Hand in hand with RZD: forward motion p. 4 St. Petersburg road-rail buses p. 16 The SU-76: difficult path to victory p. 24 MAGAZINE FOR PARTNERS OF FOR PARTNERS MAGAZINE 2 06/2015 № From design project to new diesel locomotive in 70 days p. 12 № 2 06/2015 MAGAZINE FOR PARTNERS № 2 06/2015

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

Editorial Office address: 26 Butyrskiy Val St., bldg. 1, , 127055 Hand in handprospects with RZD: Phone: (495) 660-89-50 forward motion

Published in collaboration with MediaLine Publishers www.medialine-pressa.ru General Manager Casting productioninnovations upgrade: Larisa Rudakova 12 8 short-term outlook Design Artist Ilya Malov

Editorial Director Dmitry Dorofeyev

Copy Editor From design projectcover tostory new Irina Demina 12 diesel locomotive in 70 days Design and Typesetting Emma Burlyaeva, Sergei Kukoba Alexei Sukonkin

Proofreaders Larisa Nikolina operation Alina Babich From imperial trains to Galina Bondarenko 16 road-rail buses Prepress Andrei Klochkov Anastasia Morozova

Approved for printing on 07.07.2015 Printed by Rolling axleproduction bearing: new Tverskaya Fabrika Pechati Press, 20 999 copies. period in locomotives 20 24 operation technology traditionsThe SU-76: from Mytishchi to Berlin 24

1 News Appointment Outlook New Director Special Cars TVZ has been licensed to The Board of Directors of CJSC bymanufacture TVZ new cars to Transmashholding elects Kirill transport inmates. GeneralLipa Director General of the Carriage Works (TVZ, company. a member of CJSC Andrey Andreyev is resigning as Transmashholding) has Director General of the completed certification of company, which he has headed passenger rail cars designed for since 2008. Andrey Andreyev transportation of individuals in has received a letter of gratitude legal custody, i.e. individuals signed by Vladimir Yakunin, with restrictions imposed by President of Joint Stock court in the form of Company , imprisonment or punishment, emphasizing the important role entailing deprivation of liberty of the holding’s leader in Kirillbiography Lipa was born in Moscow in 1971 and (remand detainees, convicted ’s rail transport graduated from Moscow State Law University. or sentenced felons). The new development. “Under your He worked as Managing Director of the cars (the 61-4495 model) meet guidance, cooperation between Department for Investment Banking Service of all the requirements set forth in Russian Railways and UniCredit Aton. the Customs Union Technical Transmashholding was elevated Since December 2007, Kirill Lipa has been Regulations for Rolling Stock to a totally new level. To a great member of the Board of Directors of Safety. The 61-4495 model extent, this was achieved due to Transmashholding. In the past few years, he has rolling stock for transportation your energy, lateral thinking, also chaired boards of directors of TMH‑Service, of special escort squads is an friendliness and ability to LLC and JSC Zheldorremmash, which are innovation of TVZ designers establish rapport with people”, members of the locomotive maintenance holding based on the state-of-the-art reads the message from the managed by Locomotive Technologies. 44th series of passenger cars. President of RZD. Its key distinct features as compared with earlier versions of this car type include a longer body made of antirust steel. This allowed changing the car Production interior layout and improving its The EFI-equipped diesel was installed ergonomics and environment, in the TEM18DM diesel locomotive taking into account the owned by Joint Stock Company requirements to special Russian Railways. The operation of the transportation organization. The launches production of diesel locomotive with the upgraded car’s service life is 40+ years. 1-PD4D diesels equipped with electronic fuel diesel was monitored by the design For the first time ever, water and injectionSmart system (EFI). Diesel engineers of Penzadieselmash and JSC air decontamination systems The employment of the EFI system in the VNIIZhT. The 1-PD4D diesel is installed and double-circuit air diesel design allows significant improvement in TEM18DM shunting diesel conditioning system are of operating performance and reduction of locomotives, which are widely used installed in a rail car. fuel consumption by up to 7-8%. The new both in rail transport and the production Certification enables Tver injection system’s efficiency has been sector and are marketed both in Russia Carriage Works to start series monitored for two years. and abroad. production.

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Cooperation

Partnership held in Sochi. The Special Agreement between RZDagreement providesand for cooperationTMH between the two companies until 2020. The cars accompanying freight and service trains are manufactured by Tver Carriage Works. The first rolling stock of this type (the 61-4483 and 61-4484 models) was presented to the general public in 2011 at the EXPO 1520 international exhibition. The Russian rail industry ordered 47 cars that are to be manufactured in 2015 (a total of 133 in 2011–2015). In a specialized escort car, railroad personnel are offered comfortable conditions for travel. The car features passenger compartments, shower On Thursday, President of RZD Vladimir of hopper-batchers and trains used to with water heating system, bathroom, Yakunin and Director General of carry switch assemblies of heavy track storage, clothes dryer, and workshop. Transmashholding Kirill Lipa signed an machines. Power is supplied from an on-board agreement on production and delivery The document was signed within the diesel generator unit, which allows the (for RZD needs) of escort cars for framework of the Tenth International car to remain autonomous for special rolling stock – trains consisting Rail Business Forum 1520 Strategic 30 days.

Production Double-deck

Tver Carriage Works launches new employment of state-of-the-art options – with improved or standard double-deck cars. technologies, equipment and materials, interior. The car with improved interior SeaterThe innovative double-deck Car car with with domestic components used in car features 60 passenger seats, including seats is a newcomer in the Russian rail production accounting for more than two seats in the passenger industry. It has been manufactured 90%. A key feature of the new rolling compartment. The car with standard under a contract with Federal Passenger stock in terms of its exterior is the interior is characterized by high Company signed in 2013. reshaped sidewall and radial windows, occupancy – a total of 102 seats: 50 on The 61-4492 car model is a new addition which have never been used in domestic the first floor and 52 on the second floor. to the lineup of domestic double-deck production of double-deck cars. The In 2015, fifteen cars will be delivered to rolling stock developed by TVZ and new exterior painting has considerably the customer (FPC) on a contract basis: designated for operation at speeds up improved the overall look of the car. 10 with standard interior and 5 with to 160 km/h. It is designed with Cars with seats are offered in two improved interior.

