№ 3 09/2014 MAGAZINE FOR PARTNERS OF Design outputs andprospects 2ES5: Ermak –onthewaytoward perfection Anniversary ofLocomotiveElectronic Systems Metro Safety–ourtoppriority p. p. p. 12 p. 18 4 8

№ 3 09/2014 MAGAZINE FOR PARTNERS № 3 09/2014

A Magazine for Partners Contents company Editor-in-Chief 4 Konstantin Dorokhin [email protected] news

Editorial Office address: 26 Butyrskiy Val St., bldg. 1, introduction , 127055 Hitting the target: Phone: (495) 660-89-50 Anniversary of Locomotive Electronic Systems

Published in collaboration with MediaLine Publishers www.medialine-pressa.ru General Manager Larisa Rudakova 8 Design Artist personality Ilya Malov Sergei Perov, Head of New Product Department, Editorial Director Dmitry Dorofeyev Transmashholding: “New Copy Editor metro cars to become safer Irina Demina 8 and more spacious” Design and Typesetting Inna Titova, Maria Tyrylgina Alexei Sukonkin Irina Shilina

Proofreaders Larisa Nikolina Alina Babich Oksana Sinat 2ES5: designcover outputs story Prepress 12 Andrei Klochkov and prospects Maxim Kuperman Anastasiya Morozova

Approved for printing on 00.00.2014 Printed by Union Print Press run: 999 copies. 12 operation Ermak locomotive: on the 18 24 way toward perfection

traditions Kolomensky Zavod during 24 World War I 1 NewsHappy Journey! Modern tramcar

The state-of-the-art 71–911 produced in different versions tramcar with a fully low floor is depending on the capacity and undergoing certification tests. waggonage requirements to fit toThe tramcar undergo was designed by PK lines with anytests traffic and length, Transport Systems. The first including commuter traffic. The tramcar was built this May by tramcar design features unique Tver Carriage Works (TVZ), patented flexible low-floor swivel Recognition a member of Transmashholding. bogies ensuring smooth In June-July, the tramcar movement and full compatibility successfully passed dynamic of the tramcar with Russian tests held in Moscow. Its urban infrastructure. The certification tests will take two tramcar boasts an innovative months. diagnostic and control system ЗES4K locomotive Model 71–911 features and two independent climate a single-unit fully low-floor control systems — one for the Novocherkassk Electric Locomotive Plant (NEVZ, design and has no equals in the driver’s cab and one for the getsa member ofa Transmashholding) certificate obtained world. More than 80% of tramcar passenger compartment. a certificate of compliance with the federal components are manufactured The new tramcars are expect- railway transport standards for the commercial in . Due to its modular ed to appear on Russian streets production of the Donchak ЗES4K locomotive. design, the tramcar can be as early as next year. 3ES4К is based on Donchak 2ES4K, a freight DC commutator motor locomotive. Many mechanical units of Donchak are standard - ized with AC locomotive Ermak 2ES5K. A distinctive feature of 3ES4K versus the two-section model is a two-section booster (intermediate) unit that increases its power 1.5-fold and its hauling ability up to 6,000 tonnes. Employment of locomotives will allow for heavier train loads and higher delivery speeds along with lower car turnover and rolling stock maintenance costs. Benefits of the new locomotive versus 2ES4K include motor axial roller bearings for increased mileage between scheduled maintenance and a pass-through between sections for easier shunting operations and maintenance. The certificate is effective through July 2017. ЗES4K commercial production will be launched in 2015.

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Modernization

Designers and engineers of Penzadie- nents in the Russian Federation”. Higher um-speed diesel locomotive engines selmash (PDM, a member of Transmash- efficiency of the new turbochargers will 8ChN26/26. New turbochargers will Newholding Group) havePenza completed motorless turbo improve engine-operating compressors economy. The replace the outdated 14ТK model tests of two pilot models of the new ТK25 series includes turbochargers both installed on remotorized shunting diesel 25-series turbochargers to be used to for medium-speed (ТK2502) and locomotives. The key feature of ТK2502 upgrade basic medium-speed and high- high-speed (ТK2503) diesel engines. is solid tired turbine wheels that enhance speed diesel engines. Following the tests, optimization and gas its reliability and efficiency. The expected The new 25-series turbochargers are dynamic calculations were made and turbocharger efficiency is 7–10% higher designed under the Federal Target design documents were refined. versus its equals. Service tests of Program “Industrialization of New-Gener- The basic version of the ТK2502 ТK25-series turbochargers are sched- ation Diesel Engines and Their Compo- turbocharger is suitable for medi- uled for 2015.

Production Demikhovo Machinebuilding Plant (DMZ, a member of Transmashholding Group) obtained a compliance certifi- cate with Federal Railway Transport Certification Registry for the commer- cial production of a new rolling stock, a special AC EMU EDS1R. The special EMU to transport mainte- DMZ presents nance crews to RZD’s infrastructure facilities will be placed into service for the first time ever. It includes two cars, one for work team needs, and one for equipment storage and transporta- a special-purpose EMU tion. It was built with working condi- tions in mind. The passenger com- partment meets all modern sanitary, ergonomic and safety standards and is equipped with an HVAC system and an eco-friendly lavatory that can be used along the entire route, including in sanitary protection zones. The car is fitted with 2- and 6-seat couches with tables between them and has a kitchenette with a serving table, wash sink, dish dryer, cabinets, refrigerator, microwave oven, and electric kettle. The new special-purpose EMU is designed on a standard ED EMU basis and incorporates proven solutions, standardized underframe and car body equipment for lower operating and maintenance costs.

