First EP20 supplied to railroaders page 4 : a diesel that will never fail page 6 Interview with Mikhail Zagrebailov, head of Rustranskomplekt page 18 MAGAZINE FOR PARTNERS OF 4 12/2012

№ № 4 12/2012 MAGAZINE FOR PARTNERS OF № 4 12/2012 Magazine for partners of CJSC Transmashholding Editor-in-Chief Contents corporate 2 Konstantin Dorokhin

[email protected] news Editorial office address 2 127055, , Butyrsky Val picture story Str., 26, bld. 1 Happy trails! First EP20 Phone: (495) 660-89-50 4 4 supplied to RZD The magazine is prepared with participation of MediaLine PH www.medialine-pressa.ru Director General Larisa Rudakova Penzadieselmach:cover story Design layout Ilya Malov A diesel that will never Editorial Director 6 Dmitry Dorofeev fail

Production Editor Marya Frolova

Design and make-up Elizaveta Krasnova 6 introduction Elena Khoroshiltseva Turbochargers by Alexey Kuznetzov Sergey Khvatov Penzadieselmash: 10 Proofreading powerful, reliable, timely Natalya Konnova Elena Savelyeva Larisa Nikolina 18 Ivan Shipnigov Prepress cooperation Andrey Klochkov TEM TMH locomotive: Maxim Kuperman 14 Oleg Mashkin for and Europe Oleg Nikitin

Passed for printing on October 2, 2012 Printed in Viva-Star printing office Print run 999 copies Interviewpersonality with Mikhail Zagrebailov, Director General of RusTransKomplekt 18 innovation IRIS for NEVZ and the 22 14 Holding Penza Dieseltraditions Plant: How it all began 24  News New Undercarriages

Bezhitsa Steel Foundry (BSZ) fromreceived a license Bezhitsa and order to Foundry produce castings for Barber freight car undercarriages BSZ (member of Transmashhold- ing) signed a memorandum of strategic cooperation with the United Wagon Company (UWC) and a license agreement on production of heavy castings for Barber undercarriages. order as early as 2013 for delivery Pursuant to the agreement, the of car castings to produce Barber foundry is to receive the complete undercarriages. It is expected that design documentation package to Transmashholding’s car produc- produce railway undercarriage tion facilities, such as JSC castings (solebars and bolsters), Engineering Plant and JSC and to manufacture casting sets. Transmash, are to become the Under the arrangement, Tikhvin largest consumers of castings Freight Car Building Plant, a part produced by BSZ under the The Road of UWC, is going to place a large license agreement. Transmashholding signed a memorandum of understanding with Pakistan’s Railway Ministry The memo of understanding is intended to serve as a basis for cooperation between toRussian engineersPakistan and Pakistani railroaders. The document was signed by Muhammad Arif, Secretary, Chairman of Pakistan Railways, Contribution to Innovations and Shukhrat Makhmudov, Commercial Director of Transmashholding. According to the memo, the parties have agreed to collaborate and identify projects where Pakistan might be interested in Russian products and where TMH could make invest- ments and transfer technology to local partners. A supervisory committee will be created to coordinate the activities within the memorandum with sessions to be held at least once per year. “Pakistan is a new market for Transmash- Memorandum of cooperation signed between Skolkovo holding,” said Shukhrat Makhmudov. “We are Foundation and Transmashholding ready to offer our colleagues state-of-the-art Viktor Vekselberg, President of Skolkovo Foundation, and Andrey machinery capable of increasing the efficiency Bokarev, President of Transmashholding, signed a memorandum of the country’s transport system. I hope that on issues related to innovative research and development as well our cooperation will be long-term and benefi- as the construction of Transmashholding’s corporative engineering cial to both parties.” center in Skolkovo.

 № 4 12/2012 Improving TVZ started development of new steels. As a result, the useful life of double-decker passenger cars for cars will reach 40 years. interregional transit An economy class car will JSC approved accommodate 104 passenger the technical design assignment seats arranged on both decks by Congratulations for locomotive-hauled double- the 2+2 configuration. A business decker passengerQuality cars. The class car will be equipped with project is implemented by 29 luxurious seats by the 2+1 Carriage Works (TVZ, member of configuration on each deck. In on the New Transmash-holding). addition, a separate VIP two-bed The project is being implement- compartment will be built in a Transmashholding and partners open a new ed in accordance with the partner- business class car, which will have locomotive plant in ship agreement on production of more amenities and will be much Plant!Kazakh Railways (KTZ), and Trans- double-decker passenger cars for more comfortable than the parlors. mashholding inaugurated a new plant for the interregional transit that was All cars will be equipped with air production of electric locomotives in Astana, signed by JSC Federal Passenger conditioning systems, eco-friendly the capital of Kazakhstan. Company (FPC) and Transmash- toilets, Wi-Fi for Internet access, The ceremony was attended by the President holding on May 31, 2012 at display panels and energy-saving of Kazakhstan, Nursultan Nazarbayev, KTZ “Strategic Partnership 1520” lamps. Power supply for the cars is President Askar Mamin, TMH President Andrey Business Forum in Sochi. fed from the electric locomotive Bokarev, Alstom CEO Patrick Kron as well as The agreement stipulates that a via a high-voltage static converter. Alstom Transport President Henri Poupart- rolling stock supply contract Air-tight gangways and slack-free Lafarge. should be concluded by the end of couplings diminish noise and The total amount of investments in this 2012, and the serial manufacturing vibration levels during train establishment is €50 million. The plant is of cars should launch in 2014. operation. Entrance sliding-plug operated by EKZ, a joint venture owned by KTZ Cars with seats will be used in doors will be provided with (50% of the shares), Alstom and TMH (25% of permanent interregional trains. automatic steps to ensure the shares each). The trains will also include double- passenger exit both to high-floor Initially, the plant will start operations with decker staff compartment cars and low-floor platforms. Kazakh Railways’ order for 200 freight locomo- with specially equipped seats for The designed rolling stock will tives KZ8A and 95 passenger locomotives KZ4A disabled passengers as well as complement the variety of double- totaling €1.3 billion. The partners’ ultimate goal double-decker dining cars. decker train cars produced at TVZ. is to expand their presence and to enter the The technical design assignment In 2013, the plant will build the first locomotive markets in neighboring countries. specifies two modifications: batch of double-decker long- With a total surface area of 27,522 square economy class and business class. distance trains for JSC FPC, which meters and a design capacity of up to 100 loco- The cars will be designed for will include four-bed compartment motive sections per year, the plant meets the operation speeds up to 160 km/h; sleeping cars, staff compartment best standards of the industry. Additional car bodies with smooth side wall cars, two-bed compartment employees will be needed for the increased sheeting will be manufactured of sleeping cars, as well as dining production output: from 47 employees today to corrosion-resistant (stainless) cars. 650 people by the end of 2016.

