INTEGRAL COACH FACTORY (ICF) Chennai (Tamil Nadu)

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Ernest Greene
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1 First Prize Railways Workshops Unit Profile INTEGRAL COACH FACTORY (ICF) Chennai (Tamil Nadu) ICF, a premier production unit under the Ministry of Railways, was established in the year 1955 to manufacture passenger coaches. Spread over a sprawling 475 Acre complex, ICF employs 12,000 strong work force and manufactures over 1,700 coaches every year. The annual turnover of ICF for the year was about Rs Crores. ICF is located in Chennai, Tamil Nadu, India. ICF is the first of its kind to be established after Independence for the manufacture of light weight, all steel and all welded Integral railway passenger coaches. The factory was set up in 1955 with Swiss collaboration. PRODUCTION ICF s initial plan was to produce 350 Broad Gauge Third Class shells (unfurnished body of the Railway Coaches) only, which were to be furnished by the Zonal Railway workshops. Later, in view of the severe limitation of capacity of the Railway workshops and also to take advantage of mass production, a separate Furnishing Division was added on 2nd October, The capacity was progressively expanded during from 350 shells to 750 fully furnished coaches per annum with additional inputs. This was enhanced progressively from 850 coaches during to 1000 coaches in Capacity augmentation project works from 1000 to 1250 & 1250 to 1500 were taken up in phases and completed in Capacity augmentation works upto 1700 were taken up in the year and completed. DESIGN FEATURES The design concept of the coach stipulates that the roof, side wall, end wall and the under frame are joined together by welding, to form a fully integral coach shell. The end-wall construction has been made especially strong to make it antitelescopic to ensure maximum safety to passengers. Further, crashworthy features are provided with CBC design to minimize impact on passengers during accidents/derailments. From the basic design handed down by the collaborators, ICF has diversified having established its expertise and skill in this field, to design and manufacture more than 350 different types of coaches for Indian Railways and export market. Every time a new type of coach is launched, emphasis is laid on improving passenger comfort, passenger safety and higher speeds. ICF follows standard inspection procedures to ensure quality from raw material stage to the finished coach. 246

2 ICF has been meeting the needs of the Indian Railways for varied types of coaches, however sophisticated the type may be. Some of the important types are: I. SELF PROPELLED COACHES Electric Multiple Units for suburban services in Metropolitan cities Diesel Rail Cars Metro Coaches for Kolkata Metro Railways Diesel Electric Multiple Units & Diesel Hydraulic Multiple Units for nonelectrified routes and Mainline Electric Multiple Units for long distance intercity travel Accident Relief Trains / Medical Vans OHE Inspection Cars II. AIR-CONDITIONED & NON-AIRCONDITIONED PASSENGER COACHES Air-conditioned Sleeper Coaches of first & second class Air-conditioned Chair Cars of first and second class Double Decker Coaches with seating capacity for 148 passengers as against the conventional 90 passengers Non Air-conditioned Sleeper coaches and General second class coaches III. SPECIAL COACHES Air-conditioned & Non-air-conditioned Pantry Cars High Capacity Power Cars for Shatabdi & Rajdhani Express Trains Air-conditioned Military Ward and Saloon Cars for Indian Army. Air-conditioned Saloon Cars, Dining Cars, Bar & Restaurant Cars, luxury suites for luxury tourist trains like Palace on Wheels (WR), Deccan Odyssey (CR), The Golden Chariot (SWR), Royal Rajasthan on Wheels (NWR) and Maharajas Express of IRCTC Lifeline Express for operation of hospital on wheels Jet Deflector Crane Cars, Inter Communication Coaches for DRDO IV. DESIGN & DEVLOPMENT EFFORTS Complementing the existing design capacities and facilities, a fully computerised Design & Development Cell has been set up with sophisticated state-of-the-art computer designing facilities and testing equipment both for coach components and raw materials. D&D Centre uses 3-D modelling on Solid Works platform for generating 3-D drawings and IDEAS software for Finite Element Analysis. Strain gauge testing and squeeze test are done on prototypes before commencement of series production. V. PRODUCTION WITH INNOVATION ICF has carved a niche in the Indian Railway system by constantly improving the quality of travel through its passenger coach design which has undergone a seachange from the days of bye-gone era of mere transport of passengers. There has been a steady growth both in the quality and quantity of its production. Over the years ICF has endeavoured to meet passengers expectations through innovations like 247

