First Prize Railway s Workshop s 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. 246 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 247 • 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 Revenue Earned Generation (in Crores) (in Million Units) 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 40.33 248 Energy & Specific Energy Consumption Electrical Energy Consumption of Factory Specific Energy Consumption 20 18.2 300 272 15.3 250 218 15 14.49 208 200 10 150 100 5 50 0 0 2011-12 2012-13 2013-14 2010 -11 2011 -12 2012 -13 ICF Factory Consumption ( in Million ICF Specific Energy Consumption units) 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. 249 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 WDP 1 17 17 WDM2 14 14 WDM2 M/L 05 07 Total holding 67 69 250 Infrastructure in the Shed i.