equipment is in a safe state
The integrated safety system monitors and interlocks the various sub-systems in the correct states for safe working through a combination of trapped key and electronic safety interlocks. Equipment may be controlled and operated by manual or automatic mechanisms. The safety system independently checks that the equipment is in a safe state and ensures it is disabled with an automatic or semi-automatic (monitored trapped key) interface.
“The safety ethos has been embedded throughout the facility right from depot doors, overhead platform access, retractable overhead wiring, train lift systems, and bogie turntables on designated roads,” said Dwyer.
The solution implemented will help with the safe movement of trains into and out of the maintenance depot and support the safe working of maintenance staff on trains at the facility.
“The deployment of Rockwell’s GuardLogix integrated programmable electronic safety system helped us achieve efficient operation of the maintenance depot,” concluded Dwyer.