Injury prevention requires investment in technology

The number of UK rail workers suffering serious injuries is increasing. Yes, the railways are inherently dangerous, but health and safety has never been higher on the agenda, so why are the figures not falling?

In September, the Office of Road and Rail (ORR) released its 2024 Rail Safety Report. It found that severe injuries (the most serious reportable injuries) rose by nearly a quarter to 1,727 in the last year.

Likewise, workforce injuries on the mainline were up 4% to 4,456, while 1,063 were reported on the London Underground alone, an increase of 12% on the previous 12 months.

So, where are we going wrong? Slips, trips, and falls remain the highest cause of injuries in both rail depots and on the London Underground. This is particularly concerning in areas where the third rail is still prevalent and is rarely deactivated for routine maintenance to take place.

The experts at Sheffield-based depot safety specialist, Zonegreen, believe investment in technology can drive down the number of serious incidents taking place across the industry by removing the margin for human error.

The firm – part of international safety group, Sentric – has spent almost 20 years establishing itself as a global leader in depot protection, with facilities as far afield as Australia, New Zealand, and the United Arab Emirates benefiting from its expertise.
Christian Fletcher, Zonegreen’s head of engineering, said: “The incredibly dangerous third rail was conceived in Victorian times, yet is still prevalent in the south’s underground and metro systems and can ultimately prove fatal if touched.

“Despite knowing it carries 750 volts, engineers regularly walk alongside the live system on uneven terrain, in varying weather conditions and sometimes in the dead of night to carry out maintenance. Could there be any better reason for implementing adequate measures to ensure these people can operate in the safest possible environment?

“Sadly, there is still no industry-wide picture of the wide-ranging risks in depots and with high-speed vehicles, high voltage equipment, and powerful machinery all increasing the dangers workers face, it is clear more still needs to be done to improve working conditions.”

Prioritising depot safety

Zonegreen develops technology that reduces the risks faced by depot staff, while allowing the safe and efficient control of rail vehicles.
The firm’s flagship Depot Personnel Protection System (DPPS) is installed in some of the most advanced maintenance facilities around the world, protecting people from plant and vehicle movements.

Personnel using the latest iteration of the system are issued with contactless RFID cards that can be programmed with various levels of authorisation, depending on the individual’s role and position within the depot operations hierarchy. When beginning work in an area of risk, they log on to road end panels that prevent Network Rail-approved derailers from being lowered, providing physical protection by stopping trains entering the occupied road.

Access permission must be given to a train by a supervisor, via the controlling road end panel, which is positioned at a convenient location within the maintenance building. This is usually next to the depot doors, giving the operator a clear view of incoming and outgoing vehicles. Only after the derailer has been lowered will the shunt signal change to ‘proceed.’ Audible and visual warnings are then activated to alert staff to imminent vehicle movement.

Zonegreen’s system is one of the safest on the market, boasting independent certification to prove its compliance with both the hardware and software integrity requirements of SIL 2 – a reliability assessment of the relative risk reduction provided by a safety system. It is also the most thoroughly tested and proven in use, offering a low-risk option to depots looking to improve their working environment.

In addition, Zonegreen’s third generation DPPS RFID panel has been independently certified by Eurofins to be compliant with both the EN 300 330-V2.1.1 radio emissions standard and railway standard EN50128/50129.

Reliability and traceability

Included within the DPPS package is Zonegreen’s advanced Depot Manager SCADA software, which offers an overview of the entire protection system and complete traceability. It displays the location of personnel and the status of plant and equipment, while providing key information to make operations easier and quicker to implement.

For example, the technology can identify peak movement times, allowing additional focus to be placed on safety during these highest risk periods. The system also provides additional visualisation that can run alongside other depot control software to ensure a complete operational picture.

Christian added: “We are working constantly to find new ways to develop and extend our DPPS technology to help depots reduce costs and most importantly, save lives. We future-proof our systems by using modern electronics and an innovative software design that makes them easier to modify and expand. This has improved the user experience, consolidated the safety benefits, and allowed for potential upgrades, something a number of depots have taken advantage of recently.”

Pointing safety in the right direction

Manual hand points are a significant contributory factor to the types of slips, trips, and falls in depots that result in serious injury and absences from work, costing operators and the economy millions of pounds.

To address this issue, Zonegreen has developed Points Converter. The system allows existing manual points to be operated remotely, without compromising their integrity, from a conveniently located handset, preventing handling injuries and exposure to hidden dangers, such as the third rail. It also incorporates event logging technology that enables Depot Manager to keep a record of their operation.

Earlier this year, Zonegreen installed two Points Converters at East Midlands Railway’s Eastcroft depot in Nottingham, taking the total number of automated points at the depot to three. (A single Points Converter was added to the head shunt two years ago.) The latest installations are situated on the west end of the carriage sidings and the original handset, located in the control room, was upgraded to operate all three machines.

The updates at Eastcroft are a perfect example of how Zonegreen future-proofs its technology, allowing it to be expanded to suit the changing needs of each depot. The system is now playing a crucial role in enhancing the safety of EMR staff and eliminating many of the stops and starts necessary when moving vehicles around.

Safety in numbers

As part of the Sentric Safety Group, Zonegreen has the opportunity and tools to expand its portfolio worldwide. It joins international safety brands, Castell, Kirk, STI, and Salvo, to protect people who work in high-risk environments. These respected brands have united together in the belief that there can be no compromise when it comes to safety.

Gemma Houghton, Sentric’s head of rail, commented: “Our mission is to ensure the long-term protection of people, productivity and business reputation. Zonegreen is a perfect ambassador for our group, doing exactly that through the development of innovative technology and vast sector experience.

“We are extremely proud of the innovative rail safety solutions Zonegreen provides to depots across the world and it was a pleasure to be part of the team introducing them to visitors at this year’s InnoTrans.

“Zonegreen’s reputation continues to grow, yet it remains focused on upholding the excellent, long-term relationships it has with clients. This includes leading brands such as Network Rail, Siemens and Hitachi, to name but a few.”

To find out more about DPPS, Points Converter, or Zonegreen’s suite of depot safety systems, telephone (0114) 230 0822, visit www.sentricsafetygroup.com/sector/railway-safety-solutions, or follow on LinkedIn: Zonegreen Ltd.

Image credit: Zonegreen