SPL Powerlines UK, alongside its partners, has had a landmark month with trials on 75km of newly installed overhead line electrification (OLE) between Kettering and Wigston.
As part of SPL Powerlines UK’s contract, the company was responsible not only for installing the 75km of OLE, but also for overseeing the critical task of completing and verifying train testing. This process is a legal requirement under the National Technical Specification Notice (NTSN), which mandates the testing of OLE at operational line speed using a fully instrumented pantograph.
The pantograph collects data used to assess the quality of the installation, which is then compiled into a technical file required by the Office of Rail and Road (ORR) before passenger services can begin operating on the newly electrified line.
During the trials, SPL Powerlines UK also successfully tested the largest OLE span in the country, measuring an impressive 95 metres, using a range of agnostic material suppliers to ensure system integrity.
SPL Powerlines UK faced a significant challenge, as there was no “off-the-shelf” solution available, nor the option to collaborate with train operators to borrow a train. To overcome this, the team built a custom test train, “Electra,” comprising two HST Class 43 diesel power cars, a Class 91 electric locomotive, and four Mk3 coaches for seating and brake force. With a combined output of approximately 10,000 horsepower, Electra is capable of reaching speeds of 125mph. The Class 91 locomotive is equipped with a fully instrumented HS-X pantograph, enabling precise measurements during testing.
Simon Skinner, Engineering Director at SPL Powerlines UK, said: “On Saturday night, 21 September 2024, we created the largest OLE span in the UK, and on Sunday, we conducted rigorous tests to ensure it meets Network Rail’s UKMS125 ISV system requirements.
“We worked closely with our partners, our client project team, and Network Rail’s Technical Authority to simulate, design, install, and test how the OLE behaves at this maximum span length. This achievement means future projects can install spans up to 95 metres without the need for additional testing or validation, allowing for reduced structures and lower costs. It’s an important development that improves an already robust UK system.”
He added: “This marks a significant final chapter for the Project Electra and the Midland Main Line Electrification team. It’s gratifying to see that something so innovative and cost-effective can contribute to decarbonisation while reducing expenses. Achieving something ground-breaking like this takes patience, vision, and determination, and it’s satisfying when all of that hard work pays off.”
To celebrate these achievements, SPL Powerlines UK, along with its partners Colas Rail, UKRL, Train – Rail Infrastructure Solutions (T-Ris) and Serco UK, hosted a communications day on Friday, 20 September. This event brought together representatives from delivery partners, rail industry leaders, and organisations such as the Rail Safety and Standards Board (RSSB) for a special two-hour journey aboard the test train.
The train, which travelled from Leicester to Bedford, reached speeds of up to 125mph during the event. The purpose of the day was to mark the culmination of two years of planning and collaboration, highlighting the success of this complex engineering project.
Simon Skinner, reflecting on the project, noted: “This has been one of the most complex and challenging pieces of system engineering I’ve ever been involved with. The integration of so many different requirements in a single project was unprecedented in the UK, meaning our team, alongside our partners, built something entirely new – and successfully. The results speak for themselves.”
Jorge Roque, Senior Portfolio Manager at Network Rail, said: “This was a real opportunity to testify how various partners across the railway industry have been working together and combining their expertise, to successfully drive the project through this very important stage.”
Simon Ball, Freight Director – Services at Colas Rail, said: “Colas Rail delivered 24 trains testing the OLE on the Midland Mainline throughout September. This involved complex train planning of train paths, provision of train drivers and rolling stock. The project is an excellent example of collaboration within the Bouygues group and the wider rail industry.”
Dr. Nikolaos Baimpas, Director and Founder of Train – Rail Infrastructure Solutions (T-RIS) Ltd, said: “By using enhanced assurance methods, we can achieve the same level of infrastructure performance confidence with reduced time and effort. This approach offers long-term benefits throughout the asset lifecycle, providing a spatially resolved digital ‘health’ signature that can seamlessly integrate into predictive maintenance strategies.
“SPL Powerlines and T-RIS are at the forefront of the industry, adopting a data-driven approach to construction assurance, alongside traditional NTSN testing, to validate this method. This has the potential to significantly reduce the costs of electrification projects.”
Tony Bentley, Head of Operations, Serco UK & Europe, said: “Serco Rail Technical Services were delighted to be part of the test train project. The atmosphere on the day was fantastic, and everyone on site was incredibly welcoming. It was a pleasure to meet the team from SPL Powerlines UK, UKRL, DG8 Design and Engineering, Colas Rail, and many others.
“The journey from Leicester to Bedford and back was highly informative and witnessing the pantograph testing along the newly upgraded OLE was truly remarkable. Thank you to everyone involved.”
Image credit: SPL Powerlines
