Concord Control Systems Develops 3,100-HP Hydrogen-Hybrid Locomotive for NTPC

Concord Control Systems is currently undertaking a high-capacity technology project to convert an ageing diesel locomotive into a 3,100-horsepower hydrogen-hybrid machine. The initiative is being executed for NTPC, which will supply the hydrogen for the locomotive.

The diesel locomotive has been shifted to Concord's works in Bengaluru, where it is undergoing retrofit integration and technology upgradation. According to Gaurav Lath, joint managing director of Concord Control Systems, the undertaking is treated primarily as a technology project rather than a standard supply order, focusing on railway electronics, control systems, diagnostics, embedded engineering, and system integration.

Building a hybrid hydrogen locomotive requires combining a hydrogen fuel cell and a battery within a single operating platform. The propulsion architecture also incorporates power electronics, control systems, cooling systems, safety architecture, and the locomotive interface. Lath noted that integrating these multiple systems into a single moving machine presents significant engineering challenges, particularly regarding railway-grade safety.

Safety measures such as hydrogen protection, ventilation, shut-off, and thermal protection are designed in line with the critical-use-case requirements of railway applications. The final stage of the development will involve field validation in harsh environments and long duty cycles.

The company is applying operational learnings gained from running a battery locomotive for about a year. Operating the battery platform in real-world railway environments provided data on how alternative-energy systems react over time, which is now feeding into the design and integration of the hydrogen platform.

Addressing the rationale behind the retrofit approach despite rapid rail electrification, Lath highlighted that locomotives are long-life assets capable of remaining in service for decades. A properly engineered retrofit can extend the useful life of an existing platform while upgrading it with a modern propulsion and control architecture. While India has made substantial progress in rail electrification, alternative-energy technologies like hydrogen can make economic and operational sense in specific applications where they can eventually replace diesel.

As per the tender conditions, Concord Control Systems is positioned to complete the project by early the next financial year. Over the longer term, the company aims to build deep in-house capabilities in alternative-energy railway engineering, with the potential to apply these technologies across a wider spectrum of zero-emission applications subject to validation, operating economics, and customer requirements.

"The transition of existing heavy assets like diesel locomotives into hydrogen-hybrid systems highlights a practical engineering approach toward decarbonization. For companies in the industrial and cleantech space, retrofit projects offer a viable pathway to upgrade long-life infrastructure without discarding capital-intensive assets. The success of such complex system-integration exercises relies heavily on rigorous field validation, safety compliance, and aligning alternative-energy adoption with clear operational economics." — Dr. Shishir Gupta, Founder & CEO, StartupLanes