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The Baltiets train: new rolling stock by TMH for St. Petersburg metro

30 December 2022
Reading time ~ 19 min
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The Baltiets train at the Kirovsko-Vyborgskata Line of St. Petersburg Metro
The Baltiets train at the Kirovsko-Vyborgskata Line of St. Petersburg Metro. Source: TMH
Reading time ~ 19 min

Russia: The contract to supply 950 Baltiets metro cars in St. Petersburg is one of the largest in the global market in 2022 and the biggest in the history of the city metro. Several trains of this model manufactured by TMH – one of the globally leading producers of metro cars – have been launched into operation since November. In addition to being a clear example of TMH’s inclusive approach for partnership with its clients, the train proves the company’s long-lasting commitment to pursue local production and priority development of automation technologies.

The 81-725.1/726.1/727.1 model: from Smart to Baltiets

Recognising St-Petersburg’s significant demand for new rolling stock, TMH pushed the development of a promising metro train in 2018. A mockup of a radically new design saw its premiere at the international Smart Transport Forum in 2019. As noted later by TMH’s Deputy CEO for the development of urban transport Andrey Vasiliev, “for the first time in developing of rolling stock for St. Petersburg’s metro, its representatives were so actively involved in discussing technical innovations of the future train”.

Later in February 2021, a full-size mockup of the Smart metro car was presented to St.-Petersburg’s Vice Governor Maxim Sokolov and head of the Transport Committee Kirill Polyakov at the Oktyabrsky Electric Railway Car Repair Plant (OEVRZ, part of TMH). Representatives of the city administration and experts in the industry commended both the design and the planned functionality of the new train. Subsequently, the city chose and approved the name of the train – Baltiets – in honour of the Baltic Fleet sailors, who have been faithfully serving their homeland for over three hundred years.

Mockup of the metro car for St. Petersburg presented at Smart Transport in 2019 Mockup of the metro car for St. Petersburg presented at Smart Transport in 2019. Source: Fontanka.ru

With metro’s fundamental part in the dynamic development of St.-Petersburg,  introducing new trains is vital for the city mobility. According to St. Petersburg Metro, the city’s fleet totals 1.900 metro cars, their average age being 22 years. Metro is the backbone mode of public transport in the city, accounting for more than 40% of overall passenger traffic, with an average daily ridership of 2 mln passengers. The importance of the task at hand is bolstered by the attention of the government, which allocated 96.9 bln RUR (over $1.4 bln USD) from the National Welfare Fund to St. Petersburg for co-financing the rolling stock renewal. Such support enabled the city to secure 75% of the funds required to purchase the trains.

A leasing contract for 25 years was signed between St.-Petersburg metro and Transholdleasing in August 2022. It provides for the delivery of 950 metro cars 81-725.1/726.1/727.1 model in 6- and 8-car versions in 2022-2031. The supplied rolling stock will firstly replace trains of the Em series on Line 1 (Kirovsko-Vyborgskaya) and then 81-717/714 cars on Line 2 (Moskovsko-Petrogradskaya).

The new train was designed in full accordance with the technical specifications provided by St. Petersburg Metro. However, considering the long-term nature of the contract, the customer plans to update specifications throughout its implementation to ensure that the supplied trains are equipped with the most advanced technical solutions. Thus, the trains that will operate in a few years may differ in both design and technologies.

Core innovations and technical solutions

The new metro train has been designed specifically to operate in St. Petersburg and in full view of other significant large-scale TMH deliveries experience: Yubileyny metro trains, as well as Moskva and its modification Moskva-2020, and Ivolga electric trains. The train is designed and built using local components, with more than 90% of which are produced by Russian companies. At the same time, as early as in Q1 2023 the share of the domestic components will be increased to 99%. Here the government renders assistance as well: TMH’s production sites and its partner – Key Systems and Components Group (KSC) – have received substantial soft loans from the Industrial Development Fund to implement projects of manufacturing advanced rolling stock components.

Numerous modern solutions have been integrated in the design of the Baltiets train. 81-725.1/726.1 cars are equipped with two-axle motor bogies, while 81-727.1 models have two-axle trailer bogies. The bogies are fitted with the double spring suspension, consisting of lever-spring suspension in the axle box stage and pneumatic suspension in the core stage. Smooth running is ensured by vertical and horizontal yaw dampers manufactured by Baranovichi Automobile Units Plant (BAAZ). The motor bogies are fitted with a second-class electric drive with support-axle suspension of the reduction unit and motor support-frame suspension.