3 Prospects

In 2008 RZD, JSC set the path for its scientific and technical development until 2015 (including Handlocomotive building). Currently,in mostHand objectives (12 out with of 15) have been attainedRZD: by locomotive Fo rward Motion manufacturers. hese include development of the multi-system passenger electric locomotive with asynchronous traction motors, as well as reduction of per-unit fuel and power consumption for Ttraction. The following tasks have been achieved: development of hybrid locomotives, enhancement of the coefficient of friction and increase in tyre resource. The objective of distributed traction control has been technically addressed, too. Currently, Transmashholding is ready to offer locomotives with the axle load of 27 tonnes. Speaking of locomotive building prospects, one should rely on the areas delineated in the Strategy for Rail Transport Development in the Russian Federation Until 2030. According to the

DEVELOPMENT CONCEPT FOR ELECTRIC LOCOMOTIVE BUILDING 2014 FREIGHT Phase 1 — KEY EQUIPMENT IMPORT SUBSTITUTION ELECTRIC 2ES5 LOCOMOTIVES

PASSENGER Sergei Kobzev, Technical Director at CJSC Transmashholding in 2014–2015. ELECTRIC EP20 By the publication date of this issue, he left Transmashholding and was appointed head of Northern Railways. LOCOMOTIVES

4 № 2 06/2015

— Center and Kuzbass — South VLADIMIR TUNIKOV, Deputy Technical Director operational areas. of Transmashholding: “Strategy for Rail Transport Development in the Russian Federation – Currently, all new locomotives are Until 2030” provides for high passenger Hand in Hand with RZD: Forwardbeing developed inMotion strict compliance carriage growth rates in the heaviest TRANSMASHHOLDING SUCCEEDED with the Customs Union Technical traffic areas, whereas the expected Regulations for Rolling Stock Safety and growth rate for total passenger flow by its supporting standards. This offers 2030 is 16.2–32.9%. WITH DEVELOPMENT OF A SUITE Transmashholding new opportunities It is still uncertain which methods for promoting its products within and carriers intend to use for meeting their beyond the Customs Union. transportation objectives, namely: OF TECHNICAL SOLUTIONS BASED longer trains in terms of cars, higher speeds or a wider scope of utilization of document, by 2030 rail freight traffic will double-deck cars. It is extremely ON TRACTION DRIVE WITH grow 1.7-fold; the speeds of freight important to specify these methods with trains will increase by 26%, and the the view of understanding prospects for weight of trains will reach 7,100–9,000 passenger locomotive building. ASYNCHRONOUS TRACTION MOTORS tonnes. These data are key to Meanwhile, technical requirements to understanding the desired prospective locomotives are non- characteristics of the next generation of existent. FOR BUILDING THE NEXT GENERATION freight locomotives. For example, the relatively young In the near term, Transmashholding EP20 dual-system passenger electric will deliver new locomotives for trains locomotive was developed for towing OF PASSENGER AND FREIGHT ELECTRIC weighing 7,100 tonnes to the Eastern 24-passenger car trains, but in reality it Operational Domain and 9,000 tonnes — is used to tow 12-car trains and operates LOCOMOTIVES to Kuzbass — Northwest, Kuzbass at less than 50% of its capacity.

DEVELOPMENT CONCEPT FOR ELECTRIC LOCOMOTIVE BUILDING 2015 2016 2017 2018 2019 2020 Phase 1 — KEY EQUIPMENT IMPORT SUBSTITUTION 2ES5S

Phase 2 — development of unified family of electric locomotives 2ES20 2ES4 2ES9

2ES20

EP3

5 ProspectsThe Scythian freight electric Comparison between the features of locomotive. All of them will be able to locomotives with asynchronous traction commutator and asynchronous operate trains weighing up to 9,000 motors have already proven their locomotives proves the advantages of tonnes at slopes of up to efficiency during operational tests. the latter. For example, analysis of the tenthousandths. Practical tests have shown that traction axle load on the track shows that the For towing container trains, the force per one axle of such electric 2ES5S electric locomotive developed company is planning to develop the locomotive is virtually 1.5-fold higher as on the basis of Russian elements ES20 single-section dual-system compared with electric locomotives slightly excels (by 4.3%) the 2ES5K locomotive. It should be stated that the equipped with commutator traction electric locomotive. At the same time, employment potential of dual-system motors. it significantly outperforms the latter freight electric locomotives with the (by 49%) in rail tractive effort per one asynchronous motor is still MORE EFFICIENT, MORE POWERFUL, axle. As a result, the 2ES5S two-section underestimated. Therefore, MORE COST-EFFECTIVE electric locomotive is capable of Transmashholding and RZD are In the past few years, substituting the 3ES5K three-section considering the need for such Transmashholding succeeded with electric loco. locomotives with the view of the development of a suite of technical Relying on this experience, possibility to start their development solutions based on the traction drive Transmashholding plans to develop a and production. with the asynchronous traction motor plethora of freight locomotives for heavy Employment of the unified family of for building the next generation of haul, namely: the 2ES4 and 2ES5S electric locomotives will allow the passenger and freight electric single-system locomotives and the operator to increase train weight to locomotives. 2ES20 dual-system two-section 9,000 tonnes in lowlands.

