Projects

A curated selection of major programmes and specialist engineering projects delivered across fleet and infrastructure. Each reflects Railist’s commitment to clarity, technical rigour and structured engineering leadership.

Projects are grouped by programme scale and technical focus below.

Major Programmes

Core Valley Lines (CVL) Transformation – Safety Assurance & Deliverables Leadership

Supporting the transformation of the Core Valley Lines as part of the South Wales Metro, providing safety assurance leadership across one of Wales’ largest rail modernisation programmes.

Work spanned electrification, signalling, stations and track, ensuring structured hazard management, clear safety arguments and programme‑level alignment. 

Key contributions:

  • Delivered CSM‑RA compliant safety assurance across multi‑disciplinary infrastructure works
  • Managed safety requirements, hazard registers and V&V evidence through ComplyPro
  • Chaired HAZID and Hazard Review Panels, strengthening hazard identification, assessment and closeout
  • Coordinated with client engineering teams, contractors and the AsBo to maintain alignment across workstreams
  • Mentored safety engineers, improving capability, consistency and quality of deliverables
  • Supported delivery of major CVL upgrades including 170 km of electrification, station enhancements and line speed improvements

Eurotunnel Maintenance On-track Machine - Engineering Delivery & Product Acceptance

Led the engineering delivery and Service Authorisation of Eurotunnel’s new fleet of Channel Tunnel maintenance modules, including MEWPs, cranes, catenary wire handlers, battery packs and amenity modules.

Provided structured engineering oversight from build through to full-tunnel product trials, supporting compliance with Eurotunnel requirements and readiness for safe operational use within one of the most tightly controlled rail environments in the UK. 

Key contributions:

  • Led end‑to‑end Product Acceptance, ensuring compliance with operational, safety and regulatory requirements
  • Produced Technical, Provisional, Product Trial and Final Authorisation Certificates for each First of Class module
  • Oversaw engineering modifications to S70 wagons enabling module integration
  • Acted as Resident Engineer, resolving production issues and safeguarding engineering quality
  • Led engagement with ICB, AsBo and ISA, securing all required certificates and endorsements
  • Delivered a fully certified, battery‑operated maintenance fleet ready for operational deployment

High Speed Milling (HSM) OTM – Engineering Authorisation & Certification

Led the engineering authorisation of the UK’s first High Speed Milling On-Track Machine, establishing a new rail remediation capability for Network Rail.

The role covered approvals, safety and engineering governance activities under demanding timescales.

Key contributions:

  • Secured full engineering authorisation for the UK’s first HSM OTM
  • Managed NoBo, DeBo and PAB submissions and represented the project at Network Rail Acceptance Panels
  • Established structured project phases, improving planning accuracy and risk visibility
  • Coordinated inspections, testing and documentation requirements with manufacturers and clients
  • Resolved technical queries across structures, fire safety, EMC, bogies, traction, software and compatibility
  • Delivered certification on budget and within a compressed programme

Significant Engineering & Assurance Projects

Class 321 Mid-Life Upgrade

Led the coordination of design, assessment and approvals activities across structural, electrical, gauging, EMC, bogies, fire and PRM requirements. Compiled and integrated multi-disciplinary evidence into structured conformity arguments, supporting external Designated Body endorsement and enabling full certification of the mid-life upgrade programme.

Class 730 AVENTRA Platform

Led cab and passenger comfort systems engineering for West Midlands Trains’ Class 730 fleet, covering system requirements, supplier alignment, integration, testing and V&V across the EMU vehicle environment. Delivered robust engineering governance through design gateways, with assurance documentation recognised by independent assessors as best-in-class.

Class 377 Bogie Monitoring System

Managed independent safety case development and approvals to support the introduction of a bogie monitoring system to Class 377 vehicles. Undertook Railway Group Standards review, contributed to hazard identification and analysis, reviewed the safety case, and produced the Independent Competent Person (ICP) report endorsing system introduction.

Specialist Engineering & Technical Investigations

Traction Motor Rotor Failure Investigation

Conducted and led a detailed investigation into early-life (<2.5 years) rotor bar failures in an electric train traction motor. Forensic examination and fatigue assessment identified crack propagation consistent with torsional resonance linked to inverter frequency at low speed. Applied Miner’s Rule fatigue damage summation and modal frequency analysis to confirm the failure mechanism. Developed targeted design modifications to mitigate resonance, eliminating the failure mode and extending expected rotor life to 25 years. The revised design was subsequently implemented by the TOC.

Track Corrugation Analyser – Structural Assessment

Delivered full structural FEA of a bogie-mounted Rail Corrugation Analyser, assessing performance under operational load cases defined in BS EN 13749. Evaluated proof stress, fatigue life, weld integrity and bolted joint behaviour to ensure compliance and in-service robustness. Implemented targeted design improvements and produced formal structural assessment documentation for NoBo/DeBo/AsBo scrutiny.

C44 Grinder Traction Locker – Structural Validation

Performed full structural FEA and optimisation of Loram’s C44 Grinder traction locker, housing critical traction equipment including inductors, rectifiers, inverter drives, brake choppers, capacitors and AC busbars. Validated structural integrity under operational load cases to BS EN 12663 and implemented targeted design modifications to ensure compliance. Delivered the formal structural validation report supporting vehicle authorisation.

Level Crossing Risk Assessments

Delivered safety risk assessments for level crossings in accordance with the CSM framework, supporting major programmes including the East Coast Main Line, Cambrian Main Line and Sheffield–Doncaster Electrification. Conducted site surveys, facilitated stakeholder workshops, performed ALCRM modelling and developed safety benefit–cost analyses to inform option selection and risk reduction strategies.