 Picture story Happy Trails!

ransmashholding and Alstom products, recent achievements, and supplied their customer JSC met with NEVZ employees. Russian Railways with the first EP20 is the first Russian locomotive passenger dual-voltage locomotive that can haul passenger trains at 200 EP20. The EP20 ceremony took place km/h. No locomotives of this type Tat Novocherkassk Electric Locomo- have ever been produced in Russia tive Plant on November 30. This event before. These locomotives will be was attended by Russian Prime utilized in the Olympic trains during Minister Dmitry Medvedev, Senior the Sochi Olympics in 2014. Vice-President and Chief Engineer of The EP20 locomotive is an embodi- RZD Valentin Gapanovich, Governor ment of all most advanced achieve- of Rostov Region Vasily Golubev, ments of the global locomotive Transmashholding President Andrey engineering. Adoption of this locomo- Bokarev, Alstom President Patrick tive will raise the efficiency of fleet Kron and Transmashholding General control substantially. Director Andrey Andreev. By 2020, Transmashholding will The Prime Minister was offered a produce 200 electric locomotives tour of the facility, introduced to its EP20 for Russia’s railways.

 № 4 12/2012

Aleksandr Popov, the first EP20 driver Patrick Kron, Alstom President

Andrey Andreev, Transmashholding General Director, and Aleksey Vorotilkin, JSC RZD Vice President

Dmitry Medvedev with NEVZ employees

JSC RZD Senior Vice-President Valentin Gapanovich, NEVZ Prime Minister examines modern electric General Director Sergey Podust, and Russian Prime Minister locomotive control desk Dmitry Medvedev

 Cover story Penzadieselmash: A Diesel that Will FOR YEARS, PENZA DIESEL PLANT HAS BEEN ONE OF THE LEADERS IN THE PRODUCTION OF DIESELS, TURBOCHARGERS AND ASSEMBLIES FOR DIESEL ENGINE-BUILDING PLANTS. THE HISTORY SPANNING SIX DECADES SHOWS: THE PRODUCTS OF THIS ENTERPRISE ARE IN DEMAND NOT ONLY IN RUSSIA NeverBUT WORLDWIDE AS WELL. Fail he economic importance of the boats, spare parts for diesels and entire period of the plant’s existence. diesel machinery produced by turbochargers, water and oil pumps, Currently, these products are widely Penza Plant cannot be overestimat- turning gears and pistons. In total, over used at the railways of Russia as well as ed. The enterprise produces diesel 20,900 diesels and 207,500 turbocharg- in countries worldwide. engines for marine vessels and river ers have been produced throughout the Consumers of Penzadieselmash Т products are mainly Russian and CIS companies. The largest among them are JSC Russian Railways, Bryansk Engi- neering Plant, Kolomna Plant (Kolomen- sky Zavod), Volgodieselmash. There are regular corporate customers in Mongo- lia, Kazakhstan, , Poland, Latvia, Cuba, and Guinea. The widely known D50 diesel genera- tors (1-PD4A and 1-PD4D for locomo- tives, 5DG50M and 6DG50M for ships) are the base models of the enterprise. Solid reliability, high mileage and low maintenance costs warrant their steady market positions. The plant constantly upgrades its products. Its specialists develop new designs and engineering solutions and implement cutting-edge technologies. Some of the latest modifications on the

 № 4 12/2012

D50 increased the diesel generator Penzadieselmash regularly holds NIKOLAI SIMONOV, output and reduced the specific fuel professional skills contests to determine General Director of Penzadieselmash: consumption over the entire range of the best craftsmen in various fields of operating modes. expertise and sporting events. The plant «At our plant has its own in-house music band and we never stop FOCUSING ON PEOPLE folk choir which has been in existence for working on the new Today, the plant‘s total employment more than 25 years. The company machinery. We are stands at two thousand (with an average sponsors guided tours and excursions well aware that age of 45). Among them, 28% of for its employees. we cannot afford employees have higher education and Healthy life style is encouraged among being stagnant. To 21% of them have secondary vocational employees. An in-house radio network maintain our position on the sales market, training. offers a daily stretch & flex program; it takes much more than just a reliable The employees continually receive yearly free medical checkups, vaccina- and proven, yet outdated, baggage. If an training in classrooms available on the tions and MRI are conducted. Sanato- enterprise no longer produces competitive plant’s premises. Many of them receive rium-and-spa treatment is available in new products, it will soon cease to exist. continuing part-time professional the Penza Region’s health resorts. There This is the reason why a new turbocharger education parallel to their work at the are also saunas, recreation lounges and of the TK32 family has been developed at plant. relaxation areas (decorated with flowers, the plant’s design office. The executive management devotes garden sculptures, paintings, and Today, JSC Penzadieselmash is a time to social programs and strives to fountains). participant of the New Generation of provide the employees with comfortable Nikolai Simonov is in charge of the Diesels program. We realize perfectly well conditions for work and leisure. It is no health and recreation programs. He has that our enterprise will have to develop coincidence that the plant became the come up through the ranks – from a new solutions for many challenges we will winner of the All-Russia Contest “Rus- regular foreman to the general director’s face. But our vision is clear, and we have sian High Social Efficiency Organization.” position. the determination to overcome them all.»

