Rolling Stock - Indian Railways · PDF fileINDIAN RAILWAYS ANN uAL REpORT AND ACCO NTS 2012-13...

67INDIAN RAILWAYS ANNuAL REpORT AND ACCOuNTS 2012-13

Rolling Stock

Rolling stock placed on line during the year is given in the following table:

Type of Rolling Stock Units placed on lineReplacement

accountAdditional account

Year B.G. M.G. N.G. B.G. M.G. N.G.Diesel Locos 2011-12 59 - - 157 - -

2012-13 68 - - 225 - -Electric Locos 2011-12 49 - - 264 - -

2012-13 30 - - 300 - -Wagons(in vehicle units)

2011-12 778 - - 12,273 @ - -2012-13 1,070 - - 11,810$ - -

Electric Multiple UnitsMotor Coaches 2011-12 93 - - 68 - -

2012-13 20 - - 88 - -Trailer Coaches 2011-12 246 - - 76 - -

2012-13 18 - - 198 - -Main line Electric Multiple UnitsMotor Coaches 2011-12 - - - 32 - -

2012-13 - - - 28 - -Trailer Coaches 2011-12 - - - 96 - -

2012-13 - - - 84 - -Passenger Carriages 2011-12 1,276 - - 1,591 - -

2012-13 1,037 - - 2,253 - -Other Coaching Vehicles

2011-12 15 - - 173 - -2012-13 10 - - 183 - -

(@ including 5,951 on Deposit A/c)($ including 5,542on Deposit A/c)

Stock condemned during the year was as under:

Type of Rolling Stock (in units)

B.G. M.G. N.G.

2011-12 2012-13 2011-12 2012-13 2011-12 2012-13

Diesel Locos 116 106 22 19 - 5

Electric Locos 51 49 - - - -

Wagons(in Vehicle Units)

4,972 3,319 433 365 9 -

Electric Multiple Units

Motor Coaches 71 41 - - - -

Trailer Coaches 51 48 - - - -

Passenger Carriages 969 686 76 57 12 16

Other Coaching Vehicles 86 103 4 19 1 -

Rajdhani Express, Northeast Frontier Railway

2300 HP MG Locomotive for export to Malaysia

2300 HP MG Locomotive for Angola

68 INDIAN RAILWAYS ANNuAL REpORT AND ACCOuNTS 2012-13

1000th High Horse Power (4500HP WDP-4D Dual Cab) locomotive DLW, Varanasi

Rail Maintenance Van KRCL

Traction

The entire passenger and freight traffic, in terms of both Gross Tonne Kilometres (GTKMs) and Train Kilometres was carried by diesel and electric locomotives. Steam locomotives, however, continued to run on certain steam circuits including Hill Railways as icons of IR’s glorious past.

The traction-wise fleet as on March 31, 2013, was as follows:

(in units)Locomotive As on

March 31, 2012As on

March 31, 2013Steam 43 43Diesel 5,197 5,345Electric 4,309 4,568Total 9,549 9,956

Manufacturing of Rolling Stock

The performance of Production Units during 2012-13 was as under:

Chittaranjan Locomotive Works (CLW), Chittaranjan ymanufactured 270 BG electric locomotives including 110 state-of-the-art 3-phase 6000 HP electric locos.

Diesel Locomotive Works (DLW), Varanasi manufactured y294 BG diesel locomotives including 231 indigenous high HP locomotives. Out of these, 30 diesel locomotives were supplied to Non-Railway Customers (NRCs) and 13 locomotives were manufactured for export. During 2012-13, through export and sale of locomotives to NRCs, the total value of sales accrued to DLW was to the tune of `386.81 crore.

Integral Coach Factory (ICF), Chennai manufactured y1,592 coaches including 292 Electric Multiple Units (EMUs), 116 Diesel Electric Multiple Units (DEMUs), 40 Kolkata Metro coaches, 15 self propelled accident relief trains (SPART) and 30 coaches for export to Sri Lanka worth `32.91 crore.

Rail Coach Factory (RCF), Kapurthala manufactured y1,635 coaches including 136 main line Electric Multiple Units (MEMUs) and 470 light weight LHB coaches with higher passenger comfort and amenities. It manufactured 3 coaches for NRCs during 2012-13.

Narrow gauge Diesel Loco, Northeast Frontier Railway


Rail Wheel Factory (RWF), Bengaluru produced 60,100 ywheel-sets. It also manufactured 1,90,501 wheels and 1,00,001 axles. RWF executed orders worth `97.75 lakhs for NRCs.

