Northern Railway Carriage & Wagon Workshop Jagadhri

Presentation by :

Sh P S Meena : Dy Chief Electrical Engineer

Sh Navtej Kumar : Sr Section Engineer Electrical

Presentation for National Award

for

“Excellence in Energy Management”

C&W Workshop Jagadhri -Introduction• First POH workshop of Northern Railway established in August 1952 under

the Ministry of Railway, Govt of India.

• Stretched over 286 Acres of land at Yamunanagar District of Haryana state.

• Work force employed – 5400 nos.

• Undertake Periodic/Inter-mediate overhauling of carriages & wagons.Turning out about 6200 of wagons & 2300 AC & Non AC coaches every year.

• Achieved certifications: ISO:50001:2011, ISO:9001:2008,OHSAS:18001:2007, ISO:14001:2004, ISO:3834-2, 5-S & Green Co GOLD Rated by CII-SGGBC.

• Energy Sources: Electrical Power Supply @ 66KV for 10923 KW connectedload, Contract Demand of 5200 KVA, and thermal fuels such as Coal, BMCG,DA, HSD, LDO.

• Renewable Energy (Solar PV Panels): On-site 1MWp SPP generates 33% oftotal electrical energy required.

• Annual Energy Consumption 609 MTOE.

• Periodic/ Intermediate overhauling of LHB & ICF types, Rajdhani,Shatabdi and other AC & Non AC coaches of Indian Railways.

• Periodic overhauling of all type of Wagons, except BTPN & BOBRN.

• Periodic overhauling of Maharaja & Buddhist Tourist coaches of IRCTC.

• Conversion of condemned coaches to NMG, Exhibition & Camp Coaches.

• Supply of turned wheels of different sizes to Railway’s other divisions.

• Supply of Intermediate overhauled Bogies (LHB/ ICF types) to divisions.

• Supply of components for Coaches & Wagons to Railway Divisions.

ACTIVITIES UNDERTAKEN

➢ 2016 - ISO:50001-2011 (EnMS) certification.

➢ 2017- Developed Centre of Excellence for CTRB, Electronic Repair & test laband Model RMPU repair section.

➢ 2017- 3rd Best innovation award for Development of Disc brake cylinderspecial tool & test bench for Knorr Bremse & FTIL make

➢ 2017 - 5-S Certification.

➢ 2017 - Certified for ISO: 3834-2 (Welding Quality Standard).

➢ 2017 - Certificate of Merit Awarded in Rly Workshop Category by BEE.

➢ 2018 - Green Co Gold Certified by CII-SGGBC.

➢ 2018- Energy Efficient Unit Award by CII during 19th Energy Summit.

➢ 2019- Energy Efficient Unit Award by CII during 20th Energy Summit

➢ 2019 - Got Overall Best Workshop Efficiency Shield from Rly. Boardsince last five consecutive years 2015, 2016, 2017, 2018 & 2019.

➢ 2020- Excellent Energy Efficient Unit Award by CII during 21st Energy Summit

MILESTONES OF JAGADHRI WORKSHOP

• POH Activities of the workshop were rescheduled with 50% staff

• Intake of LHB coaches in place of ICF coaches increased resultedin energy as well material savings

• Energy bill reduced by 7% in by shutting down light loads

• Partial working during lockdowns resulted in reduced energyconsumption by Air compressors, Furnaces and water pumps

• Working from homes resulted in reduction in Lighting loads by60% in offices

• Compressed outturn targets & redistribution of work in shifts hasresulted in resource optimization & minimum energy wastages.

• Overall SEC reduced by 23% by compressing the targets andincreasing productivity by work distribution in shifts by 15%w.r.t FY 2019-20.

IMPACT OF COVID-19

Fuel Wise Energy Consumption : 2020-21

280, 46%

42, 7%72, 12%

100, 16%

60, 10%

51, 8% 4, 1%

Distribution of total 609 MTOE

Electrical

RE Solar

LDO

HSD Oil

DA

BMCG

Coal

Energy Consumption TrendsEnergy Source 2017-18 2018-19 2019-20 2020-21

Electricity (lakh KWh) 41.72 38.24 35.23 32.54

Renewable Energy (lakh KWh)

