1 00:00:05,004 --> 00:00:08,258 {\an8}Forged in fire and cast in steel... 2 00:00:08,258 --> 00:00:10,552 It's big, it's huge, it's intimidating. 3 00:00:10,552 --> 00:00:13,471 ...giant metal machines are engineered to make 4 00:00:13,471 --> 00:00:16,683 human efforts at work and play easier. 5 00:00:16,683 --> 00:00:18,059 It's like a monster. 6 00:00:18,184 --> 00:00:21,146 Metal touches every aspect of human life, 7 00:00:21,146 --> 00:00:24,441 from trains and ships to factories. 8 00:00:24,441 --> 00:00:27,110 It is a part of building bigger and better technology 9 00:00:27,110 --> 00:00:29,446 to keep our world turning. 10 00:00:35,285 --> 00:00:37,287 {\an8}London, England is home to the oldest 11 00:00:37,287 --> 00:00:40,415 {\an8}and one of the largest subway systems in the world... 12 00:00:43,084 --> 00:00:45,420 ...the London Underground. 13 00:00:45,545 --> 00:00:49,049 We are now one in every ten journeys in the UK. 14 00:00:49,174 --> 00:00:51,843 Millions of tons of metal twisted 15 00:00:51,843 --> 00:00:53,219 into an intricate labyrinth of rails. 16 00:00:53,219 --> 00:00:56,264 - It's like a monster. -Hundreds of trains, 17 00:00:56,389 --> 00:00:58,516 seemingly endless amounts of track 18 00:00:58,641 --> 00:01:00,977 and a multitude of stations. 19 00:01:00,977 --> 00:01:02,896 WOMAN (Recorded:) This is an Elizabeth line service 20 00:01:03,021 --> 00:01:04,230 to Sheffield. 21 00:01:04,356 --> 00:01:07,067 Moving over 1.3 billion riders each year. 22 00:01:07,067 --> 00:01:10,195 It's about six million customer journeys a day, 23 00:01:10,195 --> 00:01:11,613 so it's a busy, busy network. 24 00:01:11,738 --> 00:01:16,659 Transporting people seamlessly beneath the city. 25 00:01:16,785 --> 00:01:19,120 No separate access available at Harrow on the Hill station. 26 00:01:19,245 --> 00:01:21,122 Never a dull day here. 27 00:01:21,247 --> 00:01:22,791 But to keep it going... 28 00:01:22,791 --> 00:01:25,251 We're ready to race. 29 00:01:25,251 --> 00:01:28,046 ...takes constant maintenance and repairs. 30 00:01:34,260 --> 00:01:35,679 {\an8}The London Underground subway 31 00:01:35,679 --> 00:01:38,807 {\an8}is this giant machine. It's a huge network of tracks 32 00:01:38,932 --> 00:01:41,810 {\an8}moving incredible amounts of people every minute of the day. 33 00:01:41,810 --> 00:01:45,313 WOMAN (Recorded:) The next station is Liverpool Street. 34 00:01:45,438 --> 00:01:47,315 But this 400-kilometre system 35 00:01:47,315 --> 00:01:51,111 comes from humble beginnings. 36 00:01:52,404 --> 00:01:54,280 The London Underground is old, and to put it in perspective 37 00:01:54,280 --> 00:01:57,367 of just how old it is, think of it this way. 38 00:01:57,367 --> 00:02:00,120 The subway system was built before the automobile, 39 00:02:00,120 --> 00:02:01,871 even before the light bulb. 40 00:02:01,871 --> 00:02:04,124 In fact, Abraham Lincoln was the President of the United States 41 00:02:04,124 --> 00:02:06,501 when the London Underground 42 00:02:06,626 --> 00:02:08,169 first opened its doors. That's crazy. 43 00:02:08,169 --> 00:02:12,257 In 1860, London, England 44 00:02:12,257 --> 00:02:14,175 was the largest city in the world, 45 00:02:14,300 --> 00:02:16,344 with a population of over three million, 46 00:02:16,469 --> 00:02:18,972 and nearly a quarter million people commuted by bus, 47 00:02:19,097 --> 00:02:20,098 rail or on foot each day. 48 00:02:20,098 --> 00:02:22,142 To relieve the congestion, 49 00:02:22,142 --> 00:02:24,936 the trains were moved underground, 50 00:02:24,936 --> 00:02:27,147 resulting in the world's first subway. 51 00:02:30,859 --> 00:02:32,902 {\an8}The London Underground was first constructed using 52 00:02:32,902 --> 00:02:34,029 {\an8}the cut-and-cover method, 53 00:02:34,154 --> 00:02:36,239 {\an8}where a trench was dug along the streets 54 00:02:36,239 --> 00:02:37,699 {\an8}and then covered over. 55 00:02:37,824 --> 00:02:39,701 {\an8}The initial trains were gas-lit 56 00:02:39,826 --> 00:02:43,163 {\an8}wooden carriages hauled by steam-powered locomotives. 57 00:02:43,288 --> 00:02:44,497 {\an8}They burned coal 58 00:02:44,497 --> 00:02:46,833 {\an8}to heat the water in a boiler to create steam. 59 00:02:48,460 --> 00:02:49,544 {\an8}Along with steam, 60 00:02:49,544 --> 00:02:52,005 {\an8}it created a ton of air pollution. 61 00:02:52,130 --> 00:02:53,882 {\an8}To eliminate the pollution and improve 62 00:02:53,882 --> 00:02:56,009 {\an8}the overall efficiency and reliability of the service, 63 00:02:56,009 --> 00:02:58,219 {\an8}the London Underground began shifting 64 00:02:58,344 --> 00:03:00,388 {\an8}to electric power in the 1890s. 65 00:03:02,307 --> 00:03:05,977 {\an8}And by 1905, the entire network was electrified, 66 00:03:05,977 --> 00:03:08,188 {\an8}including the locomotives. 67 00:03:09,314 --> 00:03:12,108 {\an8}Today, the network 68 00:03:12,108 --> 00:03:14,277 {\an8}is an integral part of daily life in London. 69 00:03:14,277 --> 00:03:17,489 {\an8}So, it's approximately five million customer journeys a day 70 00:03:17,489 --> 00:03:20,200 {\an8}on the London Underground network. 71 00:03:20,325 --> 00:03:23,745 If you look at that for the whole of the United Kingdom, 72 00:03:23,870 --> 00:03:26,039 that's more than all of the other mainline 73 00:03:26,039 --> 00:03:27,916 train services combined. 74 00:03:28,041 --> 00:03:29,501 Good afternoon. 75 00:03:29,501 --> 00:03:31,336 This is James at the London Underground Control Centre 76 00:03:31,336 --> 00:03:33,713 with a network information broadcast. 77 00:03:33,838 --> 00:03:35,882 The biggest challenge is keeping the Underground 78 00:03:35,882 --> 00:03:37,258 running smoothly and on time. 79 00:03:37,384 --> 00:03:40,220 Any downtime or delays can cause a snowball effect 80 00:03:40,345 --> 00:03:41,930 throughout the system. 81 00:03:42,347 --> 00:03:44,474 So, even when things 82 00:03:44,474 --> 00:03:46,434 seem to be running smoothly on the tracks, 83 00:03:46,559 --> 00:03:50,397 the potential for trouble is always brewing. 84 00:03:55,485 --> 00:03:59,447 So the only other option we have is to suspend it so that we can put a good train at Mill Hill. 85 00:04:00,031 --> 00:04:02,742 Push this one past towards Mill Hill, so it's there. 86 00:04:03,201 --> 00:04:06,329 We've got a train that's broken down at this station. 87 00:04:06,329 --> 00:04:08,248 We had two trains stuck behind it, 88 00:04:08,248 --> 00:04:09,749 which had customers on board. 89 00:04:09,874 --> 00:04:12,460 And now, we're looking at how we can recover this train. 90 00:04:12,585 --> 00:04:16,381 No set free access available at Harrow on the Hill station. 91 00:04:16,506 --> 00:04:18,133 This is due to a customer incident. 92 00:04:18,258 --> 00:04:20,427 Never a dull day here. 93 00:04:20,552 --> 00:04:23,596 Yesterday, we had a person that wasn't breathing on a train. 94 00:04:23,722 --> 00:04:25,765 We had a CPR ongoing because of that situation. 95 00:04:25,890 --> 00:04:27,350 {\an8}We couldn't move the person from the train, 96 00:04:27,350 --> 00:04:28,601 {\an8}so the line was suspended. 97 00:04:32,480 --> 00:04:37,444 And when things go wrong, things build up really quickly. 98 00:04:37,444 --> 00:04:39,446 Woman over PA: Train out of Platform B 99 00:04:39,446 --> 00:04:42,073 with service to Reading... Platform B, Reading. 100 00:04:42,073 --> 00:04:43,867 -Prime Whiskey-7-8. 101 00:04:43,867 --> 00:04:44,909 What have you done there? 102 00:04:44,909 --> 00:04:47,704 We've done... shut the doors. 103 00:04:55,795 --> 00:04:59,007 We shift a lot of people, up to 800,000 people a day. 104 00:04:59,132 --> 00:05:02,469 {\an8}So, a three-minute delay down here can be catastrophic. 105 00:05:02,469 --> 00:05:06,598 So, our next station is Bond Street. 