At the KSC electrotechnical products manufacturing facility At the KSC electrotechnical products manufacturing facility. Source: KSC

The train is fitted with a Russian-produced fourth-generation traction drive with asynchronous electric motors that are 30% more energy-efficient compared to DC motors. The new modification of the driving unit was developed by KSС in 3 months on a component base set to replace previously used Japanese parts. In addition, the Baltiets makes use of another KSС technology, a silicon carbide based auxiliary converter. It is 35% lighter and 27% smaller than the previous generation while having a significant increase in energy efficiency, performance and reduced acoustic noise.

Asynchronous traction drive enables smooth and quiet electrodynamic (regenerative-rheostatic) braking down to 2 km/h.  Full braking is performed by engaging an electropneumatic brake. For shunting operations at the depots, the trains are fitted with alkaline batteries manufactured by Autonomous Power Supply Plant based in Saratov, Russia. These batteries provide operational range of up to 200 m and have a 10-year lifespan.

Main specifications of the Baltiets metro trains (enlarge)

The Baltiets ventilation system is capable of air purification and disinfection, thus significantly reducing the risk of spreading pathogens. The design of air intakes and ventilation grids ensures that air is distributed uniformly across the train interior. By the decision of St. Petersburg Metro, the Baltiets is not equipped with air conditioning, however its body configuration allows for installing AC units if undercarriage equipment and electrical devices are appropriately modified.

The flat-side car body is made of stainless steel which ensures high repairability and corrosion protection. The streamline shape of the body without depressions and protrusions improves aerodynamics of the train by reducing air resistance.

The customer’s technical specifications for Baltiets do not provide for inter-car gangway systems. At the same time, the train is fitted with maintenance-free intercar couplers manufactured by Metrowagonmash (part of TMH) without foreign-produced components. The coupler design ensures a car-to-car passage through end doors if necessary, as well as passing curves with a radius of 60 m or more. At the same time, Metrowagonmash is employing reverse engineering method to develop local analogues of automatic couplers and other units.

Sliding plug doors with LED lightning in Baltiets metro trains 81-725.1/726.1/727.1

Sliding plug doors with LED lightning in Baltiets metro trains 81-725.1/726.1/727.1 Sliding plug doors with LED lightning in Baltiets metro trains 81-725.1/726.1/727.1. Source: gov.spb.ru

For the first time in the history of St. Petersburg Metro, sliding plug doors with an increased width of 1,400 mm and better soundproofing will be installed. These doors have an automatic drive developed by KSС, with Russian-produced small commutatorless motors and proximity sensors.  Wide door openings provide for faster passenger boarding as well as reduced dwell time, which will increase carrying capacity of metro lines.

Video surveillance systems in Baltiets were installed by MaximaTelecom. There are 60 superwide-angle digital cameras in total: 12 in head cars (5 in the driver’s cab, 7 in the passenger zone) and 6 in trailing cars. Two cameras in the cab provide an overview of the track while the other two – rear view video mirrors – help the driver to control the train; an additional camera monitors the driver’s actions. Beyond that, the equipment is integrated with train control systems, route information for passengers and “passenger-driver” voice communication. Among other things, each train of the new series is fitted with Wi-Fi network equipment.

The Baltiets driver’s cab The Baltiets driver’s cab. Source: TMH

The Baltiets cab is designed to significantly improve working conditions. Increased visibility provides for additional occupational safety. The control panel has a terminal with a colour touch screen. Roman Yakimov, Head of Avtovo depot, which is the first to receive the Baltiets trains, notes that the control system requires almost no additional driver training, as the train can be operated with one joystick also allowing brake control. In addition, the cab features integrated heating and air disinfection systems as well as an ergonomic vibration-absorbing seat.

The design of Baltiets: bringing together the past and the future

The exterior and interior of the new train were designed with the National Center for Industrial Design and Innovation 2050.LAB. In the train’s interior the designers strived to embody the heritage of the city and its aspirations for the future. A key element of the interior’s pattern is the Palace Bridge – one of the city’s symbols – appearing in its raised position on the prints of passenger seats that are made of durable materials. The rounded car sides represent the architecture of the stations, the geometry of lines observes the Art Deco style, and the walls are of light-coloured. Thanks to the sliding plug doors Baltiets is visually larger than its predecessor, the Yubileyny train.

Colour solutions employed in Baltiets are designed to simplify passenger navigation. A highly visible line traverses the train, its colour matching that of the interior – this creates an association with a particular metro line. For example, trains on the Kirovsko-Vyborgskaya line will have red accents while trains with brown and bronze elements are planned to be launched on the currently under-construction Krasnoselsko-Kalininskaya line.

