ICF – “ Green Factory”

 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 11,000 strong work force and manufactures over 2,200 coaches every year.  ICF, conscious of its commitment to Society, strives to minimize the environmental impact of its operations and reduce its carbon foot-prints. An 'Environmental Policy' has been adopted by the organization which lays down guidelines to create a safe, harmonious and ecologically balanced environment for its members and the community at large. In this direction, ICF has taken several measures in the recent past turning ICF to a “Green Factory”.  ICF is the only Railway unit to fully source its Electrical Energy requirement from Renewable Energy Sources  ICF is certified with Quality Management System, Environmental Management Systems & Occupational Health and Safety Assessment since 1997, 2001 & 2010 respectively.

Variants of Coaches @ ICF Electrical Distribution System  50000 coaches manufactured at single facility Electrical Infrastructure  500 + variants  All varieties of Self Propelled Vehicles – Description Details EMUs/Metros/DEMUs/DHMUs/DETC/Maintenance Cars Connected load 71 MVA  More than 2200 Coaches manufactured in 2016-17 Maximum Demand (avg.) 8,500 kVA Maximum Billable Demand 7,650 kVA  1200 Stainless Steel Coaches per Annum Average consumption per month Factory - 1.185 MU Exponential Growth Of Outturn Domestic - 0.788 MU Sub – Station Details ( Total – 30nos) Shell - 11 Furn- 10 Colony- 9 Incoming Feeder Details from ICF -1 & ICF 2 - Factory Supply TANGEDCO ICF - 3 – Domestic Supply (33 / 11kV ) Implementation of SCADA system is under progress and it is planned to Connect the SCADA Monitoring System Main Receiving Sub-Station of Shell , Fur, & Hospital. Captive Power Details ( Stand by) ICF will be manufacturing prestigious state of the art 160 kmph speed Train Set, 1000 KVA, 11 KV – 4 Nos called “Train-18”. This will have 3 phase propulsion equipment under slung and all coaches inter-connected with fully sealed gangways. The best in class train set will be DG Set 1250 kVA ,11 kV - 3 Nos manufactured at two-third the cost of the same train set in international market. 250 KVA 415 V - 2 Nos

1 Major Energy Consumption Equipment in plant Energy Conservation Measures Adopted ABSTRACT OF CONNECTED LOAD PARTICULARS

SL SHELL Load FURN. & LHB SHOP-74 Load DESCRIPTION Total Air Compressors: IN KW Load IN KW IN KW NO (IN KW) As Air Compressors consume substantial Electrical 1 MACHINARIES & PLANT 9412.58 4272.80 156.03 13841.41 Energy, The measures taken for reduction are HEAT TREATMENT 2 1543.07 204 405.75 EQUIPMENTS 2152.82 1.As recommended by Energy Auditors ‘Pressure 3 MOTORS AND PUMPS 313.64 518.3 828.14 1660.08 Bandwidth’ Adjustment on Compressor was 4 AIR COMPRESSOR 1278.3 2845.65 15.6 4139.55 reduced from 6.5 -7.3 kg/sq.cm to 6.2 – 6.8 MATERIAL HANDLING kg/sq.cm. 5 2386.07 822.15 15 EQUIPMENTS (incl LIFT) 3223.22 6 WELDING SETs 12795.3 1148 431.86 14375.16 2.Air Leakages from Pipe Lines & Tapping terminals reduced from 36% to 9.8% . 7 ALL LIGHTING FIXTURES 658.17 694.22 928.65 2281.04 REF & AIR CONDITIONINIG 8 1267.1 465.26 518.6 3.Motorized Isolation Valves provided at vantage EQUIPMENT 2250.96 points to isolate Non-working areas on Holidays. AIR CIRCULATORS & 9 524.68 356.08 485.68 EXHAUST FANS 1366.44 There was a significant reduction of Compressor UPS,BATTERY CHARGERS & 10 1120.46 936 23616.31 Load contributing to decrease in Specific OTHERS 25672.77 Electrical Energy Consumption. Sub -TOTAL 31299.37 12265.81 27401.62 70966.8

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Transformer Idle Working: Natural Illumination:

As Transformers consume substantial Energy by Workshops in ICF have been so designed to way of Copper/Core Losses during Idle facilitate diffusion of Natural Sunlight during day Working, decision was taken to switch off time from Roof and Windows to avoid artificial Stand-by Transformers in all Sub-stations in illumination through Electricity. Total covered ICF. Switching over to Stand-by Transformer(s) area of Workshops in Shell & Furnishing is undertaken once in 15 days by rotation in Divisions: 1,24,941 sq. mtrs. every Sub-station for saving No Load loss. This Total Natural lighting provided by Translucent methodology has resulted in cost benefit of Sheet & North Light Glazing: 66,000 sq.mtrs. Rs.10.2 lakhs / Annuam & Units saved 1.5 Natural Wind Turbine lakh. Turbine Air Ventilators which operate on natural Solar Light Pipes draft without Electrical Power have been installed in Workshop Roof Tops to exhaust hot gas 12 Nos of Solar light pipe provided at various emanating from Welding Operation, Furnace etc. locations in Buildings & Shop floor areas. Through This annual savings of Rs.6.87 lakhs / Through this installation Rs. 0.37 lakhs / annuam & Units saved 0.20 lakh. Annuam was savings& Units saved 0.05 lakh.

2 Contd.. Contd..

LVHS Fan Energy Efficient Air Conditioners 11 nos of Low Speed High Volume (LSHV) The conventional Window/Split Air 24ft sweep celling fan of capacity 1.5kw with conditioners are replaced with the state of the VFD control has been installed in shell & art Variable Refrigerant Flow (VRF) Furnishing division. Through this installation Centralized Air Conditioning System in both Rs. 11.27 lakhs / Annuam was savings& Units Shell and Furnishing Offices, which consume saved 1.7 lakh. 40% less Energy Occupancy Sensor Energy Efficient Fan Occupancy Sensors have been provided in Super fans are provided in place of Officer’s Chamber to switch off automatically Conventional ceiling fan. Through this Air Conditioners and Room Lights when the installation Rs. 1.35 lakhs / Annuam was Room is unoccupied. Through this installation savings & Units saved 0.2 lakh. Rs. 2.21 lakhs / Annuam was savings& Units saved 2.1 lakh. Star Rated Equipment: Energy Efficient Pumps ICF has implemented policy of procuring only High Horse Power Pumps in Colony Pump BEE approved Star Rated Electrical Products Houses are being replaced with Energy such as Ceiling Fans, Air-conditioners, efficient Submersible Pumps in a phased Geysers, Refrigerators, Water Coolers etc. manner. Through this installation Rs. 16.01 lakhs / Annuam was savings.

Contd..

Facade Lighting Air Handling Unit In Administrative Building 2 Nos of 30 TR Air The GM Administrative & Other Service buildings are Illuminated with LED Façade Handling Units replaced in AC plant. After Light fittings. replacement the temperature of G. Floor has come down from 30ºC to 24ºC

All Neon signages at ICF are replaced with Automatic Timers LED signages Timers are provided to Bay Lights and air Circulators to switch off them automatically during non-production hours. LED fittings are provided in place of Converted Five nos of HT substation to LT conventional High bay fitting of Sodium switch room in Shell division (SS-05, SS-06 & Vapor Lamp / Metal Halide etc.,. for factory & CFL /Fluorescent tube light in office SS-18), Furnishing division (SS-16 & SS-25). building with increase in lumens level. This methodology has resulted in cost benefit of Resulted in achievement of 61.3 % reduction Rs.10.2 lakhs / Annuam & Units saved 0.93 in lighting load. lakh.

3 Energy Conservation Measures Adopted by ICF Energy Conservation Measures Adopted by ICF

 First Unit on Indian Railways to provide ‘Smart Meter (200 Nos.) in ICF  Passenger lift VFD drive is provided in place of Over aged passenger lift in Colony which would help in Energy Monitoring. Administrative building at Shell division and conventional drive and control  50% LED Fittings provided in ICF Factory (Shell/Furnishing Division) and has been replaced by VFD control in Eastern end lift of the building 100% LED Fittings planned entire ICF premises by Oct.’17.  2000 LPD Solar water heaters provided various locations  Installation of ‘Supervisory Control and Data Acquisition System (SCADA)  200 nos of occupancy sensor was provided in the Office building &ICF for Main Receiving Station (MRS) which would help in ‘On-Line hospital premises ( officer’s cabins, common toilets), Monitoring’ of Electricity consumption in different Units.  65 Nos. of Ceiling fans (super fan) have been replaced in ICF Hospital and  ‘Energy Audit’ conducted by M/s PCRA in Sept.’15 and all the Office buildings. recommendations implemented.  9 nos of Energy Efficient Submersible pumps are provided in Colony pump house.  158 HP VRF air conditioners has been commissioned at Administrative building/Shell division duly replacing 95 nos energy intensive Window /Split  11 nos of Low Speed High Volume Fan (LSHV) with VFD control are air-conditioners. provided in place of air circulators at shop floor areas.