Diesel Loco Modernisation Works (DMW), Patiala ysuccessfully upgraded 79 number of 2600 HP WDM2 diesel electric locomotives to 3100 HP, thus increasing the hauling capacity to the extent of 3 to 4 additional coaches. DMW also manufactured 54 new locomotives for IR and exported spares worth `2.13 lakhs to Malaysia and Sri Lanka.

Innovations in EMU/MEMU rakes and Kolkata Metro

Introduction of new state-of-the-art technology AC/DC EMU rakes in Mumbai area: So far a total of 129 AC/DC EMU Rakes (114 rakes of 12 car & 15 rakes of 9 car) with new state-of-the-art IGBT technology have been manufactured by ICF. Out of these rakes, 128 rakes have already been inducted into services which generated 35% additional carrying capacity. These rakes are energy efficient having regenerative features and also provided with forced ventilation system. With regenerative braking feature, about `1 crore/rake is saved per annum in energy consumption.

In addition to the above, 15 car EMU services have been introduced in Mumbai area.

Introduction of stainless steel EMU rakes: M/s Bharat Earth Movers Ltd., Bengaluru has already manufactured two stainless steel EMU rakes against a developmental order placed on them. First stainless steel EMU rake is already in operation in Eastern Railway and second rake is under dispatch from the Firm’s premises.

Toilets in MEMU coaches: Toilet facilties are now being provided in newly manufactured MEMU trailer coaches to meet the commuters’ demands. First MEMU rake with toilet facilties was turned out by RCF in the month of April 2010.

Kolkata Metro: 18 non air conditioned rakes of 8 cars each have been working on Kolkata Metro network. With the construction of elevated corridor, it has been decided to induct air conditioned rake. Thirteen air-conditioned rakes with indigenous technology have been introduced. The new rakes have higher acceleration and deceleration besides improved riding characteristics with air suspension arrangement. A view of Metro Rail Bhawan, Kolkata

DEMU for Sri Lanka made in ICF Chennai

3100 HP BG ALCO Locomotive for Bangladesh made in DLW


AC Metro Rake at Noapara, Metro Railway Kolkata

Workshop Inspection of ICF

Import content of raw material/components, in terms of percentages of total production cost (excluding proforma charges) for different types of rolling stock manufactured in Indian Railway Production Units is furnished below:

Production Unit

Locomotives Import content(%) 2011-12 2012-13

DLW BG mixed traffic diesel electric (WAM-3D) 2.08 22.63BG mixed traffic diesel electric (WDS-6) 2.52 2.93WDG-3A* 1.94 1.92WDG-4 35.12 31.08WDP-4B 32.94 31.08

CLW BG goods traffic diesel electric (WAG-9) 1.78 1.78BG passenger traffic diesel electric (WAP-7) 1.66 1.70BG passenger traffic diesel electric (WAP-5) 1.41 2.38

CoachesICF AC EMU A – 3.12

AC EMU B 0.80 0.80AC EMU C 3.38 3.12AC EMU D 3.25 3.32AC EMU D HC – 3.41AC DC EMU B 0.51 –AC DC EMU C 2.38 –AC DC EMU D 2.33 –AC DC EMU D/HC 2.42 –DEMU DPC HHP 0.72 0.74DEMU TC HHP (Gen) 3.13 –DEMU TC HHP (Ven) 3.13 –DEMU TC HHP J&K 3.01 –DEMU DPC HHP J&K 0.71 0.68DEMU DPC HHP (HALDIA) – 0.81Kolkata Metro DMC – 0.50Kolkata Metro NDMC MC – 0.58Kolkata Metro NDMC INV – 0.55Spart DPC I – 0.83Spart DPC II – 0.83DMU DPC 1600 HP – 0.59DMU TC HHP II (J&K) – 2.40DMU TC HHP III (J&K) – 2.40DMU TC HHP (GEN) HALDIA – 4.05DMU TC HHP (VEN) HALDIA – 4.05DMU TC 1600 HP (GEN) – 2.49DMU TC 1600 HP (VEN) – 3.59

Spart TC – 2.19Kolkata Metro MC 0.55 –Kolkata Metro TC 2.55 –

RCF SCZAC/LHB 2.56 4.45FCZAC/LHB 2.32 4.28ACCN/EOG/LHB – 4.36ACCW/EOG/LHB – 4.27An interior view of Rail Wheel Plant, Bela


FAC/EOG/LHB – 4.30

WLRRM/EOG/LHB – 2.53

ACCB/EOG/LHB – 4.25

LFCWAC – 3.83LWCZDAC – 2.54LWSCN – 7.97LWSCZ – 5.65LGS – 7.29WLRRM/LHB 2.19 –

WFAC/LHB 2.59 –

ACCW/LHB 2.54 –ACCN/LHB 3.15 –

CBAC/LHB 2.57 –

WCZDAC/LHB 1.45 –WSCZ/LHB 2.95 –SCN/LHB 3.27 –GS/LHB 3.28 –

*NRC

IR’s bulk requirement of wagons is met by wagon manufacturing units both in public and private sectors, as well as PSUs under the administrative control of Ministry of Railways and supplemented by Railway Workshops. In 2012-13, production of wagons totalled 16,894. Out of these, 1,455 wagons (including 767 BLC wagons) were manufactured at Railway Workshops and the remaining 15,439 wagons including 501 BLC wagons and other private wagons were manufactured by wagon industry.

