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Millions of kilometres and wear and tear: A locomotive repair guide

Chengfan Zhao — Fri, 11 Aug 2023 06:30:48 +0000

Millions of kilometres result in significant wear and tear for locomotives, so periodical repairs become essential to prolong the life of trains. 60 kilometres east of Prague, a railway repair station has been rejuvenating the locomotives for over 80 years. How do they repair locomotives? Railfreight.com talked with METRANS DYKO to bring the repair backstage into the light.

History of the rail repair workshop

The rail repair workshop has been a locomotive retreat and repair site for over 80 years. It went under the name of METRANS Group for the past fifteen years. It started with steam locomotives, but those times are long gone. The latest modern electric locomotives on European rails are now entering the premises. They leave once the thorough maintenance and repair work is finished.

Image: © METRANS.

A milestone reached

In the summer of 2023, METRANS DYKO reached a significant milestone when all twenty Traxx MS2 locomotives delivered in the first batch to METRANS got their TR1 general repair after eight years of operation. With the first twenty locomotives repaired and returned to operation, the workshop is getting ready to start the same process this autumn again: twenty more Traxx locomotives from the METRANS fleet will come there to rest. The workshop is open to any operator needing rolling stock repair and maintenance. But most importantly, it ensures that 120 METRANS locomotives and 3,700 intermodal wagons are always in their best shape with an in-house solution.

Disassemble the locomotive

The repair work starts when the bogies of locomotives have reached 1,2 million kilometres run. The repair will be divided into R1 repair for the bogies and TR1 repair for the locomotives.

The R1 repair requires dismantling and cleaning traction motors. The bearings will be changed before the test runs start. The gearboxes will receive similar treatments, with new bearings and oils attached. The TR1 repair is more complex. Various parts of the locomotives will be dismantled and refurbished before they are combined. One of the most challenging tasks is repairing the converter. Dry ice cleaning will be applied first; after that, selected earthing switches and contactors will be dismantled and refurbished. Condition checks are also part of the procedure for charging resistors and optical lines.

Image: © METRANS.

These are just a few of the hundreds of steps to disassemble a train properly. Multiple electrical and electric-mechanical components will be thoroughly monitored and refurbished at METRANS DYKO, to name a few: main switches, air conditioners, fans, pantographs, and converters of auxiliary drives. Besides that, it is equally important to repair the pneumatic equipment. All breaking panel modules need to be dismantled and sent to the manufacturer. In the meantime, the in-house team will help with the bogies’ hoses replacement and overhauling the compressor, dryer and brake units. All the effort is to ensure that a locomotive functions properly and safely.

Reassemble the locomotive

Check, clean, refurbish, renew and exchange; once all the components have gone through these stages, they are ready to be put together again. But it’s always easier said than done. To reassemble the locomotive, a thorough testing period will be needed. It is essential to test the operation of the cooling systems of the inverter and transformer since the coolant pumps of these components have been replaced. Other components, such as fans, contractors, and brake systems, will be carefully examined. Once a locomotive passes the test, it will be reassembled. From then on, METRANS DYKO technicians will conduct a test drive to ensure the overhaul’s success. After that, the train will be returned to METRANS train drivers across Europe to continue their mission of transporting the containers across the METRANS network.

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Energy prices reach new record high, this is how rail freight adapts

Majorie van Leijen — Fri, 03 Jun 2022 11:03:09 +0000

With energy prices hitting new record highs in May, rail freight carriers face new challenges to keep their costs in check. Surcharges have become inevitable, efficiency is becoming the norm and in some countries, it is more attractive to run a diesel locomotive than an electric one.
As a result of the war in Ukraine, energy prices have risen sharply in 2022. The decision by European countries to ban Russian oil is expected to put further pressure on energy prices in the second half of the year. This has an impact on fuel prices, but the price of electricity directly correlates to the rising energy price. The rail freight industry is facing the consequences of both.

First time in our history

“It is the first time in our 30-years of history that we had to adapt our rates halfway through the year”, says Martin Koubek from Metrans. The company, which operates but also runs a train fleet over all of Europe, has added a surcharge to all its transport on 1 June, including traction on rail.

