2TE25KM: THROUGH COLD AND HEAT Р. 4 MAGAZINE FOR PARTNERS № 1 03/2018

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Alexander Loshmanov New Solutions for Metrovagonmash on the Perspectives the Trains of Modernizes the of Ivolga Electric Train Production TABLE OF CONTENTS MAIN TOPIC № 1 03/2018

MAGAZINE FOR PARTNERS № 1 03/2018

Partner magazine The magazine is issued with the participation of ZAO Transmashholding of FuturaMedia OOO NEWS 1 www.medialine-pressa.ru Editor-in-Chied Director General Konstantin Nikolaevich Dorokhin Larisa Rudakova MAIN TOPIC [email protected] Signed to print: March 30, 2018 Diesel locomotive 2TE25KM: Printed at Mediakolor printing house Address of the Editorial Office: Address: 28, Volnaya st., Operation 127055 - Moscow, 999 printed copies 26, bld. 1, Butyrsky val in Cold and Heat 4 Phone: +7 (495) 660-89-50 Distributed for free INTERVIEW Alexander Loshmanov BESIDES 1 Previously DMZ produced EP3D electric trains for export on the Perspectives to . Since 2016, four six-car trains assigned to the Karaganda depot have been successfully operated of Ivolga Electric on routes connecting Astana, the capital city of Kazakhstan, to other major cities. Train 10

TECHNOLOGY New solutions of OEVRZ 4 for the Metro Trains EP3D: MOVING SOUTH of Saint Petersburg 14 10 Demikhovo Machine Building Plant (DMZ) signed a contract with PRODUCTION to supply 22 EP3D electric trains. The cars will be operated on both the North Metrovagonmash ­Caucasus (depot Rostov) and (depot Volgograd) railways. Opens up New

CarSurface The contract was signed on January 18th. On March of all passengers transported by the North Preparation Shop 14th – in Rostov-on-Don – as part of the opening of Caucasian suburban passenger company in the 20 the modernized city railway station, Oleg Belozerov, Rostov region of the North Caucasus Railways. In 14 Director General and Chairman of the Board of JSC addition, the new rolling stock is intended for Russian Railways; Kirill Lipa, Director General of transporting passengers on the routes of the Rostov HISTORY In the photo (from left to right): Transmashholding and Vasily Golubev, Governor of city train and during the upcoming FIFA World Cup. The 14th Anniversary Governor of Rostov Oblast Vasily Rostov Oblast inspected the new EP3D. According Compared to foreign trains, the cost of operating Golubev, Director General of to the head of Russian Railways, 18 new electric on Russian lines – specifically, the cost of EP3D Transmashholding Kirill Lipa, of Ermak Electric trains will be supplied to Rostov Oblast (while the ownership during its whole 40-year life cycle – is 24 Director General of DMZ Vladimir remaining four will arrive in Volgograd). lower by 20–50%. This reduction of costs is achieved Locomotive Moiseev and Director General of 24 Investments in the purchase of rolling stock for the through the use of a set of energy-conserving JSC Russian Railways Oleg North Caucasus Railways will amount to more than electrical equipment and low-maintenance units. Belozerov. 4 billion roubles. The use of modern equipment allows for an increase Two four-car electric trains have already arrived in the distance between overhauls, while reducing to the North-Caucasian railroad line. EP3D will run the cost of mandatory periodic maintenance and on the Rostov-Taganrog section, accounting for 35% scheduled repairs by 20–40%. 12+ 1 НОВОСТИ КОМПАНИИ № 1 03/2018

repairs. The diesel locomotive 3TE25K2M is “MOSCOW” COMING TO BAKU 1.5 times more powerful than the locomo- tives currently used at the BAM. OAO Metrovagonmash than the previous models, as The total reduction in operating costs for builds two modern well as a new door opening/ the use of combustive and lubricating trains for the Baku closing light warning system. materials, as well as maintenance and repairs Metro. The first of them Trains are also distinguished can reach 30%, depending on the adopted has already been sent to by a number of innovations. operational model. A good amount of Azerbaijan.­ Wheels of low-stressed, attention is given to the comfortable Baku will receive trains of noise-absorbing design were working conditions of the 3TE25K2M model 81–765/766. Each train designed for a new generation locomotive crew in the harsh conditions of will have two head and three of metro cars. The car’s design the Far East. The driver's cab includes intermediate motor cars. The also implements the new a climate control system; an independent cars of this series are produced modern asynchronous traction heater provides warmth during a long by the Mytishchi plant for the drive, providing for a reliable, OAO Metrovagonmash and have a long history of locomotive standstill in the open air – all the needs of the ecological noise reduction and mutually beneficial cooperation. The plant has been supplying necessary living conditions are in place. under the name "Moscow" heat insulation. rolling stock to Baku since 1967. Today, Baku subway operates The two first 3TE25K2M diesel locomo- from the beginning of 2017. In The head cars have space 280 metro cars which were manufactured by the Mytishchi tives built at BMZ are currently under contrast to the Baku order, allocated for bicycles and plant. controlled operation on the Baikal-Amur six-car and eight-car trains are wheelchairs. The passenger ­mainline freight, and its two-section Mainline. To confirm a full compliance with delivered to the Russian compartments are equipped said Andrey Vasiliev, Commer- Azerbaijan took place in