3 Cushioned seats in General Second Class and SLR coaches. Provision of Controlled Discharge Toilet Systems. Anti-injury features in the passenger areas of A/C 2-tier and Sleeper coaches. Enhanced carrying capacity in A/C 2-tier, First A/C & Garib Rath Chair Car. Provision of forced ventilation, PIS/PAS in AC/DC EMUs for WR and CR. UIC vestibules in mainline coaches. Disabled friendly features in SLRD/SRD coaches. Modular toilets in passenger coaches. Stainless steel panelling, handholds in EMUs. Provision of laptop and cell phone charging points in passenger coaches. Use of stainless steel in Pantry Cars including interiors and the equipment. ICF goes about its motto, for better travel, with single-minded devotion. Comfort, speed and safety are the hallmarks of ICF built coaches. Every coach produced at ICF stands proof of ICF s commitment to live up to its motto and its pursuit of excellence. In simple words, the coaches at ICF are custom-built to delight the individual. ICF s major customers in India are the Zonal Railways of IR, Mumbai Rail Vikas Corporation, Metro Railway, Kolkata, Military and Tourism Development Authorities. After assessing the requirements of various zonal railways, the Ministry of Railways prepares the annual production programme and coaches are manufactured according to the production programme and dispatched to zonal railways. ICF has also bagged sizable export orders for various Asian countries. Against stiff international competition from more advanced countries like Japan, etc., ICF secured several export orders, most of which are repeat orders. So far, 359 bogies, 11 stainless steel coach shells and 565 coaches including air-conditioned coaches have been exported to 13 Afro-Asian countries. ICF has exported 110 self-propelled coaches to Srilankan Railways during Green Energy: Wind Mill (10.5 MW installed capacity) ICF is the first organization amongst all Government production units to entirely source its electrical energy requirement from a renewable source of energy. Seven wind mills of 1.5 MVA capacity each, which ICF has put up in the Tirunelveli District of the Tamil Nadu, generate enough electricity to meet the entire requirement. Year wise Windmill generation & Revenue earned are shown below. Year Wind Mill Generation (in Million Units) Revenue Earned (in Crores) Total

4 Energy & Specific Energy Consumption Electrical Energy Consumption of Factory ICF Factory Consumption ( in Million units) Specific Energy Consumption ICF Specific Energy Consumption Energy Conservation Measures Implemented during Energy efficient package AC units of total capacity 100HP (73.5Kw) of VRF type replacing 2.0 Ton old split & package A/C units of total capacity 100kw. 2. Air Circulator control box with timers where installed. 3. Provision of Energy savers in ARC welding set 4. Turbine type Air ventilators where used in place of Energy driven Roof Exhaust fans. 5. LED street lights have been provided in place of conventional MH/HPSV/MV luminaries. 6. T-5 fitting of type 4x14W, 2x28 & 4x54 have been provided for lighting applications. 7. Induction Lights have been provided for lighting applications in place of conventional lamps such as MH, HPSV etc,. Environment & Safety In general, there is no environmental sensitive target identified in and around ICF. As ICF is a Zero discharge factory, the effluents generated both at Shell & Furnishing factory are being treated and the same is reused for gardening purposes. The effluents of Paint Booth at Furnishing factory are treated first by Reverse Osmosis method and on second stage by Effluent Treatment Plant process which is also used for gardening purposes. With respect to Ambient Air & Stack Gases emissions, the samples are regularly monitored and the test results are well within the prescribed limits of Tamil Nadu Pollution Control Board. These results are also submitted periodically to Tamil Nadu Pollution Control Board. 249

