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Important Achievement of PS & EMU Directorate during Last Five Years

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Important Achievement of PS & EMU Directorate during Last Five Years


Financial Year

Broad Area of Achievement

Title of Achievement

Description of Achievement

Likely Benefits

Current Status of Implementation



Efficiency & Passenger Amenities

Increase in passenger carrying capacity of EMU 18 coach EMU 29 Coach MEMU

Suburban services started with 8 coach train length, which has been now increased to 15-coach EMU train. This has increased the passenger carrying capacity per train thereby reducing overcrowding in EMUs. RDSO has already finalized operation of 18-coach EMU trains and 20 coach MEMU train in future.

Improved illumination and energy saving.

One coach with LED light was rolled out by RCF in Aug. 2009.



Green Technology

Coach Illumination with LED light

Lighting system in the coach changed from incandescent lamp to fluorescent lamp and now CFLs lamp are provided in coaches. Further, PS&EMU Directorate has now developed state-of-art, energy efficient LED based lighting system for coaches. One coach with LED light was rolled out by RCF in Aug. 2009. Use of high power white light emitting diode (LED) in lighting application with life of more than 50,000 of work hours will result in energy saving to the tune of 50%. Illumination level in this coach is 120 Lux.  In addition to energy saving, these are eco-friendly as well. Shortly this new lighting system shall be introduced in all the coaches.

Improved illumination and energy saving.

One coach with LED light was rolled out by RCF in Aug. 2009.




Reverse Cycle air conditioning system

Presently, the air conditioning system is having a heater coil which provides warm air inside the coach during winter. In order to eliminate the heating coils PS&EMU Directorate has designed and developed an air conditioning system with reverse heat cycle system. The equipment works on the concept of reverse cycle operation of refrigeration system. One such coach has been provided with this air conditioning unit in Jan. 2010.

Provide warm air to the passenger in winter without heating element

On trial basis, one 3 Tier AC coach has been working in Marudhar Express since 2010




Development of Head-on-generation (HOG) power supply system for coaches

Different power generation schemes are in use on Indian Railways to cater to hotel load requirements of the mail/ express trains. Two common schemes being used presently are Self-Generation (SG), wherein the train configuration has some air-conditioned coaches along with non-air-conditioned ones, and End-On Generation (EOG), wherein the train is constituted of all air conditioned coaches such as Rajdhani, Shatabdi and Duronto trains. RDSO has developed Head-On generation (HOG) scheme owing to its advantage of being environment friendly and energy efficient. Scheme          Approx.Cost of energy in Rs. per unit (kWH) SG                    8.33         EOG                         9.91    HOG                          4.85                                     In year 2007, Railway Board approved RDSO’s proposal for provision of Hotel load converter in electric locomotive. First electric locomotive no. 30277 WAP-7 equipped with Hotel load converter was manufactured by CLW. RDSO further developed the scheme to modify power car and coaches and conducted extensive trial to ensure satisfactory operation of air-conditioning and pantry equipments. Based on satisfactory trial, Railway Board has approved the introduction of HOG power supply scheme in commercial service.

Energy saving and  reduction in pollution & noise

The electric loco with HOG power supply has been hauling train no. 12005/12006, NDLS-Kolkata Shatabdi since 21.02.2011.



Green Technology

Specification for adoption of solar energy based systems

Specifications for the following items have been issued to Railways: a. Grid-connect solar generating system. b. Solar photovoltaic LED based street lighting system. c. Solar based water heating system for hospital/running rooms.

Environmental friendly technology & energy saving

Railways are installing these equipments as and when required.



Green Technology

Use of Eco Friendly Refrigerant

Under-slung air conditioned system for railway coaches was initially designed with R-12 refrigerant. This refrigerant is not environment friendly as it causes depletion of ozone layer in the atmosphere. As a part of Montreal Protocol, it was supposed to convert its entire air conditioning and refrigeration system of 1000 coaches to more environment friendly R-134 refrigerant. RDSO finalized the design and method by which the existing system can be made suitable to work with R-134 refrigerant in place of R-12 refrigerant. With the scheme issued by RDSO, the conversion work of 480 coaches was completed ahead of schedule in 2009, instead of 2010. Roof Mounted Air Conditioned Unit was developed initially in 1991 with R-22 refrigerant, which is also not environmental friendly. Basically, R-22 refrigerant is of the family of Hydro Chloro Fluoro Carbons (HCFC). HCFCs are not only depleting ozone but also are a potent greenhouse gas. The phase-out schedule for this refrigerant was accelerated through a decision of Montreal Protocol in September 2007. RDSO has already designed an alternative system by which new roof mounted air conditioning unit is to be developed with eco-friendly R-407 refrigerant in place of R-22 refrigerant. Prototype has already been tested. It is expected that shortly all the new coaches shall have air conditioned equipment working with R-407 refrigerant.  All the new air conditioning systems which were developed recently for Kolkata Metro and Double Decker are with eco-friendly R-407 refrigerant only. Thus, Indian Railways is way ahead in meeting the target and contributing in its own way in maintaining a green earth.

Environment friendly

Prototype of RMPU (Conventional) has been tested and are under trial (SCR). Prototype of RMPU (LHB) is under development as per the approved specifications.