TICKET TO LIFE version. the assigned tasks, each of them will have capital, while each of them with air conditioning, cial Director for the Urban 2015, when OAO Metro- Engineering Plant (BMZ) 3TE25K2M is designed specifically for to traverse 50 000 kilometers with the set includes non-motor intermedi- ventilation and air disinfection Transport Development, vagonmash, together with received a certificate for the Baikal-Amur Mainline (BAM) and has of cars of the available tonnage rating in ate cars, specifically, model systems. Transmashholding. "We are , transferred to Baku 3TE25K2M, the most powerful a number of modern technical solutions areas with challenging terrain, character- 81–767 (six-car trains have one, "In updating the rolling very pleased that our col- Metro three five-car cargo locomotive in . that are capable to allow for a successful ised by the presence of mountain ranges and eight -car trains have two). stock fleet, Baku Metro prefers leagues chose our offer." 81–760.B/761.B/763. The new document – the certificate of operation in severe climatic conditions in and crossings. The trains have a through the most advanced and The previous delivery of B models with a through compliance with the requirements of the areas with a complex track profile. The The locomotives with these characteris- passage and wider doorways promising technical solutions," Mytishchi metro cars to passage. Technical Regulations of the Customs design of 3TE25K2M includes high tics will solve issues of freight capacity and Union "On the Safety of Railway Rolling propulsion performance, increased prompt delivery to the Far East, creating Stock" TR TC 001/2011 – was received for distance run between the servicings and the conditions for further development of of the light line type. The inner decoration 3TE25K2M, a three-section a lower frequency of maintenance and the region. CONTRACT PERFORMED of the walls take advantage of low- Transmashholding has completed combustible, moulded, plastic panels. The the delivery of the 81–717.6/714.6 floor is covered by the wearproof linoleum. IVOLGA TOOK metro cars to the Metrovagonmash has been cooperating short and medium term perspective. Metro. with since its OPTIMISTIC According to the forecast, the free cash FLIGHT UPON The supply contract between OAO establishment in 1985. In total, Nizhny FORECAST flow of the company will remain THE CAPITAL Metrovagonmash and AO Sberbank Novgorod Metro operates 27 cars of the positive, which may affect the rating Leasing was concluded in November 2017. 81–717.6/714.6 series and 64 cars of the Fitch has improved the Trans- upgrade. TVZ signed a contract with OAO The cost of rolling stock amounted to about 81–717.5/714.5 model, manufactured over mashholding international Among the important factors Tsentralnaya PPK for the production 1.3 billion roubles. A total of 23 subway cars the years by the Mytishchi plant. ratings outlook to a positive affecting the rating of Transmashhold- of 23 Ivolga electric trains for Mos- (10 head cars and 13 intermediate cars) rating and placed it under the ing, the analysts of the rating agency cow Central Diameters. were transferred under the contract to BB– category. focus on: its leading positions in the In accordance with the contract, the trains of our cooperation" said Maxim Dyakonov, Nizhny Novgorod (Proletarskoye Electric Fitch Ratings Inc. has improved the Russian and CIS markets, diversified will be supplied during this year. The first 9 Director General of OAO Tsentralnaya PPK. Depot). ZAO Transmashholding ratings outlook product portfolio, long-term and trains will be transferred to the customer in EG2Tv was created on the basis of a new Cars of the 81–717.6 and 81–714.6 series from stable to positive affirming its successful cooperation with the Russian the third quarter, and the rest will arrive in universal platform, enabling the appearance of were built on the basis of previous long-term ratings in national and Railways and the Moscow Metro, the fourth quarter. a whole family of rolling stocks intended for 81–717.5/81–714.5 models. They meet the foreign currencies at "BB-". The decision reducing the debt burden and high "Concluding the contract with the various operating conditions. The level of techni- most stringent requirements for the safety of the rating agency was announced on liquidity. Carriage Works (TVZ), we are counting on the cal solutions, comfort and economic efficiency of passenger transportation. Among the January 25th, 2018. highest results from joint activities. Over the of the Ivolga train correspond to the best foreign features, implemented in the According to the published report, past year, we received a large number of counterparts, even surpassing them in some compartments are: a video surveillance Fitch's positive outlook reflects the positive responses from satisfied passengers parameters. system, forced ceiling ventilation, allowing expectation of a further deleverage in who traveled by Ivolga along the Mos- for air exchange not only during the the capital of Transmashholding in the cow-Novoperedelkino route in the Kiev For details on creating and operating movement, but also during the stops. The direction. “This highlights the high potential the Ivolga train, see page 10. lighting is provided by luminescent lamps

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The 2TE25KM diesel locomotive has been operating at Tugnuysky mine for more than a year. What did it bring to the coal-mining enterprise? An increase in the volume of cargo transportation and comfort for its drivers. So, the diesel locomotive does its job very well!