Roadmap for next three years List of energy saving projects implemented in the year 2016-17 Si.No Description Lighting 1. Provision of one more 2MWp Solar rooftop PV system under Power Purchase  68 Nos of 150 W LED Light fitting were replaced against 250 Watts Metal Agreement (PPA) in proposed LHB Phase II halide lamps in shell division.  78 nos. of 45 Watts LED Street Light fittings provided in various locations 2. Introduction of Solar panels in roof top of passenger coaches for meeting lighting & duly replacing the 150 W MH fitting in ICF premises. ventilations load.  Authorized control Mechanism has been provided for switching on the 1200 3. 5 nos of 5 HP Solar Pumps comprising of Panel, structure, VFD Drive, Motor Pump Nos of Tube lights that are provided in three Paint Booths in Paint Shed Furnishing Division 4. Conversion of 10 nos of High mast conventional flood light fittings of 400W into Energy Savers / Timer Control 250W LED flood light  20 nos. of Energy Savers are provided in Furnishing Admin building Conversion of 756 nos of Conventional Street lights into LED 5.  13 nos. of Timers provided for Roof Exhaust Fans in ‘B’ Shed of Shell 6. Conversion of 29 nos of Higher rating Centrifugal pump into Submersible Pump of division for automatic switching ’ON’ during factory working hours lesser capacity.  Timers are provided higher rating Press Brakes to reduce Idle run. 7. Provision of VFD control for Centralized Pneumatic Compressors Pumping System 8. Provision of VFD Control with Re-Generative braking in 40 nos of over head cranes  One no. of 30HP and one no. of 40 HP Drinking water Pumps were replaced at shop floor areas. by 20 HP energy efficient submergible Pumps in North Colony & Perambur 9. Replacement of 175nos of old non-star rated ACs into 5-star rated ACs in ICF Officers’ Flats  12.5 HP floor mounting pump replaced with energy efficient 7.5 H.P 10. Extension of SCADA system to all Substations in Shell Div., Fur Div. & Major submersible pump at colony pump house consumption areas. For effective Monitoring

4 Cont… Solar PV Rooftop Plant Specific Energy Consumption w.r.t coach production last 5 years  As a trial measure 180 Wp Solar Photo Voltaic panel installed on Platform Truck for charging the battery  2X50KWp capacity ON-Grid Solar Rooftop PV System is commissioned at roof top of GM Admin Building  A 30kWp On-Grid Solar PV system installed in ICF school rooftop  10 no of Light Pipe for illuminating through Natural Light in various locations of Service Building & Shop floor are installed Compressor  6 Nos of Motorized valves installed at Furnishing compressor main line.  2 Nos of Portable Compressor procured and provided in Fur. Div for use during holidays or feeding one area

Bench marking with world class

Energy monitoring System Cont… Benchmarking is done with other Railways production units who carry out similar type & maintenance activity. The Details of benchmarking done with RCF is given below. Equated Coach Unit in kWH

9000 Financial Year ICF RCF 7764 7348 6850

6000 5091 2014-15 6850 8737 4511 ECU PER KWH 3000 ECU 2015-16 5091 8438

0 2012-13 2013-14 2014-15 2015-16 2016-17

kWH per ECU Linear (kWH per ECU) 2016-17 4511 7678

5 Energy efficient EMU for MRVC

MRVC Phase-I & II Project,  ICF manufactured 203 Rakes with state-of- the-art 3 Phase Technology which consume 30% less Energy compared to conventional EMU Rakes. The following main features: • 3 Phase IGBT (Insulated Gate Bipolar Transistor) based propulsion System • It reduces energy consumption by adopting VVVF [Variable Voltage Variable Frequency] drives. • It works on Regenerative Braking System for energy savings.  Electrical Energy consumption reduced by about 200 million units per Annum for Mumbai Suburban Rail Network. INNOVATIONS  ‘Roof Mounted Air Handling Units (AHU)’ have been provided in all the Coaches which reduces Carbon-dioxide level inside the Coaches and provide better ventilation,