106 00:05:06,598 --> 00:05:09,350 Of the 11 subway lines in the London Underground, 107 00:05:09,350 --> 00:05:12,103 the Elizabeth Line is the busiest, 108 00:05:12,103 --> 00:05:14,147 transporting nearly a million riders 109 00:05:14,147 --> 00:05:18,860 along its 118-kilometre track every day. 110 00:05:18,860 --> 00:05:20,695 {\an8}With the introduction of the Elizabeth Line, 111 00:05:20,820 --> 00:05:24,282 {\an8}we are now one in every ten journeys in the UK. 112 00:05:24,282 --> 00:05:27,827 {\an8}So, we are the most frequently used train in the UK, 113 00:05:27,827 --> 00:05:30,830 {\an8}and that's from Scotland, all the way down to in London. 114 00:05:32,082 --> 00:05:35,502 This system is the backbone of London Transit. 115 00:05:37,754 --> 00:05:40,757 And it takes a significant beating. 116 00:05:40,757 --> 00:05:42,342 We're going into the shed 117 00:05:42,342 --> 00:05:44,636 because this train is due planned maintenance. 118 00:05:44,636 --> 00:05:47,514 All that bumping and grinding on the tracks 119 00:05:47,514 --> 00:05:50,517 results in a constant flow of repairs 120 00:05:50,517 --> 00:05:54,187 for depots across the city, 121 00:05:54,187 --> 00:05:56,481 like here at Old Oak Common. 122 00:05:59,609 --> 00:06:01,319 Okay, your route should be coming up shortly for you. 123 00:06:01,319 --> 00:06:03,196 MAN Thank you. 124 00:06:03,321 --> 00:06:05,073 {\an8}On a 12-hour shift, 125 00:06:05,198 --> 00:06:06,741 {\an8}roughly between midnight and midnight, 126 00:06:06,741 --> 00:06:09,035 {\an8}we could have over 100 train moves. 127 00:06:11,037 --> 00:06:14,541 I think it's something like 112 trains arriving and departing. 128 00:06:14,541 --> 00:06:15,917 So, it can get pretty busy. 129 00:06:15,917 --> 00:06:18,795 Each line of the London Underground 130 00:06:18,795 --> 00:06:20,714 has at least one maintenance depot to service 131 00:06:20,714 --> 00:06:24,592 and maintain its trains overnight. 132 00:06:24,718 --> 00:06:26,678 There are 14 depots throughout the system 133 00:06:26,803 --> 00:06:30,181 to address the variety of challenges that come 134 00:06:30,181 --> 00:06:31,891 with such heavy use. 135 00:06:34,561 --> 00:06:36,938 So, this is old O'Connor depot. 136 00:06:37,063 --> 00:06:41,276 We do all planned preventative maintenance, which is our exams, 137 00:06:41,401 --> 00:06:43,695 all the way through to corrective repairs. 138 00:06:43,695 --> 00:06:46,406 So, this is the sole location 139 00:06:46,406 --> 00:06:49,284 to maintain the Class 345 Elizabeth Line fleet. 140 00:06:49,409 --> 00:06:50,785 It all starts 141 00:06:50,785 --> 00:06:53,455 with the Automatic Vehicle Inspection System, 142 00:06:53,455 --> 00:06:55,623 or AVIS for short. 143 00:06:55,623 --> 00:06:58,251 As the train rolls into the depot, 144 00:06:58,251 --> 00:07:01,921 the AVIS uses special cameras, lasers, and thermal imaging 145 00:07:02,047 --> 00:07:03,590 to scan every component of its structure, 146 00:07:03,590 --> 00:07:07,469 from the roof and body, to the wheels, brakes, and axles. 147 00:07:07,594 --> 00:07:11,306 It collects data on the condition of the components, 148 00:07:11,431 --> 00:07:13,933 anticipating problems before they occur. 149 00:07:13,933 --> 00:07:16,186 Once the train has cleared the system, 150 00:07:16,186 --> 00:07:17,854 AVIS details the repairs needed, 151 00:07:17,854 --> 00:07:21,399 optimizing maintenance. 152 00:07:24,402 --> 00:07:28,239 {\an8}AVIS is like a doctor scanning your entire body 153 00:07:28,239 --> 00:07:30,200 {\an8}and doing every test 154 00:07:30,200 --> 00:07:32,869 {\an8}all at once to see how healthy you are. 155 00:07:32,869 --> 00:07:36,164 So, you can see AVIS building has now illuminated. 156 00:07:36,289 --> 00:07:38,500 So, this section here we're coming into takes photographs 157 00:07:38,500 --> 00:07:40,877 of the outside of the trains. 158 00:07:40,877 --> 00:07:43,296 There are two AVIS sheds, with washers, 159 00:07:43,421 --> 00:07:45,757 processing 35 trains per day - 160 00:07:45,757 --> 00:07:48,301 half of the Elizabeth Line fleet. 161 00:07:48,426 --> 00:07:51,471 They allow the team to stay on top of maintenance and address 162 00:07:51,596 --> 00:07:54,391 potential issues before they lead to breakdowns. 163 00:07:55,642 --> 00:07:57,727 But the AVIS doesn't stop there. 164 00:08:01,648 --> 00:08:03,358 And the lasers below, 165 00:08:03,483 --> 00:08:05,568 they'll be measuring the brake pad thickness. 166 00:08:08,154 --> 00:08:11,324 Getting this kind of intricate report helps maintenance crews 167 00:08:11,324 --> 00:08:15,829 to plan out repairs that are needed for the fleet super fast. 168 00:08:16,663 --> 00:08:17,580 Before the AVIS, 169 00:08:17,580 --> 00:08:20,208 a train would be manually inspected 170 00:08:20,333 --> 00:08:21,876 once every month. 171 00:08:21,876 --> 00:08:24,504 But now, maintenance technicians scan 172 00:08:24,629 --> 00:08:28,758 and even wash the train in about five minutes. 173 00:08:30,343 --> 00:08:32,637 It's done every time a train comes back onto depot. 174 00:08:32,637 --> 00:08:36,141 They go through AVIS and the wash. 175 00:08:36,141 --> 00:08:39,936 So, every 48 hours, roughly, we get every train back to depot. 176 00:08:43,148 --> 00:08:47,193 However, not everything is a quick fix. 177 00:08:47,318 --> 00:08:50,697 When there's more significant damage or maintenance is needed, 178 00:08:50,822 --> 00:08:53,950 it calls for major overhauls. 179 00:08:55,910 --> 00:08:57,829 The Elizabeth Line is the busiest 180 00:08:57,829 --> 00:08:59,873 of all the London Underground lines. 181 00:08:59,873 --> 00:09:02,250 Collectively, trains on this line 182 00:09:02,250 --> 00:09:05,920 travel over 32,000 kilometres a day. 183 00:09:06,046 --> 00:09:08,631 That causes a lot of wear on the trains, 184 00:09:08,757 --> 00:09:10,842 especially on the bogies. 185 00:09:15,680 --> 00:09:17,724 Bogies are sets of four wheels 186 00:09:17,724 --> 00:09:20,477 attached to each axle of the train car. 187 00:09:20,477 --> 00:09:22,812 When these bogies travel along the twists and turns 188 00:09:22,812 --> 00:09:26,566 of the tracks, the outside wheels wear differently 189 00:09:26,566 --> 00:09:28,568 than the ones on the inside. 190 00:09:28,568 --> 00:09:31,905 That uneven wearing can cause big problems. 191 00:09:32,030 --> 00:09:34,282 So, like rotating the tires on a car, 192 00:09:34,407 --> 00:09:37,786 these wheels have to be moved to different positions, too. 193 00:09:37,786 --> 00:09:40,163 MAN Have my permission 194 00:09:40,163 --> 00:09:43,583 to pass the stockyards and enter the shed on line 9. 195 00:09:43,708 --> 00:09:44,834 - Understood. 196 00:09:44,834 --> 00:09:50,256 So, we're coming into Road 9, Maintenance Road 9. 197 00:09:50,256 --> 00:09:52,592 This road is specifically designed 198 00:09:52,592 --> 00:09:55,261 to be able to lift this train up into the air. 199 00:09:56,596 --> 00:09:58,973 This track leads to the synchronized jacking system, 200 00:09:58,973 --> 00:10:03,311 where 36 high-pressure hydraulic cylinders lift 201 00:10:03,436 --> 00:10:06,022 all nine cars of the 200-meter-long train, 202 00:10:06,022 --> 00:10:10,193 giving maintenance workers access to the bogies. 203 00:10:12,904 --> 00:10:15,323 About 50 meters to go still. 204 00:10:15,448 --> 00:10:18,743 Changing the position of the wheels is a major job, 205 00:10:18,743 --> 00:10:20,662 which starts by lining up the trains anchor points 206 00:10:20,787 --> 00:10:23,123 with the jacks. 207 00:10:23,248 --> 00:10:25,500 MAN Okay, slow down, James. 208 00:10:25,500 --> 00:10:29,838 Five, four, three, 209 00:10:29,963 --> 00:10:30,839 two, go in. 210 00:10:30,839 --> 00:10:33,091 Lovely. 211 00:10:34,092 --> 00:10:35,385 Lovely. 212 00:10:35,385 --> 00:10:38,722 {\an8}So, we're just putting in the last jack to move up the train. 213 00:10:41,641 --> 00:10:43,309 Okay, we're ready to race. 214 00:10:43,309 --> 00:10:44,811 JAMES Yeah, in position. 