“This was needed, because it was not possible anymore to absorb the high prices. We have waited a long time to do this because we are quite conservative that way. We usually do not change our rates halfway through the year, but we could not avoid this any longer”, he explains.

Metrans locomotive

Different in each country

It is difficult to tell in numbers what kind of increase the industry is dealing with, as it depends on the country and type of transport. But there are anecdotes of a threefold, or fourfold increase in the price of electricity, knows Luuk von Meijenfeldt, CEO of locomotive leasing company NexRail. “The price of electricity is currently rising more than the price of fuel.”

In some countries, such as Hungary and Germany, it is even more attractive at the moment to run a diesel loc than an electrical unit. “This does not mean that railway undertakings are putting their electric units on the side. The diesel units are often old, and can no longer be run in an efficient way. What you see is that energy efficiency is now starting to play a much bigger role in the choice for rolling stock”, he explains.

In Hungary, where electricity price increases are most dramatic, rail freight operators have become well aware of the need to be more efficient. “Due to the quadrupling of electricity costs, each unplanned stop, slowdown and acceleration due to a slow signal is much more costly for railway companies than before” says industry association Hungrail Magyar Vasúti Egyesület.

“Unfortunately, the Russian invasion of Ukraine has further raised the price of electricity, so a further twenty-five to thirty percent price increase is expected based on the trend of the first months of 2022. Thus, only the cost of electric traction can take away 22 per cent of the sales revenue of freight railway companies.”

Locomotive in Hungary

Role of rail

On the positive side, some transport analysts expect that continued high energy prices will cause a dramatic shift in transportation, with significant new volumes moving to rail as new technology enables better efficiency and lower emissions.

Despite the challenges ahead, Fatih Birol, executive director of the International Energy Agency (IEA), discussed the benefits rail can bring in navigating the energy crisis and highlighted the significant benefits rail can bring to the energy sector and the environment. By diversifying energy sources and providing more efficient mobility, rail can reduce transport energy consumption and reduce emissions of carbon dioxide and local pollutants, he concludes.

Sale of SNCF’s freight locomotive leasing company enters home stretch

Stuart Todd — Fri, 13 May 2022 14:12:38 +0000

SNCF is continuing its strategy of disposing of non-strategic assets after moving out of the red last year thanks largely to the €3.2 billion sale of its rail wagon leasing company, Ermewa.
According to French business newspaper, Les Echos, France’s state railways has triggered the sale of its freight locomotive leasing company, Akiem and is being advised by investment bank, Rothschild.

It said the deadline for the submission of “non-binding” offers for the subsidiary, which SNCF co-owns 50/50 with the German infrastructure asset manager DWS, passed earlier this week. Together, they hope to make around 2.5 billion euros from the sale.

Several potential bidders

After an initial selection of candidates, SNCF and DWS will draw up a short list this with a view to deciding on firm offers at the end of June or beginning of July.

Among the bidders is said to be Canada’s Caisse de Dépôt et Placement du Québec (CDPQ), which, in association with DWS, acquired Ermewa in October last year. Also in the running is French infrastructure fund, Vauban, which was also a candidate to acquire Ermewa. The investor is currently in the process of conducting a takeover bid for German wagon hire company, Aves One.

According to unidentified sources, quoted by Les Echos, Sweden’s EQT is also interested and has joined forces with EDF Invest, another rejected Ermewa suitor. The infrastructure fund Infravia, which has just raised some €5 billion, is also said to be studying the Akiem dossier.

Competitors in the running

In addition to financial investors, Akiem’s direct competitors are also expected to submit bids, including the UK’s Beacon Rail while other medium-sized players have asked to examine the company’s data file such as Alpha Trains (Luxembourg), Angel Trains and Porterbrook (UK) and Germany’s Railpool.

“There is a real potential for business growth because freight is part of the decarbonisation plans with the switch from road to rail and there is an investment plan to be carried out in the electrification of the fleet. The market share of locomotive hire is still small compared to that of wagon leasing, so the potential for outsourcing is strong,” people close to the matter told Les Echos.