During April-September, 2013, 5,725 wagons were produced, out of which, 661 wagons (including 120 BLC wagons) were manufactured at railway workshops.The balance 5,064 wagons including 450 BLC wagons and others against private orders were manufactured by wagon industry.

Maintenance of Rolling Stock

The number of units of rolling stock given periodic overhaul (POH) in railway workshops during the year is given in the following table:

Type of Rolling Stock(BG + MG)

Periodic overhaul (nos.) undertaken during the year

2011-12 2012-13

Diesel Locos 519 509

Electric Locos 338 377

Coaches 26,621 27,205

Wagons 42,205 42,896

Long View of DMU Maintenance Shed South East Central Railway

DEMU for Angola

Interior View of a DEMU Coach, South Eastern Railway


A train passing through the Automatic Coach Washing Plant developed by Konkan Railway

DMU for Senegal

The percentage of ineffective stock to the total stock on lien for different types of rolling stock was as follows:

Type of Rolling Stock Percentage of ineffective stock to the total stock on line

B.G. M.G.2011-12 2012-13 2011-12 2012-13

Steam Locos – – 17.64 17.10Diesel Locos 8.80 8.90 11.31 11.27Electric Locos 6.97 7.25 – –EMU Coaches *10.70 10.40 – –Passenger Carriages 6.26 6.19 7.62 8.11Other Coaching Vehicles 6.09 6.81 1.10 1.89Wagons 3.93 4.06 11.18 7.57*revised

Export Order

The total value of exports of rolling stock during 2012-13 was `229.23 crore. The cumulative value of export of rolling stock/spares up to the end of March 2012 and March 2013 was `1,568.77crore and `1,798 crore, respectively. The value of export of rolling stock/spares during April-September, 2013 was `269.23 crore.

The exports during 2012-13 include locomotives, DMUs, coaches, lease and maintenance services etc. to developing countries like Myanmar, Sri Lanka, Bangladesh, Senegal and Malaysia.

Innovations in Electric Locomotives

(i) Production of three-phase electric locos at CLW and adoption of IGBT technology:-

CLW manufactured its first three-phase freight locomotive in the year 1998 and christened it ‘Navyug’. Since then CLW has manufactured 510 three-phase locos upto 2012-13, out of which, 110 three-phase electric locos were produced during the year 2012-13 which is the highest ever. Production of three-phase locos at CLW during the last three years is given below:

Year WAG-9 WAP-7 WAP-5 Total

2010-11 40 18 12 70

2011-12 45 19 12 76

2012-13 57 40 13 110

Arrangements for spring cleaning of stations on daily basis on South East Central Railway


Hydraulic Baling Press, ICF

The heart of the 3-phase locomotive is traction converter which is responsible for conversion of single phase AC drawn from OHE to 3-phase AC which drives the traction motor. At present, switching device used in these converters is Gate Turn Off (GTO). Considering the obsolescence of the GTOs and inherent advantages of Insulated Gate Bipolar Transistor (IGBT), Indian Railways is migrating from GTO technology to IGBT technology retaining same transformer and traction motors which has superior switching speed which enables better control over the voltage and current waveform with higher operation temperatures, modular design thus leading to better maintainability and better adhesion performance with single axle control.

During 2012-13, 34 out of 110 three-phase electric locos were fitted with IGBT traction systems and trials were conducted successfully thereby opening possibilities for its adoption in large scale.

(ii) Vigilance Control Device and Emergency Stop Button:-

In a bid to prevent train accidents due to lack of alertness of Loco Pilots, all electric locomotives are now equipped with Vigilance Control Device (VCD) to enhance passenger safety by automatically stopping the train if a Loco Pilot doesn’t perform a regular task such as accelerating or braking for a stipulated period of time. In addition to VCD, an emergency Stop Button (BPEMS) is also now being provided on locomotives to enhance the safety during the event of obstruction on line, road vehicle on line at level crossing etc.. When the train is required to be stopped immediately, the train can be stopped by simply pressing a BPEMS button available on driving desk. The pressing of BPEMS button results into opening of main circuit breaker, lowering of pantograph automatically and application of emergency brake.