DEVELOPMENT CONCEPT FOR DIESEL LOCOMOTIVE BUILDING 2014 2015 2016 2017 2018 MAINLINE DIESEL 2TE30K LOCOMOTIVES 2TE25A 2TE25AU

2TE25KM 3TE25KM 2TE25KU

2TE25KD COMMON PLATFORM

TEP7OBS TEP35

SHUNTING TEM19 TEM23 DIESEL LOCOMOTIVES TE18DM TEM28

6 № 2 06/2015

Operating costs will decrease significantly due to reduced power and sand consumption. An increase in service interval mileage and overhaul life, in its turn, will raise the locomotive’s utilization rate. Additionally, the THE MAIN PLANS OF TRANSMASHHOLDING IN THE AREA OF DIESEL unification of components will considerably improve the electric locomotive’s maintenance conditions. LOCOMOTIVE DEVELOPMENT ARE FOCUSED ON CREATION OF NEW-

A Path Towards Import Substitution GENERATION DIESELS UNDER THE FEDERAL TARGET PROGRAM “NATIONAL The challenging economic situation of the recent period has been one of the major stimuli fostering search for the TECHNOLOGICAL BASE” most optimal and acceptable technical solutions in modern locomotives with the asynchronous traction motor. its traction properties, reliability and locomotive building are related to the Specifically, it was decided to safety. This will make the locomotive next generation of diesels under the upgrade the structure of the 2ES5 more affordable to customers. Federal Target Program “National electric locomotive without undermining Traction motors, bogies, electric Technological Base.” From the power equipment, sanitary module, standpoint of technical characteristics, driver’s cabin and other equipment will they are equal to state-of-the-art be replaced with their domestic foreign models. As soon as the counterparts. company launches production of D300 It should be stated that and D500 diesels, it will start equipping 2019 2020 Transmashholding will remain future locomotives with these motors. committed to the principles of the basic Transmashholding proposes 2TE30A platform; the unification of models even development of a diesel locomotive with under the existing conditions will 2TE30K eight-axle sections to operate exceed 80%. The underframe, braking heavy-tonnage trains on steep-grade equipment, control and safety systems railroads. It will be equipped with new will be the same irrespective of the high-capacity diesel generators on the model. basis of the D500 power supply unit. Development and testing of its 3TE25KU Diesel Locomotives of Tomorrow underframe may be followed by Transmashholding will keep adhering to development of the 2TE30А diesel the platforming principles in the diesel locomotive with an asynchronous locomotive building as well. The 2TE25A traction motor. diesel locomotive is a pioneer of the The lineup of shunting locomotives, next generation of freight locomotives. with the TEM18DM diesel locomotive as The experience in operating these its core element, will incorporate the machines allowed devising optimal TEM23 four-wheel locomotive. The proposals for further development of TEM18DM locomotive will be upgraded the model lineup. Specifically, this year in compliance with the requirements set BMZ has built the 2TE25KM – the first forth in the Technical Regulations. In the domestic freight diesel locomotive future, these locomotives will be meeting the requirements set forth in equipped with D200 state-of-the-art the Customs Union Technical diesels. Four-axle underframe Regulations. There are plans to build a The unified six-axle platform of gamut of locomotives with the shunting diesel locomotives will serve Six-axle underframe commutator traction motor on the basis as a basis for building locomotives with Eight-axle underframe of 2TE25KM. a gas reciprocating engine as well as The main plans of Transmashholding dual-diesel and hybrid diesel for development of the diesel locomotives.

7 he past 20 years have not been Innovation the best period in the history of Russia’s iron and steel industry. Reasons include strong competition with Western manufacturers as well as TChinese industrialists (which have accumulated enormous steel production capacity of some 830 million tonnes).

A Burdensome Heritage The industry has been suffering from almost total long-term lack of investments in production development and Casting maintenance and the resulting employment of obsolete technologies and rundown equipment. The rolled product manufacturing sector keeps afloat in the current situation, whereas the casting production sector has been fully exposed to all challenges of recent years. In the USSR, casting production Production development followed two paths. One path consisted in construction of large specialized foundries, which provided machine-building enterprises or the industry in general with casting products. The other path involved construction of foundry shops within machine-building enterprises. In the latter case, during the Upgrade: formation of corporations and holding companies, casting production was perceived as an auxiliary activity and, accordingly, received funding when funds became available. Naturally, due to the absence of production development during that period, the existing casting Short-Term production technologies have not evolved since the 1950s and band aid approach is unable to improve the situation as such. IN THE POST-SOVIET ERA, Considerable capital investments are required to solve the problem CASTING PRODUCTION WAS fundamentally. However, since the payback period in casting production OVERLOOKED COUNTRYWIDE. businesses is fairly long, their owners are Outlook reluctant to incur costs and would rather THE SITUATION HAS CHANGED. invest solely in production preservation TODAY, TRANSMASHHOLGING IS and critical local upgrades. The only exception is specialized foundries. They SUCCESSFULLY UPGRADING THIS have several parallel process chains and therefore can upgrade their full process SEGMENT AND ALREADY cycle gradually, without significant non-recurring capital investments and STRIVING FOR IMPLEMENTATION suspension of production. Alexei Yelagin, Chief Steelworker at CJSC OF INTERNATIONAL BEST Earlier, Transmashholding production Transmashholding facilities were in a similar situation. Before PRACTICES. 8 № 2 06/2015

TMH centers of excellence

Center of excellence Center of excellence in Center of excellence in light in steel casting steel casting for electrical iron casting and casting for rail car and machinery production for braking equipment at locomotive building at Novocherkassk Electric Liteinoye Proizvodstvo, LLC at BSW Locomotive Plant (Tver Carriage Works)