 DIESELS TO EVERY TASTE grade engine, it can be operated in any designed to replace outdated diesel CoverThe leading positionstory in the production of extreme conditions. The full power generators PDG1M. diesels at the enterprise is occupied by capacity of the engine is 882 kW. Penza Diesel Plant is known as one of the 1PDG4A locomotive diesel genera- Diesel generators 6DG50M (600 kW) the leading manufacturers of turbo- tor. This diesel-electric engine has stood and 5DG50M (690 kW) are widely used chargers. It produces turbochargers the test of time. Its main advantages are as main and auxiliary engines for marine engineered by the SKBT – Special high fuel efficiency at medium loads and vessels and river boats. Diesel generator Turbocharger Design Office exceeding quick transient response. A really high- 1-PDG4D (993 kW) is specifically 110 modifications in 10 sizes for 92 types of diesels and gas engines. Other products of great popularity from Penzadieselmash are water pumps and oil pumps. Penza’s constructors provide their consumers with integral spare parts for diesels and turbochargers, such as flexible couplings and anti-vibration devices, turning gears, pistons, and other products.

A KEY TO THE FUTURE For over 30 years the plant’s products have been supplied abroad. Products can be found in 60 countries of the world. In 2006, Penzadieselmash proudly received the national “Gold Mercury” award for the “Best Engineer- ing Exporter” category. The plant is continuously working on cost reduction, introducing new tech- nologies aimed at quality improvement and promoting a flexible marketing policy. In response to the market’s new demands, the enterprise has launched manufacturing of added value products that are cost-effective, easy in operation, durable and reliable. The enterprise is working extensively on projects involving efficient upgrade of TEM2 and ChME3 diesel locomotives, railway and marine diesel generators, gas and diesel fuel power packs, gas supply systems for locomotives, diesel generators for hydraulic drive locomo- tives. The products are continuously updated and diversified. In 2011, Penzadieselmash concluded four government contracts on engineer- ing research and development under the Federal Target Program “National Technological Base” for 2007-2011 within the subprogram “Creating and organizing the production of new generation diesel engines and compo- nents in the Russian Federation.” In pursuance of the governmental contracts and in close cooperation with

 № 4 12/2012

the Kolomna plant, Penzadieselmash is gram will also lay the foundation for engineering diesel engines, test research and development so as to benches, and turbochargers. The maintain the competitive edge of the program is scheduled until 2015. At the Russian diesel engineering in the long early stages it will encompass engineer- term. In 2014, a new trial diesel will be ing and technological development. THE PLANT manufactured, tested and fine-tuned. Its Later on the governmental contracts will serial production is scheduled for 2015. be executed by all departments within IS CONTINUOUSLY WORKING Reportedly, the output parameters of the plant. They will have to manufacture this diesel will be on par with the world’s breadboard and trial models of new best competitors. The most up-to-date products, create basic products, ON COST REDUCTION AND components and materials, such as an produce a pilot batch and, finally, accumulator fuel injection system, new develop preprocess engineering for turbocharger, self-cleaning full-flow oil serial production. Currently, technical INTRODUCTION filter, heavy-duty air and oil intercoolers, project activities are under way and key high-strength cast iron etc., will warrant characteristics of diesels are being lower specific fuel consumption, determined. OF NEW TECHNOLOGIES reduced oil consumption through The subprogram is intended for burning, a smaller weight and size of the development and organization of of shipbuilding and transport engineer- engine, lower emission levels and production of advanced versions of ing, the military industrial complex, operating costs. They will also ensure diesel engines of varied capacity and backup and emergency power plants, higher cylinder output and better speed, weight and size parameters that manufacturing of heavy machinery and acceleration capability. Such products meet the contemporary requirements nuclear power engineering. The subpro- are the future of Penzadieselmash.

 Introduction Turbochargers by Penzadieselmash: Powerful, Reliable, Timely

PRODUCTION OF TURBOCHARGERS FOR ENGINE BOOST SYSTEMS IS ONE OF THE PRIORITY AREAS OF PENZA DIESEL PLANT. WITH CUTTING-EDGE TECHNOLOGIES AT HAND, THE ENTERPRISE CREATES UP-TO-DATE PRODUCTS THAT ARE ALWAYS IN DEMAND FOR A VARIETY OF DIESELS. RELIABLE AND DURABLE, THE TURBOCHARGERS BY PENZADIESELMASH HAVE LONG BEEN ITS BRAND IDENTITY. 10 № 4 12/2012

A NEW PAGE IN THE LIFE OF PENZADIESELMASH n the 1950s, the Government of the USSR took a stronger interest in the development of national turbocharger engineering. The main bulk of diesels manufactured for the national economy Iat that time were technologically behind their foreign competitors, particularly, because they lacked turbocharging. In early 1959, the Soviet Government issued a decree on establishing the production of turbochargers for diesel engines with aggregate capacities of 600 to 8,000 h.p. Integration of the turbocharg- ing was called to enhance the capacity of diesels by 40% and considerably reduce their specific fuel consumption. Penzadieselmash faced a difficult task: to switch to manufacturing of new machinery of the day. A new page in the plant’s history was turned. In order to create high-quality turbo- chargers and improve the performance of domestic diesel engines through the Since then, Penzadieselnash has 5000 kW diesels. Today, over 110 ver- integration of standardized turbocharg- been the only enterprise in the CIS that sions of size types TK18, TK23, TK30, ers, Penzadieselmash established specializes in engineering and manu- TK32 and TK34 are in large-scale Turbocharger Design Office (KBTK). facturing of turbochargers for 300 to production. Advanced research is underway to develop conceptually new turbochargers with high efficiency, environment-friendliness and boost capacity. In total, over 100,000 turbochargers designed by KBTK have been produced and applied in mainline and shunting locomotives as well as marine vessels and river boats.

