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Tata Chemicals Magadi
Magadi, Kenya
November 2020
Established in 1911, Tata Chemicals Magadi (TCM) is Africa’s largest soda ash manufacturer and a key exporter for Kenya, working around the clock to load and export around 1,800 tonnes of soda ash daily.
Located at Lake Magadi, the company operates a 146km private rail line to deliver product from Magadi to Konza, which then joins the Kenya metre gauge main line to reach the port at Mombasa.
Train control operations on the branch line relied on the use of paper forms and manual train graphs. Previous safety incidents highlighted that this process did not adequately protect trains, work on track staff or on-track maintenance vehicles.
4Tel was chosen via a tender process to implement a new digital train control system to improve rail safety and efficiency.
4Tel was commissioned to deliver a real-time, virtual-block system to manage train orders and work on track activities. 4Tel’s proven solution, 4ASW, is a communications-based train control system that creates and issues clearance authorities.
The 4ASW virtual block system allows for the secure reservation of track. As part of clearance creation, the safety checks of the system verifies that the track section is clear of other trains or work on track.
A tablet loaded with 4ASW-T was installed in each locomotive and track machine to enable train drivers to receive and manage electronic movement authorities. The ASW-T application also allows the driver to electronically release the previous section as the train progresses along the track, making the track available for other rail activities. In addition to these authority functions, ASW-T automatically reports the train’s location to the 4ASW control system, providing improved situation awareness.
Proximity alerts onboard the locomotive and at network control provide a visual and audible warning when the train is approaching the clearance limit or is out of authority. Additionally, 4Tel provided beacons equipped with alarms to improve safety around work on track activities.
The software suite incorporated functionality from existing 4Tel systems, including:
The project faced unique challenges due to the operating environment. The location’s remoteness made access challenging and a patchy mobile signal resulted in no reception at various points along the line. After extensive analysis, the team identified a series of check points with mobile coverage and established them as reporting points to ensure trains are still protected when out of coverage.
Based in Newcastle, Australia, the 4Tel team embraced new procedures to commence operations in Africa, working through shipping considerations and government requirements to import electronic goods. A Kenyan local was employed by 4Tel to manage African operations and the TATA project.
As part of the roll-out, the 4Tel team led training programs with train drivers and network controllers to upskill them from the manual, paper-based processes to the more sophisticated technology system.
The COVID pandemic forced international borders to close as the project was scheduled to launch. The team successfully overcame the challenge of implementing the project remotely, supporting the commissioning from Australia in November 2020.
4ASW was enthusiastically accepted by the local team. From its launch in November 2020 to the start of 2025, operations management has included:
4ASW maximises reliability, safety, and efficiency and provides crew planning tools without being tied to physical wayside signalling systems. The onboard device avoids costly track-based solutions and helps to minimise the risk of theft.