With the reduction of WDS4 locomotives and increase in Electric traction in BZA Division, DEMU services started in Vijayawada from the year 1996 with 5 consists placed under Diesel Loco Shed,

5 Second Prize Railways Workshops DIESEL LOCO SHED SOUTH CENTRAL RAILWAY Vijayawada (Andhra Pradesh) Unit Profile Diesel Loco Shed, Vijayawada was established in the year 1979 at the cost of about Rs. 170 lakhs to maintain 20 WDS4 locomotives. With the reduction of WDS4 locomotives and increase in Electric traction in BZA Division, DEMU services started in Vijayawada from the year 1996 with 5 consists placed under Diesel Loco Shed, Vijayawada to ease severe traffic constraints both in passenger/express services and also in suburban traffic of BZA, GNT, GTL and SC divisions. In March 2007, 2 RAIL BUSES were received from NED division to run between COA-KLPH section of BZA division. Holding Locos of the DLS/BZA Holding DEMU WDP WDM WDM2 M/L Total holding

6 Infrastructure in the Shed i. Coach Turn Table: Coach Turn Table provided is suitable for directional change of DEMUs ii. De-Mineralised Water Plant: The De-mineralized water plant installed produces cooling water required for diesel locos with a capacity of 8000 liters per cycle. iii. High Pressure Jet Cleaning System: The High Pressure Jet Cleaning system facilitates the internal and external cleaning of DEMU formations and Locos for quick and better washing and glazy look. iv. Reverse Osmosis (RO) Plant: As a Staff welfare measure, Reverse Osmosis (RO) Plant of 200 Ltrs per hour capacity has been installed caters the needs of Shed Staff. v. Availability of Important M&P: a) Charger in LR Bay (80 kw) b) Oven (25 kw) c) Centre Lathes (38 kw ) d) Radial Drilling Machine (3 HP ) e) Air Compressor ( 165 HP) f) Lifting Jacks (5 HP -16 Nos.) g) EOT Cranes (20 Tn-01 No and 40 Tn-01 No ) kw h) Welding Plants ( 64 kw) Energy Consumption DESCRIPTION UNITS Total Units purchased per annum Lakh kwh Self Generated per annum Lakh kwh Total Energy Consumption per annum Lakh kwh Specific Energy consumption kwh/ Loco

3 2 1 Energy consumption in Lakh Units (Purchased + Generation) 3.00 2.

conservation measures Sr. No. Measure Images 1. Provision of 62 Nos.

7 3 2 1 Energy consumption in Lakh Units (Purchased + Generation) Specific Energy Consumption kwh/loco Implementation of Energy conservation measures Sr. No. Measure Images 1. Provision of 62 Nos. of Five Star rated fans in place of over aged fans leading to saving of 7,200 units per annum amounting to Rs.59,300/-. 2. Provision of 03 Nos. of occupancy sensors in officers chambers for controlling of lights, fans and AC circuits leading to saving of 3,800 units per annum amounting to Rs. 31,000/- 3. Provision of 56 Nos. of T5-28W fittings in place of 40W FTLs leading to saving of 8,800 units per annum amounting to Rs. 72,300/- 4. Provision of 12 Nos of 250 W MH fittings in place of 400 W MH fittings to save 10,300 Units per annum amounting to Rs. 83,900 /- 252

8 5. Provision of Automatic Power Factor Correction (APFC) panel of 100 KVAR capacity to save 6,230 units per annum amounting to Rs. 51,023 /-. Energy Conservation Policy To avoid idle running of air compressors and welding plants by regulating the time of operation and bringing awareness among the operators. Air leakages from the compressors are being monitored closely and attended if any leakage noticed. Centralized high capacity compressors were eliminated with low capacity individual compressors to switch ON depending upon the requirement of the section. To replace over aged high power consuming electrical equipment with energy efficient / three star and above rated equipment. To take maximum advantages of natural light during day time through perplex sheets provided and to switch ON the shed lights only at the work space during night. The average power factor of the Shed is being maintained at 1.0 by providing Automatic Power Factor Control (APFC) panels. To conduct energy audits on regular basis to identify the areas having potential of saving of electrical energy and to minimize the energy losses. To implement the 20 point action plan items circulated by the Rly. Board and to monitor its outcome. To reduce specific energy consumption by continuous energy efficient measures and minimizing energy wastages. To create awareness among the employees at all levels in energy conservation initiatives by continuous counselling and organizing seminars. To use energy efficient IGBT type welding sets in place of over aged transformer type / rectifier type welding sets. To minimize the working of Ovens by planning consolidated heating of armatures. Standardize & adopt use of appropriate energy efficient design/innovative technology. 253

