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About Smart Rail Services

Founded in 2009, Smart Rail Services is an independent supplier of a unique range of Professional and Technical Services, Equipment and Components to a extensive range of clients and customers, including:

  • Rolling Stock Owning Companies
  • Train Operating Companies - Passenger and Freight
  • Rail Vehicle Manufacturers and Overhaulers
  • Independent Vehicle Owners
  • Technical and Engineering Consultancies
  • Equipment and Component Suppliers

Support provided by Smart Rail Services is tailored to meet the individual requirements of each client and is based upon extensive experience underpinned by a fundamental understanding of the rail industry. For more information on how Smart Rail Services can support your organisation to achieve its goals, please follow the links above or if you have a specific enquiry, please Contact Us.


Smart Fuel Meters

Since 2022, Smart Rail Services has also incorporated the former JPS Engineering business, manufacturing and supplying Smart Fuel Consumption Meters for clients in the Automotive, Rail, Off-Highway and Auxilliary Power sectors. Further information about our range of Smart Fuel Meters and associated services can be found HERE.

The installation of Smart Fuel Consumption Meters provides vehicle owners and operators with the ability to accurately and quickly evaluate fuel consumption usage on their fleets. Utilising in-house technical, engineering and operational expertise, Smart Rail Services supports operators to develop and implement effective fuel saving strategies and to evaluate the impact on overall fuel usage of vehicle modifications and component upgrades.

The design and configuration of the FMR (Fuel Meter Rail) range of Fuel Consumption Meters specifically designed for Rail Vehicle applications, provides:

  • Unequalled performance and proven reliability in Rail Vehicle applications
  • Tailored solutions to suit all engine power outputs
  • Ultra-high resolution measurements with less than 1% error
  • Integrated temperature monitoring for supply and return fuel
  • Simple integration into extensive remote engine monitoring systems
  • Approved and proven solutions for rail use

Utilising extensive experience and expertise in rail vehicle design, engineering and operation, Smart Rail works with key industry partners to develop, design and install remote monitoring systems to provide rail vehicle owners and operators with uprecidented levels of information. Smart Rail also supports owners and operators to transform the raw data generated by these system into valuable information, supporting the enhancement of preventative maintenance programmes, providing critical component performance alerts, supporting general health monitoring and inspiring component improvements and enhancements.

For more information on the FMR and our wider range of Fuel Consumption Meters, Remote Monitoring Systems for Engines, Transmissions, Cooler Groups and other major components please follow the links above or if you have a specific enquiry, please Contact Us.


Turnkey Modifications

Smart Rail Services has successfully delivered a number of Turnkey Modification packages for major clients, undertaking a wide range of activities including:

  • Evaluating Client requirements to develop outline design options
  • Assisting Clients to make informed decisions based on options available
  • Developing equipment and system designs, using 2D & 3D Computer Aided Design (CAD) tools
  • Providing detailled 3D models and 'photo-realistic' graphics to enable the aesthetics of new components to be evaluated
  • Providing physical models of key components utilisting in-house 3D printing capabilities
  • Undertaking Finite Element Analysis and Model Frequency simulations to optimise component design to simplify manufacture and to demonstrate compliance with GM/RT2100
  • Producing detailed Technical Files demonstrating how compliance with applicable Railway Group and Rail Industry Standards (RGS & RIS) has been achieved, as part of the 'Management of Engineering Change' process
  • Authoring Modification Procedures, Vehicle Maintenance Instructions, Technical Bulletins and other docuemntation required to manage and support the installation of new systems and equipment
  • Manufacturing and procuring equipment from chosen suppliers, components and other items in accordance with Bills of Materials (BoMs) in advance of physical installations
  • Working on-site at Client facilities, in collaboration with other Engineers to undertake the physical installation and functional testing of new equipment and systems
  • Providing ongoing post-installaltion support for equipment and undertaking periodic checks and overhauls to agreed schedules

Utilising these and other skills, Smart Rail Services recently completed the installation of Remote Fuel Consumption and Engine Data Stream Monitoring systems on Class 170 TurboStar Diesel Multiple Unit - 170521 for CrossCountry Trains. Working with CrossCountry Engineers and in collaboration with Instrumentel Limited, this Project was delivered in just three months from award of contract - a demnostration of the expeience, expertise and rigour which Smart Rail Services brings to Turnkey Modifications.