0.01 2.01 5.04 4.92

HSD Oil (KL) 74.7 78.67 79.86 88.56

Hard Coke (MT) 40.8 13.0 8.46 9.5

Furnace Oil (KL) 130.3 123.5 120.1 75.5

BMCG (MT) 18.1 32.5 34.52 42.15

DA (Lakh m3) 0.60 0.49 0.52 0.05

Total Energy Usage MTOe 686 662 665 609

Equivalent Outturn Unit 8002 8304 8493 9238

SEC (MTOE/Eq Outturn) 0.086 0.080 0.078 0.066

%age Reduction in SEC - 7.0 2.5 15.4

SEC reduction w.r.t. the base year 2017-18= 23.3%

THERMAL ENERGY CONSUMPTION TRENDS

124.0118.0 115.0

72.0

84.088.5 90.0

99.6

22.0

39 42.050.7

80.0 65.0 69.4

60.0

16.3 5.2 3.43.80.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

2017-18 2018-19 2019-20 2020-21

LDO

HSD

BMCG

DA

Coke

MTO

E

Reasons for increase in consumption of HSD & Bharat Metal Cutting Gas:•HSD Oil : Non availability of Public transport during lockdowns has put additional load on inhouse transportation system for material Supply & collection.•BMCG: Workshop is switching over to BMCG from DA, hence the there is raise in BMCG during the year 2020-21

SPECIFIC ENERGY CONSUMPTION TRENDS

0.041 0.038 0.037 0.031

0.0450.042 0.041

0.035

0.0860.08 0.078

0.066

0.025

0.035

0.045

0.055

0.065

0.075

0.085

2017-18 2018-19 2019-20 2020-21Thermal Electrical Overall

MTO

E

23.3% Overall Reduction in SEC w.r.t base year 2017-18 is achieved through:•Regulated & Decentralize use of large sized Air Compressors.•Replaced 05 Reciprocating air compressors with VVFD controlled screw compressors•Replacement of conventional oil cooled welding sets with energy efficient IGBT based welding sets•Replaced old EOT cranes with VVFD controlled EOT cranes•Providing energy savers on 110 conventional welding sets•Replacement of Non star AC units with 3/5 star rated AC units.•100% replacement of conventional lights with LED lights and fans with Energy efficient fans•Use of natural day light by making provision of translucent sheets in roof sheds

NATIONAL BENCH MARKING

Details2020-21 2021-22

SECTarget

SECAchieved

Target for SEC Reduction

Internal Bench Marking kgOe/ Eq. Out turn

72.04 (8% reduction w.r.t

2019-20)

65.86(23.3%)

59.27(10%)

Lalaguda Workshop (137.22 kgOe/ECU during 2019-20

130.36(5% reduction)

-- --

Road Map to Achieve targets:➢ Phase wise replacement of Old and inefficient Air compressors & other M& P items ➢ Replacement of MS/GI compressed air pipes with Aluminum pipes.➢ Phase wise replacement conventional welding plants with IGBT based welding plants➢ Replacement of overage inefficient EOT cranes with new VVVF drive controlled cranes.➢ Provision of cooling towers in place of water Pond arrangements for Air Compressors➢ Relocation of distribution transformers as per load concentrations➢ Provision of VVVF drives on Traverser & EOT cranes➢ Segregation of essential, non essential, light & machines loads for better monitoring & control and

Introduction of online EMS system for entire workshop.➢ 1% value of every on going projects is utilised in Energy / Environment Saving projects.➢ Capacity Building & Training programme for all staffs through Saksham Project ➢ Periodic Internal & External Audits of the activities.

Targets To Reduce SEC:Short term targets:

➢ Periodic Internal & External Audits of the activities, Capacity Building through

regular Training programmes.

➢ Segregation of essential, non essential, light & machines loads 70% - 30%

lighting arrangement for better control & monitoring

➢ Online EMS system for another 25 locations.

➢ Provision of timer switches on light towers & occupancy sensors in offices.

Mid term targets:

➢ Relocation of distribution transformers as per load concentrations.

➢ Provision of remote switch on EOT cranes to ensure driver less operation.

➢ Replacement of 02 reciprocating air compressor with energy efficient screw

compressors of smaller hp.

➢ Replacement of hydraulic tools with electrical energy driven tools.

➢ Energy monitoring of all machines having load above 7.5kW/10hp.

Long term targets:

➢ Installation of Pf capacitors at load/motor end to minimize internal distribution

losses.

➢ Replacement of overage inefficient EOT cranes with new VVVF drive controlled

cranes.

