Feature Rolling Stock Viva Vivarail’s D-train transformation! here have long been calls for more requirement for more DMUs.” “Yes, they do have to comply with the maximum speed of a ‘172’ Turbostar. Surely diesel multiple units (DMUs). And Vivarail Chairman ADRIAN SHOOTER is confident The D-train concept uses only the same requirements as any other NEW train. that is going to cause some problems if the with the recent Invitation To Tender that his company’s conversion of London Underground bodyshells, bogies and traction motors from They already comply with an automotive D-train cannot keep up with other DMUs on for the Northern franchise promising the D78 ‘donor train’ - everything else will requirement that is more stringent. the network? atT least 120 new carriages and the phasing out D-Stock trains will help to resolve the shortage of diesel be new. Because the D78s are sub-surface “An engine has recently been on test at “They have a maximum speed of 60mph, of Pacers by 2020, those calls are going to start Underground trains (having operated on Revolve [Vivarail’s supplier], who have an but they have acceleration which is much more getting much louder very quickly. multiple units. STEFANIE BROWNE reports the District Line), the overall size and profile instrumented test bed that has been used to rapid than some of the older DMUs - well, Last year, the Long Term Passenger Rolling is similar to that of other national network certify the engine to 3B.” certainly the Pacers or Class 150s, things like Stock Strategy said that rail would require RAIL Photography: JACK BOSKETT trains. The plan is to convert them to diesel As it stands, no DMU has yet been built with that. We have done computer simulations of fewer than 100 new diesel vehicles (not in operation by adding under-floor diesel engines a 3B-compliant engine. Would that make the some of the routes, which shows that over the present decade). Now, the Government Overground and Chiltern Railways) thinks he having bought the last ones in this country. I and generators. D-train the first? about an hour’s journey, we actually get there is talking of “a potential requirement for 350 has a solution. know what they cost as well, which is a lot of It is an unusual choice of engine, however. “It is certainly likely to be the first DMU about four and a half minutes quicker.” (See to 500 non-electric vehicles, for a variety of Adrian Shooter was chairman of Chiltern money! Each D-train has four five-cylinder Ford with 3B engines,” replies Shooter, although he table on page 63). urban stopping, rural stopping and inter- for 18 years (retiring in 2012), and has “So I could see that there was going to be a Duratorq 200hp automotive engines that are doesn’t believe it will be long before someone Shooter explains that the trains will not urban express services”. worked on the railway for over 40 years. But shortage, and got talking to a school friend of normally used in Transit vans, Ford Rangers else builds a compliant DMU. “When there be suitable for every route: “You wouldn’t, It is no secret that there is a shortage of retirement has not been a relaxed affair for mine, Malcolm Dobell, who retired as a chief and Land Rover Defenders. Shooter even is a demand for a product, the market usually for example, take one of those trains and go available DMUs, and increased pressure to Shooter - he is now chairman of Vivarail, the engineer at LU in September 2014. bought a Ranger to test the engines out for finds a solution.” from Leamington to London on Chiltern, replace the much-maligned Pacers means that company that has bought 156 Driving Motor “Malcolm and I went to school together, we himself in their native setting. But why not use Off-the-shelf, the Ford the industry will need to find some units from Cars and 70 Trailers of retiring D78-Stock ran a railway society. He was actually part of a locomotive engine? engines cannot just be put somewhere. from the London Underground, to transform the engineering team when the D78s were “We were talking about putting a big in a D-train - they need to But just what is going to reduce the into DEMUs (diesel electric multiple units) for ordered brand new, so he told me about them. engine inside. But when it came to discussing be customised for use in the shortage? And where are the Pacer the national network. He explained that the bodyshells were nearly wavelengths and vibrations and all sorts of new type of vehicle. Shooter’s replacements going to come from? What made Shooter decide to buy a ‘job lot’ all aluminium, and there is no corrosion on things, I thought ‘well, if we’re going to make supplier, Revolve, is a British The man who ordered the last DMUs of Underground trains? them. They’re as good as the day they came this work, we’re going to have to have an company that has a franchise bought in the UK (the Class 172s for London “It didn’t all happen absolutely overnight. out of the factory in Birmingham, 30-or-so engine that can go underneath the floor’. And for converting small numbers I had been aware for quite some time that years ago.” traditional DMU engines won’t fit because of Ford engines for different An artist’s impression of a D-train, with a there was going to be a big shortage of DMUs, That was when Shooter enlisted the help they’re too big. applications, such as use in redesigned front-end compared with the donor of Neil Bates, director at Midlands-based “So, with a chap who had been my boats. It