In total, Akiem, a company created in 2008 with the opening of the French freight market to competition, has some 600 locomotives in its portfolio, “the largest fleet on the continent”, operating in 17 European countries. Its fleet grew in 2020 with the acquisition of Macquarie European Rail’s equipment rental business (137 locomotives and 30 additional trains).

Strong growth outlook

European rail freight is viewed as having strong potential for growth between now and 2030, according to a recent study by ECM Ventures for ERFA, the association of European rail operators.

This is particularly true in France, where the modal share of rail has long since plateaued at 9% of total freight transport, compared with the European average of 18%. In France, the government’s recovery plan makes provision for specific aid to the rail freight sector of around 170 million euro annually.

Meet the AMPS all-battery electric locomotive

Malcolm Ramsay — Tue, 15 Mar 2022 05:00:20 +0000

Rail operator OmniTRAX has acquired its first all-battery electric locomotive, expanding capacity on its northern Ohio rail lines. The firm purchased the new GP9-based battery-electric switching locomotive from engine developer Alternative Motive Power Systems (AMPS) Traction.
“OmniTRAX is committed to operate safely and responsibly in the communities we serve, and AMPS Traction’s innovative technology is an important addition to our fleet and an important step for our industry”, Dean Piacente, CEO of OmniTRAX, said.

Zero emissions switcher

The new locomotive will be deployed by OmniTrax’ subsidiary Newburgh & South Shore Railroad (NSR) and is fully compliant with Federal Railroad Administration (FRA) standards.

The new NSR locomotive is a 250,000 lb unit and produces 1,700 gross horsepower and 80,000 lb dispatch. Thanks to its innovative technology the locomotive has around half the fuel costs of a comparative diesel engine and removes nitrogen oxide (NOx) emissions and particulate matter completely.

The product

“AMPS legacy of innovation in rail and hybrid electric power generation has resulted in their latest product, the 100 per cent battery electric IS2-70 zero emissions switcher”, a spokesperson for AMPS Traction explains. AMPS’ technology includes an A.C. traction system that is liquid cooled for continuous duty with minimal maintenance requirements and precise traction control. It is powered by a 315-630 kilowatt-hour lithium battery pack. The cab also features upgraded ergonomics with HVAC system and control stand designed for greater operator comfort.

“The AMPS IS2-70 Zero Emissions Switcher is an innovative, newly designed platform that requires drastically less maintenance than conventional and hybrid switchers and delivers a simple, clean, powerful and easy to use rail switcher”, AMPS Traction notes.

Headquartered in Denver, OmniTRAX is one of the largest privately-owned railroad companies in the US. The firm is a subsidiary of private investment firm The Broe Group and owns and operates a network of 21 short-line and regional railroads in three Canadian provinces and 12 US states. The company also provides transportation and supply chain management services, as well as intermodal and industrial switching operations.

DMTF programme

The new locomotive will be deployed by NSR as part of a strategy to improve environmental performance on its network.

In October last year, NSR received an award of 1.89 million US dollars (1.72 million euros) from the Ohio Environmental Protection Agency’s Ohio Diesel Mitigation Trust Fund (DMTF) programme. This 75 million US dollars (68,4 million euros) grant initiative has been running for four years and provides funding to remove older more polluting diesel engines from use in priority Ohio counties. Grants cover applications for both repowering and replacement as well as a range of alternative solutions such as clean diesel, alternative fuel, and electric engines.

“We are thankful to Governor DeWine and Ohio EPA for their commitment to clean air and the grant program that has made this emission-saving equipment upgrade possible in our Ohio operations”, Piacente of OmniTRAX comments.

Under the terms of the award, the new all-battery switcher will replace a 1971diesel-powered switcher, with the grant covering 75 per cent of the cost. NSR estimates that the new battery-electric switching locomotive will reduce emissions for the operator by 77 per cent and prevent emissions of around 4.2 tons of nitrogen oxide.

Operating in the heart of Cleveland’s interstate highway system, NSR originally served the network of steel mills operated by US Steel in the Cleveland area. In recent years, the company has refocused on wider growth, developing a range of new freight services, including rail-to-truck and truck-to-rail transloading and inventory management solutions. Based in Cuyahoga County, NSR operates along a five-mile line with interchanges to Class I’s CSX and Norfolk Southern.