215 00:10:44,811 --> 00:10:46,896 Okay, going to start lifting now. 216 00:10:47,772 --> 00:10:49,816 Each hydraulic jack is connected 217 00:10:49,816 --> 00:10:51,443 to a central computer-controlled unit 218 00:10:51,443 --> 00:10:54,529 that ensures all the jacks are synchronized while lifting 219 00:10:54,654 --> 00:10:56,740 or lowering the train. 220 00:10:58,575 --> 00:11:00,035 Lift complete. 221 00:11:00,035 --> 00:11:01,661 The next step is to rotate 222 00:11:01,661 --> 00:11:04,539 the bogies as fast and as safely as possible. 223 00:11:04,664 --> 00:11:05,707 Enter the bogie drop - 224 00:11:05,707 --> 00:11:08,043 a custom-made system 225 00:11:08,043 --> 00:11:09,711 that carries bogies down through the floor, 226 00:11:09,836 --> 00:11:14,007 along a conveyor, and back up to the waiting train. 227 00:11:16,176 --> 00:11:18,970 {\an8}Today, we're rolling the bogie onto the bogie drop. 228 00:11:18,970 --> 00:11:22,057 {\an8}From a bogie workshop, we're going to be dropping it down 229 00:11:22,182 --> 00:11:25,268 {\an8}and round onto a Mike-7, ready to fit to another train. 230 00:11:28,855 --> 00:11:32,400 If my leading axle or wheelset has hit, you know, a tree branch 231 00:11:32,525 --> 00:11:34,819 or something like that and it's made the wheelset defective, 232 00:11:34,819 --> 00:11:38,406 we can utilise the bogie drop to replace that wheelset 233 00:11:38,531 --> 00:11:40,033 within maybe an hour. 234 00:11:41,701 --> 00:11:44,663 Going to drop down to the bottom of the bogie drop. 235 00:11:44,663 --> 00:11:49,042 Going to traverse across around 30-40 meters. 236 00:11:49,042 --> 00:11:52,879 So, this is a brand new system for this depot. 237 00:11:53,963 --> 00:11:56,049 And then, come back up 238 00:11:56,174 --> 00:11:57,884 in line with the rails in front of that train. 239 00:12:01,888 --> 00:12:06,267 The new Old Oak Common Depot opened in 2018. 240 00:12:06,393 --> 00:12:10,730 It's a transport super hub, capable of servicing 70 trains. 241 00:12:10,897 --> 00:12:12,941 We can do maintenance 242 00:12:13,066 --> 00:12:14,859 in a lot more timely fashion... 243 00:12:17,529 --> 00:12:18,780 ...than other depots that are older 244 00:12:18,905 --> 00:12:21,908 because we have the better equipment on our site, 245 00:12:21,908 --> 00:12:23,410 which is really good. 246 00:12:27,330 --> 00:12:28,873 Just as important as the trains, 247 00:12:28,873 --> 00:12:31,543 the tracks also need continuous upkeep 248 00:12:31,543 --> 00:12:34,629 due to the relentless pounding they take. 249 00:12:34,629 --> 00:12:38,299 {\an8}The fact of the passenger trains going over 250 00:12:38,425 --> 00:12:40,218 {\an8}just constantly, literally just grinding down 251 00:12:40,218 --> 00:12:44,472 {\an8}the profile of the track, normally, 252 00:12:44,597 --> 00:12:47,142 {\an8}it happens more over to one side if you're on a corner, 253 00:12:47,142 --> 00:12:49,728 {\an8}where the train will ride up 254 00:12:49,728 --> 00:12:53,523 {\an8}and it will take out the curve of the rail over constant use. 255 00:12:53,523 --> 00:12:55,317 Back in the old days of the Underground, 256 00:12:55,317 --> 00:12:58,320 when it first opened, the workers had to walk the tracks 257 00:12:58,445 --> 00:13:01,865 and visually inspect the rails to check for any damage. 258 00:13:03,825 --> 00:13:06,411 {\an8}The workers used hammers to strike the rails 259 00:13:06,411 --> 00:13:09,164 {\an8}and listen for unusual sounds, 260 00:13:09,164 --> 00:13:11,499 {\an8}and then use the manual grinding or filing tools 261 00:13:11,624 --> 00:13:13,877 {\an8}to remove all the surface irregularities. 262 00:13:15,545 --> 00:13:18,173 {\an8}Or even worse, having to cut out the defective part 263 00:13:18,173 --> 00:13:20,467 {\an8}and weld in a new section by hand. 264 00:13:22,260 --> 00:13:23,553 But today, 265 00:13:23,678 --> 00:13:26,806 it's a much more technologically advanced endeavour. 266 00:13:26,931 --> 00:13:30,143 When the London Underground shuts down for the night 267 00:13:30,143 --> 00:13:33,021 and the city goes to sleep, 268 00:13:33,146 --> 00:13:37,275 the work of the rail milling train begins. 269 00:13:37,275 --> 00:13:39,653 - Okay, on the move. 270 00:13:39,778 --> 00:13:42,322 So, we always mill overnight. We don't mill during the day. 271 00:13:42,322 --> 00:13:46,576 Otherwise, it can disrupt the passenger train services. 272 00:13:48,078 --> 00:13:51,373 Before the rail milling train can get started, 273 00:13:51,498 --> 00:13:54,584 a series of safety checks must be completed. 274 00:13:55,543 --> 00:13:59,255 TPWS and AWS operational. 275 00:13:59,255 --> 00:14:00,924 {\an8}So, it's now in work mode 276 00:14:00,924 --> 00:14:02,133 {\an8}and Marcin can test out 277 00:14:02,258 --> 00:14:03,843 {\an8}all the equipment's working as it should be. 278 00:14:03,843 --> 00:14:06,346 {\an8}And we'll be able to operate the milling machine. 279 00:14:06,346 --> 00:14:08,390 - Ready to drop down. 280 00:14:08,390 --> 00:14:11,101 {\an8}Every night we have to simulate the operation. 281 00:14:11,101 --> 00:14:15,647 {\an8}To check the machine is actually operating as it should before, 282 00:14:15,647 --> 00:14:19,859 {\an8}because on the shift, there's not time to fix that. 283 00:14:19,985 --> 00:14:21,236 Right. 284 00:14:21,236 --> 00:14:24,656 Basically we have to ensure that the machine is faultless. 285 00:14:24,781 --> 00:14:26,991 I'm looking now at the Eddy current system 286 00:14:26,991 --> 00:14:30,537 to make sure that there's no springs or anything broken, 287 00:14:30,537 --> 00:14:32,789 all the cylinders are in the correct places, 288 00:14:32,914 --> 00:14:35,709 making sure there's nothing physically damaged. 289 00:14:35,834 --> 00:14:38,378 I'm just checking the polishing unit and the grinding unit. 290 00:14:38,503 --> 00:14:41,381 Sometimes, after constant use, you get some damages 291 00:14:41,381 --> 00:14:43,466 along the edges there 292 00:14:43,466 --> 00:14:48,054 and up the top there where the grinder dust is going through. 293 00:14:48,179 --> 00:14:49,431 When the tests are complete, 294 00:14:49,431 --> 00:14:52,183 the rail milling train gets the okay 295 00:14:52,183 --> 00:14:54,394 from dispatch to head out. 296 00:14:54,519 --> 00:14:57,647 - Okay, releasing the brakes. 297 00:15:03,528 --> 00:15:06,906 But this incredibly advanced machine 298 00:15:06,906 --> 00:15:08,700 only has a four-hour window 299 00:15:08,700 --> 00:15:12,328 to complete its work before the subway reopens. 300 00:15:17,500 --> 00:15:20,128 {\an8}The rail milling train 301 00:15:20,253 --> 00:15:22,672 {\an8}restores the rails to their correct profile, 302 00:15:22,672 --> 00:15:25,300 {\an8}reducing wear on both the wheels and the tracks. 303 00:15:25,300 --> 00:15:29,679 {\an8}Okay, grinders on 62 and 10 speed. 304 00:15:29,804 --> 00:15:31,181 {\an8}Correct profile means the cross-section 305 00:15:31,181 --> 00:15:33,391 {\an8}looks like it should, that if you looked on it straight on, 306 00:15:33,391 --> 00:15:34,559 {\an8}it's just the right shape. 307 00:15:34,559 --> 00:15:36,478 Guided by magnets and lasers 308 00:15:36,478 --> 00:15:38,521 that scan the tracks for problems, 309 00:15:38,521 --> 00:15:40,607 the first task of the rail milling train 310 00:15:40,607 --> 00:15:42,609 is to smooth out the rails by shaving them 311 00:15:42,609 --> 00:15:45,612 with metal brushes and carbide shears, 312 00:15:45,612 --> 00:15:48,907 essentially cutting out deep wear, 313 00:15:48,907 --> 00:15:50,450 cracks and surface dents. 314 00:15:50,450 --> 00:15:53,328 {\an8}If you've ever been on a subway 315 00:15:53,453 --> 00:15:56,081 {\an8}and heard that screeching sound 316 00:15:56,206 --> 00:15:57,248 {\an8}during a curve... 317 00:15:59,334 --> 00:16:01,461 ...you'll appreciate the importance 318 00:16:01,461 --> 00:16:03,546 of these grinding units. 