HIGHLY COMPETITIVE Penzadieslmash products steadily sustain the tight competition within both domestic and international markets of turbochargers. The keys to success are: high standards of research and develop- ment, skilled engineering staff, state-of- the-art technological design and manufacture. Distinctive features of the plant’s turbochargers are reliability and durability. Turbine blades and disks are made of heat-resistant materials, and friction bearings are manufactured of special bronze on modern high-precision equipment. The quality management system of the enterprise is certified to ISO 9001 international standard. Quality certifi-

11 cates are issued for each product. In IN COMPLIANCE WITH THE LATEST turbochargers: TK32. They are designed Introductionaddition, there is a procedure for STANDARDS for installing on diesels 12ChN 26/26 acceptance by the locomotive inspector- In 2008, Penzadieselmash’s design and 16ChN 26/26 by JSC Kolomensky ate of the Technical Audit Center by JSC office developed and launched a new, Zavod (Kolomna Plant). Russian Railways. more efficient and up-to-date family of Turbochargers TK32 are produced in order to replace turbochargers 6TK made by the Kolomna plant and TK41V- 21 & TK41B-25 made by Special Turbocharger Design Office. Such turbochargers are made in several modifications: 1) TK32-07: designed for diesel generators 1A-9DG (ver.3) in locomo- tives TE10MK. They are interchangeable with turbochargers 6TK and TK41-25. 2) TK32-09: designed for diesel generators 1A-9DG (rev.2) in locomo- tives TE116. They are interchangeable with turbochargers 6TK and TK41-21. In April of the same year, the Kolomna plant conducted comparative testing of diesel generator 1A-9DG (rev.3) with turbochargers TK32-07 and TK41B-25. Positive results of the tests set the foundation for the mutual decision by the Kolomna plant and Penzadieselmash to make an agreement on supply of turbochargers TK32-07. The contemporary TK32 turbocharg- ers differ from turbochargers 6TK by several parameters: 1) construction arrangement (rotor supports on the ends) typical for the turbochargers manufactured at Penza- dieselmash. This arrangement ensures lower bearing speed and, consequently, higher durability and longer life of the bearings. The bearings remain operable with a rotor imbalance ten times the initial value; 2) design of main assemblies (bearings, rotor, intake, compressor housing) unified with serial turbochargers TK30S-

12 № 4 12/2012

02 installed on locomotives TEM7 and proven over a long (over 30 years) operation period; 3) spare parts for turbochargers TK32 (bearings, sealing rings, etc.) are cheaper since they were unified with the serial TK30S-02. The differences between turbocharg- ers TK32 and TK41B-25 are described below: 1) a complex of engineering and experimental activities has yielded a charger with an increased throughput capacity, which makes it possible to use a charger with a smaller wheel diameter on diesel generator 1A-9DG (rev.2, rev.3). Correspondingly, the housing parts have been made smaller in size, permitting to decrease the weight of the turbocharger almost 1.5 times compared to TK41B-21 and TK41B-25. And this, in turn, predetermines a lower price; 2) turbochargers TK32 have a higher efficiency ratio and lower (double) rotor inertia. This results in lower operating fuel consumption and turbine inlet gas temperatures both in steady-flow and transient processes. Achieving high performance has become possible thanks to close cooperation with the skilled engineers of JSC Kaluzhsky Dvigatel, TURBOKOM LLC, JSC Kolomensky Zavod, as well as leading research institutions: All-Russian Railway Research Institute, Central Diesel Research Institute, Samara State Aerospace University, etc. The efficiency level of the newly engineered turbochargers has been suc- cessfully boosted through the implemen- tation of modern gas-dynamics design software FlowVision and strength analysis tool NXNastran. A considerable portion of the finalizing work on achiev- ing the desired parameters has been shifted to the design and documentation development phase. This has resulted in a shorter lead time for new products. While mastering new products, the plant is developing advanced turbo- chargers. Staying ahead of the competi- tion is one of the main challenges of the enterprise’s designers. The products by Penzadieselmash are likely to stay in demand in Russia and abroad for many years to come.

13 Cooperation

TEM TMH Locomotive: TRADITIONALLY, RUSSIAN LOCOMOTIVES HAVE BEEN SUPPLIED PRIMARILY TO THE DOMESTIC MARKET AND THE CIS COUNTRIES. IN WESTERN AND CENTRAL EUROPE, DUE TO STRONG COMPETITION, RUSSIAN LOCOMOTIVES HAVE BEEN RARE. Against this backdrop, the series TEM TMH shunting locomotive created through forthe joint efforts Russia of Transmashholding, Czech company and CZ LOKO and VEuropeilnius Locomotive Repair Depot is a very good example of Russian manufacturers entering the European market. It is successfully used in the Baltic States. 14 № 4 12/2012