This heavy freight locomotive will soon cross Azerbaijan

Majorie van Leijen — Mon, 14 Feb 2022 05:00:30 +0000

Alstom in Kazakhstan has delivered the last of 40 Prima T8 AZ8A heavy freight locomotives to Azerbaijan Railways (ADY). This is a milestone, as it means the order from the Kazakh joint venture signed in 2014 has been delivered.
“The final delivery is a milestone that we always celebrate. The shipment of locomotives for Azerbaijan is of particular importance for us, as this is our first export contract for Kazakhstan. Despite all the difficulties posed by the pandemic, we have been able to reach this milestone as a result of the commitment of our team”, said Kanat Alpysbayev, managing director of Alstom in Western and Central Asia.

Trans-Caspian railway corridor

According to Alpysbayev, the locomotives play a key role in boosting the freight transportation capacity within Azerbaijan, and, moreover, they contribute to the ambitious goals of increasing the transit potential of the Trans-Caspian railway corridor. “

We are continuing to develop our close partnership with Azerbaijan Railways, including the organization of the locomotive fleet maintenance and the implementation of railway signaling projects.”

The deal

In 2014, ADY signed a contract with Alstom for 288 million euros for 50 electric locomotives, which includes 40 Prima T8 AZ8A heavy freight locomotives produced at Alstom’s JV EKZ in Nur-Sultan, Kazakhstan and 10 Prima M4 AZ4A passenger locomotives produced in Belfort, France.

Alstom’s Prima T8 is a 25 ton per axle two-section freight locomotive, capable of towing up to 9,000 tons and running at 120 km/h, with installed continuous power of 8.8 Megawatts. The Prima T8 AZ8A is designed to operate in temperatures ranging from -25°C to 50°C. It requires minimum maintenance and provides high reliability levels and low lifecycle costs thanks to its modular design.

About Alstom

Alstom’s Prima range covers locomotives from heavy-haul, freight and passenger operation and shunting or track work operation. Over the past 20 years, more than 3,200 Prima locomotives (more than 4,600 sections) have been sold worldwide.

EKZ, a joint venture of Alstom, employs around 850 people and is working on supplying and maintaining the Prima electric locomotives ordered by KTZ, Kazakhstan’s national railway company and export markets, like Azerbaijan.

These modern locomotives are all coming DB Cargo’s way

Majorie van Leijen — Thu, 03 Feb 2022 11:41:36 +0000

In three years from now, the fleet of DB Cargo will be complemented with innovative locomotives of Siemens, Vossloh and Toshiba. Next year alone the German operator receives 150 new locomotives as part of its moderisation efforts.
“DB Cargo locomotives have it good. They cannot age. Components of our powerhouses are continuously replaced on rails at fixed intervals – before anything can break. That’s why our diesel locomotives are also very fit – but not modern”, says Sigrid Nikutta, COO of the company on Linkedin.

“For the foreseeable future, we will need powerhouses that will bring our heavy trains to customers even in marshalling yards, ports or terminals without electrical overhead lines. That will be realised. We will modernise our locomotive fleet and equip it with climate-friendly hybrid technology.”

Siemens and Vossloh

In 2023, DB Cargo expects the arrival of around 150 new two-engine locomotives from Siemens Mobility. These units can distribute the cargo electrically to any location and with low-emission machine power.

What is more, the company has awarded Vossloh Locomotives the contract to build at least 50 heavy hybrid shunting locomotives. “The ingenious thing about the construction principle is that the machines have a modular design. So as technology evolves, we can replace engines and technology relatively easily. So, even these locomotives will never age”, Nikutta says.

Hybrid shunting

“We are doing the same with our third project: From 2024, hybrid shunting locomotives of the Toshiba brand from our DB Cargo plant in Rostock will experience their rollout. It is the first time that we as a freight railway have built our own locomotive from a manufacturer’s kit. This is an exciting project, especially since Toshiba’s state-of-the-art battery technology is also used here”, the COO concludes.