Eco-friendly CNG DEMU Solar Roof Top Coach ICF has manufactured the first eco-friendly Compressed Natural Gas (CNG) Diesel Electrical Multiple Unit (DEMU) in 2014. The  6 Trailer Coaches fitted with each 4.8 KW following features are: Panels in 2016-17 . This CNG DEMU has the mechanism to run on  Each Coach has 120AH, 110V Battery for Dual Fuel Engine using CNG (Compressed Charging Natural Gas) as an Alternate Fuel to Diesel. . CNG emits fewer toxic and carcinogenic  Average yield per coach is 8-12KWH per pollutants and no Particulate Matter. day . 20% diesel substitution  Trails going on in the rake at Northern . CNG emits fewer toxic and carcinogenic Railway Shakurbasti pollutants and no Particulate Matter. . Reduction in emission level  90 – 97% Carbon Monoxide  25% Carbon-di-oxide  35– 60% Nitrogen oxide . Compressed Natural gas stored in onboard cylinders. . Working on Rewari-Rohtak section of Northern Railway

6 Inventories 2016-17 CO2 Emission per ECU Year 2013-14 2014-15 2015-16 2016-17 Value (in terms of t Description Source Total emission (ton CO2) 5214.607 5054.456 6925.894 3517.67 CO2e) (SCOPE 1 & 2) Furnace oil 1440.22 ECU manufactured 2099.31 2300.4 2978.68 3326.31 Emission (in ton CO2)/ECU Diesel 789.79 2.484 2.20 2.217 1.06

Oxy -acetylene 68.52 % reduction from previous year Scope 1 - 11.43 -.0077 0.523 CO2 used for GMAW 1612.75

LPG 89.74 Emission / ECU 3 Refrigerant 331.23 2.484 Emission / ECU 2.5 2.2 2.217 Purchased Electricity 11936.50 2

1.5 Scope 2 1.06 Electicity generated from wind 12751.08 1 mill and added to grid. 0.5

0 2013-14 2014-15 2015-16 2016-17

Awareness programs for Officers/Employees Cont…  27,000 Nos of 7 watt LED lights have been distributed to ICF Family under Domestic Efficient Lighting Programme (DELP scheme).

 An interactive session carried out by Smt.G.Anandhi, Executive Engineer/ Tamilnadu Generation and Distribution Corporation Limited (TANGEDCO) on “Energy Saving Techniques and Electrical Safety” for employees of ICF on 12.08.2016 at AWTI auditorium

7 Cont… Cont…

 . As per the directives of Railway Board, Energy Conservation Day was celebrated at ICF on  A Technical Seminar organized for Electrical Maintenance Officers & Supervisors 14.12.2016. A technical seminar was also organized which was attended by Officers & regarding “How to Improve Energy Efficiency & Reliability in Electrical Systems” by Mr. Supervisory staff. John Kochkutty, Joint General Manager, M/s L & T Mumbai., on 02.03.2017 at Vichar Sabha Grah

 A Technical Seminar organized for Electrical Maintenance Officers & Supervisors Energy conservation Banners regarding training programme in ‘HVAC and pumping systems in ICF’ by Mr. Vasudevan, Consultant, M/s PCRA, Chennai on 09.03.2017 at Vichar Sabha Grah.

EnMS - ISO 50001 ENERGY MONITORING SYSTGEM

ICF Certified with ISO 50001- Energy Management System since Sept 2015.

8 Energy monitoring System Cont… ENERGY MONITORING SYSTGEM

Quarterly Energy Consumption Statement Energy monitoring System

Energy Profile: Factory & Ancillary area (Consumption in %)

Process ( Machines & Welding) 57.7

Compressor Air System 14.7

Illumination & Ventillation 9.7

Administrative Office 9.2 Admin+Data Center+D&D+F.Woff)

Hospital 3.2

Miscelleneous 2.8 ( AWTI,Sports Complex,Schools,etc.,)

Water Supply 2.6

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0

9 COMPRESSOR DETAILS

Compressor Details Shell Div. Fur Div.