319 00:16:03,546 --> 00:16:07,550 So, we've got a total of six milling heads on our unit here. 320 00:16:07,550 --> 00:16:09,636 They're interchangeable 321 00:16:09,636 --> 00:16:11,930 and on the heads, you've got rights and lefts, 322 00:16:11,930 --> 00:16:14,307 and it's critical that they go on the right one. 323 00:16:14,307 --> 00:16:16,351 Otherwise, it will cause damage to the milling head 324 00:16:16,476 --> 00:16:18,520 and the rail head surface. 325 00:16:18,520 --> 00:16:20,855 We had a batch of older, like, teeth, 326 00:16:20,855 --> 00:16:22,899 as we call them, which are on the milling heads. 327 00:16:23,024 --> 00:16:26,444 They were only lasting 400 to 500 meters, 328 00:16:26,444 --> 00:16:29,531 but we've had over a thousand meters on these new heads, 329 00:16:29,531 --> 00:16:33,827 so they are much better and much more efficient. 330 00:16:41,126 --> 00:16:44,504 Just let me know when the radio is on channel three 331 00:16:44,504 --> 00:16:46,339 because the camera is a bit dark. 332 00:16:46,339 --> 00:16:48,717 Overnight, alone in the Underground, 333 00:16:48,842 --> 00:16:50,885 the work of this team is invaluable 334 00:16:50,885 --> 00:16:52,971 for the lives of millions of riders. 335 00:16:53,096 --> 00:16:55,557 If mistakes are made during the rail milling process, 336 00:16:55,557 --> 00:16:59,060 it can be catastrophic for commuters. 337 00:17:00,437 --> 00:17:03,690 Just felt a bit of jumping there, mate. 338 00:17:03,815 --> 00:17:04,691 Okay. 339 00:17:04,816 --> 00:17:06,818 A bit of the bogie steering jump. 340 00:17:06,818 --> 00:17:07,986 Just keeping an eye. 341 00:17:07,986 --> 00:17:09,946 I didn't see nothing on the camera though, mate. 342 00:17:09,946 --> 00:17:13,616 Yeah, if you're not careful when you do cut the track too deep 343 00:17:13,742 --> 00:17:15,702 or for whatever reason, depending on the severity 344 00:17:15,702 --> 00:17:18,872 of the damage to the rail, it could cause derailments. 345 00:17:18,872 --> 00:17:20,290 So, it's really important, obviously, 346 00:17:20,415 --> 00:17:22,751 you concentrate on what you're doing. 347 00:17:22,876 --> 00:17:24,002 The London Underground, 348 00:17:24,127 --> 00:17:27,589 like all rail systems, has a history of derailments. 349 00:17:27,714 --> 00:17:31,259 So, the importance of the overnight milling train 350 00:17:31,259 --> 00:17:32,594 and maintenance crew 351 00:17:32,594 --> 00:17:34,763 to keep this massive transport system running smoothly 352 00:17:34,888 --> 00:17:37,724 and safely cannot be understated. 353 00:17:39,351 --> 00:17:42,979 To make sure that things run on time and not have accidents, 354 00:17:42,979 --> 00:17:46,858 we need to see where defects are and identify them for repair. 355 00:17:46,858 --> 00:17:48,568 Next, the milling train polishes 356 00:17:48,568 --> 00:17:51,529 and buffs the rails, so they make better contact 357 00:17:51,529 --> 00:17:53,656 with the wheels of the train. 358 00:17:57,285 --> 00:18:00,372 The engineering that's gone into this machine is unreal. 359 00:18:00,497 --> 00:18:03,291 And it's really-- it's a-- 360 00:18:03,416 --> 00:18:07,087 it's a big machine and it's capable of doing great things. 361 00:18:07,087 --> 00:18:09,047 Yeah, profile's all good, mate. 362 00:18:09,047 --> 00:18:12,425 Longitude's good and the trans is good as well. 363 00:18:12,425 --> 00:18:14,594 Finally, 364 00:18:14,719 --> 00:18:16,638 with the track maintenance complete, 365 00:18:16,763 --> 00:18:19,599 the milling train returns to the depot. 366 00:18:28,358 --> 00:18:31,820 Now that the night has ended and the sun rises over the city, 367 00:18:31,945 --> 00:18:33,613 the London Underground is ready to open its gates 368 00:18:33,738 --> 00:18:35,699 and do it all over again. 369 00:18:39,160 --> 00:18:42,998 The London Tube is the GOAT of transit systems. 370 00:18:43,123 --> 00:18:46,292 It's the reason that we have subways around the world. 371 00:18:46,418 --> 00:18:48,586 And so, it's so exciting because it's where the idea came from. 372 00:18:48,586 --> 00:18:50,755 It's the first people to say, 373 00:18:50,755 --> 00:18:52,424 "We should run trains underground 374 00:18:52,424 --> 00:18:54,801 "and it would make better transit for our system." 375 00:18:54,801 --> 00:18:56,845 London sets the example for what you can do 376 00:18:56,845 --> 00:18:58,680 if you build a city connected to really good transit. 377 00:19:00,849 --> 00:19:02,642 With miles of gleaming rails 378 00:19:02,642 --> 00:19:04,019 and fleets of trains in motion, 379 00:19:04,019 --> 00:19:08,648 it truly is one of the world's mightiest metal machines. 380 00:19:13,111 --> 00:19:17,449 {\an8}This is the Carnival Celebration. 381 00:19:17,449 --> 00:19:19,951 {\an8}It's more than one of the world's biggest cruise ships. 382 00:19:21,536 --> 00:19:25,957 This is a self-sustaining home away from home 383 00:19:25,957 --> 00:19:28,793 for its 6,500 passengers, 384 00:19:28,793 --> 00:19:32,005 transporting them from port to island port. 385 00:19:32,005 --> 00:19:34,299 It's a floating city. 386 00:19:34,299 --> 00:19:36,176 The Celebration is a floating oasis, 387 00:19:36,301 --> 00:19:40,638 bringing the comforts of a city to the open seas. 388 00:19:45,143 --> 00:19:48,480 Coming in at nearly 200,000 tonnes, 389 00:19:48,480 --> 00:19:50,815 this massive steel hull 390 00:19:50,940 --> 00:19:53,777 has 19 decks for guests and entertainment, 391 00:19:53,902 --> 00:19:55,528 as well as crew and the many engines, 392 00:19:55,653 --> 00:19:59,240 machines and parts that keep this cruise on course. 393 00:19:59,366 --> 00:20:03,078 And this travelling paradise would not be possible 394 00:20:03,078 --> 00:20:05,497 without liquid natural gas - 395 00:20:05,497 --> 00:20:09,084 the lifeblood of the Celebration. 396 00:20:09,084 --> 00:20:11,961 As the name would imply, natural gas is a gas. 397 00:20:11,961 --> 00:20:13,421 {\an8}But it's hard to transport 398 00:20:13,421 --> 00:20:15,173 {\an8}because it takes up so much space. 399 00:20:15,173 --> 00:20:17,926 {\an8}If you take that natural gas 400 00:20:17,926 --> 00:20:20,095 {\an8}and cool it down really, really, 401 00:20:20,095 --> 00:20:24,599 {\an8}really cold, it turns from a gas into a liquid 402 00:20:24,724 --> 00:20:27,602 {\an8}that can then be transported anywhere in the world you want. 403 00:20:27,602 --> 00:20:30,188 But a ship this size, using specialized fuel, 404 00:20:30,313 --> 00:20:34,067 can't just pull up to the pumps. 405 00:20:34,067 --> 00:20:37,445 The pumps need to pull up to it. 406 00:20:37,570 --> 00:20:40,156 {\an8}So, this is a barge that was specially built to carry 407 00:20:40,281 --> 00:20:43,368 {\an8}liquefied natural gas. 408 00:20:43,493 --> 00:20:45,370 These purpose-built barges store 409 00:20:45,370 --> 00:20:46,913 and transport the equivalent 410 00:20:47,038 --> 00:20:49,457 of nearly four million litters of fuel - 411 00:20:49,582 --> 00:20:52,252 enough to refuel two massive ships 412 00:20:52,252 --> 00:20:54,963 headed for a seven-day cruise. 413 00:20:54,963 --> 00:20:56,464 This ship can hold 414 00:20:56,464 --> 00:20:59,718 approximately 3,500 cubic meters. 415 00:20:59,843 --> 00:21:02,053 It is brought down to approximately 416 00:21:02,053 --> 00:21:04,180 170 degrees negative Celsius 417 00:21:04,180 --> 00:21:07,684 or around 280 degrees negative Fahrenheit. 418 00:21:07,684 --> 00:21:10,812 The cryogenic state of liquid natural gas 419 00:21:10,937 --> 00:21:13,148 is so important for the storage needs of the ship. 420 00:21:13,148 --> 00:21:15,442 It saves a tremendous amount of space. 421 00:21:15,442 --> 00:21:18,653 Bridge fire patrol from LNG station everything is fine. 422 00:21:22,991 --> 00:21:25,493 Once on board, the LNG is used to power the motors 423 00:21:25,493 --> 00:21:27,954 and generators that provide energy 424 00:21:28,079 --> 00:21:30,248 for everything necessary 425 00:21:30,373 --> 00:21:32,417 to keep the guests comfortable in transit. 