3 Introduction Reliable electronic equipment is vital for safe and efficient operation of rolling stock. Therefore, Transmashholding seeks to develop and expand its R&D units. One of them is Locomotive Electronic Systems (LES), a producer of electronic train control systems. This September, LES celebrates its 10th Hitting anniversary. the target

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Data processing server

Telemetry database

Service center engineer Warranty service engineer work station work station SSL/TLS SSL/TLS

SSL/TLS GLONASS Internet

GSM/GPRS SSL/TLS

Locomotive en route

Figure 1. Remote monitoring system

he Company has had a long and 35 electrical engineers qualified to Setup and warranty services are fruitful history. Today, it grades from 4 to 6 with a vast experi - provided by 8 engineers with higher T manufactures the electronic ence in electronic equipment installa- education and extensive work experi- ‘core’ of rolling stock management tion make up the backbone of the ence. LES representatives work at systems and test equipment, develops production unit. Average age of a each depot that operates warranty design documentation and software specialist is 40 years. locomotives ensuring prompt control for locomotive control systems. system troubleshooting. Additionally, LES develops new 22 engineers are engaged in equipment, updates design documen- development and upgrade of electron- tation and software, and offers ic equipment. Qualified specialists, warranty and aftersales service. some with a degree in science, devise Its major clients include PK NEVZ, current activity and strategic develop- Kolomensky Zavod (Kolomna Plant), CURRENTLY, MORE THAN 1,850 ment plans. and Luganskteplovoz. LOCOMOTIVES ACROSS RUSSIAN BACKGROUND OUR TEAM The Company started its operations in A company’s success always depends late 2004 with the production of pilot on its close-knit and dedicated team. REGIONS AND CIS COUNTRIES ARE models of the MSUD-N control system Currently, LES’s headcount is 94 for AC passenger locomotives EP1. At people. the time, the system was launched LES operates five business units: EQUIPPED WITH LES CONTROL into commercial production and design unit, production unit, software installed on electric locomotives unit, quality unit, and setup and EP1М, EP1P, 2ES5K, 3ES5K, E5K and warranty service unit. SYSTEMS 2ЕL5.

5 In 2005, the Company’s engineers MSUD-001 (for freight DC locomotives pilot sample of microprocessor control Introductionjointly with All-Russian Scientific 2ES4K, MSUD-K (for the upgrade of system MSU-013 to be employed in Research and Design-Engineering freight AC locomotives VL80ТМ/SM diesel locomotive ТEP70BS. It was Institute of Electric Locomotive for Kazakhstan Railways), and manufactured and successfully Construction (VElNII) embarked on the MSUD-R (for pilot locomotive 3ES5K passed bench tests. development of design documentation with enhanced package of features). In 2013-2014, LES engineers and and software for control systems: From 2005 to 2007, the Company VElNII specialists designed documen- manufactured and tested several tation and software for microproces- system samples and began prepro- sor control system MSUD-015 for the ALEKSEY IVANOV, duction. At the same time, the Compa - 2ES5К class locomotives (3ES5К, DIRECTOR GENERAL, LES: ny launched commercial production of 4ES5К) with enhanced diagnostic MSUD-007 control systems for PJSC functions and individual axis control, “Kolomensky Zavod.” as well as designed control system In 2008, batch deliveries of control MSUD-001-01 for the booster section systems for freight DC locomotives of the 3ES4К locomotive. 2ES4K began. The systems were successfully In 2008-2010, control systems tested and installed on the 3ES5K and MSUD-N and MPSU-007 underwent a 3ES4K pilot locomotives. complete hardware and software upgrade, enabling the production FOCUS ON QUALITY according to own design documenta- One of LES’s top priorities is a product tion adjusted to operation experience quality control. The Company has and tailored to client needs. introduced and certified a quality In 2011, the Company’s experts management system (QMS) integrat- designed BRPD-004, a data recording ed into its overall management and transmission tool that is integrat - system. QMS focuses on continuous ed into locomotive positioning sys- operating improvement with regard to tems and transmits measurements to the needs of all interested parties, the server in real time. Since 2012 the primarily the consumer. unit has been supplied to PK NEVZ. Striving for continuous quality In late 2012, LES launched commer - improvement, higher reliability and cial production of equipment for competitive edge of LES products, control systems of the EP20 dual and aspiring to boost business voltage locomotive and started profitability in 2015, the Company is “The cutting-edge concept of deliveries to PK NEVZ. planning on adoption of the Interna - designing rolling stock control systems Additionally, in 2011-2013, LES tional Railway Industry Standard is based on a modular principle. Each developed design documentation for a (IRIS). module is an independent subsystem with an integrated control and diagnostic system and standardized interface links to other subsystems. All rolling stock systems should incorporate maintenance-free and low-maintenance equipment and LOCOMOTIVE ELECTRONIC SYSTEMS (LES) WAS INCORPORATED ON SEP - energy-efficient solutions. To reduce the costs and time required for rolling stock building, the TEMBER 23, 2004 AS AN ENGINEERING COMPANY INVOLVED IN DESIGNING technical solution design phase should include development of a standardized base platform for modular rolling stock AND COMMERCIAL PRODUCTION OF CONTROL AND DIAGNOSTIC SYSTEMS control and diagnostic systems that can be used, like bricks, to construct FOR LOCOMOTIVES MANUFACTURED BY NOVOCHERKASSK ELECTRIC LOCO - a control system for any type of rolling stock. Standardization ratio of such control systems should be at MOTIVE PLANT AND KOLOMENSKY ZAVOD (KOLOMNA PLANT) least 85%.”

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Kandalaksha

Saint Petersburg Moscow R Kotovsk U Nizhny NovgorodSS ION Saratov IAN AT Rossosh FEDER Kvartaly

Kavkazskaya Novosibirsk Belogorsk Krasnoyarsk Khabarovsk Barabinsk Vikhorevka Irkutsk Belovo Smolyaninovo

Figure 2. Operating geography of locomotives utilizing LES systems

The Company’s efforts in the field THERE IS NO END TO PERFECTION Diagnostic and measurement recording were awarded with 10th Anniversary LES does not only design new systems, software monitors equipment en route European Quality Gold Medal. but upgrades the existing ones as well. on an ongoing basis and displays error messages in case of emergency. Malfunction analysis helps improve the system’s efficiency.