Energy consumption in 2012-13 & 2013-14 In 2012-13 electricity consumed from the grid was 3.7 lakhs units and in 2013-14 electricity consumed from grid were 3.0 lakh units.

9 Certificate of Merit Railways Workshops Unit Profile ELECTRIC LOCO SHED Eastern Railway Asansol (West Bengal) Electric Loco Shed, Asansol is a repairing shop of electric locomotives. It was commissioned on 1959 and having a holding capacity of 138 Locomotives with the involvements of IOH/AOH of the Locos. Energy consumption in & In electricity consumed from the grid was 3.7 lakhs units and in electricity consumed from grid were 3.0 lakh units. There was a total savings of 0.7 lakhs units i.e % saving with respect to and this saving of units was achieved without affecting the system efficiency. Energy conservation measures /Energy management policy Effective energy utilization was taken as an energy management policy by the top level & according it the following efforts were made for these units saving as: a) Efforts made without expenditure: Review of use of high capacity light fitting: Many fittings of high wattage capacity were made removed/ disconnected as it were not required. At Electric Loco Shed, Asansol, total 34 Nos. fittings, (400 watt X 11, 250 watt X 14, and 150 watt X 9) were removed/ disconnected from Loco Shed Yard area, Loco Shed approach road and entrance point, pathway to wheel lathe machine shed, trip shed etc. It resulted into saving of units (approx.) considering 10 hrs /day as working during compared to

06 nos. of 400 W fittings of high mast tower were made switched off as these fittings were illuminating unnecessarily jungle, bushes etc. Hence, 8760 units (approx.

At Electric Loco Shed, Asansol, 02 nos. of ACs were removed. Hence, considering 6 months period (8 hrs/day), 4320 units (approx.) saved.

level was increased and the same time unnecessary T-5 fittings were removed. It also added to energy conservation.

10 06 nos. of 400 W fittings of high mast tower were made switched off as these fittings were illuminating unnecessarily jungle, bushes etc. Hence, 8760 units (approx.) saved considering 10 hrs of its working. Review of ACs: As ACs are measure power consuming machines. A review was carried out and AC machines were removed as per Railway Board s circular. At Electric Loco Shed, Asansol, 02 nos. of ACs were removed. Hence, considering 6 months period (8 hrs/day), 4320 units (approx.) saved. Lowering down of indoor T-5 fittings at office premises and removing unnecessary fittings: At Electric Loco Shed, Asansol the T-5 fittings were made lowered down & it was found that illumination level was increased and the same time unnecessary T-5 fittings were removed. It also added to energy conservation. b) Efforts made with expenditure: A review was made & as per requirement, high wattage fittings were replaced by energy efficient fittings like low wattage fittings, T-5, CFL etc. At loco shed total four numbers 400 W HPSV were replaced with 250 W MH. 06 nos of 250 W HPSV were replaced with 150 W MH. 10 nos of 150 W HPSV were replaced with T-5 fittings. It contributed into saving of 7811 units. 255