➢ Provision of VVVF drives on Traverser & EOT cranes

Encon Projects in pipeline for the year 2021-22

SN Project description Quantity Expected annual

saving in lakh kWh

1 Replacement of One old 3ton EOT crane 01 no 0.07

2 Replacement of two old 10 ton cranes 02 nos 0.27

3Replacement of one old 150hp reciprocating Air

Compressor with 75hp screw compressor01 no. 2.67

4 Provision of Solar Light pipes 10 nos 0.12

5Replacement of oil type welding plants with IGBT based

welding plants20 nos. 1.28

5Provision of astronomical timer switch on High MastTower

20 nos. 0.27

6 70% - 30% lighting arrangement in sheds 05 sheds 0.11

7 Online GPS based Energy Monitoring System 01 Job 0.12

Expected savings during 2021-22 4.91

Total Pre COVID Electrical Energy Consumption 2019-20 40.27

% savings 12%

Considering unforeseen delays in project implementation target for Electrical SEC reduction has

Energy Saving Projects Implemented in 2018-19

SN Action Taken QtyInvestments (Lakh of Rs.)

Annual Saving (Lakh

of kWh)

Annual Saving @ Rs.

9.5/kWh (Lakh of Rs.)

Payback Months

1 Replaced inefficient

reciprocating 150hp air

compressors with 75hp screw

type Compressors.

02 Nos

41.16 6.22 59.2 09

2 Replaced non star AC units with

3/5 starred AC units

61 Nos

22.25 0.28 2.68 100

3 Installed 1MWp rooftop SPV

Panels

07Sheds

Nil Investment

4.28 26.19 0

4 Replaced old EOT crane of 5 toncapacity with energy efficientVVVF controlled new EOT crane

01 No. 25.19 0.13 1.24 20 yrs

5 Replaced old diesel operatedfork lift truck with batteryoperated version

04

Nos.

10.71 5.92 Mtoe 3.08 42

6 Replaced old MS/asbestos roof

sheets of sheds with translucent

sheets to maximize use of day

lights

20 Sheds

37.38 83.16 7.90 57

Energy Saving Projects Implemented in 2019-20

SN Action TakenQty

(Nos)Investments (Lakh of Rs.)

Annual Saving

(Lakh of kWh)

Annual Saving @ Rs.

8.52/kWh (Lakh of Rs.)

Payback Months

1 GPS based Control water pumpoperation. 2 3.86 0.67 5.72 8

2 Replacement of oil type weldingplants with IGBT inverter basedplants

14 22.62 1.18 10.07 27

3 Replacement of 90W ceiling fanswith energy efficient 50W ceilingfans

200 1.6 0.24 2.04 9

4 70% - 30% light switchingarrangements done in shed

1 0 0.02 0.19 0

5 Replacement of 100W exhaust fanwith 40W energy efficient exhaustfan

10 0.13 0.018 0.15 10

6 Replacement of 150 HP oldreciprocating air compressor with75 HP air cooled screw compressor

1 8.6 1.34 11.44 9

7 Replacement of Diesel operatedplatform trucks with Batteryoperated trucks

5 21.72HSD @ 12.5 KL

6.75 39

SN DescriptionQty

(nos)

Investment (in Lakhs of

Rs.)

Estimated Annualsavings

Pay back

months(lakh of kWh)

(Lakh Rs.)

1

Online GPS based Energy

Monitoring System (25

locations)

1 job 4.92 0.88 7.9 8

270% - 30% lighting

arrangement in sheds05

Inhouse

resources0.10 0.9 0

3

Replacement of 150 HP

old reciprocating air

compressor with 85 HP

screw compressor

2 48.38 2.32 20.85 28

4

Replaced convectional

welding sets with IGBT

base welding sets

10 7.50 0.84 0.75 13

Energy Saving Projects Implemented in 2020-21

Removal of Water Pumps used for water intake in RO systems

Objective: To overcome frequent failure of water

pumps and save electrical energy used for pumping

existing water pumps were removed and Feed of

water to 250 LPH capacity RO system was ensured

from overhead tanks by means of Gravity feeding.

Total 05 locations covered and 05 x 1.306kW pump

load removed.