INTO THE FUTURE WITH CONFIDENCE After 10 successful years of significant achievements, the Company looks into the future with confidence. LES engineers stay current with global trends in control unit and system design and manufacture and tailor their systems employed in rolling stock to customer needs. The Company is committed to personnel development and training in advanced electronic equipment production technologies. LES works in close cooperation with locomotive building plants, best designers and manufacturers of electronic equipment, and research institutes. During these past ten years, the high scientific and technical potential of LES has earned the Company the position of Transmashholding’s leading enterprise in the field of electronic devices.

7 Personality Sergei Perov: “New metro cars to become safer and more spacious”

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In many Russian cities the metro has always been the most popular and democratic public transport. It is no wonder that designers and developers seek to create the most up-to-date and comfortable rolling stock models. SERGEI PEROV, HEAD OF TRANSMASHHOLDING’S PRODUCT DEVELOPMENT DEPARTMENT, SPEAKS ABOUT THE MOST PROMISING PRODUCTS ergei Victorovich, the new law on technical regulations affects metro car manufac- turers. What changes could this entail for rolling stock manufactur- –Sers and passengers? — Passengers, who ride Transmash- holding cars, will not notice any changes. The new regulations do not imply a review of the existing standards. In fact, the new regulations make the existing standards mandatory for all manufacturers. We will still have to meet the mandatory durability requirements, sanitary and fire standards. From now on, structural changes in new car models will be governed by the law and not by technical documents alone. This means that all manufactures will have to obtain certificates for each product. Until now it was voluntary. The new law makes it mandatory for all manufactur- ers regardless of their wishes. Additionally, the new law provides for higher liability limits on the part of manufacturers and will make passen- gers confident that the new rolling stock fully meets safety requirements.

— The recent tragedy on the Mos- cow metro calls for a question as to how robust and safe modern metro cars are and what can be done to

9 minimize passenger risks in case of able transportation of handicapped Personalityemergency? passengers (on wheelchairs) or baby — Today, over 6 thousand cars manu- carriages. factured throughout these years by The car interior layout has been Metrowagonmash carry more than 15 improved significantly for easier million passengers in 19 cities of The design features of our entrance and movement around the car. 11 countries worldwide. There is more standing room; handrails However, traffic safety is basically are installed in a more convenient a matter of efficient traffic manage- trains deliver a much higher location for easier access by standees. ment. Notably, the subway is least New models will have more visible and prone to accidents among all ground simple warning lights (to consider the transport. As far as the design features level of safety for passengers needs of poor-sighted people). of cars are concerned, I would like to Meanwhile, safety and comfort to underline that in Russia we maintain a large extent depend on passengers a much higher passenger safety level than in many other countries themselves. Therefore, passengers are than in many other countries. Our frequently warned through the pub- metro trains stop automatically at red Additionally, it is worth mentioning lic-address system that the metro is light or, for example, if the driver loses that very few metro cars across the a high-risk mode of transport. Design- conscience, which is an extraordinary globe are equipped with video-surveil- ers take every effort to minimize the event. Speaking about durability, our lance systems or emergency communi- risks. For example, currently, there is car bodies are made of stainless steel. cation lines either with the driver or, like less chance of a passenger or clothing Aluminum is, of course, lighter, and our cars, with a dedicated situation getting trapped between doors. Doors aluminum car bodies are more cost-ef- center that monitors the entire Moscow in new cars are equipped with so-called ficient. However, it is less durable and metro. trapping sensors. If doors are not tightly can even inflame in some situations. Our developers integrate innovative closed, automatic devices get activated A number of tests conducted in solutions into new model designs. For and the train won’t start until the driver Russia proved that in the event of example, today, the cabin’s front walls makes sure it is safe. thermal action (for example, when the are equipped with ramp doors so that in undercar electric equipment ignites) case of emergency passengers can — Recently, the world has seen new the aluminum car quickly loses its form escape not only through the ‘regular models of metro rolling stock, and breaks down. This involves door’, but through the exits along the differing by a streamlined and, in a greater risk for passengers inside the train as well. a manner of speaking, futuristic car and makes evacuation of the form. Is this a matter of improved damaged train from the tunnel very — Apart from reliability and safety, aerodynamic performance? difficult. Nevertheless, in some there are certain expectations in — Honestly speaking, this is done for countries aluminum is still used for terms of comfort. Even during peak aesthetic reasons. The way of life is metro car production for economic rea- hours passengers do not want to changing, and people want to see sons. In Russia, steel is the prime arrive at their destination totally stylish trains. For a train moving like material. exhausted... a piston in an enclosed space of I would like to stress that Russian — Unfortunately, optimization of a tunnel, the form and streamlined front standards prescribe much stricter peak-hour passenger traffic and train do not play a significant role in aerody- requirements to passenger and rolling schedule are outside of our area of namic performance. So, it is a matter of stock safety than anywhere else in the competence. Our responsibility is to aesthetic appeal. On the other hand, it world. The same is true for sanitary ensure most comfortable conditions for is important, since we are not living in standards to ensure comfortable passengers inside the car. We never the 1930s when the first metro lines environment in the passenger com- stop working — even at the launch of were launched. partment and the driver’s cabin, and commercial production of a new model requirements to car interior. Fire safety we keep searching for more efficient — What is, in your opinion, the basic is also a priority — potential fire points solutions. For example, in Moscow and difference between Russian and are equipped both with automatic fire some other cities there are passenger foreign-made metro cars? alarm and automatic fire fighting cars with wider doors for easier — It lies in operating conditions of a city systems; fire-resistant materials are entrance and exit. Starting next year, we or country and infrastructure properties. used in the car interior finishing. plan to manufacture cars with even For example, London’s underground is Therefore, even serious metro acci- wider doors. In line with our new one of the world’s oldest, with small-size dents have never led to car barrier-free design concept, new cars tunnels. Sometimes it is impossible to inflammation. will have a special platform for comfort- install air conditioning systems in cars