has carried out similar D78 Underground train. Creactive Design, which (among other things) engineering director on Chiltern for years, projects in the past. designs and develops railway vehicles. Shooter Andy Hamilton, we previously came up with Shooter signed a contract and Bates first worked together in 1996, when an idea which looked at doing something with with Revolve last summer to Bates designed the exterior livery and internal small automotive engines on the Class 165s produce the engine modules layout of Chiltern’s new ‘168s’. They worked on Chiltern, to power the air-conditioning. We for the D-train, and the first together on the Mk 3s and ‘168s’, and several didn’t actually do it, but we thought about it. one is due to arrive at Vivarail’s other things in between. “I took some advice from Ricardo (the site at Long Marston in the Says Shooter: “Neil took me to a strange people who are consulting on the engines) next couple of weeks. Polish restaurant, and I think that was the day about what might be a good engine, and they Says Shooter: “A two-car or when I decided ‘right, stop messing about with pointed me in the direction of the one that I’ve three-car train will have four this, let’s get on with it’.” gone for.” of those [200hp engines], so Were any other vehicles considered instead There is another important factor to consider 800hp, which gives us a higher of the D-Stock? with these engines - they will comply with power-to-weight ratio than the “The only alternatives (and they were current emissions standards as governed by existing older DMUs.” actually scrapped too soon for us) were the the European Commission. Current rules state The maximum speed of A-Stock (which has had a history of problems that new diesels must comply with Stage 3B the D-train is 60mph, which is the same as over many years, and contains asbestos) emissions standards (RAIL 754-756). As these that of the donor D78. This is 15mph slower and the C-Stock, which again hasn’t been are automotive engines, are they still governed than a Class 142, ‘143’ or ‘144’ Pacer or a tremendously reliable. They have corrosion by the same rules? ‘15x’ Sprinter, and 40mph slower than the problems because they were aluminium on a steel frame, which is not good. They also have asbestos in them. The cost for buying the trains is “Whereas the D-Stock, which is the only other sub-surface line stock that’s going to roughly a third of the price, but be scrapped for years and years and years, is devoid of corrosion, asbestos and fractures. there are some further benefits Frankly, it was the only one that was beyond that, because these trains practicable. “At one point, these were going to be run for will use less fuel - certainly less another ten years in London. In fact, LU had been doing reliability modifications on these than the existing trains, but trains until very recently. also than a modern “It’s a happy coincidence, that there is the availability of these particular trains from LU, equivalent train. when the previous ones were not suitable. So there’s that coincidence, with the fact Adrian Shooter, that for ten years there is still going to be a Chairman, Vivarail

60 RAIL 771 April 1-April 14 2015 Subscribe at railmagazine.com Subscribe at railmagazine.com Feature Rolling Stock

because it’s a 100mph railway. It wouldn’t be the right train for that. “But there are lots of branch lines where you actually never really exceed 60mph. The line speed on a lot of branch lines isn’t more than 60mph anyway. And even where it is, trains Performance simulation: don’t get up to it because you’ve got curves, or there are big restrictions at the stations. Huddersfield-Sheffield* “We’re not by any means saying this train is suitable for everything, because it’s not. But there are quite a number of applications where Station Line speed Seconds between stops it is.” (mph) D-train Class 142 Class 150 So are there specific lines or branches for 3-car 2-car 2-car 2-car which the D-trains would be perfect? “Oh yes. We’re talking to two or three Huddersfield 50 143 138 160 161 customers who I can’t reveal at the moment, in Lockwood 126 119 147 146 other parts of the country. But what I can say Berry Brow 117 111 136 137 is that we’re talking to all of the three bidders Honley 112 106 135 128 for the Northern franchise, and they’re all very Brockholes 192 183 220 216 interested. Stocksmoor 95 91 109 104 “I can’t actually give you any more specific Shepley 219 214 233 233 detail on that because we have non-disclosure Denby Dale 377 373 390 390 agreements with all of them, because Penistone 274 270 283 283 obviously they’re all competing. But what we “London’s cast-offs”, while the BBC’s One Vivarail Chairman Adrian Shooter explains the Silkstone Common 135 133 143 143 can say is that the train is suitable for a lot of Show on March 16 quoted the Department significance of the Ford Duratorq automotive Dodworth 287 280 299 301 lines in the North - there are lots of branch for Transport as saying they could not be engines that are being used in the D-train. Barnsley 70 297 287 310 311 lines. The one we did the simulation on “converted London Underground trains”. Wombwell 145 140 163 164 (Huddersfield to Sheffield) is an example.” Isn’t that a pretty clear message that the Invitations To Tender (ITT) for the Northern Elsecar 256 242 287 283 RAIL visited Vivarail shortly after the D-train will not be heading north? and TransPennine Express franchises