Wagon repair workshop Jhansi Under North Central Railway. Workshop budget Rs Crores. Established in year 1889

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Owen Smith
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Wagon repair workshop Jhansi Under North Central Railway Workshop budget Rs. 376.76 Crores Established in year 1889 Total area 3.

Box N Wagons POH of Tank Wagons POH of Special and Military Wagons Wheel turning of various types and supply to other Units Modifications of Wagons for adopting New Technologies Modernization of

1 Wagon repair workshop Jhansi Under North Central Railway Workshop budget Rs Crores Established in year 1889 Total area 3.4 lac square meter (60% covered by green plantation) Staff strength 5810 Outturn target 7800 Wagons wheel/annum POH of over due Wagons and Tower Wagons ROH of various Wagons Rehabilitation of Box N Wagons POH of Tank Wagons POH of Special and Military Wagons Wheel turning of various types and supply to other Units Modifications of Wagons for adopting New Technologies Modernization of Workshop - Conventional welding plants replaced by IGBT/Inverter based plants. -18 Nos EOT cranes installed with VVVF drive - XLPE insulated HT/LT cables installed - Replacement of old Transformers with High efficiency Tfrs - Replacement of old M & P with energy efficient and output 2.5 times 1

2 3.8 MWp Rooftop Solar PV Plant - Project is based on DBFOT with 25 years PPA Agreement - Cost of energy is Rs per unit - Saving of Rs on each unit generated from solar plant. 1. Year All 70 watt Ceiling Fans of wagon repair workshop were replaced by 50 watt Ceiling fans - Replacement of 40 W TL fittings with 28 W T-5 2. Year Conversion of All Incandescent/HPMV/HPSV lamps to CFL and MH lamps - Optimum voltage setting of Distribution Transformers - Sensitization of staff to switch off load when not required - Installation of APFC panels, timers for shed and street lights - Step Reduction of Compressed Air Pressure from 6 Kg/cm 2 to 5.6 Kg/cm 2 (Artificial demand made zero) - System leakage loss minimized by Aluminum Pneumatic pipeline Policy Convey commitment to all concerned. Provide directions Guidance for setting target Target Setting Internal performance Percentage reduction over the previous year External benchmarking Based on best performance month/week Comparison with plants in the same group 2

3 60% of energy conservation project have been completed. 40% of total energy conservation (SPV & LED lights) is under pipeline which is about to be completed in Dec Specific energy consumption year wise Jhansi workshop receives wagons involving heavy repairs as compared to other units in India Various types of Wheels turning work is done and supply to other units unit/wagon consume as compared to wagon workshop kota 529 unit/wagon Biggest Project for renewable energy sources (solar power plant) i.e 3.8 MWp in NCR zone Energy saver Device for Welding plants and AC units Project 1 Minimize air leakage in Pneumatic pipeline Replaced all pipe lines with aluminium pipe Replacement of inefficient compressors Project 2 Sensitization of personal to switch off unnecessary load & run AC on degree 3

4 Project 3 Distribution of load on transformer in such a manner that transformer are evenly loaded and better voltage profile is obtained with more efficiency Project 4 Implementation of ring main system in workshop for more efficient distribution 1.LED LIGHTS Replacement of all types of lights with LED lights Cost of project - Rs. 2.5 Crores. Reduction of 213 KW connected Load Saving of 2130 KWH per day Payback period of 4.5 years Continuous monitoring of GHG emissions of DG Sets Following the guidelines of CPCB & State PCBs Data sharing with state PCB SFC of old DG was 0.33 and New is 0.26 Efficiency increased by 26.93% About 500 new Trees are planted every year Old DG Sets replaced with Latest Technology High Efficiency DG Sets, forming combination of appropriate capacity DG sets for load feeding for minimizing the GHG emissions. 4

5 Employees are Motivated to save energy. Two teams are formed for ENCON, each team consisting leader and 5 members. Both teams are headed by Electrical in-charge one team has been allotted production areas and other non-production areas Each team submits monthly reports to Electrical in-charge with collected data and recommendations. S.No Location Energy Consumption Remarks Previous Month Present month Energy meters are provided on all major load centers Energy meters on service building feeders As per remark of Reporting format,action is taken to save the energy About 100 ton of AC has been provided in last one &half year for employees amenities Though load increased but by continuous monitoring, SEC has been decreased gradually ENCON Monthly meeting are organized Reports received from teams are discussed with in-charges of concerned areas Electrical in-charges of all electrical sections are handed over their tasks Summarized reports are prepared and sent to Heads of production areas (Mech.) for necessary action to reduce the energy consumption Action taken by them is reviewed by ENCON teams in the next month 5

6 ISO 50001:2011 and Greenco ratings certifications of workshop are in final stages 0.70% of turnover has been invested in energy conservation projects. Sr. No Feeder Name Present reading Previous reading Units consumed Remarks Difference of Present and Previous Month consumption is taken and compared with the production to arrive at the energy saving of that shop/shed Solar Rooftop PV plant Waste oils & Grease released from various activities are used in furnaces of Blacksmith shop Transparent roof sheets are provided in shed to utilize sun light during day 6

7 Green supply chain policy is made in such a way that no contract vehicle more than 15 yrs of life is allowed to operate. Transportation by Rail Awareness creation &Training program is organized every year Audit and monitoring program is also organized for Energy,water and waste management Supplier is motivated to reduce their waste and also in factory premises Vehicle is not permitted to enter factory without valid PUC( pollution under control) certificate Wagons are dispatch and receipt in the form of rakes and sent to nearest point of utilization. Effort is made to load them fully as soon as possible & run them at maximum speed for best efficiency The storage of materials is done closest to the point of consumption The entire workshop process is monitored to ensure smooth unidirectional process The scrap generated is tried to be utilized either as serviceable or e-auctioned No plastic zone in Workshop Electrically or battery operated methods are use in place of fossil fuel in workshop THANK YOU 7

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