The first 2TE25KM diesel locomotive arrived at Tugnuysky mine in 2016 and was put into opera- tion on December 1st. It was purchased in ex- change for the old worn-out 2TE19 diesel locomo- tive made in 1974. Tugnuysky mine also operates newer diesel locomotives, the «youngest» of which was built in 1982, but many of them still objective- ly exhausted their performance potential and have become outdated both morally and physically. THROUGH COLD Even the repair of such locomotives is becoming increasingly difficult, as some of the components they need have already been taken out of produc- tion. So, the Tugnuysky PTU (Loading and Transport Department) needed a new and modern diesel locomotive. A choice was easy: 2ТЭ25КМ is at the moment the only Russian diesel locomotive built completely from Russian accessories. That condi- tion is paramount in order to ensure a rapid loco- motive repair: should this need arise, it will not be necessary to wait half a year in order to receive parts and components from abroad. Putting the 2TE25KM diesel locomotive into operation allowed Tugnuysky PTU to increase working efficiency and the volume of cargo trans- portation without changing the number and composition of locomotive crews. Yaroslav Surov, chief engineer of the Tugnuysky PTU, explains: «Tugnuysky mine is the flagship of the Russian coal mining, and we chose the 2TE25KM diesel locomo- AND HEAT tive, among other things because its axle traction force control is a sequence higher than that of the diesel locomotive of 2TE10 series. With a new diesel locomotive we can transport up to 5 600 tons, while the former one carried only 4 000 tons. So we face now a 30% increase and that difference is quite significant!»

BESIDES In total, Tugnuysky mine has 12 mainline diesel locomotives; of these, two are of new models.

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A day in the life of 2TE25KM The diesel locomotive is operated by the Tugnuys- ky PTU on the mountain pass section. Its task is to get through the export work. How is the work or- ganised? A 5,600-ton convoy with a locomotive at the head end is prepared at the Tugnuy station. The locomotive pushes the cars, overcoming the 16-kilometer mountain area. Then, the pusher locomotive is uncoupled, and the rest of the route to the station Tatarsky Klyuch is up to the 2TE25KM locomotive. Arriving at the station, the trains for different coal routes (6,300 tons each)

INFORMATION 2TE25K The abbreviation stands for a «two-section locomotive with electric transmission, 25 series, with collector-type traction generator». This is the first Russian freight mainline, two-section, locomotive with six-axle sections, electric AC/DC transmission and collector traction electric mo- tors. It is produced at Bryansk Engineering Plant. The base model 2TE25K was produced from 2005 to 2009. In 2014 began the mass production of an advanced version of 2TE25KM, featuring a higher-powered engine. 3TE25K2M, a three-section version with even more powerful engines in each section, first appeared in 2017, while similar, two-section locomotives 2TE25K2M are planned for production at the moment. In total (as of 2017), 270 diesel locomotives of this series were manufactured.

YAROSLAV SUROV, chief engineer of the Tugnuysky Pogruzochno- system displaying the information on the Transportnoe Upravlenie (PTU, Loading and Transport Department), operator’s console display, allowing the highlighted several advantages of operating the 2TE25KM diesel technical condition of the equipment to locomotive: be monitored and optimising the traction and braking characteristics of the loco- • By increasing the capacity of the loco- consumption is much lower. Furthermore, motive; motive, the weight of the train increases, with the help of electronic controls, the • a complex locomotive safety device as, in this case, so does the amount of coal monitoring of fuel consumption of each KLUB-U-120; carried by the train. particular locomotive is an easy task. • a telemetry system for driver wak- • Modern diagnostic tools allow to quickly • Cab ergonomics improve the working ing-state monitoring (TSKBM); identify errors and, thus quickly eliminate conditions of the locomotive driver. The • ASK, an automated parameter control them. level of workplace comfort of locomotive system for diesel rolling stock operation • Screw compressor and the compressed crews has significantly improved too. and diesel fuel metering; air cleaning and drying systems allow • Noise and vibration levels have • the main automatic pneumatic brake eradication of the freezing tanks issue decreased. In comparison with 2TE10 and auxiliary direct-acting brake; and prevent the appearance of moisture locomotives, noise and vibration are • a parking lever brake, which is able to in the braking system with variations in practically absent. hold the locomotive on a 30% slope; temperature. • electric cooling dynamic braking; • A four-stroke diesel is more efficient than The locomotive is equipped with: • a unified braking equipment complex a two-stroke one that had been installed • a multifunctional microprocessor with a 395M driver’s controller and 215 on 2TE10 diesel locomotives, so its oil control, monitoring and diagnostics auxiliary brake valve.