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because there is not enough space. The RER lines operate double-decker trains. cars. However, such trains are soon to widest cars run in Oslo, in tunnels cut in Much depends on a given metro’s come. The Mytishchi plant has already the rock. They are even wider than our infrastructure capacities, including the manufactured pilot models. customary commuter trains. In Paris, train size and equipment. Our cars are Speaking about the metro in general, designed for very heavy loads. On the comfortable trips are not only a matter of , an average number of good cars, but efficient traffic manage- passengers departing from and arriving ment as well. Despite some drawbacks at a station is larger than anywhere else that are unavoidable in operating such in the world. Modern Russian cars are a big facility, it is notable that Russia is fully consistent with the Russian under- the best-performing operator globally in Our cars are designed for ground railway conditions, and this is terms of traffic intensity: during peak how they differ from others. hours trains arrive every minute and As for everything else, just like almost a half. Smooth traffic and accident-free very heavy loads, and in all modern electric trains, Russian metro operation in such conditions are a diffi- trains are equipped with electronic cult task that is successfully solved by public-address and warning systems, air the Metro personnel and car manufac- terms of their technical level conditioning, airtight and soundproof turers. In the future, through a well-coor- doors. There is only one difference dinated technical policy of national between our trains and many for- metro-car manufacturers adjusted to the they are on a par with the eign-made trains — we did not have Moscow metro plans, we are going to a pass-through along the entire length of deliver cars with even better perfor- the train that could help passengers mance that, we hope, will match the world’s best analogs move between more and less crowded growing demands of our passengers.

11 Cover story

The 2ES5 locomotive, 25 kV DC 50 Hz, is designed for hauling freight trains on 1520 mm track gauge. 2ES5: DESIGNThe first Russian mainlineOUTPUTS freight electric AND locomotive PROSPECTS with asynchronous traction engines was developed by Transmashholding jointly with Alstom, a French machine-building giant, based on TRTrans, a Russian engineering center. What sort of a locomotive did the y develop? You can read about it in this article. 12 № 3 09/2014

control, management and protection according to the required freight traffic devices, traffic-safety management parameters and featuring commuta- systems, information and data torless asynchronous traction motors. exchange and transmission technolo- The locomotive’s design utilizes gies. dozens of state-of-the-art engineering solutions focused on improved work ERMAK’S POWER environment for drivers and mainte- In mid 2000s, a number of perfor - nance personnel, enhanced reliability mance properties of RZD’s freight and increased time between repairs. locomotives were improved when the The locomotive is highly compatible new generation locomotives 2ES5K with the existing infrastructure. (‘Ermak’) joined the fleet. However, the loco’s power (6,200 kW) was not Geographical vastness of Russia sufficient for hauling heavy trains Quality improvement of the rail freight (over 5,000 t). A booster section was traffic is impossible without timely designed for heavy trains, which is as re-equipment of the available fleet of powerful as one section of 2ES5K. The electrically propelled vehicles and model was entitled 3ES5K. The first enhancement of its technical level. A 3ES5K running results displayed an persisting demand for international enhanced traction performance. transportation services, intensification However, regular operation of three of overland traffic along the South- traction modules for lighter train East Asia-Europe transportation hauling decreased the locomotive’s corridor and, in this context, good energy efficiency. There remained a chances for the Trans-Siberian line to need for a freight two-section AC become an important transportation locomotive for trains with a load rate link between the countries of Eu - exceeding 6,000 t. Analysis of traction ro-Asian regions make re-equipment and power properties of a prospective of the existing electric rolling stock a mainline locomotive showed that vital problem for railroad transporta- hauling of freight trains would require tion companies. a locomotive with a continuous Taking into account difficult operat- ost of the innovative ideas running duty over 8,000 kW. It exclud - ing conditions on the railroads of Sibe - implemented in the 2ES5 loco- ed the possibility of a traditional rian and Far-Eastern regions and motive design were developed as design solution - the commutator pending annual freight traffic growth, early as the 1990s and are based on traction motor. locomotives equipped with asynchro- the extensive experience of operating nous traction motors could become a MVL80 class locomotives. However, the promising type of locos suitable for NEW HERCULES ideas could only be implemented when This inspired design engineers to those conditions. For the first time the market offered affordable cut- design a conceptually new electric ever, domestic manufacturers em- ting-edge electronic components, locomotive capable of performing braced the production technology of

2ES5Purpose key performance parameters Freight carriage

Design speed, km/h 120

Nominal overhead system voltage, kV 25

Wheel arrangement 2 х (2о — 2о)

Service weight at 2/3 sand capacity, t 200

Continuous shaft rating, kW 8,400

Starting rail tractive effort, kN, min 784

Efficiency rate in continuous operation, %, min 86

13 CoverBelow are only story some advantages of the 2ES5 loco versus the previous-generation VL80 and 2ES5K locomotives: Improved traction properties due to new traction drive control algorithms:

• individual axis control; • adaptive slippage and skidding protection; • rigid traction motor characteristics; • higher adhesive weight utilization factor due to the design of bogie-to-body tractive effort transmission unit, and lower center of gravity due to traction transformer location under body

Lower traction power consumption:

• maximum efficiency in load range from 0.5 to nominal; • power factor at 0.99 in load range from 0.25 to nominal; • lower resistance to motion; • lower auxiliary power consumption; • power efficient control algorithm in automatic piloting mode; • automated use of regenerative brake instead of pressure brake Improved long-train traffic safety:

• automated control of a locomotive operating in distributed traction mode; • automatic reduction of axial dynamic force in long and heavy freight trains and double trains; reduction of axial dynamic force due to appropriate substitution of electric brake with pressure brake

Adaptation to operation in insufficient power supply conditions:

• increased nominal power utilization range in overhead system voltage from 21 kV to 29 kV. One-man operation option for the driver:

• extensive implementation of remote operating systems; • enhanced diagnostic systems; • high degree of control automation; • engine-room video monitoring Increased service life:

• use of low-maintenance equipment (traction motor, traction reducer, traction transformer, oil-free main compressor, driver’s brake valve); • body: 45 years; • bogie frame, traction transformer: 40 years; • electrical equipment: 20 years; • traction tooth-gear transmission: 2 M km; • bogie wheel: up to 1 M km; • axle box bearing: 3 M km; • rotor bearing: 2 M km; • motor-axial bearings: 5 M km Design features:

• two-axle bogie (welded, Flexicoil springs, cartridge axle box bearings with transmission of traction (brake) effort through slant thrust); • 1 grade rod gear; • traction drive with asynchronous motor and individual voltage inverter (axis control); auxiliary power consumption converter with automatic performance regulation and smooth air fan and compressor start; • microprocessor control and diagnostic system; • oil-free piston-type compressor with air drying and cleaning option; • distributed ventilation system with regulated performance; • energy absorbing devices for locomotive crew impact safety; modular pneumatic installation of stainless pipes and electrical installation by using spring clamps; • equipment arranged in the body with pass-through along taxis

14 № 3 09/2014 such electric locomotives, the 2ES5 being the first loco with this design. World experience speaks in favor of such possibility, since the develop- ment of asynchronous traction motor locomotives is given priority across the globe. Owing to the low specific consumption of active materials, asynchronous traction motors as compared with commutator motors possess better mass and dimensions parameters and require lower mainte- nance costs. Moreover, the rigidity of mechanical/electrical characteristics provide for high values of coefficient of traction. A combination of these factors allows an increase of the locomotive’s axial thrust to provide better traction performance, reduce maintenance costs and enjoy a number of other significant operating advantages. Nevertheless, the acquisition cost of the electric rolling stock with asyn - chronous motor drives is by far higher (up to several times) than the cost of the electric rolling stock with similar axial thrust of constant-current commutator (intermittent-current)

motors. This factor by no means locomotive, which had been prepared decreases the competitive edge of the by the customer – . electric rolling stock with asynchro- The parameters indicated in the The locomotive design utilizes nous motor drives and does not pose design specification of the 2ES5 an obstacle to their purchase for locomotive were formulated based on re-equipment of the existing electric the Company’s plans to handle freight hundreds of state-of-the- rolling stock, taking into account the traffic in the years to come in the lifecycle cost of various types of the context of annual freight traffic growth new (fifth) generation locos and that and critical operation territories. As to art engineering solutions of previous generations. A solution to some characteristics of onboard this seeming problem can be reduc - information systems of the 2ES5 featuring improved work tion of the lifecycle cost with simulta - locomotive, a number of requirements neous reduction of the acquisition were included in the requirements cost of the electric locomotive with specification. They require that the environment for drivers asynchronous traction motors. information systems be equipped with cutting-edge devices based on the The rugged workhorse locomotive latest global achievements in the field and maintenance personnel, The 2ES5 electric locomotive boasts of electronics, mechanical engineer- high cost-performance ratios. These ing and other high-tech industries. characteristics were not simply Their design allows for longer runs enhanced reliability and proposed by the electric locomotive between repairs as opposed to those designers, but they were a result of of the previous-generation locomo- strict observance of technical specifi- tives. This entails a considerable increased time between repairs cations for development of the electric reduction of locomotive maintenance

15 Cover story A combination of technological factors allows an increase of the locomotive power per axle to provide better traction performance, reduce maintenance costs and enjoy a number of other significant operating advantages

costs and substantial improvement of The brake-track master system allows A modular operator’s cab with the management of the Company’s for reduction of the length of brake path automatic climate control meeting all fleet. in unfavorable weather conditions and at modern sanitary, ergonomic and The first-class mechanical suspen- high running speed and wheel wear. safety requirements allows for reduc- sion rod makes it possible to reduce Tread-free (one-piece-rolled) wheels tion of the locomotive’s assembly dynamic loads both on the railway with service life of one million kilometers cycle time. track and all units and parts of the enable an increase of mileage between A new fully integrated microproces - electric locomotive. major repairs. sor-based control and fault detection

Tread-free (one-piece rolled) wheels with service life of one million kilometers enable an increase of mileage between major repairs