The following video shows the completed installation of the Smart Rail Services FMR30 Fuel Consumption Meter, Bypass Manifold and Modified Fuel System on 170521 and a more detailed Case Study based on this project is provided here.


Professional Services

Smart Rail Services works with a wide range of Clients in the UK rail industry, providing an extensive variety of services to support the development, enhancement and approvals of new and upgraded components, products and equipment. Professional Services which Smart Rail provides include:

  • Ground-up design of new equipment and components for rail vehicle applications
  • Equipment and systems inegration of new components and equipment onto rail vehicles
  • Finite Element Analysis and Modal Frequency simulations to evaluate component and equipment designs as part of Engineering Change approvals
  • Independent Competent Person (ICP) approvals of new equipment and component designs in accordance with the requirements of RIS-2700-RST
  • On-vehicle functional and performance testing of new equipment and components as part of construction verification

A brief summary of some recent projects where Smart Rail Services has provided Professional Services support to key clients are provided below.


Client: Belvoir Rail

Following an enquiry from CrossCountry Trains, Belvoir Rail commissioned Smart Rail Services to undertake the development and design of Main Reservoir Pipework Guards for use on Class 170 DMUs. Following an initial vehicle survey, the design of a suitable bracket was developed in 3D CAD, from which 2D piece-part, assembly and flat-panel drawings were derived. These were used to manufacture the initial prototype guard, which was trial fitted to identify design enhancements for the production items.

Rendered 3D Model Finite Element Analysis - Impact Study

In support of the Management of Engineering Change review, Smart Rail Services undertook a detailed review of the design and installation of the new Main Reservoir Guards to demonstrate compliance with the requirements of applicable Railway Group and Rail Industry Standards. Key to this was the demonstration of compliance with the requirements of GM/RT2100 - 'Requirements of Rail Vehicle Structures', as part of which Finite Element Analysis (FEA) and Modal Frequency Analysis (MFA) simulations were undertaken. These studies confirmed that the structural performance of the new Guards in the 'standard' and 'ultimate' load cases were acceptable with siginficant safety factors. In addition, given the exposed position of the new Guards on the Class 170, an additional study was undertaken to evaluate the way in which the structure would be expected to deflect in the event of a bird-strike at 100mph. In this case it was confirmed that the levels of deflection were within the expected limits and would provide effective protection for the Main Reservoir Pipework and Isolation Cocks which the Guard is designed for.


Client: Thornhill Rail Ltd

As part of the development of a new Class 158 'hemmed-fin' radiator design, Thornhill Rail Ltd commissioned Smart Rail Services to act as their Independent Competent Person to underake a detailed review of the functional performance and a detailed review of compliance against the requirements of Railway Group and Rail Industry Standards. On completion of the Design Review, as documented in the Design Technical File, it was identified that there were certain aspects of compliance and component performance that could not be confirmed without on-vehicleperformance testing.

In conjunction with Arriva Trains Wales, Thornhill Rail Ltd fitted one of the new radiators on 158828 at Machynlleth Depot. Using temperature sensors fitted within the Cooling Water, Engine Oil and Transmission Oil circuits, Smart Rail Services logged performance data during two test runs on the infamous Talerddig Bank using a PicoLog Signal Recorder. This performance data, when combined with contextual information from an additional GPS logger, was analysed to confirm that the new radiator design achieved a superior cooling rate than that of the previous radiator design. On the basis of this information, Smart Rail Services was then able to provide a Letter of Endorsement to confirm that the new 'hemmed-fin' radiator design was considered to be a Direct Replacement Component for the original type and suitable for use on all Class 158 Units. This enabled Thornhill Rail Ltd to successfully offer the new radiator as a fully validated and approved product to all Class 158 operators.


Project Management

Smart Rail Services has been responsible for the delivery of a number of major rail vehicle projects, integrated within Client organisations to effectively manage in-house and external stakeholders and achieve successful completion in accordance with key success-criteria. Project management activities delivered by Smart Rail Services include:

  • Development of strong relationships with staff within client, supplier and customer organiations
  • Provision of project leadership, maintaining progress in accordance with agreed timescales
  • Provision of technical and engineering expertise based on extensive experience in the design, development and implementation of Rail Vehicle modifications
  • On-site engineering services, including management and reporting of progress, resolution of arising issues and stakeholder management
  • Post installation functional, performance and system development testing support, working with Train Operators to complete in-service vehicle testing
  • Assisting Traincrew/Driver Managers and individual Drivers to understand how modifications to vehicle systems affect them

A brief summary of some recent projects where Smart Rail Services has provided Project Management support to key clients are provided below.