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are formed and pulled out by the electric tract RAUL DUSEV, a diesel locomotive driver of an on the public railways (to the Chelutay station) of OAO RZhD. export column, shares his personal impressions Then they follow the Trans-Siberian Railway on 2TE25KM: to their destination – to the port of Vanino, to Nakhodka, to Zabaykalsk, to China. Every day “I was one of the first who started working on this diesel locomotive at 450 cars (up to eight pairs of trains) move from our company. I have something to compare it with, as I used to work the Tugnuy station to the Tatarsky Klyuch sta- on TE10. The TE10 and the new locomotive are worlds apart. The new tion. one has become much more convenient: the driver’s cab is warm, About nature... comfortable, and not noisy – the noise insulation is really good on these The specificity of the Tugnuysky PTU locomotive locomotives. We have a fridge and a microwave: now we can have brigades’ work is the track profile: it is complex, a snack without leaving the workplace. We have an air conditioning and has many descents, long uphills and small radius a comfortable chair. I like that! curves. “There are no such profiles on RZhD. This The locomotive is also working perfectly. Since we are rewarded for the is a very difficult area for the mainline diesel amount of exported coal, the merit of new diesel locomotives is that they carry locomotives, “says Yaroslav Surov. “Not every much more than the previous models; we could not do as much using those. machinist will be able to drive the train through this site on their first try – it requires a certain The management of a new locomotive is much easier. It’s the same as ability, experience, knowledge and skills. using a computer. Everything is automated, there is no manual control, so we The equipment of a new diesel locomotive don’t have to do any unnecessary manipulations; we have no distractions and helps the driver concentrate on the complex can completely focus on driving a locomotive through a challenging area.” track profile. The control of the train brakes, and the driver’s controller were changed. There is a display that shows the total capacity of the locomotive and each separate traction motor, allowing for a monitor of the diesel generator’s parameters. It is extremely convenient when everything is at hand and visualised! The driver’s armchair is equipped with vibra- tion suppressors and work well. Modern safety devices take away a part of the attention load. For example, when driving a train in curves, the driver no longer presses the vigilance lever thanks to the driver, waking-state, monitoring system. ... And weather What kind of climatic challenges does the diesel locomotive face in the vast expanses of Buryat- ia? First of all, the temperature changes: the climate here is sharply continental, with a long cold winter and a short, but hot, summer. A turboprop compressor is installed in this series of diesel locomotives which does not al- low freezing of the brake lines and cranes of the main tanks. Also, electric heaters of the heating system allow the locomotive crew to feel com- fortable even when the “overboard” tempera- ture is at -40 °C. Summer heat is easily endured thanks to the air conditioners. In 2017, AO mine Tugnuysky purchased anoth- er diesel locomotive 2TE25KM and sent an ap- BESIDES plication for the third one. The company does Transmashholding created a unique large-scale diesel locomotive production at Bryansk Engineering Plant, investing more than 6 billion roubles over the last four years. The plant not intend to stop there – they are planning to can annually produce 300 sections of modern locomotives. completely swap the old park for new 2TE25KM diesel locomotives by 2020.

8 9 INTERVIEW № 1 03/2018 UNDER THE WING Almost a year ago Ivolga*, the new generation suburban electric trains, started to circulate on the route: Kievsky railway station – OF IVOLGA Novoperedelkino. On March 16, 2018 a contract to supply a batch of 23 five-car trains for operation on the first of Moscow’s central diameters was signed, connecting Odintsovo and Lobnya. Alexander Loshmanov, Commercial Director for the Transport Development, ZAO Transmashholding, comments on the first results of exploitation, Effectiveness in every detail considerable money on their expenses. In addition, advantages and prospects of Alexander, Ivolga, after all, was built in rather Ivolga, on average, accelerates 30% faster than its short terms. Let’s remind the readers of the counterparts, which is especially important in the Ivolga. history of the project. stressed urban and suburban communications. Discussion on the prospects of modernisation of * golden oriole the Moscow transport hub has been going on for How much time did it take from creating many years. Of course, we were following it closely a model to producing the first train? and waiting for the moment when the project ПThe full-scale model of the EG2Tv mainline would take a real outline. On the other hand, we electric train was manufactured in May 2014 at Tver realised that the city and the region needed an Carriage Works. For Transmashholding this project electric train with new, consumer-oriented charac- became a landmark – the company started to build teristics at a higher level of quality. After all, RZhD a promising fleet of electric trains for the needs of has long had joint projects with the administration urban, suburban, timed and local passenger traffic. of Moscow and the Moscow Oblast on the con- The main goal that Transmashholding has when struction of additional railways with a new ap- creating new technology is to be as close to the proach to passenger transportation. Simply put, consumer as possible. Thoroughly understanding the very concept of Sputnik as a faster and more the features of its work and being ready to form comfortable train was already there, but we were a proposal that, from the technological and eco- lacking a special rolling stock. nomic point of view, will prove to be most effective Based on these prerequisites, we decided to too. In September 2014, the model was exhibited design and build such a train. As a base site, Tver in front of the Kazansky railway terminal. The po- Carriage Works was chosen, as it is one of the most tential passengers of the new train had the oppor- technologically advanced plants in Russia. In fact, tunity to appreciate its merits and express their we progressed from the start of the project to the wishes to the developers as to what exactly they release of the pilot copy in only a year. At the same expect from the new city and suburban train. Then, time, we managed to create a technology that the model was displayed within the framework of makes it possible to quickly change the train com- the international forum «Strategic Partnership position from 4 to 14 cars. A customer can, for ex- 1520», which was followed by several other pres- ample, use a long train during the peak hours – in entations. We organised special focus groups with the morning and in the evening, and in the after- participation of various demographics, consulting noon quickly unhook half of the cars and save with the drivers and representatives of units