Savings:

Energy: 297 days @ 2kWh/day/RO = 594 kWh

Total saving for 5 ROs = 2970 kWh

Annual Monetary Savings = Rs. 26730/-

Waste water Utilisation:

Approximately 150 to 250 litters of Waste water

generated by ROs is being utilised for watering of

near by vertical gardens and green patches

developed in the workshops. Annual water saving

potential of 250L x 297 days x 5 RO = 371.3 kL

generated

Innovative Project Implemented

RE TypeYear Investment

MadeInstalled Capacity

Annual Power

Generation (Lakh Kwh)

% of overall

electrical energy

On-site Grid

connected roof top

SOLAR PV Panels

2017-18 Rs. 6 Lakh 6KWp 0.067 0.16%

2018-19 RESCO Model 1.006 MWp 4.34 10.2%

2019-20 RESCO Model 1.006 MWp 12.18 28%

Solar Power

Plant in pipeline

2020-21RESCO model, tender under finalisation

3.15 MWp 46 100%

Utilization of renewable energy sources

Type of waste generated Qty. Method of Disposal

Outlived Passenger Coaches (Codal life of 25yrs)

65 nosRefurbished into NMG & Campcoaches (life extended by 15 yrs)

120 nos Auction to recyclers

Condemned Wagons 72 nos Auction to recyclers

Ferrous Waste 18099 MT Auction to recyclers

15 MT Utilized for Sculptures makingNon-Ferrous Waste 105.6 MT Auction to recyclers

E-waste 70 Kg Sale to HSPCB approved recyclers

Canteen bio-degradable waste 25 Kg/Day Feed to Bio Gas plant of cap. 25kg

Released Grease mixed with Kerosene Oil

85 kgReused as lubricant for Rail JunctionPoints lubrication

Battery Waste/ Used Batteries 494.57 MTAuction to HSPCB approvedRecyclers

Hazardous Waste

(Paint & ETP Sludge)120 Kg

Disposal through HSPCB approved agency, M/s GEPIL- Faridabad.

Released Oil/Used Oil 182.4 MTAuction to HSPCB approvedRecyclers

Utilization/disposal of Waste Material

Use of waste for Artistic Sculpture Making

GHG Management, Monitoring & Public disclosure System

• Excel Sheets are Developed to monitor, update & validatethe scope of emissions on monthly basis.

• Scope-1, 2 & 3 GHG emission data are collected centrallyby the planning cell on Monthly basis.

• GHG emission of JUDW is discussed & analyzed in everyEnergy Review Meetings held periodically.

• GHG emission of workshop displayed through digitaldisplay boards at the Entrance gates for General Public.

• Online continuous stack emission monitoring system(OCSMS) has been installed & Real -time data availabilityto CPCB, HSPCB and to public domain is under process.

GHG INVETORISATION

Absolute GHG Inventorization(in MT of CO2 eq.)

707 679 668594

3420

2785

2200

1686

312 249 238 2840

500

1000

1500

2000

2500

3000

3500

4000

2017-18 2018-19 2019-20 2020-21

Scope1

Scope2

Scope3

Absolute GHG Emission Reduction in w.r.t fy 2017-18:Scope -1 emission intensity reduction= 16.0 %Scope-2 emission intensity reduction = 50.1 % Scope-3 emission intensity reduction = 9.0 %

Specific GHG Inventorisation(in MT of CO2 eq/ outturn)

Specific GHG Emission Reduction in w.r.t fy 2017-18:Scope -1 emission intensity reduction= 27.3 %Scope-2 emission intensity reduction = 57.1 % Scope-3 emission intensity reduction = 20.5 %

0.088 0.082 0.0790.064

0.427

0.335

0.259

0.183

0.039 0.03 0.028 0.0310

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

2017-18 2018-19 2019-20 2020-21

Scope1

Scope2

Scope3

GHG MITIGATION EFFORTS➢ 28% substitution of overall energy consumption with RE (Solar PV) achieved

through 1MWp roof top Solar Plant . Further installation of additional 3.15MWp capacity is in pipeline through RESCO Model.

➢ Online stack emission monitoring system (OCSMS) installed on all LDO firedfurnaces. Emission parameters are available to the public domain & PCBauthorities.

➢ Wet scrubbers installed at all six LDO fired furnaces.➢ Emphasis is on bulk purchase of materials by increasing procurement powers of

the officials and hence utilisation of full capacity of transport vehicles.➢ Setting up of Divisional Store Depots having three months stock holding

capacity to avoid frequent material logistics.➢ Re-use of waste wherever possible. For e.g. Conversion of 211 nos Out-lived

Condemned coaches into NMG & camp coaches,➢ Internal Availability of material at Workshop Store Depot has increased to 98%,

this has resulted in less movement of staff and vehicles for material collectionfrom other depots.

➢ 2000 staff quarters are available at out-skirt of workshop and around 2600 staffas suburban pass holders commute through passenger trains ensure scope-3emission to negligible.

➢ Regular plantation drives, Planted about 5000 new plants in last three years.