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mechanical engineering industry and information technologies with regard to engineering and styling design, energy saving and information technologies in the area of transport. The 2ES5 new-generation electric locomotive developed by PK NEVZ is capable of satisfying the growing demand of Russian Railways in the segment of AC freight transportation. Outside-air filtering system, sol- id-state relays in low-voltage circuits, electric apparatuses for protection and control, new technologies to control thrust and auxiliary electric motor drive were among technical solutions and devices that ensure efficient operation of the loco’s equipment. Localization of production of import parts in the vicinity of the main assembly plant will provide for sub - stantial reduction of the locomotive cost at serial production. Additionally, the competitive edge of system is employed in the locomo - the 2ES5 may be increased through a tive. The 2ES5 electric locomotive leasing system if it is purchased by surpasses Ermak in terms of traction railway companies. and output performance, which On June 28, a meeting of the makes it possible to use the 2ES5 interagency panel at Novocherkassk electric locomotive (twin-unit loco) Under the agreement signed Electric Locomotive Plant (NEVZ is a instead of the triple traction unit of part of Transmashholding) that the 3ES5K locomotive in some considered the commissioning of the operation territories. The 2ES5 JSC RZD will purchase 2ES5 AC freight locomotive with electric loco is capable of operating asynchronous traction motor. The in any point of traction area being panel ascertained that the 2ES5 limited by adhesion and maximum 200 locomotives 2ES5 by 2020 locomotive meets all requirements of power of traction motors. the requirements specification and With a view to secure operation in transporting the locomotive to the test complies with all railroad transport different climatic zones of the Russian area with extreme ambient tempera- safety regulations. Federation, a number of efforts were tures. At the same time, it saved time A certificate for production of the made to adapt electronic components for engineering and excluded possible pilot batch consisting of 35 electric to winter conditions. design shortcomings. locomotives was obtained. The used system architecture of the Calculation of the body strength In total, five electric locomotives will 2ES5 locomotive features a high facilitated optimization of the design be manufactured this year. According speed of data exchange between of the body’s load-bearing elements, to an approved supply schedule, control devices and reliability. prevented unnecessary material electric locomotives will be manufac- Among other enhancements, consumption and retained the required tured and delivered to RZD on a modeling of thermal processes of the safety margins of the construction. monthly basis starting in 2015. operator’s cab and the body under The said works contributed to Development of a service base for different ambient temperatures was comprehensive designing of the maintenance of electric locomotives in performed, complex body strength locomotive. turnover areas is soon to be analysis was conducted. completed. Modeling of thermal processes IN EARNEST AND FOR LONG In accordance with the agreement made it possible to assess the opera - The 2ES5 electric locomotive incorpo- signed RZD will purchase 200 electric bility of equipment in the body without rated latest innovations of the global locomotives by 2020.

17 Operation Locomotive Ermak: on the way toward perfection

THE 2ES5К and 3ES5К electric locomotives ARE THE MOST MASS PRODUCED LOCOS IN RUSSIA TODAY. HIGH DEGREE OF RELIABILITY, EASE OF OPERATION, HIGH-POWER CAPACITY AND COST EFFECTIVENESS — THESE ARE BUT A FEW ADVANTAGES of Ermak locomotives, WHICH ARE CONTINUOUSLY IMPROVED AND UPDATED BY ITS DESIGNERS. THE OPERATION EXPERIENCE ACCUMULATED OVER THE PAST 10 YEARS IS ALSO OF GREAT SIGNIFICANCE. GIVEN BELOW IS OUR STOR Y OF HOW IT HELPS DEVELOP AND IMPROVE THE ERMAK PROJECT. 18 № 3 09/2014

Mogocha (Transbaikal Railway), ment of ТМH-Service, LLC,” says Sergei Smolyaninovo and Khabarovsk-2 Mitin. “It means that under the warranty (Far-Eastern Railway).” service we are able not only to monitor Warranty warehouses were set up in the locomotives status, but at any time Vikhorevka, Mogocha, Smolyaninovo, to carry out full maintenance and repair Locomotive Ermak: on the way towardKhabarovsk-2 and Amurskoye perfection depots to right after detection of failure as well. maintain stocks of materials and spare This experiment proved to be a success parts to be used for eliminating the and was extended to other depots, most common defects. This allowed us where Ermak series locomotives to reduce maintenance downtime undergo maintenance. during unscheduled warranty repairs and increase an inherent availability ONE STEP FROM PROPOSAL ratio. Readiness for repairs without TO IMPLEMENTATION additional time expenditure is only one July of this year saw the Company’s of the measures taken. Routine mainte- new approach to a feedback between nance is of great significance as well, let the locomotive manufacturer (PK NEVZ) alone continuous efforts aimed at the and its operators. An extended session improvement of the design of locomo- of JSC RZD and PK NEVZ representa- tives and the enhancement of reliability tives was held in Rostov-on-Don. of their units and assemblies. Representatives of the Far East and This is why a great deal of attention is paid to the analysis of causes of failures and their prevention in the future. Therefore, there are technical repre- Sergei Mitin, Head of Quality Management sentatives of PK NEVZ (Novocherkassk and Operation Analysis, Technical Electric Locomotive Plant) at each Department of CJSC Transmashholding, depot who are always ready to render At each depot, where warranty shares about his company efforts hands-on assistance to depot employ- ees and a service company, where warranty locomotives are parked. At the locomotives are parked, there TWENTY-FOUR-HOUR CONTROL same time, technical knowledge of Vast experience in employment of locomotive crews, repairmen of repair twin-unit and triple-unit Ermak locomo- depots and employees of the service are technical representatives tives is at the core of the integrated company is very important to maintain- system of performance reliability ing locomotives in serviceable condi- control, which helped significantly tion. For a few years, PK NEVZ has been of PK NEVZ who are always reduce the number of defects and the providing employees of JSC RZD and downtime of locomotives. the service company with mechanical ready to render consulting “Provided that approximately one training both at the plant’s training fourth of all manufactured locomotives center and at the depot. Such training undergo warranty maintenance at our brings positive results. and hands-on assistance to de- premises, a decision to establish such “A transfer of locomotives, full mainte- a system was quite logical,” says nance and, as first practical experience, Sergei. “Currently, 731 locomotives are organization of full maintenance at the pot employees and the service assigned to six depots — Vikhorevka Vikhorevka locomotive repair depot and Irkutsk-Sortirovochnoye (East-Si- became another important phase of the berian Railway), Amurskoye and program launched after the establish- company

19 OperationInherent availability ratio values of warranty fleet of the 2,3es5k locomotives broken down by months of 2013–2014