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Continuing the conversation on the technical solutions used in the Ivolga construction, I would like to turn the attention to the modular principle of car space organisation. What does this mean and what practical benefits does it give? This means that we can quickly change the con- figuration of the cabin based on the needs of the customer. For example, a denser urban passenger traffic calls for more standing places, while a sub- urban traffic, allowing people to travel long dis- ­responsible for the maintenance and repair of the transport operators, they are very pleased with tances, needs more seats. Also, the design provides trains. The assembly of the first train, consisting of the full service contract we tested for the first time. a means to create cars of different classes. IVOLGA FOR two head and three motor intermediate trailing According to this contract, we completely removed PASSENGERS cars, was completed in February 2014. from the customer all the obligations on the tech- Russian technology, The EG2Tv electric train “Ivolga” is a completely nical condition of the trains. Now our customers European design Increased smoothness new train, fully designed from ground zero. It has want the same system to include all the next train 90% of components used in the creation of of its movement. encapsulated all of the world’s best in modern supplies. The cost of ownership of Ivolga is 50% Ivolga are Russian made. What are the parts transport engineering. From the point of view of lower than that of the trains of previous genera- you have to buy abroad? Reduced noise and technology, operation economy and comfort, it tions, the service intervals are five times longer and Abroad, we purchase some of the electrical vibration due to air surpasses all the imported models that operate in the maintenance time is reduced by three times – equipment. As I have already said, the train was systems, special folding seats and, soft surfaces of suspension Russia today. from 12 hours to 4 hours. In this respect, this ben- built quickly, so for some individual elements the spots, on which the passengers are usually leaning IVOLGA FOR technology. efits both transport operators and us. Another im- designers were aiming for foreign solutions. But we and spaces equipped for transport of both bicycles TRANSPORT System of automatic What are the results of the first year of practi- portant point: our train spends 20% less electricity are ready to ultimately create a 100% Russian train. and large-sized luggage. New models of Ivolga will microclimate cal operations? What are the opinions of pas- than its modern counterparts and 30% less than Moreover, our partners in Russia are already devel- have all of that. OPERATORS maintenance with air sengers and railway industry professionals on the previous generations. Partly, this was achieved oping relevant counterparts of constructive ele- Five times longer service disinfection in the Ivolga? through the use of modern, energy-saving, electri- ments. The degree of localisation will depend on What are the company’s plans to expand the intervals. compartments. We listen very carefully to the opinion of our cli- cal equipment. In general, the success of the pro- the order volume. Objectively speaking, we can Ivolga’s fleet of trains? ents, and therefore regularly participate in ongoing ject was facilitated by the fact that the train was produce everything inside this country. Ivolga was originally intended to be a base for Maintenance time reduced Modern toilet meetings with passengers and transport operators. designed for these specific conditions. developing trains for different operating conditions three fold. modules. Together, we discuss the vital issues related to the The design of the Ivolga was developed with and solving a wide range of tasks. Today, we clear- The car body is made of Wireless Internet train’s operation. I should mention that there are no The Transmashholding engineers managed the participation of the Spanish design office ly see the tasks facing the customer and the oppor- stainless steel, providing an access. complaints about Ivolga. Passengers give credit to to increase the service life of the train by 30%. “Integral Design and Development” (IDD). tunities for further transformation. There are three extended car, working the train comfort – cosy seats, many handrails, What made it possible? What have they brought to the project? main directions of rail transportation – urban, lifespan without major repairs An elaborate handrail a through passage between the cars and a quality We make the car bodies from stainless steel. It is We wanted to release a product that was radical- suburban and interregional. And the Ivolga fleet of 40 years. system. climate control which maintains a comfortable more technically difficult, but the production base ly different from anything our designers had done allows to cover all of them. We can increase the Electricity consumption is temperature in the car throughout the year. As for of TVZ allows for the use of such technology. before. We made a careful selection among the train speed, equip it with more comfortable seats, 20% lower than that of its leading European design offices and finally picked upgrade the interior solutions, allocate space for counterparts and 30% less IDD, who has a history of cooperation with Alstom, a vestibule which results in an interregional train. compared to the previous one of the world’s largest producers of railway In fact, we are already doing this within the frame- generation of trains. transport, our partner and shareholder. The Span- work of the new EP2Tv project that is also built on ish designers offered a whole series of solutions the base of Ivolga. But, again, the result of this Wide doors and the absence that have become a pleasant surprise both for us work depends on its demand, and therefore, on the of vestibules, allowing for and for our passengers. One example is the hand- customer. a high speed of loading and rail system. At the car entrance, the handrail forms unloading passengers. a circle and emphasizes the style of a round ceiling Summing up our conversation, what are Modular configuration of the light, being both beautiful and functional. the main advantages of Ivolga to its competi- space provided means a quick tors? adaption for the composition What elements and solutions will be im- Firstly, the economic indicators. Ivolga is cheaper of urban, suburban and proved upon the results of operation? Ivolga itself and much cheaper in terms of operation, interregional traffic. still has ways to move forward in terms of com- which is achieved through a whole range of solu- Real time system of fort and efficiency, does it not? tions, including localisation. Secondly, its flexibility. monitoring the train’s The project continues to develop, and of course, The ability to adapt for different conditions, and technical condition. we carefully study the world’s best Ivolga counter- quickly change the composition depending on the parts to borrow certain elements which could be task at hand. And thirdly, Ivolga looks more mod- High level of comfort for the useful to passengers. These are the USB-connectors ern and attractive, which is also very important, driver and train personnel. for charging mobile devices, passenger information especially when using the train every day.

12 13 TECHNOLOGY № 1 03/2018 PRIORITIES ON COMFORT AND SAFETY

Passengers of the already appreciated convenience and comfort of the subway cars, built by Transmashholding at its plant in Saint Petersburg. Their design uses the most modern technical solutions to ensure the comfort of travel and safety in operating a rolling stock.