Chapeltown 102 99 109 110 publication of the Northern franchise “It is quite specific in the ITT - yes,” containing obligations to withdraw all Pacer Ecclesfield Crossover 192 192 186 186 Invitation To Tender, which promised that 120 acknowledges Shooter. “There’s a huge vehicles by 2020 and to bring into operation Meadowhall 35 35 39 38 new-build carriages would be acquired by the amount of politics in the Northern franchise. a minimum of 120 new-build vehicles” (see Wincobank Junction 80 171 159 181 180 new Northern franchise and that the Class 142 I presume you’ve seen the exchange of letters Network News, pages 14-15). Nunnery Main Line Junction 109 107 112 112 and ‘144’ Pacers would be phased out by 2020 which is on the public record between Philip Rutnam says the benefit:cost assessment (RAIL 770). Rutnam [Permanent Secretary of the DfT] and suggests this represents “poor value for Sheffield Midland The ITT stipulates: “These must be newly- the Secretary of State [for Transport, Patrick money” to bring the replacement forward to Total seconds 3384 3279 3642 3626 built (not re-using components from existing McLoughlin]?” 2020, and reasons that “new-build vehicles Total h:m:s 00:56:24 00:54:39 01:00:42 1:00:26 rolling stock)”, which indicates quite clearly Shooter is referring to a letter Rutnam sent will be much more expensive than Pacers”. Average station stops 16 16 16 16 that the D-trains are not an option for that to McLoughlin on February 26 in his role as He continues: “There may be better ways Average time between stations (sec) 212 205 228 227 requirement. Accounting Officer, in which he expresses Rail Minister Claire Perry then compounded his “reservations about the proposal to issue *Note: Simulations run using information derived from initial design data so results its chances further by telling BBC North East are indicative at this stage. More accurate simulations will be undertaken. journalists that the 120 carriages cannot be

Two ‘donor’ D78 London Underground trains sit outside Vivarail’s site at Long Marston. There are now 24 vehicles on site ready to be converted. Feature Rolling Stock

They have a maximum speed of 60mph, but they have acceleration which is use less fuel - certainly less than the existing Adrian Shooter, trains, but also than a modern equivalent chairman of Vivarail. much more rapid than some of the older DMUs - well, certainly the Pacers or Class train. “And the maintenance costs will be lower 150s, things like that. We have done computer simulations of some of the routes, than the Pacers. The maintenance costs for which shows that over about an hour’s journey, we actually get there about four these will be certainly less than half what something like the Class 150 would be, similar and a half minutes quicker. to other trains that are running, and the fuel consumption will be of that order. Adrian Shooter, Chairman, Vivarail “The reason for the fuel consumption of achieving value for money than the ITT], and it quite specifically excludes our things that you can do with this train…” being less is: first of all, the vehicle is lighter - precise stipulations in the ITT.” trains. But that’s not a problem, because if you Shooter explains that community railways driving motor cars are going to be 31 tonnes, McLoughlin directed Rutnam to release do some sums on the requirements of the 214 are another area Vivarail is exploring. compared with about 36 tonnes on a Class the ITT, including those specifications in they’re getting rid of, plus the overcrowding “There are lots of very enthusiastic people 150. particular, because of the Pacers’ “negative anyway, plus more services, you find that who have improved stations, put flowers in the “They’ll have start-stop technology like you impact on the reputation of rail services in the the requirement is several hundred. So we’re gardens, painted them, distributed leaflets and get in cars [technology that has also recently Northern area”. He said that he believes “it getting about 120 new ones. Fine. Great.” that sort of stuff, and some of them have seen a been trialled on Class 66s], so when the train is right for us to require bidders to introduce So what you’re saying is that the North 100% increase in passengers. is coasting, braking or standing at a station, new-build diesel vehicles” because “the could still have the D-train, just that the 120 “When community railways first came most of the engines will be stopped most of railway needs a long-term solution that will committed to already cannot be D-trains? out, that was all part of it, but the other very the time.” secure continued provision of services on lines “Yes. I don’t think we have enough to supply important part was reducing the cost. Here is Of course, public perception is still going that are never likely to be electrified”. them actually. I think we’re going to run out of a way where the biggest part of the cost - the to be an issue that Shooter will need to Ultimately, doesn’t that still mean the trains. We can make up about 75 units [from train - is lower. address. The D-train has attracted a ‘London’s D-train is out? the 326 D78 vehicles bought], and I don’t “One of the things that we are especially cast-offs’ stigma that he’ll need to shake. Shooter responds: “The reasons why we’re actually think that will be enough. doing is configuring this train so that if you Passengers want a ‘new train’. actually very pleased with the ITT is as follows. “I