426 00:21:35,462 --> 00:21:37,047 O-25. 427 00:21:37,172 --> 00:21:39,424 Up above, it's a vacationer's paradise. 428 00:21:41,843 --> 00:21:43,928 But below deck, it's a mechanical maze of machines, 429 00:21:44,054 --> 00:21:48,767 cables and pipes that connect to every component of the ship. 430 00:21:48,767 --> 00:21:50,727 {\an8}The engine room, 431 00:21:50,852 --> 00:21:55,065 {\an8}it's all the way from the aft of the ship to the forward. 432 00:21:55,065 --> 00:21:57,942 Below the waterline on Deck Zero 433 00:21:57,942 --> 00:21:59,235 is the beating heart of the Celebration - 434 00:21:59,235 --> 00:22:03,698 the place where all that fuel is transformed into power 435 00:22:03,823 --> 00:22:06,117 for each of the ship's operating systems. 436 00:22:06,242 --> 00:22:09,954 This is the motor and this is the generator. 437 00:22:09,954 --> 00:22:11,373 The difference 438 00:22:11,498 --> 00:22:13,291 between the motor and the generator 439 00:22:13,416 --> 00:22:16,294 is that the motor produces mechanical power, 440 00:22:16,294 --> 00:22:18,963 just the movement. 441 00:22:18,963 --> 00:22:23,426 The generator converts the movement in electrical power. 442 00:22:24,552 --> 00:22:26,971 To power these four enormous engines, 443 00:22:27,097 --> 00:22:32,185 liquid natural gas is converted back to its original form - gas. 444 00:22:32,394 --> 00:22:34,646 Inside the engine, 445 00:22:34,646 --> 00:22:36,981 the gaseous fuel is then mixed with air 446 00:22:37,107 --> 00:22:38,316 and introduced to a pilot fuel that ignites, 447 00:22:38,316 --> 00:22:40,819 creating combustion. 448 00:22:40,819 --> 00:22:44,197 The resulting pressure pushes down on the pistons, 449 00:22:44,197 --> 00:22:47,909 creating a powerful movement. 450 00:22:50,704 --> 00:22:53,957 All four generators power up the network. 451 00:22:54,082 --> 00:22:57,085 Without this, we will not run anywhere. 452 00:22:57,085 --> 00:22:58,712 The ship is a piece of steel. 453 00:22:58,837 --> 00:23:02,590 With no power, no electricity, no light, no water, nothing! 454 00:23:02,590 --> 00:23:05,260 When the power is flowing, 455 00:23:05,260 --> 00:23:07,721 it's the ship's state-of-the-art propulsion system 456 00:23:07,846 --> 00:23:12,350 that keeps this floating oasis alive and moving on the water. 457 00:23:15,520 --> 00:23:18,314 My name is Vincenzo Alcaras. 458 00:23:18,314 --> 00:23:21,693 {\an8}I am the captain of the Carnival Celebration. 459 00:23:21,693 --> 00:23:23,445 This ship is a little bit different 460 00:23:23,445 --> 00:23:28,491 from any other traditional ship because it is a pod ship. 461 00:23:28,491 --> 00:23:31,202 Historically, ships relied on simple tools 462 00:23:31,202 --> 00:23:32,662 to navigate the open waters, 463 00:23:32,662 --> 00:23:38,126 from the sun, moon and stars to compasses, sails and runners. 464 00:23:38,251 --> 00:23:40,378 But boat steering systems 465 00:23:40,378 --> 00:23:43,339 have undergone significant modernization, 466 00:23:43,339 --> 00:23:45,800 propelled by advanced technology, 467 00:23:45,800 --> 00:23:47,927 leading to the introduction 468 00:23:48,053 --> 00:23:51,639 of azimuth pod systems for cruise ships in the late 1990s. 469 00:23:53,725 --> 00:23:56,394 {\an8}What you'd expect to see on a boat is a fixed propeller 470 00:23:56,394 --> 00:23:57,437 {\an8}and a rudder right behind it. 471 00:23:57,437 --> 00:24:01,650 Now, what the pod does 472 00:24:01,775 --> 00:24:04,444 is move that propeller and the rudder kind of into one thing. 473 00:24:04,569 --> 00:24:07,614 The propeller itself will push the ship 474 00:24:07,739 --> 00:24:09,824 in whatever direction it needs it to go. 475 00:24:09,824 --> 00:24:13,078 Azimuth pods are a gearless steerable 476 00:24:13,078 --> 00:24:15,789 propulsion system where the motor is housed within the pod, 477 00:24:15,789 --> 00:24:19,000 outside the ship's hull. 478 00:24:20,335 --> 00:24:22,837 They allow huge ships, like the Celebration, 479 00:24:22,837 --> 00:24:24,673 to navigate narrow waterways 480 00:24:24,673 --> 00:24:28,134 with the ease of a much smaller vessel. 481 00:24:28,134 --> 00:24:30,011 This advanced technology 482 00:24:30,011 --> 00:24:33,807 can rotate 360 degrees, providing unparalleled control 483 00:24:33,807 --> 00:24:36,226 over the ship's direction and speed. 484 00:24:36,726 --> 00:24:40,522 It's a revolutionary propulsion system that allows massive ships 485 00:24:40,647 --> 00:24:44,025 to manoeuvre with incredible precision and efficiency. 486 00:24:49,364 --> 00:24:51,449 Once in open water, this ship is designed 487 00:24:51,574 --> 00:24:54,828 to be an island unto itself, responsible for the lives 488 00:24:54,828 --> 00:24:57,497 of every guest and every crew member on board. 489 00:24:57,622 --> 00:24:59,457 {\an8}The Carnival Celebration is a cruise ship 490 00:24:59,582 --> 00:25:01,042 {\an8}that carries thousands of people. 491 00:25:01,042 --> 00:25:03,169 {\an8}As soon as the ship leaves the dock, 492 00:25:03,294 --> 00:25:05,338 {\an8}there's no connection to shore. 493 00:25:05,463 --> 00:25:08,091 Even though it's surrounded by water, 494 00:25:08,091 --> 00:25:11,803 freshwater is the key to survival at sea. 495 00:25:13,430 --> 00:25:17,142 The earliest European sailors used barrels laced with alcohol 496 00:25:17,142 --> 00:25:19,519 to keep algae from growing on their supply. 497 00:25:19,644 --> 00:25:23,022 And the most important task whenever a ship reached land 498 00:25:23,022 --> 00:25:27,068 was to replenish its freshwater stock. 499 00:25:28,486 --> 00:25:31,614 In the 1700s, distillers were introduced to ships 500 00:25:31,740 --> 00:25:34,367 to create freshwater through evaporation. 501 00:25:34,492 --> 00:25:38,079 And then, in the 1980s, reverse osmosis systems 502 00:25:38,204 --> 00:25:40,248 were added to desalinate water. 503 00:25:40,248 --> 00:25:44,669 These are our freshwater generators. 504 00:25:44,669 --> 00:25:46,004 {\an8}This equipment 505 00:25:46,004 --> 00:25:50,300 {\an8}is taking water from the sea 506 00:25:50,300 --> 00:25:51,968 {\an8}and producing freshwater. 507 00:25:51,968 --> 00:25:57,766 Onboard, we are keeping 4,500 cubic meters of water, 508 00:25:57,891 --> 00:26:01,061 which is approximately 1,200,000 gallons, 509 00:26:01,061 --> 00:26:05,315 to supply the water to our ship. 510 00:26:05,440 --> 00:26:08,068 These four water generators produce enough water 511 00:26:08,068 --> 00:26:10,779 to fill and maintain the equivalent 512 00:26:10,779 --> 00:26:13,948 of nearly two full Olympic-sized swimming pools. 513 00:26:14,074 --> 00:26:17,035 The Celebration draws ocean water into the vessel 514 00:26:17,035 --> 00:26:21,498 that makes its way through a reverse osmosis system. 515 00:26:21,623 --> 00:26:25,168 There, tubes force the water through a multi-layered membrane 516 00:26:25,168 --> 00:26:27,253 that allows small water particles through, 517 00:26:27,379 --> 00:26:30,465 but filters out salt and impurities. 518 00:26:30,590 --> 00:26:33,718 Then, the resulting freshwater is re-mineralized 519 00:26:33,718 --> 00:26:34,969 and chlorinated for use 520 00:26:34,969 --> 00:26:37,222 throughout the network of the ship. 521 00:26:37,222 --> 00:26:40,141 Without this equipment, we will not have the water 522 00:26:40,266 --> 00:26:44,354 for taking a shower, we will not have the water for laundry, 523 00:26:44,479 --> 00:26:46,439 for flushing the toilet. 524 00:26:46,564 --> 00:26:49,484 While saltwater is readily available, 525 00:26:49,484 --> 00:26:52,070 it is a hard mineralized water 526 00:26:52,070 --> 00:26:53,947 that would corrode and ultimately destroy 527 00:26:53,947 --> 00:26:57,242 the ship's plumbing system. 528 00:26:57,242 --> 00:27:00,829 Those are one of the vital equipment onboard the ship. 529 00:27:04,833 --> 00:27:07,460 All the water for the ship is provided by this system 530 00:27:07,585 --> 00:27:08,712 and the freshwater pumps 531 00:27:08,712 --> 00:27:12,590 that send potable water to every deck, sink, faucet, 532 00:27:12,590 --> 00:27:14,634 and facility. 