he decision to build this locomotive driver’s cab), microclimate parameters, services,” adds Sergei Grechukas. “With was made in May of 2009. Two etc. different load cycles, the fuel consump- versions were considered: one for On April 24, 2012 the locomotive was tion could sometimes reach 46%, which, the European Union and one for Russia. granted a certificate of conformance by with today’s diesel fuel prices, is a very The locomotive’s design is based on the the Russian State Register of the strong argument in favor of purchasing Tmodules that have proven their value on certification system No. SSFZhT RU. our locomotive.” upgraded locomotives. CT03.A.09076. According to Sergei Grechukas, in Such technological design that is “The very fact that our locomotive is parallel with the orders that have been unconventional for Russia was actually certified to the federal register system is placed, another modification of the the reason why CZ LOKO was recruited a warrant for entering the large Russian locomotive is being developed today: the as a co-designer. The Czech company market, as well as the markets of CIS six-axle design is being converted into a has expertise in upgrading various types countries,” says Sergei Grechukas, head four-axle machine. of locomotives with the application of of TMH Baltic representative office. “The “This locomotive is intended for JSC module structures, including series 770 demand for it is growing in the Baltic Lietuvos Geležinkeliai – Lithuanian locomotives. In some countries they are States as well, though, understandably Railways,” explains Sergei Grechukas. “It marked as T669.0, ChME3, S200, LDE enough, the number of locomotives will meet the strictest environmental 1500, DES 3100 (over 300 locomotives ordered there is smaller.” requirements of EU Stage IIIB standards of the former ČKD Praha have already thanks to the state-of-the-art 700 kW been upgraded with these modules). engine CAT C27. Creation of such a These modules can be used for the machine will further extend our capabili- construction of new locomotives, ties in marketing shunters. Our confi- including diesel locomotive TEN TMH dence is confirmed by the orders from 001. JSC Port of Sillamäe. Our locomotive is The upgrading project has been TEM TMH DEVELOPED performing there successfully in every developed and approved by Zeppelin single operational area. Today, it Power Systems GmbH & Co. KG, CZ replaces two series TEM2 locomotives LOKO, Vilnius Locomotive Repair Depot UNIFIED LOCOMOTIVE MODULES and hauls trains up to 6,000 tons in (VLRD) and Bryansk Engineering Plant. weight. The locomotive with good For assembly of the first two locomotives technical and economical performance the Vilnius depot was selected, which THAT CAN BE USED characteristics gained an excellent has sufficient expertise in upgrading reputation, so two more locomotives locomotives with the integration of CAT were acquired for the port’s needs. diesels in conjunction with CZ LOKO. The IN THE UPGRADES Sergei Grechukas adds that the total scope of upgrades made includes VLRD’s capabilities do not allow to fully 60 sections of locomotives 2M62 and satisfy the emerging demand for TEM 2M62U, 23 locomotives ChME3 and AND CONSTRUCTION OF NEW TMH: “In total, we can assemble up to prototype locomotive TGM4. 35-40 locomotives per year, so, if All agreements were signed in early anything, the main work load will be July 2009. On July 20th, the first LOCOMOTIVES assigned to the Bryansk plant. For such components were received at the VLRD. production volumes ever to become an Bryansk Engineering Plant delivered a According to Sergei Grechukas, issue, much has yet to be completed. locomotive main frame with a fuel tank currently, Estonian Railways operates 30 For instance, we need to prove that TEM and undercarriages pre-assembled with new locomotives, and the Port of Sillamäe TMH is not just more fuel-efficient than motorized wheel blocks. has ordered a third locomotive. The any other locomotive of its class but it is With the previous experience in growing demand is attributable to the much more innovative, it is simple and upgrades, the first locomotive TEM TMH fact that, in comparison with the locomo- cheap in terms of maintenance and was refurbished by the 150th anniver- tives manufactured ten or more years repairs. Currently, the VLRD manufac- sary of JSC Lithuanian Railways that was ago, TEM TMH shows significant savings tures one new TEM TMH locomotive a celebrated last August. in oil and fuel economy, which, depend- month.” (In total, 18 locomotives of this The first locomotive TEM TMH 001 has ing on the model and operation condi- series were assembled in Vilnius by the successfully passed the field tests, tions, can reach up to 25% or more. beginning of 2012). certification and acceptance tests, and it “According to our clients, the locomo- What other advantages does TEM TMH meets all requirements of fire safety, tive ensures considerable reductions in have, in its users’ opinion? functional and environmental safety, diesel fuel and oil consumption in all The most considerable advantages are electromagnetic compatibility, ergonom- operating modes, including the marshal- the unique modular design allowing for ics (including the limits of vibration in the ling yard operations and clean-up train improving the driver’s working conditions

15 arrangement that provides a panoramic Cooperation view. Special attention is given by the designers to substantiate locomotive driver comfort. Inside the cab, which is fitted with special noise and heat insulation, there are two diagonally placed control panels and, correspond- ingly, two sprung armchairs. The cab is heated by an independent air heating unit and four XEROS-4000 heat ex- changers that utilize the heat coming from the diesel’s cooling system. There are two fans and an air conditioning unit. “Based on our experience with the TEM TMH locomotives, we can point out that the use of such unified modules in upgraded existing locomotives and new ones ensures lower capital and operating costs, and easier operation and mainte- nance. This is attributable to the fact that, regardless of the capacity of the locomotives, there is a uniform author- ized parts list, there are identical controlling algorithms and service and simplifying the maintenance work. new locomotives of many variants of technology,” says Stasys Dailydka, This will not entail considerable expens- types with the number of axles ranging General Manager of JSC Lietuvos es – as has been stated before, the from two to eight. Geležinkeliai. “The comprehensive creators of TEM TMH have developed In particular, the modular design with unification of the fleet of locomotives unified locomotive modules that can be low hood units makes it possible to install became possible with the new TEM TMH used for upgrading and construction of the driver’s cab of a so-called turret and it brought about fundamental chang-

