INTEGRAL COACH FACTORY (ICF) - Knowledge Platformknowledgeplatform.in/wp-content/uploads/2016/03/28... · 2016-12-21 · INTEGRAL COACH FACTORY (ICF) Chennai (Tamil Nadu) ... WDM2

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First Prize Railways Workshops

INTEGRAL COACH FACTORY (ICF)

Chennai (Tamil Nadu)

Unit Profile

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 2013-14 was about Rs.

2200 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, 1962. The capacity was progressively expanded

during 1973-74 from 350 shells to 750 fully furnished coaches per annum with

additional inputs. This was enhanced progressively from 850 coaches during 1986-

87 to 1000 coaches in 1990-91. Capacity augmentation project works from 1000 to

1250 & 1250 to 1500 were taken up in phases and completed in 2011-12. Capacity

augmentation works upto 1700 were taken up in the year 2012-13 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 anti-

telescopic 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.

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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 non-

electrified routes and Mainline Electric Multiple Units for long distance inter-

city 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 sea-

change 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

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• 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 2011 - 13.

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)

2009-10 23.79 7.85

2010-11 20.17 7.66

2011-12 18.64 7.22

2012-13 22.41 10.52

2013-14 16.31 7.08

Total 101.32 40.33

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Energy & Specific Energy Consumption

Electrical Energy Consumption of Factory Specific Energy Consumption

Energy Conservation Measures Implemented during 2013-14

1. 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.

18.215.3

14.49

0

5

10

15

20

2011-12 2012-13 2013-14

ICF Factory Consumption ( in Million

units)

272

218 208

0

50

100

150

200

250

300

2010-11 2011-12 2012-13

ICF Specific Energy Consumption

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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 2012-13 2013-14

DEMU 31 31

WDP1 17 17

WDM2 14 14

WDM2 M/L 05 07

Total holding 67 69

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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 ) – 138.75 kW

h) Welding Plants ( 64 kW)

Energy Consumption

DESCRIPTION UNITS 2012-13 2013-14

Total Units purchased per annum Lakh kWh 2.55 2.21

Self Generated per annum Lakh kWh 0.45 0.23

Total Energy Consumption per annum Lakh kWh 3.0 2.44

Specific Energy consumption kWh/ Loco 4478 3536

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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 /-

3.00

2.44

0

1

2

3

2012-13 2013-14

Energy consumption in Lakh Units

(Purchased + Generation)

4478

3536

0

1000

2000

3000

4000

5000

2012-13 2013-14

Specific Energy Consumption

kWh/Loco

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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.

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Certificate of Merit

Railways Workshops

ELECTRIC LOCO SHED

Eastern Railway Asansol (West Bengal)

Unit Profile

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 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.

There was a total savings of 0.7 lakhs units’ i.e. 18.65% saving with respect to

2012-13 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 33763 units (approx.) considering 10 hrs

/day as working during 2013-14 compared to 2012-13.

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• 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.

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• 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)

1. 400W 11 16060

2. 250W 14 12775

3. 150W 9 4928

Total 33763

Fittings replaced by Energy Efficient fittings

Sl. No. Description Replaced

with Nos.

Wattage

Reduced

Units

Saved

1. 400 W HPSV 250 W MH 4 150 W 2190

2. 250 W HPSV 150 W MH 6 100 W 2190

3. 150 W

HPSV

2X28 W 10 94 W 3431

Total 7811

Energy Consumption

The details of energy consumption is appended in tabular form

Sl. No. Year Total units

1. 2011-12 3.9 lakhs

2. 2012-13 3.7 lakhs

3. 2013-14 3.0 lakhs

Bar charts (specific energy consumption year-wise)

Bar chart indicating year-wise consumption is as:

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Energy Conservation Achievement

Through effective energy utilization, the energy consumption during 2013-14

compare to 2012-13 was 18.65% less. In 2012-13 electricity consumed from the

grid was 3.7 lakhs units and in 2013-14 electricity consumed from grid was 3.0 lakh

units.

Thus, there was a total savings of 0.7 lakhs units during 2013-14 with respect to

2012-13 i.e. 18.65%.

0

1

2

3

4

11-12 12-13 13-14

3.9 3.73

Year Wise Energy Consumption (in Lakhs)

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Certificate of Merit

Railways Workshops

CARRIAGE WORKSHOP

Lallaguda (Telangana)

Unit Profile

Carriage Workshop, Lallaguda was established Under ‘NIZAM’S GUARANTEED STATE

RAILWAY’ in 1893. 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 2012-13 & 2013-14

Year Connected load (in kW)

Energy consumed (in lakh units)

2012-13 7759 22.7

2013-14 10250 20.65

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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.

There was a total savings of 0.7 lakhs units’ i.e. 18.65% saving with respect to

2012-13 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 2013-14 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

2013-14 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 39200 units and amount savings up to Rs.3,44,200/-.during

2013-14

4. 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

19

20

21

22

23

2012-13 2013-14Energy consumed

(in lakh units)

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energy saving of about 58800 units and amount savings up to Rs. 5,16,300/-

during 2013-14.

5. 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 2013-14.

6. 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 29400 units and amount savings upto Rs. 2,58,100/- during 2013-

14

7. 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

19600 units and amount savings up to Rs. 1,72,100/- during 2013-14