Interior of the Baltiets metro train cars Interior of the Baltiets metro train cars. Source: TMH

The eight-car Baltiets accommodates 1,478 people, having a total of 252 seats (36 in head cars, 46 in intermediate cars) and high padded seats to rest against the car wall. Passengers can move through the car freely and evenly thanks to the streamlined interior layout. In addition, there are special zones for comfortable accommodation of parents with baby carriages and passengers with limited mobility.

Passenger information options have been expanded considerably. For instance, each car has eight 920 mm LCD displays installed above doors and two LCD information boards on the ceiling.

A vote initiated by St. Petersburg Governor Alexander Beglov was held in social networks to determine the need of equipping cars with gadget charging outlets, resulting in more than 70% of respondents supporting the proposal. It is technically possible to install USB outlets in Baltiets.

Lighting solutions harmoniously complement the train’s look. A colour-coded indication on diode tapes on door portals and bright LED strips in door leaves informs passengers about doors opening and closing. There is adaptive headlight control: the intensity of LED headlights is reduced when approaching the platform or passing another train.

A modern digital train

Baltiets is also a milestone in implementing of one of TMH’s strategic goals to increase automation of its rolling stock. The systematic development in this direction is provided by the TMH Smart Systems company.

For instance, the train makes use of a fully automatic movement and target stop functionality. The technology was introduced by TMH Smart Systems and Scientific Research Institute for Precision Mechanics (NII TM). In particular, train safety and automated control equipment was installed. The system includes an automatic locomotive signalling subsystem with automatic speed control and an ATO subsystem. As long as appropriate infrastructure devices are present, this allows for the implementation of the GoA3 level of automation, which is the last one before a completely unmanned train operation. In an interview with the Delovoy Peterburg media Head of St. Petersburg Metro Evgeny Kozin noted that the driver becomes an “onboard engineer” who controls the system operation whereas automated devices ensure smooth running, accurate stopping at stations, opening/closing doors and departing from station.

Baltiets has a data collection system with more than 2,000 parameters. The control system also has enough computing power to implement a predictive approach to rolling stock maintenance, thereby significantly increasing its efficiency.

System partnership

Baltiets was presented to the public before the tests in mid-September this year, leaving for its first trip on November 12: Governor of St. Petersburg Alexander Beglov joined the ride from the Avtovo depot to Baltiyskaya station. In 2022-2023 TMH is to supply 144 cars of new trains to St.-Petersburg.  In total, the contract establishes the following sequence of deliveries of metro cars: 304 units (8-car trains) in 2022-2025, 462 units (6-car trains) – in 2026-2030, and 184 units (8-car trains) – in 2030-2031.

The trains will be supplied by OEVRZ in St. Petersburg. The plant joined TMH in 2005 and started manufacturing metro cars in 2009, producing over 700 vehicles for Saint Petersburg, Moscow and Novosibirsk metros to date.  The experience of Metrowagonmash clearly demonstrates how such large orders foster production development. Large-scale and long-term deliveries for Moscow in recent years allowed to significantly modernise the Metrowagonmash site, making it one of the most advanced in the world.

The Baltiets train arrives at Akademicheskaya station The Baltiets train arrives at Akademicheskaya station. Source: TMH

Similar prospects await OEVRZ. At the St. Petersburg International Economic Forum this year Alexander Beglov and TMH CEO Kirill Lipa signed an agreement to implement an investment project for developing electric transport production in the city. The volume of investments in 2022-2024 should amount to 3 bln RUR ($44 mln), and the newly created capacities will be used to produce rolling stock not only for St. Petersburg, but for other Russian cities as well. Baltiets is a clear example that the city and the producer are planning to cooperate effectively for many years to come.

TMH

TMH 2022 logo

№ 1 among railway and urban rail rolling stock manufacturers in Russia & CIS, № 5 in the world. The company offers a full range of products and services: from new rolling stock design and development to modernisation, life cycle maintenance contracts and digital traffic control systems. TMH is a Russian company headquartered in Moscow with international subsidiaries in Switzerland, Egypt, Argentina, Belarus and Kazakhstan. The holding structure includes 12 production and assembly sites in Russia and other countries worldwide. TMH supplies passenger trains and coaches, metro cars, locomotives, engines, and components to railway operators and manufacturers in 30 countries. This year the company celebrates its 20th anniversary. Website: tmh.global