9 casting production business was Innovationlaunched by the company, it existed at almost every facility but was extremely inadequate due to the above reasons. Partial upgrading was performed locally. The only exception is complete RESTRUCTURING CONCEPTS modernization of foundry shop 3 at Bezhitsa Steel Works without production suspension and output reduction, which FOR STEEL CASTING AND IRON will result in additional capacity for producing 75 thousand tonnes of car casting per year. Currently, modernization CASTING PRODUCTION HAVE is undergoing its final phase. BEEN DEVELOPED WITH THE VIEW NEW WAY OF CASTING Proizvodstvo, LLC (Tver Carriage Works). Restructuring concepts for steel casting To that end, state-of-the-art bar-type, and iron casting production have been OF OPTIMIZATION OF CASTING shot-processing and melting equipment developed with the view of optimization of has been installed. Partial modernization Transmashholding’s casting production. allowed expanding the lineup by adding They provide for more efficient utilization PRODUCTION castings made of high-strength cast iron. of the existing facilities, implementation of state-of-the-art technologies, OPTING FOR IN-HOUSE development of intra-holding and PRODUCTION external cooperation, and establishment mechanical processing tolerances, thus It should be emphasized that the of centers of excellence by casting types. significantly increasing metal utilization concepts of iron casting production Restructuring is aimed at reducing rate and decreasing labor-intensity of restructuring and the import substitution production costs and improving product subsequent mechanical processing. This program overlap with regard to diesel quality, as well as offering the possibility allowed launching small-batch casting locomotive building. A critical objective of more flexible management of the production for the holding’s production associated with arranging diesel holding’s casting production. facilities without the existing casting production is the availability of key Additionally, restructuring includes efforts conveyers designated for medium and components. These include slip cast under the import substitution program large batches and utilizing an obsolete block of cylinders, cover and cylinder that focus on the key components of technology of casting in sand clay forms liner. Currently, fine-tuned production of diesel locomotive building. Currently, the and molding by jarring machines. cast V-shaped cylinder blocks of a concept is undergoing an implementation A center of excellence in steel casting required standard size is not available at phase. for electrical machinery production was the holding’s production facilities in Activities include creation of a center of created at Novocherkassk Electric particular and in Russia in general. Some excellence in steel casting for rail car and Locomotive Plant. Production upgrading time ago, the Kolomna plant, locomotive building at BSW and has been accompanied by the launch of a manufacturer of these blocks, development of the casting section with molding in cold hardening mixtures for developed slip cast block technology. The employment of the “foscon” process large- and medium-size castings, technology consists in section-by-section (cold hardening mixtures) within foundry including the castings of the traction block manufacturing, i.e. the so-called shop 2. This technology allows producing motor framework. The innovation allowed stands – segments of cylinder blocks — more accurate molds with lower significant (manifold) reduction of the are cast from steel at the initial stage. number of defects, improvement of Casting is followed by mechanical production culture and reduction of processing. At the next stage, a weld- production costs. During 2016–2017, fabricated blank of the block is molded efforts will be aimed at switching over to from machined stands with utilization of cold hardening mixtures and demolishing a unique resistance welding machine and the old mixing shop. This will free up then processed thermally and production space and improve the overall mechanically. The technology is very environmental situation, which is labor-intensive and costly. In addition, especially important. “stand” casting as such is very non- A center of excellence in light iron technological, difficult to carry out and casting and casting for braking has a very high rework rate at the initial equipment was created at Liteinoye stage of mechanical processing. Rework

10 № 2 06/2015 after preliminary mechanical processing holding’s specialists were forced to look 2,000 liners per year and manufacturing can increase the labor-intensity of for other solutions in order to ensure large- and medium-size iron castings for casting up to 15%. The domestic and competitiveness on the market. the holding’s production facilities, international markets of large-size iron Currently, Transmashholding is including key diesel components for casting were thoroughly studied for the implementing a program aimed at Penzadieselmash. The project’s purpose of abandoning this labor- creating a new lineup of diesels. Diesel implementation provides for significant intensive technology. A number of locomotive enterprises of the holding reduction of the cost of end products due potential suppliers that satisfy quality and participate in the program. The new to abandonment of import supplies, lower cost parameters were found. Currently, lineup of diesels is designated for a rework rate, shorter production cycle, the plant purchases cast and one-piece casting block made of staff reduction, and reduced costs mechanically processed serial blocks of high-strength cast iron. The objective of associated with energy resources and cylinders abroad. Cylinder covers and complete abandonment of import equipment operation. For example, new bushings are partially supplied from supplies of cast blocks, covers and shop costs will be reduced more than abroad due to the lack of domestic cylinder liners was attained through the six-fold. production capacity and casting quality project for rehabilitation of iron casting The restructuring of casting production issues. However, the existing economic production at KZ, JSC. The project calls will allow enhancing its efficiency and will and political situation gives reasons to for a new iron ¬casting shop with a fully conform to the objective of making doubt the feasibility of this approach. capacity of up to 15 thousand tonnes per the holding’s products more competitive Drastic EUR rate growth significantly year and will allow producing up to in the domestic and international increased the cost of end products; the 1,200 blocks, 2,000 covers and markets.

11 Cover story

FromTRANSMASHHOLDING Design Project to New Diesel Locomotive in 70 Days PRESENTS THE 2TE25KM — THE NEW MAINLINE DIESEL LOCOMOTIVE. THE FIRST TWO LOCOMOTIVES HAVE ALREADY BEEN DELIVERED TO RZD. he diesel locomotive presentation was hosted by Machine Building Plant. The event was attended by President of RZD Vladimir Yakunin and Director General of TransmashholdingT Kirill Lipa. The heads of both companies noted the advantages of the new machine, the new project’s implementation time frame and the quality of work performed.