Too much of a good thing is actually not good for nothing Since 2014, Oktyabrsky Electric Railway Car Repair Plant (OEVRZ) has been building trains of the 81- 722/723/724 series and their modifications for the Saint Petersburg Metro. For the first time in its history, the Saint Petersburg Metro used the prin- ciple of painting the cars in accordance with the color of subway lines. Thus, the first trains of this series were supplied for the renovation of the fleet

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by the city residents. A special emphasis in the cars development was given to the organisation of space for people with limited mobility. The head cars provide special areas for wheelchairs, designed to ensure their securing in the cabin and minimize the time necessary for that. The hardware components also underwent some changes. A number of design solutions for the an- ti-skid system have been revised. At the suggestion of St. Petersburg Metro SUE, the rail lubrication of the Moskovsko-Petrogradskaya Line and system of the trolleys, protecting them from wear had a black-blue coloration of the body and blue at the curved sections of the road, was readjusted. soft seat details in the cabins. Then came the turn An asynchronous traction drive was implement- of the red, Kirovsko-Vyborgskaya Line, so the plant ed, allowing now to save up to 30% of electric built the trains with the red version of the body power in comparison with the cars of the previous and seat details. Currently, OEVRZ is working on series. mainly green-colored cars for the Nevsko-Vasile- To improve safety, the end walls of the cars are ostrovskaya Line. The application of the color equipped with devices preventing passengers from schemes also stems from the upcoming FIFA World falling onto the road. An electronic route indicator Cup, which will be hosted by the Saint Petersburg’s is placed in the head cars of the train. sports facilities. The city will welcome many guests The cabin is designed for maximum driver con- both from this country and abroad, and we hope venience and comfort; it has air conditioning and that the modern metro cars will be highly appreci- a vibration-absorbing chair. Modern control panels ated by the city guests. are equipped with color touch screen terminals. During the manufacturing process, a new rolling stock for the green Nevsko- Line, OAO OEVRZ took into account the operational ex- perience of the previously produced trains for the Moskovsko-Petrogradskaya and Kirovsko-Vyborg- skaya Lines. The employees of the plant worked in close collaboration with the operating company – St. Petersburg Metro SUE. Together, they constant- ly monitor the feedback of residents and guests of Saint Petersburg on the rolling stock, as well as the drivers’ reports on the operation in the electric depot. On the basis of the data obtained, new

ideas have been implemented in building the green cars, allowing the improvement of consumer properties of the train. No limit to perfection To make the passengers’ stay in the compartments more comfortable, the designers reviewed the al- gorithms of the forced ventilation system which evenly distributes the airflow in the passenger compartment. The volume of supplied air was in- creased by 1.5 times relative to the values of regu- latory documents, allowing to achieve an optimum ratio of the amount of supplied air during the au- tomatic operation of the ventilation system. Also, based on the car operating experience, the fabric that had been used to cover the soft seat details, was changed. The work done by the fabric supplier on changing the technological process of its manufacture allowed an increase in density and anti-vandal properties, which will be appreciated

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Attention to every detail the plant confirmed compliance with the stand- Alexey Shishin, Car Assembly Shop Superinten- ards, including the extraction of the windshield dent, will share the details on the technical and evacuation ramp, and bringing the evacu- CAR MODIFICATIONS DIFFER BY solutions and features of the new cars. ation ramp into the working position, and en- suring the passengers exit into the tunnel. I SEATS (FABRIC, FOLDING would like to hope that these security meas- ures, though not excessive and meeting all the MECHANISM), INTERNAL modern requirements, will never actually prove useful to the passengers of our cars. VENTILATION, ANTISKID AND

Alexey, what do the compartments look BRAKE SYSTEMS, AND DOOR like? The car compartments interior is decorated MECHANISM (ELECTRIC OR with lightweight aluminum ceiling panels, fiberglass window panels, fiberglass windows PNEUMATIC) and door casings. Ergonomic handrails made of satin stainless steel, passenger semi-rigid con- sole type seats are responsible for the passen- ger comfort. The compartment is also equipped with LED light lines and high-performance ceiling fans. Cavity doors of the passenger compartments are operated with an electric motor.

And finally we come to the chassis. Have they also undergone changes in comparison with the previous cars? Of course! The bodies are equipped with an individual traction drive of the second class: the support frame suspension of the traction motor and the axial support axial suspension of the gearbox. The case of the traction gearbox is non-detachable in the axis of the wheel pair, Alexey, let’s start with the main and basic with labyrinth seals and made of cast steel. The factor – the body. How is it different from its frame of the is welded. Two-level bogie predecessors? swing suspension. Bolsterless spring base sus- The car body is all-metal, it has a welded pension. The are equipped with current construction with a load-carrying outer skin collectors located on the bar, allowing for re- made of stainless steel. The body frame is made mote release, manual fixation of the released of extra strong low-alloy steel. The walls and position and an alarming the control cabin of roof of the body are made of a set of aerofoils the released status. We also equip them with and clothing sheets with a thickness of 1 to 3 friction shoe type operation brakes and parking mm, made of stainless steel, providing addi- brakes. I would like to also note that one of the tional strength and durability. shops of OAO OEVRZ is now setting up a pro- duction line that is going to allows us produc- The cabin looks modern as well. ing bogies on our own. You’re right. In building the cabin, we use a The plant successfully opened up the produc- new fiberglass mask with original LED head- tion of new metro cars in 2010 and since that lights, sidelights and a panoramic windshield time has already transferred to the Saint Peters- that greatly improves the view from the driver’s burg Metro more than 200 cars of various seat. The cabin is equipped with an emergency models. In accordance with the terms of the exit that can be used for a quick, passenger contract, the customer will receive a total of 27 evacuation in the case of an emergency. The six-car subway trains in 2017-2018 (in 2017, Saint driver standard for preparing an evacuation is Petersburg Metro received 15 trains, and in 2018 only one minute. The recent emergency drills at will receive another 12).

