Russia: In the year of the 50th anniversary since the start of construction of the Baikal-Amur Mainline (BAM), connecting central regions of Russia with its Pacific coast, it is becoming increasingly obvious that this project has played a pivotal role in ensuring national sovereignty and the growth of the Russian economy. The continued advancement of the project is essential for expansion of Russian products in the APAC countries. TMH, the largest domestic manufacturer of rolling stock, is providing support to Russian Railways in the development of the railway network in the east of the country.
This year BAM saw the introduction of a new 3TE28 mainline diesel locomotive. This vehicle is yet another evidence that TMH adheres to the principles of technological independence that were established over a decade ago.
First steps
TMH has been developing diesel locomotive business since its inception in 2002. At that time, TE10 and TE116 locomotives, built in the 1960s-70s, were the predominant choice. After the decline of the 1990s, the Russian railway industry and economy were in dire need of modern freight locomotives.
The Peresvet 2TE25K mainline diesel locomotive. Source: railtrain.pro
Then, Bryansk Engineering Plant (BMZ), which had previously produced only shunting locomotives, joined TMH. The objective set for the plant was to gain expertise in the production of mainline locos, and this was successfully achieved with the rolling off the Peresvet 2TE25K, the first diesel locomotive, in 2005.
The modern cabin design represents a significant departure from the existing fleet. The 2TE25K features microprocessor controls and independent traction control on each axle, which enhance traction properties, reduce fuel consumption, and minimise wear on tyres and rails. The most significant outcome is that the Peresvet has become another significant step forward for TMH in terms of technologic independence of the Russian railway industry. It is a times less expensive option than the alternatives available from foreign companies on the Russian market.
Produced one year later, the Vityaz 2TE25A mainline diesel locomotive was delivered to BAM to support and further enhance freight traffic in the eastern region of the country, in line with Russia’s strategic objectives. Serial production of an AC transmission and a Russian asynchronous motor is arranged at Elektrotyazhmash-Privod, one of Russia’s leading manufacturers of power electrical equipment. The solution provides a significant increase in continuous tractive effort, with the 2TE25A now capable of exerting almost 780 kN compared to the 2TE25 with a DC motor, which had only 600 kN.
Launch of serial production
However, the large-scale production of mainline diesel locomotives at BMZ did not commence until the middle of the 2010s. The Russian railway network still had a pressing need for a substantial number of new high-performance mainline diesel locomotives. Due to the geopolitical turbulence that affected the Luhansk Locomotive Works, a decision was made to scale up the serial production of mainline locomotives at BMZ.
As a time-sensitive the first 2TE25KM locomotive project was developed aiming to haul trains weighing up to 6,400 t. It was built in a record-breaking time of just 70 days in 2014. An impressive 90% of the components were produced by Russian companies, marking a first in the history of domestic diesel locomotive manufacturing. This was a crucial input in achieving the most significant goal of technological self-reliance. The locomotive builds on the technical innovations of the previous TE25 vehicles, offering an enhanced driver-friendly control system, diagnostics systems, and a maintenance-efficient layout of internal equipment.
The 2TE25KM diesel locomotive. Source: BMZ
The commencement of large-scale production of the 2TE25KM represents a significant milestone for TMH, reinforcing its position as a leading player in this segment of the Russian railway industry. Concurrently, the expansion of trade with the APAC countries underscores the strategic importance of BAM, which is now calling for even more powerful vehicles to haul heavy trains over the challenging mountainous terrain.
TMH responded to this request in 2017 by offering the market the 3TE25K2M diesel locomotive. TMH has released the 9,300 kW three-section locomotive, with a continuous tractive effort of 971 kN. Furthermore, the company implements numerous updates to the design of its locomotives, taking into account the experience of operating locomotives in cold climates. The locomotive utilises the most advanced wheel-motor blocks with axle-axle rolling bearings, which, together with powerful power units, enable the 3TE25K2M to haul trains of up to 7,100 t. The improved component base facilitates a significant reduction in maintenance requirements and an increase in repair intervals.
Understanding the risks associated with use of the US-made engine in the 3TE25K2M, TMH continued the development of domestic analogues, which should not be inferior to imported solutions.
Peak sovereignty
TMH’s accumulated experience and R&D allowed it to meet the new economic conditions facing Russia in 2022 well prepared. In response to the intensifying sanctions pressure, the company unveiled a new three-section freight locomotive, the 3TE28, to Russian Railways just a few months later. The vehicle, constructed at BMZ, has a capacity of 8,550 kW and incorporates a Russian engine, while retaining the traction properties of the 3TE25K2M.
The 3TE28 diesel locomotive with a freight train at the Kuryan–Tynda stretch. Source: Maksim Morozov/youtube
The developers of the 3TE28 took into account the requirement to ensure unification with another model that was already in serial production, the 3TE25K2M. The new locomotive is distinguished mainly by the characteristics of the 18-9DGM diesel engine, which has a rated power of 2,850 kW. The engine was developed at the TMH engine engineering centre.
