'GenSet' Locomotives

Over the last five years, an important trend in the U.S. freight railroad industry has been the introduction of "GenSet" locomotives to reduce fuel consumption and air pollution. While a proven technology, widespread use of GenSet locomotives has been slow due to high capital costs compared to the older-technology locomotives that they would replace.  A new GenSet locomotive is approximately six times more expensive than the cost of a traditional diesel locomotive in rebuilt condition.

What is a GenSet?

GenSet technology (short for "Generator Set" or sets of engines turning a generator) replaces the large diesel engine and generator found in almost all existing freight locomotives with two or three much smaller diesel engines and generators. These smaller engines are similar to large off-road diesel engines and are EPA Tier III off-road / Tier II railroad compliant. Advanced computer technology allows for precise control of the engines, starting and stopping only as their power is needed.

While the outward appearance of the GenSet is similar to existing, older-technology locomotives, fuel consumption and exhaust emissions are significantly reduced by using smaller engines only when needed.

Environmental benefits of GenSets include:

  • Fuel savings of more than 20%, compared to existing diesel locomotive technology in side-by-side use, have been demonstrated.
  • Compared to a traditional locomotive in the same application, GenSet units have been shown to reduce NOx by 58%, HC by 94%, CO by 37% and PM by 80%.

GWI GenSet Program

By utilizing off-the-shelf components in kit form and its own workforce, GWI is completely rebuilding older yard locomotives into “new” GenSet locomotives. These rebuilt units are 30%-40% less expensive than a newly purchased GenSet locomotive.

The GWI in-house rebuild program reduces the cost of a GenSet locomotive to the point that a public–private partnership becomes an economically viable means to introduce this technology to its short line freight railroads.

GWI’s Buffalo & Pittsburgh Railroad (BPRR) participated in the 2007 Congestion Mitigation and Air Quality (CMAQ) Improvement Program administered by the Southwest Pennsylvania Commission (SPC) and the Pennsylvania Department of Transportation.  BPRR proposed a project to rebuild two yard locomotives into GenSet units, utilizing the workforce at the BPRR locomotive shops in western Pennsylvania.

Recognizing the public benefits provided by GenSet locomotives, SPC selected the BPRR project for funding at an 80%-20% government–railroad match. The two GenSets will replace two existing yard locomotives built in the 1960s and will operate in an area of Pennsylvania that does not currently meet air quality standards. The engines being used in the GWI GenSets are recognized by the California Air Resources Board and U.S. EPA as Ultra Low Emissions Locomotive (ULEL) technology.

The first of the new BPRR GenSets was commissioned in Butler, Pa., on July 12, 2010. Work is nearing completion on the second BPRR GenSet and on the first GenSet for the Ohio Central Railroad, as well.