must admit when I read the ITT, the first have an isolated branch (which there are Says Shooter: “Well, you can understand Number one: They’re going to scrap 214 Pacer thing I came across was these 120 new ones, in quite a number of parts of the country), their point, can’t you? The public will only vehicles. Number two: We know that there is and I thought ‘that’s not good news’. But it’s miles from anywhere, you don’t have to take have a perception based on fact when they excessive overcrowding on a lot of the routes when we analysed it that we realised it wasn’t the train in some cases 150 miles back to the actually travel on the train.” anyway, which is what half of the political that simple.” depot [for maintenance]. Because we will Is that going to put off potential buyers in problem has been about. So some of the Shooter is looking at several possibilities for build a little mini depot, and the train could be the meantime - the fear that passengers won’t existing trains are going to have to be longer. suitable routes. maintained there for ten years. like them? “Next point, when my colleague Alan Dare “We’re just doing some more speed “We will change the engine modules on the “No. The view that I’m getting from and his team at Creactive, we have got older Shooter is clearly not concerned about the [Vivarail marketing director] read the ITT in simulations at the moment in the Southport bogies, which are the only bits really where potential [Northern] bidders and others, trains, got passengers into them, and had them public’s perception or about getting orders for great detail, it reveals an enhanced frequency area, around Preston. And others like things need an overhaul. We’ll change those including leasing companies who are prepared say ‘hey, isn’t this a lovely train?’ the D-train. He is firm in his belief that the on a lot of lines. That means more trains. Now Newcastle to Hexham onto Carlisle, another on site and do it overnight, which means that to lease them, is that it looks an entirely “Mk 3s are 40 years old and I travel on them proof is in the pudding, and that the trains will also, it had been the intention to cascade a lot series of lines that would be suitable, as would the train can stay locally. credible train.” quite often, and people think they’re lovely prove themselves. of electric trains, but electrification is not going the Cumbrian Coast ones. All those places “That means often that you’d be able to Shooter is keen to emphasis that the D-train trains. “Potential customers can see that passengers exactly as it might do. where the flat-out maximum speed is not the work early morning services - I know quite a is not a ‘cast-off’ – that to all intents and “We did a similar thing in 2003-04, with the will like it if we deliver what we say we’re “So what we have here is about a ten-year issue.” lot of branches where that is not the case now, purposes it will be ‘new’. Chiltern Class 165s. At that stage they were going to deliver. And we will.” R window, because if electrification really comes Wherever the D-trains might end up, would because the train is coming back from being “What we’re actually producing is a brand about 14 years old. They were OK, but we on at the rate that it ought to, and Network Vivarail maintain them over their life? Shooter fuelled overnight from miles away. So that’s new state-of-the-art train, which is made decided that we wanted to make them so that Rail was saying it is planning, then there will estimates that the trains would be fit for another angle for the product.” affordable by using the bare bodyshell and people thought they were new. RAIL will be returning to Long be a lot of spare electric trains in due course. operation until at least 2035. Cost is one of the major selling points for the bogies of these District Line trains. “And we did that, by replacing all the glazing Marston and to Creactive’s design “Now, it is true that the Government has “Well that depends on the customer. We’ll D-train. Shooter says they cost roughly a third “Because 60% of the cost of a train is in which had the hopper lights and things with studio in Leamington Spa in a future said there must be 120 new vehicles [in the overhaul the engine power packs and bogies. of the price of a totally new train (although he the bodyshell and bogies, that means we can sealed windows, different seats, LED lighting issue to investigate the progress with We will possibly transform those. We will offer won’t be drawn on the exact figures). make the thing affordable, while at the same (which was just coming in then). And again, conversions on the first two vehicles Artist‘s impressions of the potential interior for the maintenance - very happy to do that - but “Yes, the cost for buying the trains is roughly time being really fantastic.” people thought they were brand new trains. and to find out more about what the D-train, showing possible seating types and if they want to do it themselves, that’s their a third of the price, but there are some further Shooter is no stranger to this kind of It was great - they weren’t new, but people passenger experience could be like. compliant toilet. VIVARAIL. privilege. But there are a number of other benefits beyond that, because these trains will scenario: “Several times in the past, with Neil thought they were.”

64 RAIL 771 April 1-April 14 2015 Subscribe at railmagazine.com Subscribe at railmagazine.com April 1-April 14 2015 RAIL 771 65