2013 2014

January 1.00 0.98

February 0.98 0.99

March 0.97 0.99

April 0.99 0.99

May 0.98 0.99

June 0.98 0.99

July 0.98 0.99

August 0.97

September 0.99

October 0.99

November 0.99

December 1.00

0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00

Transbaikal locomotive depots took suggestions of specialists of locomotive part in this video conference session. depots and the service company made Specialists who are directly involved in it possible to improve useful qualities of maintenance and operation of Ermak the locomotive. series locomotives put forward their For instance, throughout these years, observations and suggestions, which Internal availability ratio thanks to the cooperation with depot were incorporated in the basis of specialists, PK NEVZ specialists specific technical solutions, which are indicating the locomotive introduced more than 100 significant currently developed at PK NEVZ. changes to the locomotive design, such A result of this dialogue was not slow as locomotive cabin windows, configu- to arrive. For instance, the inherent state made 0,99, with the norm ration and geometrical dimensions of availability ratio, indicating the locomo- the spokes of driving-wheel sets, tive status, amounted to 0.99 com- software, NVA-55 hardware, casing for pared to the normative value of 0.97. It of 0,97. This means that 99 of gear and a host of other items. means that 99 out of 100 locomotives All of that made the locomotive are in a state of instant readiness for operation easier. According to the operation. 100 locomotives are always feedback of our colleagues, this loco The locomotives upgrading program became one of the most comfortable implemented in 2010–2013 serves as and reliable locomotives as compared an example of how observations and ready for operation to other models.

20 № 3 09/2014

21 Operation Compared with the last year, electric machine failures went down due to cooperation between operators and designers

CLOSE COOPERATION WITH MANUFACTURERS However, apart from the improvement of the organizational management at locomotive depots, numerous innovations were introduced in the manufacturing process. The enterprise erected what is known as locomotive quality boards. These boards carry information relating to the frequency and causes of locomotive breakdowns. Having received information from a depot about locomotive failure, quality assurance directors and managers of the quality control department hold workshop staff meetings to investigate reasons for the breakdown. If their root causes are in the manufacturing process, they will be eliminated in order to prevent breakdowns in the future. If the main locomotive design. Such recommenda- locomotive crews — ‘B’ units are cause is the misuse of equipment, tions were taken into account at the equipped with a lavatory and a lounge for appropriate recommendations will be manufacturing of the latest Ermak locomotive crews, which satisfy all current given to drivers and maintenance staff. locomotive. The other day, PK NEVZ sanitary, ergonomic and safety standards. As a result of all these efforts, reliability completed development of a more Establishment of situation centers is the parameters meet requirements of powerful model of the 4ES5К loco, next stage of development of the technical specifications. capable of carrying cargoes of up to locomotive operation control system. “This is another confirmation of the 7.1 K tonnes. Today, these centers operate not only at improved quality of our products. The state-of-the-art 4ES5К boasts an Novocherkassk Electric Locomotive To obtain performance records of the unprecedented capacity of 13,120 kW Plant, but at Bryansk and Kolomna plants plants and verify whether locomotives’ (one-hour efficiency) and enables as well. The Company’s specialists rely on reliability meets technical specifications, operating heavy-tonnage trains in the these centers for online monitoring of the Quality Day meetings are held on eastern operation territory of RZD under operation of all locomotives fitted with a regular basis. They are attended by complex terrain conditions. The 4ES5К telecommunication systems. This heads of appropriate departments and locomotive is standardized with the serial resulted in manyfold decrease of the directorates of JSC RZD and ТМH-Ser- Ermak family of locomotives of Novocher- equipment breakdown response time. vice, LLC. Based on the results of the kassk Electric Locomotive Plant. Special meetings, protocols are drawn up to offer attention is paid to the labor conditions of A FEW WORDS ABOUT PROSPECTS a job list aimed at administrative and locomotive crews. The electric locomotive The accumulated experience in operation technical measures to improve the provides comfortable environment for of Ermak locomotives and some well-

22 № 3 09/2014

known events resulted in the guaranteed manufacturing quality and technical maintenance of locomotives and active development by the Company of cooper- ation with various equipment suppliers. Set-up situational centers marked another stage of the elec- Specifically, a plant has 2–3 potential suppliers for each type of products. There are domestic manufacturers who are also tric locomotive monitoring system development . ready to supply components and parts that are now imported. “We pay special attention to the quality of In these centers the company specialists monitor operation each unit and assembly used in the manufacturing process. Therefore, a possibility to perform a complete audit of all the electric locomotives equipped with the remote data of their manufacturing process is one of the requirements to our suppliers,” says Sergei Mitin. “Overall, I can point out that transmission facilities. This allowed to drastically reduce today there is an alternative to any supplier, and we are in a position where we can choose the best one.” the time of response to equipment failures

23 Traditions

Kolomna diesel engines were installed on military ships and civil vessels. The ‘Bars’ submarines manufactured by Kolomen- sky Zavod were the first in the Imperial Russian Navy to be equipped with diesel engines. As early as 1910, Kolomna diesels were installed on the world’s first Kolomna plant riverine“ warfarek craftolomensky — Shkval gunboats. zavod” and war In the summer of 1916, the Kolomna plant’s new marine diesels were installed on the gunboats of the Amur flotilla. Kolomensky Zavod fulfilled orders of the Navy for big steel casting parts of military ships: battleships Empress Maria, Alexander II, Ekaterina II, torpedo boats, armored cruisers Izmail, Kinburn, Borodino, Navarin, etc. All castings ordered by the Navy and parts processing 1000th machine-gun cart were under constant personal supervision of marine mechanical engineers.