18 19 PRODUCTION № 1 03/2018

THE BETTER YOU PAINT, THE FURTHER YOU GO

HOW AND WHY DOES A NEW COMPLEX INCREASE OUR COMPETITIVE ADVANTAGES? Transmashholding continues to upgrade its production facilities. The plans are growing –Moscow and Russia SPEED QUALITY Metro need a renovation and an increase of their fleets. To meet the increasing needs of its customers, Many processes will accelerate and consumers Each production stage is important both on its own, and in connection with will receive their orders faster: the subsequent ones, therefore we are constantly monitoring and improving Metrovagonmash makes drastic steps towards renewal. the quality:

• The amount of labour required for cleaning will be halved (2 to 1 hour) due to the addition of additional • The quality of the coating will be improved by posts, mechanised lift platforms and the possibility of creating the necessary roughness of 60–80 μm and increasing the pressure to the amount of 10 bar. the degree of surface cleaning 1–2 according to The first shop GOST 9.402 (Sa 2.5–3 according to ISO 8501–1). As the initial stage of modernisation, a new mod- ern workshop for car surface preparation was opened up. This production stage lays the founda- tion for all further processes – priming, painting, etc. The preparation of the car surface dictates the quality and service life of the paintwork as a whole, • The amount of labor and thus – the perception of the operating compa- required for mixing the paint and lacquer ny in the eyes of passengers and its costs for the materials will be halved, renewal of the paint coating. due to the mechanisation of Preparation for further effective work was car- mixing. ried out quickly and thoroughly. In just four months, the production facility was completely overhauled: a panel fence, separating it from the • The productivity of the prime coat and mastic • Mixing accuracy will be enhanced by introducing application will increase by two and five times an electronic mixing system for the base and neighboring car assembly shop No. 217 was in- respectively, due to the introduction of combined hardener components, which will therefore, stalled, the shop was repainted, the window and airless methods of applying materials, eliminate the human factor in preparing the prime increasing the number of posts and introducing coat for work. frames were replaced. Now the shop room will The grand opening mechanised lift platforms. have a maintained temperature regime: no less of a new shop than 59° F (+15 °С) and a relative humidity of 80%.

20 21 PRODUCTION № 1 03/2018

terials. This is an important technological stage, allow to keep the pressure of the abrasive material guaranteeing a durable and reliable paint- outflow at 8 to 10 bar. It helps to obtain a neces- work even in the most severe, operating sary roughness of the surface. In addition, the new ­conditions. shot blasting technology uses an extra strong Another task of the complex is the prime coat crushed grit that allows for a slower spending rate application on the surface of car frames and bodies than the copper slag. as well as a mastic application on the inner surface The tests we conducted during the acceptance BORIS BOGATYREV, of the body and the underbody part of a car. of the chambers showed good results: the final Director General, The prime coat determines the durability and steel base roughness corresponds to all GOSTs and the decorative appearance of the paintwork in provides all the necessary surface cleaning param- OAO Metrovagonmash: general, the antivibration and antinoise mastic eters. I am confident that our consumers will be ensures the comfort of passengers and the driver. very satisfied with the appearance of new cars and – Every year Metrovagonmash increases the production The priming, the application of mastic and drying the durability of the coating. volumes. The new complex has great prospects: with its are performed by the second chamber of the com- introduction, the production quality will improve significantly, plex – the painting and drying machine. Painting and drying machine and technology will be improved. We greatly value the relations The new equipment will increase not only the The unit is equipped with an electronic dosing with our customers and consider investing in a new painting quality, but also the speed of work. The car is system for two-component paintwork materials, moved by means of hauling gear, and electrohy- uses a combined method of prime coat spraying, complex primarily as an investment in future cooperation with draulic lift platforms provide quick access to any and automatically stabilizes the ventilation flow them. part of the body. There is no longer any need to rate to maintain a stable shape of the spray swath. spend time and energy on scaffolding rearrange- Andrey Balyukin explains why it is important and ment! what the danger of the spray swath failure is: This is important for the new equipment «When the material is sprayed, an improperly ad- ­operation. Shot blasting chamber justed ventilation system leads to a failure of the The first chamber of the complex, intended for spray swath. The result is an uneven application An excellent mark for both abrasive treatment of car bodies, will prepare the and loss of paint. tasks steel bodies of 81–717/714 series cars well as stain- The new chamber has three ventilation units and The abrasive blasting and surface priming com- less steel cars (used today, for example, in trains of an automated control system. If the filters are plex consists of two chambers: a shot blasting the 765th series called “Moscow”). clogged, the air circulation in the chamber increas- chamber and a painting and drying machine. One Andrey Balyukin, Chief technologist of OAO es, and a special sensor monitors if the speed re- of the tasks of the complex is the preparation of Metrovagonmash, is satisfied with the quality of mains at 0.2 meters per second. the car body’s surface for painting: removal of work of the new equipment: «The main advantage Transmashholding plans to further upgrade its scale, corrosion, and roughening, necessary for Prime coat preparation of the shot blasting chamber is a special system of production: in the immediate future we are going Painting and drying the further application of paint and lacquer ma- system high-pressure abrasive jet boilers with tips that to improve the welding process and implement machine robotic automation. Project investments Shot blasting amounted to chamber more than