533 00:27:18,471 --> 00:27:20,265 After solving the problem of potable water, 534 00:27:20,390 --> 00:27:23,101 engineers got to answer some more unique questions. 535 00:27:23,226 --> 00:27:26,980 Like, how can a ship turn water into beer? 536 00:27:26,980 --> 00:27:30,900 {\an8}I am the brewmaster on the ship. 537 00:27:31,026 --> 00:27:33,028 Everything from grain to glass, 538 00:27:33,028 --> 00:27:36,656 ordering to serving, all falls on me. 539 00:27:36,781 --> 00:27:38,033 I can control everything 540 00:27:38,158 --> 00:27:42,412 from water flow to the brewing process. 541 00:27:42,537 --> 00:27:46,583 The soft remineralized water of the ship is less heavy, 542 00:27:46,583 --> 00:27:50,128 making it ideal for brewing several styles of beer. 543 00:27:52,255 --> 00:27:54,966 Without that desalinization process 544 00:27:54,966 --> 00:27:57,093 and without being able to pull that water in, 545 00:27:57,218 --> 00:28:00,680 we would not be able to make the beer we make on the ship. 546 00:28:00,805 --> 00:28:02,724 It takes a lot of water to make beer. 547 00:28:02,849 --> 00:28:04,559 On average, the brewery makes 548 00:28:04,559 --> 00:28:07,062 1,000 litres of beer a week, 549 00:28:07,062 --> 00:28:11,399 which takes 5,000 litres of water to accomplish - 550 00:28:11,524 --> 00:28:15,487 a fraction of the freshwater produced by the ship, 551 00:28:15,612 --> 00:28:17,405 but it's very appreciated. 552 00:28:17,530 --> 00:28:20,825 The only place you're gonna get this beer 553 00:28:20,950 --> 00:28:23,703 is right here on this ship. 554 00:28:23,828 --> 00:28:25,872 The demand for beer is high, 555 00:28:25,872 --> 00:28:27,040 but nothing beats the demand for food. 556 00:28:27,165 --> 00:28:30,335 And ferrying from port to port, 557 00:28:30,335 --> 00:28:32,587 packed to the brim with necessities, 558 00:28:32,587 --> 00:28:34,631 doesn't leave a lot of room for food waste. 559 00:28:34,756 --> 00:28:36,424 {\an8}We're working very hard to reduce food waste 560 00:28:36,424 --> 00:28:39,469 {\an8}in general from our ships, because food waste 561 00:28:39,469 --> 00:28:40,762 {\an8}is a large contributor 562 00:28:40,762 --> 00:28:42,389 {\an8}to greenhouse gases around the world. 563 00:28:42,389 --> 00:28:44,349 A ship of this size can carry around 564 00:28:44,474 --> 00:28:47,435 300 tons of food, and 30% of that 565 00:28:47,435 --> 00:28:51,022 could be wasted during a vacation. 566 00:28:53,566 --> 00:28:56,444 In the pursuit of efficiency and sustainability, 567 00:28:56,444 --> 00:28:59,948 technology is helping this ship stay on course. 568 00:28:59,948 --> 00:29:02,075 So, in our efforts to try to reduce food waste 569 00:29:02,200 --> 00:29:06,287 onboard the ships, we're integrating AI technology, 570 00:29:06,287 --> 00:29:09,165 so that we can actually scan what is left on the plates 571 00:29:09,290 --> 00:29:10,792 that come back from the tables. 572 00:29:12,210 --> 00:29:13,503 The AI tracks the weight 573 00:29:13,503 --> 00:29:15,547 and food type of the leftovers to determine 574 00:29:15,672 --> 00:29:18,758 if the culinary team should change the menu 575 00:29:18,758 --> 00:29:21,761 or portion of food being served. 576 00:29:21,886 --> 00:29:22,929 Hey. How you doing? 577 00:29:23,054 --> 00:29:24,431 It's an innovative solution, 578 00:29:24,431 --> 00:29:27,392 reducing food waste and food storage needs. 579 00:29:27,392 --> 00:29:30,311 This is a biodigester. We take food waste 580 00:29:30,311 --> 00:29:34,107 from around the ship, and we add beneficial bacteria, 581 00:29:34,107 --> 00:29:35,567 and some bio media, 582 00:29:35,692 --> 00:29:38,028 and the bacteria, they digest the food waste 583 00:29:38,153 --> 00:29:40,196 that's left on people's plates, 584 00:29:40,196 --> 00:29:42,032 and what comes out is the water that we use 585 00:29:42,157 --> 00:29:43,241 to just flush the drain. 586 00:29:43,241 --> 00:29:45,869 With a mixture of microbes and enzymes, 587 00:29:45,869 --> 00:29:48,496 this specialized equipment digests most food products 588 00:29:48,496 --> 00:29:51,666 and even bio-plastics within 24 hours. 589 00:29:53,877 --> 00:29:57,130 Our biodigesters are critical to us because it allows us 590 00:29:57,130 --> 00:29:59,257 to dispose of the food waste that's on board. 591 00:29:59,382 --> 00:30:02,302 And biodigesters drastically reduce the need 592 00:30:02,427 --> 00:30:04,095 for incinerators and bulk waste systems 593 00:30:04,220 --> 00:30:07,682 that take up valuable deck space. 594 00:30:08,391 --> 00:30:11,436 Behind the scenes, it's our job to make sure 595 00:30:11,561 --> 00:30:15,398 that we're addressing any kind of environmental impact. 596 00:30:15,523 --> 00:30:17,651 Through food waste management 597 00:30:17,776 --> 00:30:19,527 and water and waste recycling systems, 598 00:30:19,653 --> 00:30:22,697 the Celebration, along with the 29 ships 599 00:30:22,697 --> 00:30:25,533 of the Carnival cruise fleet divert nearly 9,000 tonnes 600 00:30:25,533 --> 00:30:28,286 of waste materials from landfills every year. 601 00:30:29,954 --> 00:30:31,289 So, it's important to remember 602 00:30:31,289 --> 00:30:33,208 that this is a floating city 603 00:30:33,333 --> 00:30:36,378 because most resorts aren't making their own electricity, 604 00:30:36,378 --> 00:30:38,296 they're not generating their own potable water, 605 00:30:38,421 --> 00:30:40,340 and recycling them, like we are on board. 606 00:30:40,465 --> 00:30:43,093 The Celebration is a beacon of efficiency 607 00:30:43,093 --> 00:30:44,219 and innovation, 608 00:30:44,219 --> 00:30:46,388 ushering thousands of people 609 00:30:46,388 --> 00:30:50,725 to and from their dream vacations annually, 610 00:30:50,725 --> 00:30:53,186 a metal marvel on the high seas. 611 00:30:56,731 --> 00:30:58,650 crui, 612 00:30:58,650 --> 00:31:00,110 to construction machines, 613 00:31:00,235 --> 00:31:02,153 to mining equipment... 614 00:31:03,905 --> 00:31:06,533 ...Caterpillar keeps some of the biggest 615 00:31:06,533 --> 00:31:08,868 vehicles in the world moving. 616 00:31:08,993 --> 00:31:10,620 These machines, they're a work of art. 617 00:31:10,620 --> 00:31:12,372 They're massive monster machines. 618 00:31:12,497 --> 00:31:16,418 {\an8} These mammoth off-road trucks 619 00:31:16,543 --> 00:31:17,961 {\an8}stand two stories tall. 620 00:31:18,086 --> 00:31:20,463 I mean, I'm big, but this is real strong right here. 621 00:31:20,588 --> 00:31:25,176 And they're engineered to haul 363 tonnes of cargo 622 00:31:25,176 --> 00:31:27,178 through some of the toughest terrain on the planet. 623 00:31:27,303 --> 00:31:29,055 There's nothing like this that exists. 624 00:31:29,055 --> 00:31:31,725 These trucks are born in a high-tech factory 625 00:31:31,725 --> 00:31:34,019 in Middle America... 626 00:31:34,019 --> 00:31:38,022 We have the biggest of the big, right here in Decatur, Illinois. 627 00:31:38,148 --> 00:31:40,817 ...where robots and humans work in harmony 628 00:31:40,817 --> 00:31:43,403 to bring these behemoths to life. 629 00:31:43,403 --> 00:31:47,282 This is the start of something big. 630 00:31:59,419 --> 00:32:01,046 These trucks have to be big 631 00:32:01,046 --> 00:32:03,339 to move the vast amounts of material 632 00:32:03,465 --> 00:32:05,759 needed in modern mining. 633 00:32:05,759 --> 00:32:07,093 {\an8}Mining trucks are so enormous 634 00:32:07,218 --> 00:32:08,970 {\an8}that they have to be built in segments. 635 00:32:10,430 --> 00:32:11,723 For example, 636 00:32:11,848 --> 00:32:13,224 the frame of the 797 truck 637 00:32:13,224 --> 00:32:16,728 starts with nine separate pieces or castings. 638 00:32:16,728 --> 00:32:20,315 {\an8}We have some of the most advanced welding equipment, 639 00:32:20,315 --> 00:32:21,775 {\an8}machining equipment, 640 00:32:21,775 --> 00:32:25,070 {\an8}and also assembly equipment that's on the planet Earth. 