IN THE BEGINNING OF 20TH CENTURY KOLOMENSKY ZAVOD (KZ) BY AIR During World War I, the plant fulfilled ESTABLISHED IN KOLOMNA DISTRICT IN 1863 WAS ALREADY AMONG THE military orders for development of new INDUSTRIAL LEADERS OF RUSSIA. items, namely, manufacturing of fuses, French and government-issue grenades, During World War I Kolomensky Zavod took an active part in supplying the machine tooling units designed for automatic production of barbed wire, Russian Army with arms and providing aid to the wounded. Its workers made machine-gun carts, field kitchens, wagon charitable contributions and more than 2,000 plant workers were drafted. train hubs, and water boilers. In March of olomensky Zavod with its vast the merits of the enterprise, His Imperial 1915, the Bochmanovsky plant of Emil experience in building narrow-gauge Majesty’s Edict allowed the steam Lipgard & Co partnership became an railroad equipment was the biggest locomotive to be decorated with a mono- ammunition division of Kolomensky supplier of steam locomotives and gram of Emperor Nicholas II of Russia. Zavod. It started manufacturing fuses, trolleys of different types for military Decorated with a laureate wreath and three-inch cast-iron bombs, primer Kpurposes. palm trees, the steam locomotive was cartridges and machine-tooling units for triumphantly handed over to representa- production of barbed wire. The plant BY LAND tives of the Main Military Engineering continued mass production of ma- On December 6 of 1916, Kolomensky Office. The best workers were awarded chine-gun carts, with the first order Zavod took part in festivities marking the commemorative gold and silver badges received as far back as 1910. To fulfill the 5,000th steam locomotive commission- with an engraved steam locomotive. order, a machine-gun workshop with ing, which had been built by the order of a floor space of more than 2,000 square the War Ministry and sent to the front line. BY SEA meters was built. During the war, 350 The Kolomna plant was the first in Russia World War I spurred sales of diesel handworkers were involved in that to achieve the number of 5,000 steam engines for Navy and Military Depart- process, which enabled the plant to locomotives produced. To commemorate ments as well as defense industries. produce ten machine-gun carts daily.

24 № 3 09/2014

EVERYONE TO THE FRONT was less than 150 rubles a month: the During the war, 2,376 men working at first raise was effective on April 1, 1915, Kolomensky Zavod were drafted. It was the second one — on January 1, 1916. impossible to replace them with experi- Irrespective of the monetary allowanc- enced adult workers and the plant had to es, Kolomensky Zavod started selling employ women and teenagers. basic necessities at reduced prices Servicemen’ families were rendered beginning from June 1, 1915: rye-bread Kolomna plant “kolomenskysubstantial financial aid: every monthzavod” or rye flour, sifted flour bread, or and war single men who had been drafted first-grade flour, or coarse-granular flour, received 1/3 of their wage, married men groats or millet, sunflower oil, salt, tea, and those with families of less than four sugar, and soap. children — 1/2 of their pay, and families A total value of allowances, food with four and more children — full pay. benefits and other benefits to workers An ad-hoc Committee of Representa- and employees of Kolomensky Zavod tives composed of handworkers and initiated by the plant administration from employees was set up to help families the beginning of the war until January 1, whose men had been drafted. The 1916 amounted to 562,818 rubles. Start- plant’s handworkers and employees ing from 1916, after a nine percent raise contributed money to the Committee on in pay, the size of allowance was equal to a monthly basis, with monthly deduc- almost 130,000 rubles every month. tions from the salaries — from 1 up to To offer medical treatment to wounded 3%, and equivalent sums added to those soldiers, the plant administration The EDS-4H65 diesel for Amur flotilla. deductions by the plant administration. provided 105 beds: 15 — in the plant’s 1908–1915 There were 1,620 families in care of the hospital, 83 — in the small hospital for Committee. employees and handworkers of in his own home a small hospital for Due to the increased cost of basic Kolomensky Zavod and Consumer employees and handworkers, and some necessities, war-time raises were Society, 7 — in a private hospital. The wounded lived in employees’ homes. To granted to all handworkers and workers, plant’s doctors worked for free in those maintain the small hospital, all employ- as well as to employees whose salary hospitals. The plant’s director organized ees and handworkers volunteered to contribute each month from j up to S of their pay. The plant’s X-ray room provided free services to all small hospitals of Kolomna District and some neighboring small hospitals in Ryazan Province. More than 1,000 wounded soldiers underwent treatment in those small hospitals. Today, there are many representatives of the labor dynasties of Kolomensky Zavod whose ancestors worked for the plant 150 years ago and during World War I. The plant’s employees continue the great traditions of valiant service to their Motherland.

Battleship Empress Catherine the Great. 1915 Ekaterina Bychkova

25 • Transmashholding is NO. 1 IN CIS COUNTRIES in terms of the volume of rolling PRODUCTS AND SERVICES OF THE HOLDING: stock production and • mainline and electric industrial • diesel locomotive engines sales locomotives; and marine diesels; • Transmashholding is • mainline and shunting locomotives; • diesel generators and • freight and passenger cars; turbochargers; among WORLD’S TOP TEN • electric train and subway cars; • transport components; LEADING MANUFACTURERS • rail buses and diesel trains; • spare parts; of railway equipment • car casting; • repair and service maintenance.

OVER THE PAST FIVE YEARS, • Transmashholding is THE THE COMPANY HAS PRODUCED: ONLY RUSSIAN COMPANY to have experience in over over over creation and manufacture of the machinery for the arctic service 3000locomotives 4000passenger cars 3000electric train cars • Transmashholding over over over machinery is operated IN ALL CLIMATIC REGIONS OF THE EARTH 230rail bus cars 1500subway cars 2700diesels

International Trade Fair POSTAL ADDRESS: for Transport Technology Russia, 127055, Moscow, Butyrsky 23 – 26.09.2014 Hall 3.2 Stand 320 &KQBOK>QFLK>IÐ1O>ABÐ#>FOÐ Val Str., 26, bld. 1 CLOÐ1O>KPMLOQÐ1B@EKLILDVÐ TELEPHONE: +7 (495) 744-70-93;  m   FAX: +7 (495) 744-70-94; E-MAIL: [email protected] www.tmholding.ru

DPM Diesel Multiple Unit