FAST IN ANY WEATHER The 2TE25KM diesel locomotive is unique in many respects. For instance, for the first time in its history, Bryansk Machine Building Plant devised design engineering and process documents on a very tight schedule and built the diesel locomotive in only 70 days! Currently, it is the first domestic diesel locomotive certified as compliant with the Customs Union Technical Regulations. The diesel locomotive is manufactured under the import substitution program; 90% of its components are of domestic origin. Large-batch production of mainline quality-price ratio. Even though relatively RZD, JSC in areas with moderate climate freight diesel locomotives is launched in inexpensive, the diesel locomotive and temperatures of +40˚ to –50˚ Russia for the first time ever. boasts excellent technical capabilities. Celsius. The following power unit is The 2TE25KM freight diesel The 2TE25KM is a freight two-section installed in the diesel locomotive: the locomotive compares favorably with diesel-electric switcher with axle-by- 18-9DG diesel generator manufactured currently operated machines (both in axle traction control designated to by the Kolomna plant, i. e. the Russia and abroad) in terms of its operate freight trains on the railroads of 16-cylinder diesel generator with

12 № 2 06/2015

OLEG KRAVCHENKO, OLEG KRAVCHENKO, director of the engineering директор инженерного From Design Project to New Diesel Locomotive in 70 centerDays of BMZ MC, CJSC: центра ЗАО «УК «БМЗ»:

— The 2TE25KM is a multi- purpose machine. It can be used in any conditions and is like a workhorse that will allow RZD to operate it in Bryansk, Yelets, Yershovo and Krasnodar with maximum efficiency. Currently, the 2TE25KM is the most advanced domestic diesel locomotive designed with utilization of the best technical solutions. Its advantages include microprocessor control system, which allows delivering the highest traction force possible for this type of machines. A key advantage of the system is that it allows the driver to be fully focused on operating the train. He has to set required traction parameters, and the system will a capacity of 2650 kW. In the near future, EQUIPPED TO A HIGH STANDARD select the necessary load on the the next generation of diesels will be As compared with the locomotives diesel generator and traction installed in diesel locomotives. They are currently in use, the new diesel machines and control the developed at Transmashholding’s locomotive allows increasing the weight operation of the compressor, the production facilities under the Federal of operated freight trains by 20% or more cooling system and the Target Program “National Technological and significantly reducing operating remaining auxiliary equipment of Base” (the D300 family). expenses, which results in lower the diesel locomotive

13 life-cycle costs. This is achieved due to KIRILL LIPA, Cover story the higher adhesive weight of the train director general of and increased diesel capacity efficiency, transmashholding: which, in its turn, is achieved due to utilization of state-of-the-art WITH THE NEW DIESEL components and assemblies produced by domestic manufacturers. These are mainly auxiliary load asynchronous LOCOMOTIVE THE WEIGHT OF motors with enhanced efficiency and lower energy intensity. Another noteworthy fact is the OPERATED FREIGHT TRAINS GOES operating principle of the diesel locomotive’s refrigerating chamber: depending on the necessary heat- UP BY 20% AND OPERATING dissipating capacity, from one to four condenser fan motors (with an EXPENSES ARE REDUCED asynchronous motor as well) can be operated. — We can manufacture impressive The high-performance screw technical equipment. This is possible SIGNIFICANTLY compressor package installed in the due to the efforts and the confidence diesel locomotive in combination with the in us on the part of our partner — compressed air dehydration unit ensures RZD’s management — and the longer operation of the braking system. drivers that operate it.

14 № 2 06/2015

The diesel locomotive is equipped with multicyclone filters with enhanced purification in diesel refrigerating systems of electric traction machines and air intake, which has positive impact on the reliability of these assemblies and, as a result, the reliability of the diesel locomotive itself. Additionally, it should be noted that the advantages of the diesel locomotive include the layout solutions in the design of the high-voltage cabinet built as a single module, which will have positive impact on the diesel locomotive maintenance. Design engineers focused on the working conditions for the locomotive crew. The driver’s cabin meets all modern safety and comfort requirements: it has a passive safety system designed to protect the locomotive crew in case of emergency collision; it features an air conditioning reducing materials have been utilized. maintenance and repair costs associated system and an autonomous space The ergonomics of the driver’s cabin and with the diesel locomotive fleet. heater; new noise-proof and vibration the diesel locomotive in general has As BMZ is currently launching the been improved. production of mainline diesel Key advantages of the diesel locomotives, its short-term plans include VLADIMIR YAKUNIN, locomotive include easy and convenient the development of diesel locomotives president of russian maintenance due to the easy of various (single- and three-section) railways: accessibility and maintainability of its models on the basis of the 2TE25KM principal assemblies. Switch over to the with unified key assemblies and new locomotives will allow reducing systems.

Technical characteristics Diesel locomotive capacity, KWh 2 × 2650 Service weight (at 2/3 of fuel and sand reserves), tonnes 2 × 144 ± 3% Static load of wheel set on track, kN (tonne-force) 235.4 (24.0) Wheel arrangement 2 × (30 — 30) Rail tractive effort, kN (tonne-force) – design maximum traction force at starting 2 × 419 — The fact that now Bryansk Machine Building Plant is (2 × 42.77) manufacturing these machines is – at continuous rating 2 × 323.6 very important to Russia. RZD and (2 × 33) Transmashholding have been Speed, km/h reliable partners since long ago. Russians value friendship, – design speed 100 comradeship, and partnership. – speed at continuous rating 23.6 Naturally, they value good, reliable Servicing stocks, kg and responsible work. – fuel 2 × 7000 I am confident that the new diesel locomotive will be the main machine – sand 2 × 1520 operated on railroads.