New locomotive leasing company on the market

Esther Geerts — Thu, 16 Sep 2021 08:37:28 +0000

Nexrail will focus on providing innovative, sustainable locomotives for non-electrified operations, and is currently dedicated to the freight and shunting markets. It has purchased 53 shunting locomotives, and ordered another 50 hybrid locomotives hybrid from Vossloh.

The first transaction of the new company is the purchase of the 53 shunting locomotives lease pool from Vossloh Locomotives, with an average age of less than 5 years. The main types are DE 18, DE 12, G 6, and G 1000. With the backing of their owner InfraVia Capital Partners, the company will also purchase 50 DE 18 SmartHybrid locomotives. These locomotives will be available as of 2023 and will run in Belgium, Luxemburg, France and Germany.

Vossloh Locomotives, based in Kiel, Germany, is a subsidiary of China Railway Rolling Stock Corporation (CRRC) ZELC since 2020, the world’s largest manufacturer of rail vehicles.

Flexible locomotive

The SmartHybrid locomotives are new, universal, four-axle mid-cab locomotives, and feature a 1,800 kW and fuel-efficient diesel engine. The engine has a stage V emission standard, with a reduced ecological footprint. It also has an additional traction battery of 144 kW, enabling up to one hour of emission-free operation. This should lead to fuel savings of 20 to 50 percent.

The locomotives are equipped with the European train control system ETCS, including an upgrade option to level 2. This means the locomotives can cover Belgium, France, Luxembourg, Germany and parts of the Netherlands. The companies boast about the DE 18 Stage V SmartHybrid’s flexibility, being equally suited to heavy shunting and mainline operations as well as infrastructure tasks in construction site operations. Under the agreement, Nexrail will be the exclusive provider of this type of modern locomotives for the Belgium market.

Inaugural step

Neil Bennett, Executive Chairman of Nexrail Lease: “Nexrail is already developing plans to introduce sustainable fuels and battery hybrid solutions across all its markets. This transaction with Vossloh Locomotives and the order of the DE 18 Stage V SmartHybrid for the Benelux market is the inaugural step of our own journey as a lessor.”

Alstom to build four new Traxx locomotives for PCC Intermodal

Majorie van Leijen — Mon, 05 Jul 2021 10:01:44 +0000

PCC Intermodal and Alstom have signed a contract for the delivery of four brand new Traxx MS3 multisystem locomotives, together with the provision of full maintenance service. They signed an agreement towards this end on 29 June 2021. The contract covers the production of the locomotives, the certification, the training of PCC Intermodal personel and the provision of full maintenance service. It includes in addition the option to order one additional locomotive.
The Traxx MS3 locomotives will be used in cross-border operations between Poland, Germany, Austria, Czechia and Slovakia and hit the rails before the end of 2022.

4 European voltages

The MS version can be used under the four voltages commonly found in Europe and belongs to the Traxx, the most modern four-axle locomotive platform in Europe. It consists of the Traxx AC3 (alternating current), the Traxx MS3 (Multi-System, for all main currents in Europe) and the Traxx DC3. The Traxx platform was introduced 15 years ago and more than 1,750 locomotives are in operation in Europe.

“We are very happy that signing contracts and deliveries of modern locomotives and new rail platforms take place during the European Year of Rail”, said Dariusz Stefański, CEO of PCC Intermodal SA, during the contract signing in Warsaw. “We truly believe that intermodal transport is one of the most important factors of sustainable development. It is really great that PCC Intermodal with Alstom locomotives can be a part of this modern, trans-European transport system and that we can play an active role in the European Green Deal Project.”

‘Most modern and innovative platform’

“We are proud that our four Traxx MS3 locomotives will join the PCC Intermodal fleet next year. Let’s not forget that Traxx MS3 locomotives are based on the newest, most modern and innovative locomotive platform. This locomotive is characterised by its energy efficiency, its proven ability to pull higher loads than comparable locomotives, its simplified interface with the European Train Control System and improved maintainability”, underlines Sławomir Nalewajka, managing director Poland, Ukraine and Baltic States at Alstom.