16 № 4 12/2012 es in the locomotives’ maintenance and powerful engines. Thus, to meet the of pneumatic and electro-pneumatic repair philosophy.” needs of Lithuanian Railways, they are machinery known by the acronym UKTOL. Such design offers one more possibil- equipped with 3512B diesels with the In addition to the great variety of ity for cost optimization – it is general capacity of 1455 kW, while locomotives economical and operational advantages knowledge that in many countries private supplied to Estonia have 3512C-HD of TEM TMH, one particular feature has repair companies render a full range of engines with the capacity of 1550 kW. been observed by the clientele and is maintenance services and even have worth mentioning. It is somewhat locomotives for lease. For them, these psychological in nature – the drivers who easy-to-maintain TEM TMH locomotives have operated the new locomotives soon could become very beneficial! point out the vast differences with the Train operators wouldn’t have to deal previous units. with repairs and could focus on transpor- First of all, the differences have to do tation. TRANSMASHHOLDING’S with their reliability, handy controls, com- “It’s an unquestionable advantage that fortable working environment, and the module design allows making various reduced fatigue in traveling. The better modifications of the locomotive depend- NEW MACHINERY working conditions in this modern, ing on the customer’s requirements and aesthetic and sleek locomotive led to possibilities,” states Vitaliy Ivanov, CEO changes in the mentality of drivers and of the Port of Sillamäe. “This offers an HAS CONSIDERABLY RAISED THE the level of their skills. The new machin- opportunity to operate the locomotives ery has enhanced the prestige of the manufactured, say, for Estonia, when driver’s job and become a decisive factor necessary, not only for shunting but also PRESTIGE OF THE ENGINE in choosing this occupation. Safe and for train-hauling needs, either alone or in reliable operation of railway transport dual coupling.” DRIVER’S JOB requires both powerful modern rolling Indeed, the locomotives manufactured stock and skilled specialists who enjoy by the beginning of 2012 are equipped what they do. with three diesel models differing both in There are two design options for the Good working conditions are of prime capacity and environmental characteris- braking equipment. The locomotives importance, as they facilitate high tics (depending on the country of supplied to Lithuanian Railways are fitted performance and willingness of workers operation). In particular, the locomotives with braking equipment from the Czech to improve their skills. manufactured under the Baltic orders company DAKO, while the others are This challenge is successfully mas- generally have significantly more equipped with a unified domestic complex tered with the locomotive TEM TMH.

17 Personality

18 № 4 10/2012 «Cooperating with Transmashholding Means Stability in Work

RUSTRANSKOMPLEKT IS A COMPANY THAT PROVIDES PROCUREMENT SERVICES TO TRANSMASHHOLDING. THE SPECIFICS OF THIS BUSINESS ARE PRESENTED BY ITS DIRECTOR GENERAL MIKHAIL ZAGREBAILOV. for Years‘Mikhail, what is RusTran- In order to to better understandCome the scale structure» is made up by materials and sKomplekt? Please tell us of our mission, it’s enough to just supplies, and this is a vast fertile territory about its mission.’ consider the input costs of the TMH for us to work in our everyday opera- “CJSC RusTransKomplekt is a trading products. The key constituents are such tions. and purchasing company that has been cost items as wage expenditure, which, A one-ruble gain in the company’s -Мproviding raw materials and supplies to thanks to the socially oriented policy of income yields 10-20 kopeks of net profit, Transmashholding (TMH) for years. TMH, is growing year to year, and utility while one ruble earned from purchase The main objective of RusTransKom- costs, which are growing steadily beyond cost reduction means one ruble of net plekt in the procurement field is to our control. Over 70% of the cost profit.” provide commodities needed for production with the best efficiency possible, which, in our understanding, means purchasing the commodities (1) at a reasonable price (2) of the highest quality and (3) strictly within the time limits corresponding to the manufactur- ing demands. RUSTRANSKOMPLEKT VALUES ITS OWN REPUTATION In our day-to-day operation, we try to make the best use of RusTransKomple- kt’s experience and capabilities to AS AN OPEN COMPANY AND GOOD FAITH TAXPAYER reduce the material cost ratio of TMH products by reducing the purchase price and searching for alternative AND HAS THE SAME REQUIREMENTS TO SUPPLIERS. suppliers.

19 ‘The importance of logistics for an companies. The second set of require- by the fact that RusTransKomplekt Personalityengineering enterprise is difficult ments includes the company’s work values its reputation as an open com- to overestimate. What are your key experience, prices for the commodities it pany and good faith taxpayer and has requirements to Transmashholding offers, its product quality level, ability to the same requirements to suppliers. suppliers?’ keep its warranty undertakings, and to The second set of requirements is “We could place these requirements offer payment terms comfortable for the more complicated. The majority of into two groups. The first group is formal Group, etc. enterprises manufacturing components requirements, such as capital size, bona As for the first set of requirements, our for railway machinery, unfortunately, fide status of the potential contractor as careful attention to each contractor were established in the Soviet era. They a taxpayer, elimination of fly-by-night before doing business can be explained suffered from the economic perturba- tions of the 90s. To eliminate the risks associated with the supply of poor quality products and violation of delivery terms, many of them would need radical revamping and more qualified staff. For years, the TMH enterprises have been dealing with the same issues. We try to support and be sympathetic to our contractors and jointly solve many of their urgent problems because we understand that the development of our suppliers will have direct impact on the TMH products. As a company, we place a high priority on Russian suppliers who move forward and who have managed to either keep or restore their labor potential, who perfect engineering designs, develop through innovations, and work on cost reduction. Every time we meet with our partners we point out that only mutual sustainable development will help us all be competitive. Problems emerge when a supplier fails to realize the importance of long-term cooperation, to anticipate the prospects; unfortunately, this is not uncommon. Ever-growing requirements to the quality of commodities and the need to cut costs are inescapable ways to survive in today’s competitive environment. Certain monopolistic companies have unacceptable approaches to dealing with consumers and force them like captives to work on terms and conditions extremely unprofitable for the Group. Today, it’s rather naïve to think that finding – or, in case of an impasse, creating – an alternative way out would be impossible. We consider any means of boosting competition and excluding monopoly, including joint ventures. Because of some negligent suppliers we are forced to work on the expansion of the range of foreign commodities purchased from the world’s largest