15 Operation

From Imperial Trains

OKTYABRSKY ELECTRIC RAILWAY CAR REPAIR PLANT, JSC (OEVRZ) IS SUCCESSFULLY IMPLEMENTING THE PROGRAM FOR OVERHAUL OF ROAD-RAIL BUSES. THE ENTERPRISE HAS toALREADY RESTOREDRoad-Rail TWO BUSES AND IS NOT GOING TO RESTBuses ON ITS LAURELS. 16 № 2 06/2015

EVRZ (a member of TMH) is one of the interior parts, passenger seat of the largest enterprises in St. covers, and fillers. The utilized Petersburg and will turn 190 in solutions allow improving the 2016. In the past few years, the aesthetic qualities of the car and its plant has implemented a large-scale ergonomic and operational Odevelopment program, including the characteristics due to utilization of upgrading of its production complex energy-efficient LED lamps, seat and launching of new business covers resistant to mechanical lines — construction of metro cars damage and dirt, and state-of-the- and construction and repairs of art linoleum. urban electric transport. The work performed by the plant’s On December 26, 2014, OEVRZ specialists includes painting with successfully completed its efforts state-of-the-art wear-proof paints on the overhaul of two road-rail and lacquers, whose surface is buses– rolling stock for suburban resistant to the so-called graffiti – and local rail service (RA-1 and unauthorized inscriptions and RA-2) manufactured by advertisements. The floor inside the , JSC and compartment was renovated; delivered it to the customer — RZD. state-of-the-art comfortable seats Road-rail buses are designed to were installed. Energy-efficient transport passengers along non- technologies were utilized – electrified sections of railroads and fluorescent bus lights were replaced may be used for urban, suburban with LED lamps. and interregional service. The repaired RA-1 and RA-2 will The road-rail buses manufactured be operated on Oktyabrskaya in 2007 have undergone the first Railways. The pilot project for phase of their scheduled overhaul at road-rail buses overhaul allowed the OEVRZ, which involved bus painting in RZD corporate colors, replacement of running gear parts, and full interior restoration accompanied by partial replacement OEVRZ, JSC IS A STATE- OF-THE-ART, HIGH-TECH ENTERPRISE SPECIALIZING IN MANUFACTURING AND OVERHAUL OF METRO CARS, TRAM CARS, AND COMPLEX TYPES OF ROLLING STOCK REPAIRS

17 Operation

When implementing the project for overhaul of its RA-1 and RA-2 road-rail buses, OEVRZ successfully achieved a number of engineering objectives related to the structural characteristics of this type of rolling stock. The plant prepared a set of technical activities aimed at repairing the underframe, electrical equipment, pneumatic equipment and other parts and assemblies of the road-rail bus. The road-rail bus overhaul was followed by startup and commissioning operations. The project has proven to be beneficial for cooperation between OEVRZ, JSC, DMZ, JSC and a few other companies’.

18 № 2 06/2015 plant’s specialists to master new competences, namely, to perform maintenance operations related to diesel engines installed in the buses. Successful fulfillment of the first order for road-rail buses overhaul allowed the enterprise to expand its railroad equipment maintenance capabilities. Consequently, the enterprise is successfully implementing its concept for product lineup diversification, which allows providing it with necessary output volumes and maintaining a high professional level of its employees in the context of the unstable domestic and global economic situation.

For reference

RA-1 is road-rail bus type 1. It has cabins at both car ends; no RA-2 is road-rail bus type 2. RA-2 is designated for passenger carriage turning is required. Furthermore, it can be operated both as a along non-electrified railroad tracks with intense passenger flows, as single-section and 2-3-section bus. well as for suburban and interregional service. It is a train set. It The model features two exits on both sides at the end of the consists of two head cars and one engineless trailer car (HC + ETC + car, exit for high platforms and extendable step for descending HC). Control system allows joint operation of one or two three-car to low platform. Sliding doors open automatically. It features 78 road-rail buses at a time. The road-rail bus has an all-metal body seats; its maximum occupancy is 160 people. Unladen weight is made of stainless steel with heat insulation. Vestibules feature 37 tonnes; full weight is 48 tonnes. Hydraulic retarder and individually-controlled plug doors. Adjustable foot rest allows compressed air brakes. Primary suspension with cylindrical passengers to board the train from low platforms. Head cars feature springs and absorbers, secondary suspension with pneumatic one exit in the middle. Trailer cars feature two exits at both ends. springs and absorbers. All-metal body made of corrosion- Three-car road-rail bus has 222 seats; its total occupancy is 600 resistant steel. Design speed is 120 km/h. people.

19 Production Rolling Axle Bearing: new period In many respects, their quality (steel grade, processing accuracy) affects the reliability of machines. In most cases, the magnitude of rolling friction is much in locomotiveslower compared with slidingoperation friction, technology other things equal; therefore, rolling is common for moving machinery. The advantages of rolling axle bearings over sliding axle bearings are unquestionable. Interview with Valery Zadorozhny, New foreign locomotives increasingly head of ac electric locomotives feature rolling axle bearings. Their group at OSP utilization allows performing phase 2 of locomotive maintenance after at least his type of bearing is the second 10–12 days instead of 3–4. It is for the support for a traction motor that application of axle lubricant to sliding ensures parallelism of the engine axles and the wheel set, affecting the WMU with rolling axle bearing frequency and the scope of phase 2 of electricT locomotive maintenance. Axle Disadvantages of sliding bearings include rolling axle bearings and sliding axle bearings. axle bearings: Currently, 90% of electric locomotive ● considerable amount of fleet of all types operated on Russian damages due to unsatisfactory railroads are equipped with wheel-and- lubricant feed to the working engine blocks with sliding axle bearings. area; The axle bearing unit with traction ● high consumption of traction motor (TM) sliding axle bearings is one motor lubricant due to the of the bottlenecks with regard to impossibility of reliable sealing of maintenance, longevity and reliability of axle bearings; electric locomotive bogie assemblies. ● discharge of traction motor Despite a number of improvements, the lubricant into the environment; sliding friction axle bearing with a wheel 50-60% of lubricants stay in the set is a technically imperfect assembly. side ditches of locomotive depots and on tracks; SMOOTH AND EFFICIENT ● reduction of the service life of The idea of substitution of sliding gear wheels and motor-armature friction with rolling friction was born bearings of the traction motor long ago. Nowadays, it would be a due to quick wear of the brass challenge to find a mechanism without bushings of sliding axle bearings; bearings of any form: ball, cylindrical ● high consumption of non-ferrous bearings, etc. metals (brass).