The diesel engine has been significantly modernised. It incorporates new components, including a turbocharger, high-pressure fuel pumps, a water-oil cooler, a self-cleaning automatic oil filter, and an electronic control system. The inverter start-up system permitted the exclusion of an alternator and exciter and their mechanical drives from the 18-9DGM, while simplifying the design of the camshaft drive unit. The 18-9DGM engine saves up to 10% of fuel and oilwhile the power plant meets Stage IIIA emission standards in terms of environmental parameters.
The 18-9DGM diesel generator for 3TE28 mainline diesel locomotives. Source: TMH’s plant in Kolomna
The series has been equipped with a specifically designed traction rectifier, braking equipment, and components for the installation of pneumatic and electrical systems. The cooling chamber features an increased flow cross-section in the radiator sections and motor fans with higher capacity. The upgrade of the running gear includes wheels with a wider diameter of 1,080 mm instead of the 1,050 mm used on the 3TE25K2M. This reduces wear and increases the overall durability of the vehicle.
The 3TE28 is a reflection of the style of the latest series locomotives, the 3TE25K2M, developed by the National Centre for Industrial Design and Innovation 2050.LAB. In 2020, this design concept won the international Red Dot Design Award. The only change was the LED buffer lights.
Driver’s cabin at the 3ТЭ28 diesel locomotive. Source: TMH
The 3TE28 commenced operations in January 2024, having demonstrated its ability to pull trains weighing 7,100 t along sections of BAM with challenging terrain. In less demanding conditions, the locomotive can pull even larger trainsets. This is not the limit of the developments for Russian Railways. TMH is currently working on a virtual coupling for diesel locomotives, which has already proven effective on the Trans-Siberian electric locomotive fleet.
The new diesel locomotive has not lost in maintainability compared to the 3TE25K2M. The maintenance works as part of the TO-2 (one of the types of maintenance activities under Russian regulations) can be performed every 240 hours, with intermediate overhaul and overhaul to be performed after 1.2 mln and 2.4 mln km run, respectively. These enhancements enable the operator to significantly reduce maintenance and repair costs.
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Extra opportunities
TMH is also ready to offer a two-section diesel locomotive, the 2TE28, to other railways. With an output of 5,700 kW, it is a more efficient alternative to the 2TE25KM. “The same traction engines are used in both locomotives. However, due to the higher diesel engine power, the continuous speed of the TE28 is 4% higher than that of the 2TE25KM. The use of asynchronous drives for auxiliary equipment allowed a reduction in the number of DC motors, which require more frequent maintenance. This is also an advantage in terms of reducing maintenance and repair costs”, says TMH.
The TE28 family of products is designed to accommodate up to four sections, while the 2TE28 locomotives can operate in multiple up to two vehicles. The vehicle is supplied with inter-section couplers, allowing for easy joining of sections. This results in an output of 11,400 kW and a continuous tractive effort of almost 1,260 kN, without any structural changes.
Future plans
The holding company is already working on the next generation of mainline locomotives to satisfy the needs of Russian Railways and other customers. A future unified platform will serve as the foundation for new families of 2TE30 diesel locomotives, 3TE30G gas locomotives, and 2ES9 AC electric locomotives. The initial focus is on developing a gas locomotive to meet the government’s objectives in the gas fuel market and emissions reduction. TMH notes that the main advantage of the TE30 will be the AC traction, with the ability to run on both diesel and gas.
All locomotives will be equipped with an asynchronous traction drive and bogies with a wheel-motor unit with a wheel diameter of 1,250 mm, while the diesel locomotives will be the inaugural deployment of a new family of D220 engines, comprising the 16LDG220 diesel engine and the 16GDG gas-diesel engine.
Locomotives at the Bryansk Engineering Plant. Source: BMZ
Russian Railways is experiencing a high demand for new locomotives. Only to accommodate increased traffic on the Baikal-Amur Mainline and Trans-Siberian Railway, the operator will require more than 1,000 new locomotives per year from 2025 onwards. To meet the demand, TMH is implementing a new stage of large-scale modernisation at BMZ. The 2022–2028 project provides for investment of RUB 5 bln ($56.7 mln) and the introduction of over 100 units of new equipment, enabling the production of mainline diesel locomotives to be almost doubled from 300 to 500 units per year.
This year marks a significant milestone for two reasons: the 50th anniversary of the start of BAM construction and the centenary of the first Russian mainline diesel locomotive, the SchEL1, which was produced in 1924. TMH’s efforts have been instrumental in enabling the Russian diesel locomotive industry to flourish over the past century, thereby contributing to the growth of the national industry and economy.
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TMH is the number one manufacturer of railway and light rail transport in Russia and the CIS, and the number five worldwide. It offers a wide range of products and services, from the design and development of rolling stock to modernisation, life-cycle maintenance, and digital traffic control systems. The holding embraces production and assembly sites in Russia and other countries and works in more than 30 countries. Official website: tmh.global.
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