20 № 4 10/2012 manufacturers. I’d like to point out that we are working on these problems continuously, and we have already achieved results. Every supplier should understand that only strenuous joint efforts founded on trust and openness will provide them as well as Transmashholding with orders from customers for decades in the future. I am positive that the days of short-term gains are gone, and the time has come for meticulous, far-reaching creative work. To summarize the aforesaid, I should say that today, as numerous railway machinery manufacturers are developing dynamically, and Russia is gradually inte- grated into the WTO, we have no choice but to brace ourselves and work 200%.» ‘Cooperation with such innovative company as Alstom requires that Transmashholding buy even more high-tech components, correct?’ “Speaking about our French partners, I would like to first emphasize their vast RTK procures a wide range of products – from metal to coveralls and personal experience and strategic approach. The protective equipment logistics of Alstom is a service that has been built over the years, and it is deeply ambitious plans for the future. In the integrated in the common control coming decades, the condition of the system, and closely tied with other rolling stock will require large-scale business units within the company. The renovation. The leaders of the country specifics of the Russian legislation, and JSC RZD are planning on extending peculiarities of document circulation, CREATING NEW MACHINERY, and developing the railway network. If monopolistic customer requirements Transmashholding’s suppliers maintain and many other factors are barring us the right approach and put forth great from wider implementation of the foreign CONTRIBUTING effort, they won’t be left without work.» experience. Nevertheless, Alstom’s history shows that up-to-date tools and ‘Are there any partners whom solutions in the logistics management TO THE NEW IMAGE OF Transmashholding treats as spe- should by all means be implemented and cial?’ widely used in practice. Our goal is to «I would rather not name them so examine and possibly adapt certain THE RUSSIAN RAILWAYS they don’t rest on their laurels (laughs), solutions and tools that could directly though, of course, there are some affect the cost and the quality of the leaders. I would like to thank all part- materials and commodities purchased IS IMPORTANT AND REWARDING. ners who have an understanding for the by TMH Group. implications of our joint efforts. As for It is worth mentioning that updating the me personally, I am proud of working in variety of the holding’s products in ‘What are the advantages a poten- the engineering industry. Creating new conjunction with Alstom requires the tial supplier could get from coopera- machinery, contributing to the new im- procurement of conceptually new high- tion with Transmashholding?’ age of the Russian railways is important tech components in line with the latest «I would define the main advantage of and rewarding. I’m convinced that if we trends in the railway engineering. Of working with TMH as the opportunity to combine our efforts with our partners, course, our partners are well aware of find stability in today’s unstable world. It we will be able to realize the great poten- this trend, which also serves as an wouldn’t be an exaggeration to say that tial of TMH Group to the fullest and have incentive to develop for many of our our reliable suppliers with strategic significant achievements in our uneasy suppliers.» thinking are in the position to make work.»

21 Innovations IRIS for NEVZ Director S.F. Podust and the Quality System Manager A.F. Schuchkina, the NEVZ IRIS implementation team demonstrated dedication and profes- sionalism which led to excellent audit results. During the IRIS implementation process, by combining the existing solid quality management foundation of NEVZ and thebased on ISO 9001 InternationalHolding Stand- ard, and with valuable inputs and guidance from IRIS consulting organiza- tion ZAO Centre Priority, NEVZ was able to receive a very high first audit score, and positive reviews from the German based certification audit body DQS GmbH. Today, NEVZ is the largest railway industry company based on the number Valogi Sukhinin, of employees (more than 10,000 Head of Quality Assurance employees) listed in IRIS Portal that has Administration CJSC Transmashholding been certified to IRIS in both the Russian Federation and the world. parts, electric equipment for electric n 2012, Novocherkassk Electric locomotives. Locomotive Works LLC PC success- NEVZ IRIS Audit Scope The total auditing time for NEVZ was fully passed certification audit The IRIS certification audit is conducted over 170 hours or 22 man-days. The according to the International Rail according to the International Rail audit covered the following chapters of Industry Standard (IRIS). The audit was Industry Standard, Revision 02. The audit IRIS requirements: Iconducted by DQS GmbH between 3rd covered the activity of: design, develop- • Chapter 4 - Quality Management and 7th of September of 2012. ment, manufacturing and maintenance System During twenty months of hard work for the scope of certification 18 (Rolling • Chapter 5 - Management that was carried out by each and every Stock) of freight, passenger and Responsibility one of NEVZ IRIS Process Owners, industrial electric locomotives, traction • Chapter 6 - Resource Management under the leadership of its General aggregates, components and spare • Chapter 7 - Product Realization

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The scores for the five audited chapters range from “Defined and closed” to “Optimized” (which is at the higher end of the scoring range). 80%