.Energy efficient AC-DC EMU (Mumbai suburban Area) with forced ventilation system.

RDSO has prepared the specification, designed and developed these rakes which are more energy efficient due to re-generation of power. This energy efficient system has achieved 35% saving in energy consumption due to regeneration, microprocessor control and unity power factor. They are dual voltage and can used over both AC and DC areas. The forced ventilation system will give fresh air of 14535 cubic meter per hour (CMH) per coach. This will add to passenger comfort during the peak loading of EMUs (SDCL Loading).

Project has been registered with World Bank to obtain Carbon Credits on account of emission reduction. The Project Idea Note has been approved by the World Bank. With the introduction of new technology energy efficient EMU rakes, a reduction of 606 tons of CO2 emission per rake per year has been envisaged.   Conventional DC EMU rake consumes 2.7 million units of energy every year/rake while the new technology EMU rake consumes 1.6 million units of energy every year/rake. Thus with 174 new EMU rakes after MUTP Phase I, there would be a saving of 191 million electrical units of energy per year. With per unit cost @ Rs 4, the financial savings would be INR 764 million per year after MUTP – I.

115 EMU rakes of  12 cars rake and 15 EMU rakes of  9 cars have already put in to commercial services under the GP-194 and MRVC project.



Efficiency & Passenger Amenities

Development of Energy Efficient Low Noise & higher capacity Compressor

With the introduction of Air Springs and Air Dryer in EMUs, the air requirement has increased. While developing the higher capacity compressor, low noise features have been kept in view to comply with the Central Pollution Board’s norms. This will enhance the passenger comfort besides higher air delivery compared to the existing stocks where the compressor emits lot of noise leading to discomfort to passengers in EMUs.

Energy saving & passenger comfort




Efficiency & Reliability

Improvement in ventilation system

Ventilation in coach is provided through fan which used to work initially on 24V DC and subsequently on 110V DC. These fans were provided with metal blades which used to get deformed during handling and maintenance. PS&EMU Directorate developed a fan blade of fiber reinforced plastic (FRP) which can maintain its shape and profile for long period.  Air delivery by use of these blades improved by more than 10% as compared to metal blades.

Air delivery by use of these fan blades improved by more than 10% as compared to metal blades inside the coaches.




Passenger Amenities

Mobile & Laptop charging facility

There is a frequent demand for  providing charging facility to the mobile phones in the coach. PS&EMU Directorate has designed mobile and laptop charging points.

They provide required brightness even if 25% LEDs do not work in the tail light (safety item).




Passenger Amenities

Provision of toilets in MEMUs

For improving the passenger comfort in the medium distance  Main line EMU trains, the toilets are being provided in trailer coaches of MEMUs.

Onboard washroom facility  provides comfort to passengers.




Passenger Amenities

Passenger Information System Train Location Describer  Board in Coaches

To provide the information to passengers regarding the next station & various other information related to the passengers, a GPS based system has been developed. The GPS provides the location of the train thereby announcing and displays the next station. To earn revenue, the advertising featureshave also been included. Therefore, besides adding to the passenger comfort, it will also fetch revenue to the Railways.

Better facility to passengers

Implemented in AC-DC EMUs. For AC EMUs/MEMUs prototype unit has been developed and is under implementation.



Passenger Amenities & Efficiency

New state-of-the-art air-conditioned rakes for Kolkata  Metro

Design & development of new state-of-the-art air-conditioned rakes has been taken up by RDSO as the existing rolling stock is nearing completion of its intended life and new section for Kolkata Metro from Tollygunj to Garia has been opened. Design has been finalized for these rakes and 13 rakes are being manufactured at ICF.  Based on the past experience and technological improvements in metro rolling stock, new technology with advance features has been inducted in these rakes to improve safety and passenger comfort. Some of the features are:                                              • Microprocessor based brake system                   • Electrically operated door system                           • Air conditioning                                                                  • Air spring suspension                                                     • Stainless steel fittings                                                    • Passenger information system                                     RDSO has also finalized specification for future rakes for Kolkata Metro with 3-phase AC motors and more advance features like regenerative braking for substantial energy saving, stainless steel body, disc brakes, better passenger information system, CCTV for security etc. for future requirement of coaches. Outside View of Metro Coach

Metro travel has become more comfortable with more efficient state-of-the-art trains

9 rakes are in operation, 10th rake is under commissioning at Kolkata. Other rakes are likely to be supplied by the end of 2012.




Introduction of Stainless Steel AC EMU Coaches (Two 9 car rakes)

Introduction of corrosion free stainless steel coaches with aesthetic interiors and better seating arrangement

Increased codal life & lighter  weight material.

One 9 car rake has been turned out from BEML to Eastern Railway.



Reliability & Safety

Flashing Type tail lamp for EMU/MEMU, SLR, Power cars

PS&EMU Directorate has developed LED based flashing tail Light for EMUs, MEMUs, SLR, Power cars. The tail light is an important safety item for a train. Important safety feature of these tail lights is that they continue to provide the required brightness even if 25% of the LEDs have gone defective.

They provide required brightness even if 25% LEDs do not work in the tail light (safety item).



Source : WELCOME TO RDSO CMS Team Last Reviewed on: 07-12-2012  

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