166 million roubles

The output of the new shop will reach 50 car bodies per month

22 23 HISTORY № 1 03/2018

The first mainline freight two-section eight-axle AC was the installation of modern security, fire of 2ES5K series was built in 2004 extinguishing and diagnostics systems. at the Novocherkassk Electric Locomotive Plant The chassis have also changed, which allowed (NEVZ). The plant workers decided that this beauty reduction of the impact of the locomotive on the rail of a train should get its own name. A citywide way. Thanks to an updated traction engine NB-514B, ST competition was announced, and as a result the the traction parameters of the locomotive have also name "Ermak" confidently won. This fitted perfectly, increased. The individual smoothing reactors as the locomotives were to be sent to Siberia. designed for current pulsation leveling in the traction motor circuit of electric locomotive made it 21 CENTURY: With the latest technology possible not only to increase the traction properties (state-of-the-art equipment of the locomotive, but also to improve its protective The new locomotive was built in as short a time as functions in case of emergency conditions. possible. The technical solutions implemented in the Individual smoothing reactors facilitate the transient process of designing and manufacturing the processes and reduce the electric locomotive ERMAK RECONQUERED SYBERIA locomotive allowed to significantly improve the disposition to skidding. technical and economic indicators and consumer In general, when developing and manufacturing Russian President Vladimir properties compared to the previous locomotives, this locomotive, all the advanced technology, Putin tested the first 2ES5K improving traffic safety and easing the working applicable to locomotives with collector traction Text: Anna Semenyuk Ermak electric locomotive turns 14 in 2018. Over the years Ermak at the exhibition in conditions of locomotive crews, reducing the engines, were taken into account. Photо from the press service archive of NEVZ this drudge conquered not only the endless railways Shcherbinka in 2005 specific energy consumption for transportation, and The appearance of the 2ES5K electric locomotive of ­Siberia, but all of Russia. improving the use of the adhesive weight. and the driver's cab have a modern design and Insufficient adhesive weight (weight on driving comply fully with the ergonomic requirements. An axles) with sufficient locomotive power and optimal cabin microclimate was created by the excessive weight of the train can result in skidding. implementation of wall and floor heating panels, The weight on driving axles of this electric sealed windows and air conditioning system. locomotive is optimal (24.5 tf, versus 23 tf for VL80v and VL80i). Unlike its predecessors, the In less than no time microprocessor systems used in the new locomotive, The first 2ES5K Ermak was manufactured at the end provide manual and automatic movement control, of 2004. The factory checkout tests were successfully diagnostics of movement and all the equipment completed in April 2005. In August 2005, 2ES5K operation parameters. In addition, this electric participated at an exhibition in Shcherbinka, locomotive implements a more economical Moscow Oblast and was highly appraised by Russian ventilation system. Another significant innovation President Vladimir Putin. The Russian leader personally drove Ermak for almost 6km. At the end of 2005, RZhD purchased an initial batch of 30 electric locomotives. VALERY ZADOROZHNY, In April 2006, electric locomotives of 2ES5K series Head of AC Electric Locomotives Division, received a certificate of compliance with safety OOO PK NEVZ, on the prospects of Ermak: standards in railway transport. The entire set of works for building, testing and certification was - The plant has already produced 300 Ermaks; their design has completed in record-breaking time – in only 2 years from the date of approval of the statement of work been significantly improved in terms of reliability, maintainability for the electric locomotive, whereas usually this and energy efficiency since 2009. These electric locomotives practice takes 5-7 years. Since 2006 NEVZ began to immediate implement a range of innovations. The second stage of produce electric locomotives 2ES5K in lots. The first bogie spring suspension now has flexy coil instead of the swing link. locomotives of this series began to develop Russian Modern Ermaks provide an independent traction control for each territory from the East Siberian Railway. bogie. The locomotives are equipped with traction motors NB-514 Since the release of the first 2ES5K electric locomotive NEVZ has expanded the product range with H-class insulation, eliminating the occurrence of insulation of locomotives produced on the basis of Ermak by a overheating and thermal breakdowns. Since 2015, traction motor three-section freight 3ES5K, one-section E5K and axle bearings are used in wheel-motor blocks instead of plain friction the pride of NEVZ – the world's most powerful four- bearings. Each electric locomotive is equipped with an audio and section locomotive 4ES5K. Ermaks are successfully video surveillance, as well as equipment status registration and operating on the East Siberian, Far Eastern, Trans- transmission systems. Baikal and Oktyabrskaya (October) Railways of Russia, and on the Odessa Railway on the Ukrainian territory.

24 25 TRANSMASHHOLDING