641 00:32:25,070 --> 00:32:27,447 The nine castings will form the backbone 642 00:32:27,447 --> 00:32:29,908 of the Caterpillar 797 haul truck. 643 00:32:29,908 --> 00:32:32,786 They are locked in place with hydraulic clamps. 644 00:32:32,911 --> 00:32:36,206 {\an8}These hydraulic clamps are so strong, 645 00:32:36,206 --> 00:32:39,125 {\an8}strong enough to hold a 90,000 pound truck in place. 646 00:32:40,543 --> 00:32:41,795 Once the pieces are clamped, 647 00:32:41,920 --> 00:32:43,838 they're ready for tack welding, 648 00:32:43,838 --> 00:32:47,175 which joins the pieces temporarily. 649 00:32:49,094 --> 00:32:53,515 Then, giant cranes heft the assembled 650 00:32:53,640 --> 00:32:56,684 40,000-kilogram frames 651 00:32:56,684 --> 00:32:59,979 and lower them into place on the rollover station. 652 00:33:01,272 --> 00:33:03,608 DR. EL-SAYEGH: The rollover station is a giant 653 00:33:03,733 --> 00:33:07,070 rotation mechanism, almost like a rotisserie. 654 00:33:07,195 --> 00:33:08,863 It has enormous hydraulic power 655 00:33:08,863 --> 00:33:11,324 that holds the tacked frame in place 656 00:33:11,449 --> 00:33:13,326 and can rotate it 360 degrees. 657 00:33:16,746 --> 00:33:18,039 We have nine rollovers 658 00:33:18,164 --> 00:33:20,083 in this one line here in this building, 659 00:33:20,208 --> 00:33:22,961 and each one of them rotate 45 to 90,000-pound truck 660 00:33:22,961 --> 00:33:26,965 360 degrees, so my operators can weld on them easier. 661 00:33:26,965 --> 00:33:30,051 It's like buttering a corn on a cob. 662 00:33:30,051 --> 00:33:32,512 Before rollover machines brought the workpiece 663 00:33:32,512 --> 00:33:36,558 to the welders, they would have to kneel, bend, and twist 664 00:33:36,683 --> 00:33:38,685 to reach their welds. 665 00:33:38,685 --> 00:33:42,647 If we did not have this machine, it would take 666 00:33:42,647 --> 00:33:45,483 a whole lot longer to weld these frames. 667 00:33:45,483 --> 00:33:47,986 {\an8}Because how else are we really gonna be able to flip it around? 668 00:33:47,986 --> 00:33:53,074 Once the welds are in place, the robots take over. 669 00:33:53,074 --> 00:33:55,744 You have to have big robots to make these big machines. 670 00:33:55,744 --> 00:33:58,038 {\an8} The entire concept 671 00:33:58,163 --> 00:33:59,873 {\an8}behind robots building other things is so that 672 00:33:59,873 --> 00:34:01,750 {\an8}they're precise, they're accurate the entire time, 673 00:34:01,750 --> 00:34:05,378 {\an8}and they're very predictable. 674 00:34:08,631 --> 00:34:09,799 Each frame has an individual program, 675 00:34:09,799 --> 00:34:11,843 and it tells the robots what to do. 676 00:34:11,843 --> 00:34:15,597 {\an8}So, it follows that program, and it will come to me 677 00:34:15,597 --> 00:34:16,931 {\an8}if it needs help, and... 678 00:34:16,931 --> 00:34:21,353 {\an8}Otherwise, it pretty much knows how to do its own thing. 679 00:34:21,353 --> 00:34:23,772 Here, robotic arms 680 00:34:23,897 --> 00:34:26,107 manoeuvre with precision around the frame, 681 00:34:26,107 --> 00:34:30,153 depositing over 17 kilometres of welding wire 682 00:34:30,153 --> 00:34:34,324 along a pre-programmed welding path for each 797 truck. 683 00:34:34,324 --> 00:34:38,286 So, this is actually what our welding wire looks like. 684 00:34:38,286 --> 00:34:40,246 This is what we use to weld the frames together. 685 00:34:40,372 --> 00:34:43,792 So, the weld wire is covered in a copper coating 686 00:34:43,792 --> 00:34:45,335 to make sure that it doesn't 687 00:34:45,460 --> 00:34:49,089 react to the atmosphere and that it doesn't rust. 688 00:34:49,089 --> 00:34:51,549 Copper is uniquely durable. 689 00:34:51,549 --> 00:34:54,844 When it's exposed to the air, it forms a distinctive green patina 690 00:34:54,969 --> 00:34:58,556 that protects it from further corrosion. 691 00:35:00,642 --> 00:35:03,478 So, the rollers on the back feed the wire up through this hose, 692 00:35:03,478 --> 00:35:04,854 into these rollers, 693 00:35:04,980 --> 00:35:08,024 that allow the robot to just feed all the time. 694 00:35:08,024 --> 00:35:11,069 And it keeps a consistent speed and pace. 695 00:35:13,571 --> 00:35:17,325 This automated system works continuously for 14 hours 696 00:35:17,450 --> 00:35:19,703 to weld the entire frame. 697 00:35:19,828 --> 00:35:22,831 It would take two skilled welders 48 hours 698 00:35:22,831 --> 00:35:25,083 to do the same work. 699 00:35:25,083 --> 00:35:27,836 For trucks that are used in heavy-duty mining environments, 700 00:35:27,836 --> 00:35:30,880 creating a frame that has structural integrity 701 00:35:30,880 --> 00:35:33,007 and durability is crucial. 702 00:35:35,510 --> 00:35:37,929 Mining trucks need to be able to work 24 hours a day 703 00:35:38,054 --> 00:35:40,014 in the demanding setting of a mine, 704 00:35:40,014 --> 00:35:42,976 climbing and descending steep hills 705 00:35:43,101 --> 00:35:44,894 with hundreds of tons of cargo. 706 00:35:44,894 --> 00:35:48,398 Creating trucks this tough 707 00:35:48,523 --> 00:35:51,276 requires humans and robots to work side by side. 708 00:35:51,276 --> 00:35:53,945 The robots that are in their own factories, 709 00:35:53,945 --> 00:35:56,114 working with other robots, they're just called robots. 710 00:35:56,239 --> 00:35:58,450 But robots that are working alongside humans 711 00:35:58,450 --> 00:35:59,993 and interacting with humans using sensors 712 00:35:59,993 --> 00:36:01,536 are called co-bots. 713 00:36:01,661 --> 00:36:03,997 Co-bots depend on human support to do their jobs. 714 00:36:03,997 --> 00:36:06,166 I change the torch, 715 00:36:06,166 --> 00:36:08,376 I make sure the nozzle is clean, I check the tip, 716 00:36:08,376 --> 00:36:11,671 check the weld wire, and make sure that it's good to go. 717 00:36:11,796 --> 00:36:13,631 I'm pretty much the robot's assistant. 718 00:36:15,759 --> 00:36:17,510 played such a heavy handobos 719 00:36:17,635 --> 00:36:20,096 in the manufacturing process. 720 00:36:22,182 --> 00:36:23,725 The Caterpillar Tractor Company 721 00:36:23,725 --> 00:36:26,603 was formed in 1925, and at that time, 722 00:36:26,728 --> 00:36:28,480 workers assembled machines with hand tools. 723 00:36:28,480 --> 00:36:32,067 Large components, like engine blocks and frames, 724 00:36:32,067 --> 00:36:34,736 were often produced by shaping metal under high pressure 725 00:36:34,736 --> 00:36:38,823 or casting molten steel with moulds. 726 00:36:38,823 --> 00:36:41,618 Operators had to be strong enough to physically crank 727 00:36:41,618 --> 00:36:44,162 handwheels and manipulate levers on milling, 728 00:36:44,162 --> 00:36:45,622 turning and drilling machines. 729 00:36:49,668 --> 00:36:51,044 - All right. -All right. 730 00:36:51,169 --> 00:36:52,212 All clear! 731 00:36:52,212 --> 00:36:55,215 In the 21st century, manufacturing technology 732 00:36:55,340 --> 00:36:56,966 is fabricated for the future, 733 00:36:56,966 --> 00:37:00,053 allowing Caterpillar to make bigger trucks than ever. 734 00:37:00,178 --> 00:37:02,639 We have a system of fork trucks, 735 00:37:02,639 --> 00:37:04,766 cranes, and automatically guided vehicles 736 00:37:04,891 --> 00:37:08,436 that move the components around this massive campus. 737 00:37:08,436 --> 00:37:10,855 We're going to need to go a little bit more. 738 00:37:10,855 --> 00:37:11,898 More? 739 00:37:12,023 --> 00:37:14,109 Industrial tugs effortlessly push 740 00:37:14,234 --> 00:37:16,611 gigantic steel components along specialized rails 741 00:37:16,736 --> 00:37:18,655 that run the entire length of the factory. 742 00:37:21,700 --> 00:37:23,827 - Perfect! -All right. 743 00:37:25,954 --> 00:37:28,540 This tiny thing right here pushes at least 30,000 pounds. 744 00:37:28,540 --> 00:37:30,875 {\an8}I'm strong, but I ain't that strong. 