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ELECTRIC LOCOMOTIVE RELIABILITY AND MOTION SAFETY, TO A CONSIDERABLE EXTENT, ARE AFFECTED BY UNINTERRUPTIBLE OPERATION OF THE UNDERFRAME, PRIMARILY THE ENTIRE WHEEL new period AND MOTOR UNIT (WMU). AN AXLE BEARING (AB) IS A CRITICAL Rolling Axle Bearing: PART OF WMU MOUNTING ASSEMBLIES. Electric locomotive representing the pilot in locomotives operation technology batch is being tested at the test loop of NEVZ

WMU with rolling axle bearing Axle with bearings

21 RELIABLE AXLE BEARING bearing, RZD approved the Schedule of Production Utilization of rolling bearings in Development and Implementation of the locomotives has a very good economic Running Gear Structure with Traction effect for RZD. Motors of the 2ES5K Electric The plant in collaboration with VElNII Locomotive Mounted on Rolling Axle has made repeated attempts to use Bearings. In order to fulfill it, NEVZ rolling bearings in the wheel and motor manufactured a pilot electric locomotive unit (WMU) structure. Specifically, in the – 3ES5K No. 020 with a rolling axle following electric locomotives: bearing, which underwent prior ● VL80K No. 552, 541, 551, 617 with commissioning and certification tests. utilization of two spherical double-row In March 2008, an acceptance bearings; commission was set up; as a result, ● VL80K No. 10 with traction motor NB letter O1 was assigned to the design axle bearings that 90% of the electric 418R relying on the axle through documents. This was followed by the locomotives fleet require phase 2 of cylindrical roller bearings; obtainment of a conformity certificate maintenance so frequently. ● VL85 No. 223, which was operated in for the pilot batch consisting of The design life of the rolling axle Vikhorevka Depot of the East Siberian 15 pieces. bearing is at least 5 million km of Railways from 1991 to 1994 and The 3ES5K No. 20 electric locomotive distance traveled by a locomotive. The traveled 307,790 km. was delivered to RZD for operational installation of wheel and motor units However, for a number of reasons tests at the Smolyaninovo locomotive with the rolling axle bearing makes the related to structural and technological electric locomotive more costly. characteristics, all pilot electric However, payback is achieved due to locomotives were not put into the following factors: operation. WMUs were subsequently replaced with sliding axle bearings. These ● removal of axle oils from WMU solutions were not used in mass maintenance and repair process production. and elimination of the need for In May 2006, with the view of their seasonal replacement; mastering the structure of the ● reduction of costs associated with running gear of the electric maintenance and routine repairs locomotive with the rolling axle of WMUs with a rolling axle bearing; ● enhancement of reliability and extension of service life of traction gears and traction motors due to the lack of misalignment caused by wear of brass bushings in sliding axle bearings; ● extension of the wheel set service life due to eliminated wear of axle necks underneath sliding axle bearings; ● no charge for environmental pollution due to the elimination of axle oil discharges on the track superstructure; ● improvement of cost efficiency of the electric locomotive – increased utilization rate with regard to power for machine rimpull and capacity efficiency enhanced due to the reduction of the principal resistance to locomotive motion. Wheel and motor unit test

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Rolling bearing F-579.000.24048 Stand tests and adjustment of WMU with rolling axle bearing

depot of Far Eastern Railways. After the In parallel, work was performed to manufactured the 3ES5K No. 250 electric locomotive traveled 102,000 km, ensure reliable operation of the rolling electric locomotive with the rolling axle the inspection performed as part of the axle bearing unit. When a meeting of bearing and put it into pilot operation in commissioning in May 2009 revealed STC (Scientific and Technical Council) of January 2012 at the Khabarovsk defects of rolling axle bearings, which NEVZ was held, its participants agreed locomotive depot of Far Eastern resulted in its discontinuation. to manufacture the 3ES5K pilot electric Railways. The results of the pilot NEVZ undertook a number of locomotive with employment of the roller operation and subsequent three-year measures for the purpose of reducing spherical double-row bearings by FAG monitoring of the technical condition of the downtime of the 3ES5K No. Schaeffler, Germany, installed with one the rolling axle bearing showed that the 20 electric locomotive. 3ES5K No. 20 floating support. It was decided to customer’s costs during maintenance was equipped with six serial bogies with devise design documents with due and operation were reduced by sliding axle bearings and Flexicoil consideration for positive experience in approximately 10%. springs. After restoration, this electric operating the VL60 No. 608 electric The period from 2012 to 2015 saw locomotive was kept for operation at the locomotive featuring the rolling axle manufacturing of the pilot batch of Smolyaninovo depot. All wheel and bearing, which had traveled more than fifteen 3ES5K locomotives and three motor units with rolling axle bearings 1 million km. 4ES5K electric locomotives featuring from 3ES5K No. 20 electric locomotive In early 2012, relying on the design WMUs with the rolling axle bearing. were delivered back to NEVZ. documents developed by VElNII, NEVZ Positive feedback was received as a result of their operation at Khabarovsk, Vikhorevka and Smolyaninovo locomotive depots. In accordance with paragraph 2.3.6 of the “Activities Aimed at Improving the Structure of Electric Locomotives The period from 2012 to 2015 saw manufacturing of the pilot batch Manufactured by PK NEVZ, LLC for 2014–2015” approved by the customer (RZD, JSC), since April 1, 2015, NEVZ of fifteen 3ES5K locomotives and three 4ES5K electric locomotives. has manufactured all electric locomotives — 2 (3, 4) ES5K and 3ES4K — with the rolling axle bearing. In Positive feedback was received as a result of their operation at 2015, NEVZ will produce forty 3ES5K electric locomotives and twenty-nine 3ES4K electric locomotives with the Khabarovsk, Vikhorevka and Smolyaninovo locomotive depots rolling axle bearing.