Green Supply ChainSN Project Implemented Benefits

1 Tendering through E-Procurement system (IR ePS)

• Tangible benefits: Paperless working, reduced cycle time,improved availability of material.

• In-tangible benefits: Transparency, less requirement ofbusiness travel by firms.

2 E-Working though IMMS forgenerating demands, Purchaseorder/Modifications

• Paper less working, Improve performance, time saving.

3 E-Auction for disposal of scrap • Paper less distribution of catalog to likely buyers, Improveperformance, transparency, corruption mitigation & betterprice realization.

4 I-PAS 100% online payments to suppliers

5 Vendor Development Program • Environmental awareness & capacity building, Evaluatingsuppliers/ vendor environmental performance

• Developed AWSAR exhibition hall to educate & awarevendors on Green Co Parameters

• Organized offline/online training & awarenessprogrammes for venders

• Transport Partners were extended special awareness &training programme on environmental friendly practices.

• Pamphlet distributed to visiting drivers of truck/trailers.• Firms are contacted via mail/verbal communication to

adopt green packaging practices.

ENERGY MONITORING & MANAGEMENT SYSTEMS

• Digital Multi Function Meters installed at 110 different locations.

• 25 metering locations covered with GPS based Energy metering &

monitoring system and another 25 more locations coverage under

pipeline.

• Energy Performance of Shops/sections is monitored at Shop level and

reviewed by the respective Branch officer.

• With every project 1% fund is raised as environment fund to support

energy & environment conservation projects.

• Energy & environment conservation has been made as an integral part of

every training module.

• Energy performance of the workshop is also being monitored on monthly

basis at Railway board level through EEMS (Electrical Energy

Management System) portal.

• System is already in place for awarding best performing employees and

performance is being evaluated on the basis of saving of Revenue in

form of Energy & Materials

Team for Energy Monitoring in compliance of ISO 50001

Members of Energy Management Cell1. Chief Workshop Manager2. Dy Chief Electrical Engineer3. Sr. Section Engineer Electrical4. Sr. Section Engineer EHS

Members of Energy Management Team1. Dy Chief Mechanical Engineer/P,2. Dy Chief Mechanical Engineer/Wagon3. Sr. EDPM4. AWEE5. AWMs (03)6. Sr Section Engineer Electrical (10 in-charges)7. Sr Section Engineer Mechanical (23 in-charges)

EMPLOYEE INVOLVEMENT & CAPACITY BUILDING

Various Categories of Training Programs on Energy conservation

SN Awareness Programmes No. of Staff Participated

2017-18 2018-19 2019-20 2020-21

1 Green Co Awareness Program 162 273 1028 638

2 Awareness seminar on Energy

Conservation for Staff and Supervisors

during Energy Conservation week

64 168 2242 2483

3 Slogan writing competition conducted

during Energy Conservation Week 41 - -- --

4 Awareness Training on Energy

Management System ISO 50001 - 83 430 265

5 Factory /other workshop visits by

Supervisory staff40 12 35 6

6 Presentation on Energy Audit (ISO 50001) - 58 14 --

7 Energy Conservation & GHG mitigation

Training of staff under Project Saksham750 5040 5340 2820

Energy Conservation Awareness Programs

Presentations Energy conservation week celebration

EnCon Pamphlet distribution at main gate Slogans & Hoardings

Energy Week Celebration

Implementation of ISO 50001

Implementation of ISO 50001➢110 nos. AMR compatible meters installed for online monitoring.

➢Decentralized use of compressors, arrested leakages and extrapipelines & connections removed at supply side after survey.

➢Investment done on procurement of Energy efficient M&P itemsand on EnCon Projects in the yr. 2020-21 is Rs. 66.10 lakhs.

➢Next year’s energy saving targets are set on the basis of savingsexpected to be achieved by implementation of energy savingprojects.

➢Target set for enhancing the %age share of RE from 28% to 100%.

➢ Target for IGBC Existing Green Building certification of AdminBuilding has been achieved with GOLD rating.

➢ Target set for up gradation of CII Green Co Rating from Gold toPlatinum rating.

Awards and Acknowledgements

CII Green Co-Gold certification in 2018

National Energy Conservation Award, 2017 by BEE

CII- National Energy Management Award, 2018

Awards and Acknowledgements

Awards and Acknowledgements

Thanks Contact us: P S Meena Dy CEE/JUDW @ Mob. No. 9729530305Navtej kumar SSE/Tech/Elect @ Mob no. 9729530465Email : electchgjudw@gmail.com