Client: Angel Trains

Following an extended period of ongoing technical support to the Angel Trains Diesel Fleet Team, Smart Rail Services was asked to support the Engineering Development Team and manage the final approvals, installation and evaluation of the DIWARail transmission project. The integration of the new DIWARail transmission, supplied by VOITH, was a high-profile Development project for Angel Trains for evaluation as a replacement for the original T211 transmissions fitted on Class 158 and 16X Diesel Multiple Units. To ensure the successful delivery of the project, close collaboration was required between key stakeholders in Angel Trains, Arriva Trains Wales, VOITH UK and VOITH GMBH to ensure the effective transfer of critical information.

As Project Manager, Smart Rail Services worked closely with staff at Arriva Trains Wales, initially to develop the fuel consumption measurement system installation design and to evaluate and define testing routes used to evaluate fuel useage prior to and after the installation of the new transmission. Work then focussed on defining an agreed schedule for the completion and delivery of equipment by VOITH, documentation and Engineering Change approvals and to ensure the availability of the Unit to which the new DIWARail transmission was to be fitted.

Having agreed a three-week window for the installation at ATW Cardiff Canton Depot, Smart Rail Services provided on-site installation support - acting as resident engineer on behalf of Angel Trains and providing the point of liaison between staff from ATW, VOITH UK and VOITH GMBH. During the installation process, a number of minor but critical issues with the design of new components/equipment were identified. Utilising extensive engineering experience, Smart Rail was able to identify and implement technical solutions to these issues, which allowed the full installation to be completed in just two weeks.

DIWARail Transmission During Installation DIWARail Modification Team

On completion of the installation, Smart Rail Services managed the on-track testing and commissioning process, supporting VOITH engineers to evaluate and enhance software parameters for the new transmission. After a period of mileage accumulation, 158834 equipped with the VOITH DIWARail transmission officially entered revenue earning service on the service from Cardiff Central to Manchester Piccadilly just 18 days after the installation began!

158834 - DIWARail Transmission 1st Service Run 158834 - Fuel Consumption Testing

To complete the project, Smart Rail Services undertook extensive fuel consumption monitoring runs over the agreed testing routes and worked extensively with Driver Managers and individual Driver's to explain the differences between the way the DIWARail and T211 transmissions perform. Evaluation of the data generated from these tests was analysed and merged with contextual data from the On Train Monitoring and Recording (OTMR) system to provide highly detailed analysis of fuel consumption. This analysis, which took into account of the effects of differing driving styles, weather conditions and other variables demonstrated that the DIWARail transmission generated significant overall fuel savings. The detailed report produced by Smart Rail Services based on the completed analysis was used by Angel Trains in the development of the Cost/Benefit Analysis for the DIWARail transmission.


Controlled Emission Toilet (CET) Systems

Smart Rail Services has developed Controlled Emission Toilet (CET) systems for a range of UK rail vehicles, including Mk I and Mk III coaching stock. These systems are fully compliant with the requirements of Railway Group and Rail Industry Standards (RGS & RIS) and utilise standard connections to allow tanks to be emptied by existing fixed extraction infrastructure installed on UK Railway Depots.

The key features of the Smart Rail Services CET systems:

  • Low flush volume, macerating toilets, proven in rail vehicle applications
  • Fully welded fabricated Stainless Steel retention tanks, with integral cleaning system, external insulation and ballast protection
  • Connecting and extraction pipework in Stainless Steel with RJT connectors
  • Industry standard camlock connections for solebar extraction and gravity discharge stations

Smart Rail Services CET systems can be configured to include electronic Tank Level monitoring systems to provide alerts when emptying is required. These systems can also be used interlocked with toilet flush mechanisms to prevent over-filling and uncontrolled release of effluent. Given the number of variations of vehicle types and existing equipment installations, Smart Rail Services is able to tailor systems to suit specific applications and supply complete systems in kit form for local installation, or provide a full turnkey installation service.

For more information on CET systems to suit your particular vehicle requirements, please Contact Us.