23 Traditions

TheTODAY, THE SU-76SU-76: SELF-PROPELLED from GUN CAN BE SEENMytishchi MOUNTED ON THE STONE PEDESTAL to BerlinIN FRONT OF THE OFFICE BUILDING OF METROWAGONMASH, JSC. It symbolizes the efforts of the workers, engineers and others who forged the victory on the home front during the Great Patriotic War by supplying military vehicles to the frontline. n October 23, 1942, the People’s The production of military vehicles at Plant. Simultaneously, the plant Commissariat (“Narkomat”) of the Mytishchi Carriage Works is believed launched mass (military, special) Tank Industry ordered that to date back to 1943, when an order production and established a special self-propelled guns be manufactured was issued to organize mass design office (SDO-40) headed by the on the basis of all available tanks with production of the lightweight tank famous and talented design engineer Odifferent types of artillery and (weight category: T-80) invented of lightweight military track-type assimilated on a very tight schedule. before the war at Gorky Automobile vehicles – Nikolai Alexandrovich Astrov

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morning until late at night, often sleeping at their workplaces. Individual workers and whole teams competed with each other. Assignments were fulfilled with honor! Since 1944, the plant consistently increased its output of military vehicles, primarily the SU-76. In January, its output was 50% higher than in December 1943: the plant was ranked third in the competition. In February, the number of military vehicles that rolled off the production line was 30% higher against January. The SU-76 in Berlin Many reliable military vehicles were required to defeat the fascist army. featured ammunition consisting of 60 In March, the plant’s personnel high-explosive fragmentation and exceeded their assignment by 25% as piercing shells, as well as the DT compared with February. The portable machine gun for self- enterprise was ranked first and defense. Armor protection shielded awarded the challenge red banner of the crew (four people) against small the State Defense Committee of the arms fire, high-density fragments, and USSR. Every month, the plant was machine-gun battery. All SU-76Ms given a more challenging assignment were equipped with radio stations. than in the previous month. High On the road, the maximum vehicle awards were bestowed on many speed was 45 km/h; off-road, up to workers for regular provision of military 25 km/h. Endurance distance is vehicles to the frontline. 320 km and 190 km, respectively. The self-propelled gun could overcome a SOLDIER’S FAVORITE 2 m-wide trench, 30° elevation, 0.9 m The SU-76 maneuvering small-size deep ford. Due to its small dimensions self-propelled guns made by the and low average per-unit ground machine builders of the Mytishchi pressure the vehicle was able to plant heroically made their way from successfully cross marshy and the Battle of Kursk to Berlin. Marshal forested terrain, accompanying Rokossovsky wrote in his memoirs, infantry in places where medium tanks “Soldiers were especially enthusiastic and other self-propelled machinery AT AN ACCELERATED PACE about the SU-76 self-propelled guns. were unable to move. The well- Pursuant to the resolution of the State These lightweight moving vehicles designed cooling system and faultless Defense Committee of the USSR were always fast enough to come to starting preheater allowed the SU-76M dated December 17, 1942, the plant aid to the infantry; and soldiers, in their to be operated successfully in any was renamed into Works No. 40. In turn, were eager to protect them season along the entire frontline. July 1943, the plant was ordered to against the fire of hostile anti-tank produce SU-76 self-propelled guns. riflemen with their own chests.” The SU-76: from Mytishchi to Berlin As soon as practical, it had to ensure The basis for the SPG was the that the manufacturing of vehicles running gear of the T-70, a tank that was in place, specifically to install was already being manufactured. The new equipment in the assembly motor system consisted of two shop, organize training for workers, 6-cylinder car engines for the GAZ‑202 equip workplaces, prepare technical with a total capacity of 140 h. p. documents, develop processes, and The universal division cannon design an array of fittings, stamps, (ZIS-3) was installed on the armored instruments, and tools. vehicle. From 5,000 m away, its shell For almost one month, the could penetrate up to 91 mm thick engineering team was “confined to armor that is any place on the body of barracks” working from early in the average German tanks. The gun

25 • Transmashholding — No. 1 IN CIS COUNTRIES in rolling stock output HOLDING’S PRODUCTS AND SERVICES: and sales • mainline and industrial electric • diesel locomotive and marine diesel locomotives; engines; • Transmashholding • mainline and shunting diesel locomotives; • diesel generators and turbine-driven is ranked among THE • freight and passenger cars; compressors; • electric train and metro cars; • components for transport; WORLD’S TOP TEN • road-rail buses and diesel trains; • spare parts; MANUFACTURERS of • car casting; • repairs and maintenance. railroad machinery

IN THE PAST FIVE YEARS, THE COMPANY • Transmashholding — HAS MANUFACTURED RUSSIA’S ONLY over more than more than COMPANY, with experience in developing and 3000locomotives 4000passenger cars 3000electric train manufacturing cars technical equipment for arctic conditions over more than over • The technical equipment of 230cars of 1500metro cars 2700diesels road-rail Transmashholding buses is operated IN ALL CLIMATIC ZONES

EG2Tv electric train ON EARTH TVER Postal address: Russia, 127055, Moscow, Butyrsky Val 26, bldg. 1 TELEPHONE: +7 (495) 744-70-93; FAX: +7 (495) 744-70-94; E-mail: [email protected] www.tmholding.ru