Alstom and PCC sign the contract

Alpha Trains upgrades Traxx locomotives with ETCS

Nick Augusteijn — Tue, 27 Apr 2021 05:00:50 +0000

Alpha Trains will upgrade 77 of its locomotives with ETCS train equipment for Baseline 3 Release 2 (B3R2). The upgrade is part of a broader upgrade program that replaces the current train safety system (ATB) in the Netherlands with the European Rail Traffic Management System (ERTMS).
Alpha Trains commissioned Alstom/Bombardier Transportation to carry out the retrofitting of 55 Bombardier Traxx 186 units. Besides, Alstom Belgium will upgrade another eight units of the Vossloh G1206 model and 14 units of the Vossloh G2000.

Locomotive upgrade

With the upgrade to ETCS Baseline 3 Release 2, the locomotives are continuously in contact with the tracks. In this way, the driver on duty can receive information about the permitted speed, for example, without being dependent on signals along the route.

According to Alpha Trains Group CEO Shaun Mills, the company is taking a new step in facilitating the modal shift from road to rail with the modernisation of its locomotives. The Bombardier Traxx 186 has been homologated for use in the Netherlands, Belgium, Germany and Austria, while the Vossloh is suitable to use in the Netherlands and Germany.

ÖBB launches EU Year of Rail locomotive

Esther Geerts — Thu, 18 Feb 2021 08:58:24 +0000

Austrian operator ÖBB has given one of their locomotives a special European Year of Rail design. The locomotive was presented at a ceremony at Vienna central station last week, and will be on the tracks in Austria and neighbouring countries as a sign of European sustainable mobility by rail. “The EU needs more railways so that we can achieve the climate goals, but the railways also need more Europe in order to become faster, more digital and more efficient in the future”, said ÖBB CEO Andreas Matthä.

At the start, the new design of the locomotive was inaugurated by Climate Protection Minister Leonore Gewessler, Martin Selmayr, Ambassador of the European Commission in Austria, and ÖBB CEO Andreas Matthä. Immediately after the christening, the EU locomotive with around 10,000 horsepower goes into service, runs on the tracks as ambassador for the European Year of the Rails in Austria and the neighbouring countries.

The European Year of Rails is in line with the EU’s efforts to promote environmentally friendly modes of transport and to become climate neutral by 2050 with the European Green Deal. A recent monitoring study by the Commission shows that the market share of rail compared to other land passenger transport has remained stuck at around 7.8 percent between 2015 and 2018. Despite a slight annual growth of 2.5 percent in passenger transport by rail, there is no sign of a modal shift towards rail, in passenger nor freight transport, so efforts need to be made to make this happen.

from left to right: Martin Selmayr, Ambassador of the European Commission in Austria, Austrian Minister for Climate Protection Leonore Gewessler, and ÖBB CEO Andreas Matthä. Photo: ÖBB / Scheiblecker

Climate friendly mobility

“Transport is our problem child in climate protection”, said Austrian Climate Protection Minister Leonore Gewessler. “That is why we are investing so much money today in expanding the rail infrastructure in Austria than ever before. The fight against the climate crisis also requires strong partners such as ÖBB and the tailwind of the entire EU. I am particularly pleased that the new EU locomotive is now on the tracks all over Austria under the sign of the European Year of Rail and is carrying this message for climate-friendly mobility to the outside world.”

ÖBB CEO Andreas Matthä: “The European Year of the Rails is an important sign of a climate-friendly Europe – because we are faced with the big question of how we can make transport in Europe more environmentally friendly in the future. And there can only be one answer to that: by train! The EU needs more railways so that we can achieve the climate goals, but the railways also need more Europe in order to become faster, more digital and more efficient in the future. Driving a train through Europe has to be as easy as driving a truck.”

Symbol of European cohesion

“The European Year of the Rails comes at exactly the right time”, said Martin Selmayr, Ambassador of the European Commission in Austria. “Rail links states with one another, our EU locomotive therefore also stands for cohesion in Europe. And in view of the corona pandemic, we need that more than ever. The EU locomotive symbolically shows that we are ready to start bringing trains into the vision of a strong, ecological and cosmopolitan continent.”