Network Rail’s Digital Twin of the Historic Severn Tunnel
Organization: Network Rail
Project Name: Severn Tunnel Digital Twin – Enhancing Rail Asset Management
Location: Severn Tunnel, United Kingdom (linking England and Wales)
Project Phase: Completed (digital twin in operational use)
Estimated Project Cost: Not specified (saved GBP 350,000 through in-house 3D model development)
Bentley Software: Bentley iTwin Platform, iTwin Experience, MicroStation, Bentley Descartes, OpenRail Designer, and ProjectWise
Additional Context: Network Rail created a comprehensive digital twin of the 137-year-old Severn Tunnel to modernize maintenance and improve safety. Using Bentley’s modeling, asset management, and collaboration tools, the team reduced site visits by 50%, cut manual surveys by 70%, improved document management by 60%, and saved GBP 350,000 – all while preserving a vital rail link that carries over 32,000 trains annually.
Project
The Severn Tunnel has been connecting England and Wales since 1886, running over 7 kilometers beneath the River Severn. It’s one of the U.K.’s most important rail links, with more than 32,000 trains passing through each year. But keeping this historic tunnel running smoothly is no small task. The team in charge with maintaining this tunnel deals with constant water leaks, tough working conditions, and the wear and tear of time. That’s why Network Rail has turned to modern technology to help. Using digital tools, engineers are creating a virtual version of the tunnel, a digital twin. It will make it easier to monitor, maintain, and manage the tunnel, keeping trains moving safely and reliably for years to come.
It’s a great example of how old infrastructure can benefit from new ideas, blending history with innovation to build a better future.
Facts
- A 50% reduction in site visits and a 70% decrease in manual surveys have minimized disruptions, improved safety, and accelerated rail infrastructure project timelines.
- With a 60% improvement in document management, teams benefit from better version control, faster access to critical information, and more seamless collaboration through a common data environment (CDE).
- Network Rail saved GBP 350,000 by completing the 3D rail asset model in-house, showcasing the value of digital twin technology in infrastructure planning.
"A 3D digital model provides a comprehensive and interactive view of the tunnel, allowing our engineers and planners to visualize these complex structures and systems more effectively using Bentley’s ProjectWise, design applications like MicroStation and OpenRail Designer, federated through the common data environment of ProjectWise and all visualized through iTwin."
Solution
Network Rail established a federated digital twin of the Severn Tunnel using a suite of Bentley applications. The project began by creating an accurate 3D model of the tunnel lining in MicroStation and Bentley Descartes, based on reality data from a point cloud survey. OpenRail Designer was then used to model all multidiscipline assets, including track, signaling, drainage, and overhead line equipment. To manage the immense scale and federate all the data, ProjectWise was implemented as the common data environment (CDE), storing the 3D models, reality data, and linking over 30,000 asset images. The Bentley iTwin platform made this complex, federated model accessible to all stakeholders, providing a single source of truth for visualization and interrogation. This approach allowed Network Rail to consolidate disparate information into one location, providing a holistic view of the tunnel’s condition and assets.
Outcome
The Severn Tunnel digital twin has revolutionized planning and maintenance for Network Rail. Providing remote access to a virtual model of the tunnel means that Network Rail has significantly reduced the need for costly and disruptive physical site visits and surveys. Site visits have been cut by 50% and manual surveys by 70%, while improving safety and accelerating timelines. Centralized data has boosted collaboration and improved document management by 60%, enabling faster, more informed decisions. This success is driving Network Rail’s broader digital railway initiative across 250 miles of track and major stations.
Software
- MicroStation and Bentley Descartes: Used to create the accurate 3D model of the tunnel structure from reality data.
- OpenRail Designer: Utilized to model all track and related railway assets within the tunnel.
- ProjectWise: Implemented as the common data environment to store, manage, and federate all models and project data.
- Bentley iTwin platform: Utilized to create, visualize, analyze, and manage the digital twin.
- iTwin Experience: Provided a platform to visualize and interact with the comprehensive digital twin.
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