70% 75,68 77,34 69,12 69,42 60% 67,57 66,86

50%

40%

30%

20%

10%

0 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 General

• ГChapter 8 - Management quality level and therefore promote a ment system, for example, Project Measurement, Analysis and higher quality image. This contributes to Management, Design, RAMS, LCC etc, Improvement securing a competitive future: NEVZ are based on proven techniques that becomes a more valuable and prominent further enhance an organization’s ability What is IRIS – Why UNIFE Created IRIS member of the market. to achieve high quality levels in the IRIS is a common global system for the Through the IRIS web database the challenging railway sector. evaluation of Business Management manufacturers are able to enter and IRIS certification offers the following Systems specific to the rail sector. It update their data. After certification, this specific benefits: comprises an international standard information may be made available to 1) Improved product and process based on the principles of ISO 9001, system integrators and prospective quality there is a unique IRIS questionnaire, clients, on approval of the audited 2) Improved on-time delivery based on which the maturity level is company. 3) Greater emphasis on supplier qual- evaluated and a score is given. Equipment manufacturers are able to ity improvement efforts The IRIS requirements evaluation save time by only having to apply once 4) Eliminating the need for multiple process with an assessment guideline is for the certification, for both ISO 9001 third-party certifications performed by IRIS approved global and IRIS at the same time. 5) Promises of more consistent audit- certification bodies. ing performance The IRIS certification is issued as a IRIS is “The Improvement Standard” 6) Auditors of recognized IRIS certi- single site certification (with remote With ISO 9001 as the basic quality fication body must undergo extensive locations). The certification defined management system, manufacturers training and testing to meet rigorous various rail scopes, for example, Rail achieving certification to IRIS receive qualification requirements. Equipment, Rolling Stock, and Signaling. dual benefits. As of 1st September 2012, there are UNIFE - the Association of the First, they benefit from the process 783 IRIS certified sites representing European Rail Industry created IRIS to approach, with emphasis on continuous 532 companies. manage Operators’ complaints about improvement. This means that the The railway industry worldwide has the reliability of Rolling Stock and organization knows, understands, and accepted the certification process and requested improvements. practices a philosophy that is committed is embracing and using the IRIS certifi- The successful implementation of IRIS to quality in all actions, never settles for cation process to improve its Business creates a win-win situation for all “good enough,” and understands the Management System, as well as its stakeholders, the equipment manufac- dynamics and interactions that exist Process and Product Quality through- turers, the system integrators, the between the various processes that out the supply chain. Introduction of operators or business partners. The make up the quality management IRIS at NEVZ is a milestone not only for goals of an integrated system benefit all. system. the plant itself, but for the holding as a For the equipment manufacturer like Second, the added railway specific whole. Today’s Quality is Tomorrow’s NEVZ, it enables NEVZ to improve its requirements of the business manage- Market!

23 Traditions

PTheenza history of PDenzadieselmashiesel P spanslant over 63: yearsHow. It started It onA Julyll 1st B ofegan the year 1949 in the southern outskirts of Penza, in a desolate and swampy area. Over a short period, workers and engineers managed to create a new plant and manufacture the first diesel for their country. fter World War II, the country went through a difficult period of restoration from the ruins. The Soviet Union faced a challenging task to eradicate the aftermath of the war and in Athe shortest time possible restore the national economy. Many national industrial enterprises were slowly resuming their operations. On November 8, 1948, under the order of Stalin, the Council of Ministers of the USSR passed Resolution# 4176-1673сс on the construction in Penza of a machine-building plant for manufactur- ing of main marine diesels 30D, 33D and 37D for submarines, subchasers and other naval ships. Their capacity was to attain 2,000 h.p. – the Navy’s require- ment, especially for “fighting US submarines.” One of the main goals of the plant’s operation was to manufacture medium- speed diesel engines of the D50 type with the capacity of 1,000-1,200 h.p. assigned the creation of the plant. The Two years later, in 1956, Factory #243 for railway and marine transport. Until construction started literally from was renamed into the Penza Diesel this day, the enterprise remains the scratch: pegs driven right into the bare Plant, or Penzadieselmash. only manufacturer of such diesels in ground of the steppe became the Eventually, the first diesel was produced Russia. markings of the future shops. The plant’s on April 26 of 1957. Three shifts were The new plant under the code name administration had its office in a small involved in its assembly. The Penza plant’s “Factory # 243” was of special signifi- boarded facility divided into two sec- workers received help from the specialists cance in ensuring the country’s defense. tions, with the book store “Kniga” in the of the Kolomna and Kharkov plants. The Penza Construction Trust #48 was other section… assembly of “the newborn” took a month, It’s noteworthy that the first products but, subsequently, when the production of this plant were … wooden kitchen was established, 50-60 diesels were cabinets. They were in demand and manufactured every month. All instruments generated significant proceeds for the for the assembly work were invented by the plant that was still under construction. plant’s specialists, since specialized Later on, the plant started manufactur- devices had not been produced yet. ing transporters, skip hoists, and other Since the day of its creation, the plant nonstandard equipment. The first blank has manufactured over 20.5K diesel- heat was performed on the last day of generators and over 205K turbocharg- the spring of 1954. At the end of ers. Today, its products can be seen in December, the plant started regular 60 countries of the world, where it enjoys iron casting. a very good reputation.

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 • Transmashholding is NO. 1 IN CIS COUNTRIES in terms of the volume PRODUCTS AND SERVICES OF THE HOLDING: of rolling stock • mainline and electric industrial • diesel locomotive engines production and sales locomotives; and marine diesels; • mainline and shunting locomotives; • diesel generators and • freight and passenger cars; turbochargers; • electric train and subway cars; • transport components; • Transmashholding is • rail buses and diesel trains; • spare parts; among WORLD’S TOP • car casting; • repair and service maintenance. TEN LEADING MANUFACTURERS of OVER THE PAST FIVE YEARS, railway equipment THE COMPANY HAS PRODUCED: over over over • Transmashholding is THE ONLY RUSSIAN COMPANY to have 3000locomotives 4000passenger cars 3000electric train cars experience in creation and manufacture of over over over the machinery for the arctic service 230rail bus cars 1500subway cars 2700diesels • Transmashholding machinery is operated IN ALL CLIMATIC REGIONS OF THE EARTH

POSTAL ADDRESS: Latest shunting Russia, 127055, Moscow, Butyrsky Val Str., 26, bld. 1 TELEPHONE: +7 (495) 744-70-93; FAX: +7 (495) 744-70-94; E-MAIL: [email protected] locomotive TEM TMH www.tmholding.ru