(iii) Provision of OHE sensors on electric locomotives:-

OHE sensing device is now being provided on all conventional electric locomotives which gives a visual indication in loco cab even in panto lower condition. In existing method Loco Pilot has to raise pantograph and listen to spark sound carefully to check whether catenary voltage is available or not. Sometimes it takes multiple operation of pantograph and DJ which leads to run down of batteries and failure of the locomotive. Using this sensor, such types of incidences can be eliminated.

Carriage Repair Workshop, Harnaut, East Central Railway


(iv) Use of thermo electric cooling module for improving loco electronics reliability

Three phase electric locos are equipped with various types of sophisticated electronic cards. With increase of temperature, these cards sometimes start malfunctioning and result in loss of punctuality of trains. To overcome this situation, a thermo electric cooling module working in principle of Peltier effect has been provided in 9 locos on trial basis. It is capable of reducing the temperature of electronics by 7 to 8 degrees. These cooling modules are expected to improve the reliability of high horse power three phase locomotives considerably.

(v) Distributed Power Wireless Control System (DPWCS) for electric locomotives

Indian Railway is hauling about 1000 Million tonnes per annum and major share (about 65%) is hauled by 5000/6000 horse power freight electric locos. Now, all the major electrified routes are getting saturated with growth in both passenger and freight traffic and, therefore, running of more freight trains with existing configuration (i.e. with hauling locos in front of the train) is not possible. In this scenario, need for running of longer and heavier freight trains was felt by IR and accordingly indigenous development of DPWCS for electric locomotives was initiated. This system is capable of synchronized control of multiple locomotives in a distributed manner along the length of the train thereby allowing multiple choice train configurations. This system has a huge potential for hauling of longer and heavier freight trains as two or more locos attached in the train either next to leading loco or in the middle or rear of the train are wirelessly controlled by leading loco. This arrangement not only enhances the haulage capacity but also improves the acceleration and simultaneously results in increase of line capacity and reduction of coupler forces. Further, only one crew is required to be deployed in leading loco and rest are unmanned and wireless controlled by leading loco, therefore leading to saving of manpower and operating costs. So far 11 pairs i.e. 22 electric locos are, under extensive trials, being utilized on different routes over IR.

Modernization of Workshops

Central Organization for Modernization of Workshops (COFMOW) was set up in 1979. The organization plays a major role in providing consultancy and engineering inputs

BFNS Wagon

BOXNHL Wagon


for technology upgradation and improving productivity of manufacturing units, repair workshops and maintenance depots of IR.

COFMOW has kept itself abreast of global technological developments and acquired considerable expertise over the years in the fields of machinery selection and procurement. It has been instrumental in the dissemination of technical knowledge and employing for benefit of Railway Units.

COFMOW has also been assisting IR in preparation of technical specification, procurement, delivery and commissioning of machinery and plant including special purpose machines for exclusive application by the Railways. It has been actively engaged in organizing seminars on new technologies for the benefit of its customers. It has always been the endeavour of COFMOW to work towards development of indigenous suppliers for manufacture of special purpose machines.

COFMOW has recently been entrusted with the responsibility of procurement of Machinery & Plant items for locomotive components factory proposed to be set up at Dankuni. This entails preparation of technical specification, procurement and commissioning of the equipment on turnkey basis. COFMOW has placed purchase orders for 62 machines in record time.

COFMOW has recently embarked upon the journey of handling Turnkey works including construction of Civil and Electrical infrastructure besides procurement, installation and commissioning of machines. Two Works contracts valued at `127 crore have been awarded during the year 2012-13 for composite work of augmentation of production capacity at ICF for manufacturing of LHB coaches. This work is expected to get completed within the current financial year. Similarly, a tender with estimated value of `80 crore for Coiled Spring Manufacturing facility at ICF/Chennai is under process. Additionally, a Works tender with estimated value of `202 crore for axle manufacturing facility at RWF/Bengaluru is under process. Another tender for installation and commissioning of Robotic Garnet Blasting Plant for ICF on turnkey basis has been floated.

COFMOW has entered into the area of rate contracts for items purchased regularly. Rate contracts have already been finalized for Air Compressors, Welding sets and Road Mobile Cranes and Diesel Generating Sets.

BCFC Wagon (for fly ash)

Double Stack Wagon

BTPGLN Wagon (for LPG)

Rolling Stock - Indian Railways · PDF fileINDIAN RAILWAYS ANN uAL REpORT AND ACCO NTS 2012-13...

Documents

Transcript of Rolling Stock - Indian Railways · PDF fileINDIAN RAILWAYS ANN uAL REpORT AND ACCO NTS 2012-13...