11 Replacing double holder indoor lights (2x28 T-5) by single holder tube lights & removing garden light, phasing out of incandescent lamp with CFL: Where 2x28 W fittings were not required, these were replaced with 1x28 W fitting. Garden lights were removed. Incandescent lamp from toilets, store room, was replaced with CFL. It contributed into a saving of 1500 units (approx.) Replacement of old ceiling fans with energy efficient fans: Old ceiling fans were replaced with energy efficient ceiling fans. Profile of saved units Fittings physically removed Sl. No. Description Nos. Units Saved (considering 10 hrs/day working) W W W Total Fittings replaced by Energy Efficient fittings Sl. No. Description Replaced with Nos. Wattage Reduced Units Saved W HPSV 250 W MH W W HPSV 150 W MH W W 2X28 W W 3431 Total 7811 Energy Consumption The details of energy consumption is appended in tabular form Sl. No. Year Total units lakhs lakhs lakhs Bar charts (specific energy consumption year-wise) Bar chart indicating year-wise consumption is as: 256

12 Year Wise Energy Consumption (in Lakhs) Energy Conservation Achievement Through effective energy utilization, the energy consumption during compare to was 18.65% less. In electricity consumed from the grid was 3.7 lakhs units and in electricity consumed from grid was 3.0 lakh units. Thus, there was a total savings of 0.7 lakhs units during with respect to i.e %. 257

13 Certificate of Merit Railways Workshops CARRIAGE WORKSHOP Lallaguda (Telangana) Unit Profile Carriage Workshop, Lallaguda was established Under NIZAM S GUARANTEED STATE RAILWAY in The type of work performed in the work shop is Periodic Overhaul of Different Coaches (AC, NON-AC, Inspection Cars etc.) Intermediate Overhaul Of Coach Bogies Supply of Wheels & Coach Components To Divisions. Chemical & Metallurgical Investigations. Training To Railway Staff Energy Consumption in & Year Connected load (in kw) Energy consumed (in lakh units)

14 Energy consumed (in lakh units) In electricity consumed from the grid was 3.7 lakhs units and in electricity consumed from grid were 3.0 lakh units. There was a total savings of 0.7 lakhs units i.e % saving with respect to and this saving of units was achieved without affecting the system efficiency. Energy conservation measures /Energy management policy 1. Replacement of T-5 type light fittings of 28 W in place of existing 40 W fluorescent tube light fittings: At LGD shops, so far 1991 T-5 light fittings are provided and 161 Nos during the year causing energy saving of about 7000 units and amount savings upto Rs.61,500/-. 2. Replacement of Electronic fan regulators in place of conventional fan regulators At LGD shops, so far 457 fan regulators are provided and 300 Nos during the year causing energy saving of about 1000 units and amount savings upto Rs.8,800/-. 3. Use of VVVF drives for 15 No s EOT cranes to achieve 20 % of energy saving At LGD shops, so far 21 EOT cranes are already provided with VVVF drives causing energy saving of about units and amount savings up to Rs.3,44,200/-.during Use of IGBT based charge / discharge panels for battery charging / discharging of TL & AC coaches qty 8 nos. At LGD shops, so far 13 Nos. are already provided with IGBT based charge / discharge panels for battery charging / discharging of TL & AC coaches causing 259

15 energy saving of about units and amount savings up to Rs. 5,16,300/- during Use of VVVF drive for air compressors and 20 HP water pumps to achieve 20 % of energy saving At LGD shops, so far 5 nos. of air compressors and 2 nos. of water pumps are already provided with VVVF drives causing energy saving of about 8800 units and amount savings up to Rs. 86,000/- during Use VVVF drive for testing of 25 kw alternators and RRUs at Electrical Repair shop At LGD shops, so far 6 sets of VVVF drives are already provided for testing of 25 kw alternators and RRUs for load sharing at AC shop and ER shops causing energy saving of about units and amount savings upto Rs. 2,58,100/- during Use of VVVF drive for testing of 4.5 kw alternators and RRUs at train lighting shop At LGD shops, so far 3 sets of VVVF drives are already provided for testing of 4.5 kw alternators and RRUs at Train lighting shop causing energy saving of about units and amount savings up to Rs. 1,72,100/- during

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

Wagon repair workshop Jhansi Under North Central Railway Workshop budget Rs. 376.76 Crores Established in year 1889 Total area 3.4 lac square meter (60% covered by green plantation) Staff strength 5810