No of Compressors 8 13 Total CFM 6500 13000 Renewable Energy Type Screw Type Screw Type Presure Setting 6.2 to 6.9 5.5 to 6.1

Fur Energy 2016-17 Shell Energy /CFM /CFM Apr-16 54717 8.4 142882 11.0 May-16 52531 8.1 180135 13.9 Jun-16 64386 9.9 184021 14.2 Jul-16 64013 9.8 180734 13.9 Aug-16 65083 10.0 171335 13.2 Sep-16 52503 8.1 178219 13.7 Oct-16 53969 8.3 179035 13.8 Nov-16 59522 9.2 201303 15.5 Dec-16 50427 7.8 173240 13.3 Jan-17 55038 8.5 181525 14.0 Feb-17 56529 8.7 192492 14.8 Mar- 17 72979 11.2 228525 17.6

Renewable Energy- WindMill & Solar Wind Mill Generation V/s ICF Consumption Analysis ICF’s Energy consumption Wind Mill : ICF is the first organization amongst in Indian Railways to entirely source its Wind Mill electrical energy requirement from a renewable source of energy. 7 wind mills of 1.5 MVA Generation capacity each, which ICF has put up in the Tirunelveli District of the Tamil Nadu, has Year (Units generated enough electricity since 2009 to meet the entire electrical energy requirement of in Crores) Factory Domestic Total % Share of ICF factory till date. (Units (Units (Units Renewable in Crores) in Crores) in Crores) Energy Commissioned on : 30.03.2009 Location : Tottapalli, Tirunelveli Dist., TN No. Units : 7 (Seven) 2009-10 2.37 1.73 0.82 2.55 93% Capacity : 10.5 MW Capital Cost : Rs. 66.05 Crores 2010-11 2.02 1.93 0.73 2.66 76% Project Executed by : M/s Suzlon Ltd. Gujarat Energy Generated till July’17 ( from D.O.C) : 151.16 MU 2011-12 1.86 1.82 0.77 2.59 72% Earnings till July ’17 : Rs.64.72 Crores 2012-13 2.24 1.69 1.01 2.7 83% Solar : 2013-14 1.63 1.54 0.95 2.49 65%  Order placed for installation of 2 MWp ‘On-Grid’ Roof Top Solar PV System at ICF under Private Power Purchase 2014-15 1.45 1.57 0.92 2.49 58% Agreement (PPP) Model. [PDC: Oct.’17]  165 KWp Capacity ‘On Grid Solar Roof-Top PV System’ 2015-16 1.18 1.51 0.89 2.4 49% installed in ICF, resulting in generation of 22,000 Units/Month.  40 Nos of Solar Street lights are provided at ICF area. 2016-17 1.56 1.46 0.86 2.32 67% Cumulative Total 14.31 13.25 6.95 20.2

10 Recyclable Aluminium Composite Panels for Biomass & vermicomposting Pits Interior Panelling of Coaches Turning Pollution To Prosperity •Used on Kolkata Metro, EMU, DEMU, Deen Dayalu and Antyodaya Coaches

Non Recyclable LP sheet paneling – GS Coach

Non Recyclable FRP paneling Thiruvallur Marriage Hall Chennai Rail Museum with concealed screws – 1600 HP DEMU

Recyclable Aluminum Composite Panel for Kolkata Metro

Certifications

Green initiatives & Awards

5 Star Rating for Admin ISO 50001:2011 IGBC Platinum Award for Building on 13.07.2015 on 09.09.2015 Admin Building on Nov -2015 Small Steps for a Green Future…

11 ICF – Awards BEE Awards

Golden Peacock Eco- Golden Peacock Environment Innovation Award - 2012 Management Award - 2013

“Best Production Unit” “Best Production Unit” Shield for the year 2014-15 Shield for the year 2015-16 Global Green Award – 2014 Awarded by Omac - Paris

Certification The M/s Confederation of Indian Industry (CII) is an association of Indian businesses which works to create an environment conducive to the growth of industry in the country. The Assessment audit certification of ICF for “Green Co Rating” conducted by M/s CII on 10.04.2017 & 11.04.2017 in which Team ICF Certified “Silver Rating” “Green Co Rating Silver Shield” awarded to Integral Coach Factory, Chennai on 05.06.2017 by Shri Suresh Prabhakar Prabhu, Hon’ble Minister for Railways (MR) at National Rail Museum, New Delhi.

Innovation Continues Forever (ICF) Thank you

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