745 00:37:33,169 --> 00:37:36,339 Automatically guided vehicles or AGVs 746 00:37:36,339 --> 00:37:38,758 navigate autonomously through the factory, 747 00:37:38,883 --> 00:37:41,928 delivering tools and parts to operators. 748 00:37:41,928 --> 00:37:45,306 {\an8}Autonomous systems are perfect for simple repetitive tasks. 749 00:37:45,432 --> 00:37:48,518 The machine can follow pre-mapped routes 750 00:37:48,518 --> 00:37:50,019 and programmed activities. 751 00:37:51,271 --> 00:37:53,565 So, the AGV actually helps us out quite a bit. 752 00:37:53,690 --> 00:37:55,692 {\an8}It's able to free up more operators 753 00:37:55,692 --> 00:37:58,570 {\an8}to be more efficient on their jobs, not have to worry about 754 00:37:58,570 --> 00:38:00,822 {\an8}walking across the building to get their kits, 755 00:38:00,947 --> 00:38:02,449 {\an8}to walk them back, in order to get their operations 756 00:38:02,574 --> 00:38:05,243 {\an8}done in a timely manner. 757 00:38:06,619 --> 00:38:08,496 Cranes, powerful enough to lift 758 00:38:08,621 --> 00:38:12,292 an assembled 797 chassis, move components overhead. 759 00:38:12,417 --> 00:38:16,004 These cranes consist of horizontal beams 760 00:38:16,129 --> 00:38:18,298 spanning the width of a factory, called bridges, 761 00:38:18,298 --> 00:38:22,135 with movable carriages that travel along them like trolleys. 762 00:38:22,135 --> 00:38:23,678 We couldn't do anything 763 00:38:23,803 --> 00:38:25,680 in this factory without these cranes. 764 00:38:25,680 --> 00:38:28,933 Everything weighs too much, 765 00:38:28,933 --> 00:38:30,643 they're too bulky. 766 00:38:30,769 --> 00:38:33,688 {\an8}Just without them, nothing would work. 767 00:38:33,813 --> 00:38:35,690 The assembled and welded frame 768 00:38:35,690 --> 00:38:38,568 is lifted to the inspection station. 769 00:38:38,693 --> 00:38:41,696 And now, it is time to ensure the welds can hold up 770 00:38:41,696 --> 00:38:44,532 to the punishment they'll be facing. 771 00:38:44,532 --> 00:38:46,076 The way to do that 772 00:38:46,076 --> 00:38:48,745 is to look inside the steel frame with ultrasound. 773 00:38:50,747 --> 00:38:54,000 {\an8}So, this is a ultrasonic couplet, 774 00:38:54,125 --> 00:38:57,379 {\an8}and it allows the ultrasound to go into the metal, 775 00:38:57,379 --> 00:38:59,964 {\an8}so that we can do our ultrasound inspection. 776 00:38:59,964 --> 00:39:01,841 DR. EL-SAYEGH: The factory checks the integrity 777 00:39:01,966 --> 00:39:03,968 of the welds with an industrial ultrasound 778 00:39:03,968 --> 00:39:06,971 that is very similar to a medical ultrasound. 779 00:39:06,971 --> 00:39:09,641 It just works at a higher frequency. 780 00:39:09,641 --> 00:39:11,851 The ultrasound scanner emits sound waves 781 00:39:11,851 --> 00:39:13,686 that pass through the frame. 782 00:39:13,812 --> 00:39:15,563 If they encounter an internal defect, 783 00:39:15,563 --> 00:39:17,649 like cracks or a gap in the weld, 784 00:39:17,649 --> 00:39:20,151 part of that wave is reflected back, 785 00:39:20,151 --> 00:39:24,656 showing the operator the depth and size of any defects. 786 00:39:25,740 --> 00:39:27,200 Without this technology, 787 00:39:27,200 --> 00:39:29,994 we wouldn't have a good view of the quality of the weld 788 00:39:29,994 --> 00:39:32,205 below the surface. 789 00:39:39,087 --> 00:39:42,632 Every single frame produced here 790 00:39:42,632 --> 00:39:46,720 must match the engineering specifications exactly. 791 00:39:46,845 --> 00:39:48,930 So, a handheld 3D scanner 792 00:39:49,055 --> 00:39:51,766 is used to inspect each completed frame. 793 00:39:51,891 --> 00:39:53,309 This is a MetraSCAN 3D. 794 00:39:53,435 --> 00:39:56,771 It basically scans the part and makes it a 3D model. 795 00:39:56,896 --> 00:39:58,523 {\an8}There's cameras all around this thing, 796 00:39:58,523 --> 00:40:00,650 {\an8}and you can do a whole 360 797 00:40:00,650 --> 00:40:03,945 {\an8}or even twist your wrist and it'll still see the part. 798 00:40:04,070 --> 00:40:07,157 There's nothing like this that exists. 799 00:40:07,282 --> 00:40:08,408 It's the top of the line. 800 00:40:08,533 --> 00:40:10,201 This machine can quickly 801 00:40:10,201 --> 00:40:11,494 identify any discrepancies 802 00:40:11,494 --> 00:40:14,664 between the 3D model and the original computer-aided design, 803 00:40:14,664 --> 00:40:17,751 allowing for early corrections to be made. 804 00:40:17,751 --> 00:40:20,420 I like seeing the 3D model, 805 00:40:20,420 --> 00:40:22,964 and it's very satisfying to see it get printed on screen. 806 00:40:23,089 --> 00:40:26,176 It's addicting. 807 00:40:28,845 --> 00:40:32,766 The frame is painted 808 00:40:32,891 --> 00:40:36,353 and the truck begins to take shape. 809 00:40:36,353 --> 00:40:40,273 All right, go ahead and start up, Jeremy. 810 00:40:40,398 --> 00:40:43,193 Once the steel frame is solidly locked together... 811 00:40:43,193 --> 00:40:44,736 All right, that's good. 812 00:40:44,736 --> 00:40:47,822 ...the other components of the truck 813 00:40:47,822 --> 00:40:50,742 are lifted into place with cranes. 814 00:40:52,118 --> 00:40:55,205 {\an8}It can be intense. It's big, it's huge, 815 00:40:55,205 --> 00:40:58,833 {\an8}it's intimidating, but you get used to it, so... 816 00:40:58,833 --> 00:41:01,294 The mining truck's 817 00:41:01,419 --> 00:41:03,672 nearly 2,000 kilogram radiator 818 00:41:03,797 --> 00:41:06,716 is guided into position. 819 00:41:07,634 --> 00:41:09,636 Keep going on down when you're ready. Okay. 820 00:41:09,761 --> 00:41:12,305 All right, going down. 821 00:41:14,849 --> 00:41:17,268 - South a little bit. - South, yep. 822 00:41:17,268 --> 00:41:19,688 - All right, start down. -Going down. 823 00:41:19,813 --> 00:41:22,691 We just got to watch these stabilizers here 824 00:41:22,691 --> 00:41:24,859 and make sure it all lines up. 825 00:41:24,859 --> 00:41:26,569 All right, isolators in. 826 00:41:26,569 --> 00:41:27,529 Got it? All right. 827 00:41:27,654 --> 00:41:29,155 Yeah, right in there. 828 00:41:32,909 --> 00:41:35,036 Technicians systematically attach 829 00:41:35,161 --> 00:41:37,747 each component that makes this machine functional - 830 00:41:37,872 --> 00:41:42,335 the engine, hydraulic tank, and the transmission. 831 00:41:42,460 --> 00:41:45,922 {\an8}Right here, we have the transmission of the 797. 832 00:41:45,922 --> 00:41:48,883 {\an8}Here is the 797 engine. 833 00:41:49,009 --> 00:41:52,345 Engine produces 4,000 horsepower. 834 00:41:52,470 --> 00:41:55,014 This kind of power enables the truck to move 835 00:41:55,014 --> 00:41:58,059 massive amounts of material very efficiently, 836 00:41:58,184 --> 00:41:59,936 making it an essential piece of equipment 837 00:42:00,061 --> 00:42:01,980 in industries like mining and construction, 838 00:42:01,980 --> 00:42:03,690 where transporting huge quantities of material 839 00:42:03,690 --> 00:42:05,358 is routine. 840 00:42:07,027 --> 00:42:09,195 I love just doing this stuff, so... 841 00:42:09,320 --> 00:42:11,573 It's really cool. I mean, it's, like, huge. 842 00:42:11,698 --> 00:42:14,284 And plus, we're the only people in the world that do this job. 843 00:42:14,284 --> 00:42:19,205 So, it can be kind of rewarding, I guess. So, yeah. 844 00:42:20,999 --> 00:42:23,585 Once the truck has been tested, 845 00:42:23,710 --> 00:42:26,171 it's finally ready to be sent to the mine. 846 00:42:31,217 --> 00:42:34,262 {\an8}This facility has got unbelievable capabilities. 847 00:42:34,387 --> 00:42:36,973 {\an8}We can do pretty much everything to build machines, 848 00:42:36,973 --> 00:42:39,934 {\an8}and we can handle it within the walls of Decatur. 849 00:42:39,934 --> 00:42:42,228 {\an8}This is one mighty factory. 850 00:42:42,353 --> 00:42:43,730 {\an8}Don't underestimate it. 851 00:42:43,855 --> 00:42:46,733 {\an8}These machines are sent all over the world, 852 00:42:46,858 --> 00:42:49,235 {\an8}ready to move the earth itself.