Suresh Prabhu to inaugurate FIAT Rail Bogie Plant capable of manufacturing 600 LHB Bogie Frames per annum at Yadgir

Rail Bogie Karkhana at Yadgir on South Central Railway (a Pre-engineered building)

SECUNDERABAD: The FIAT Rail Bogie Karkhana, set up at Badiyal and Kadechur Villages in Yadgir District of Karnataka is to be inaugurated by the Union Minister for Railways Suresh Prabhakar Prabhu on 18th August, 2017. This will be the first Railway Production Unit to come up on South Central Railway.

The foundation stone for the Rail Bogie Karkhana at Yadgir was laid in February, 2014 and the work was awarded to M/s. Tata Projects Ltd., with the executing agency being the Rail Vikas Nigam Limited (RVNL). The Karkhana was completed at a cost of Rs. 80.92 Crore and has come up on 150 acres of land given free by Government of Karnataka to Indian Railways. The Karkhana is located 40 Kms from Raichur Railway Station on the way to Saidapur Railway Station and approximately 10 Kms from Saidapur Railway Station.

The background for setting up of Rail Bogie Karkhana, Yadgir

Indian Railways has taken a giant step in modernizing its fleet by replacing the conventional coaches, in a phased manner, with Linke Hofmann Busch (LHB) coaches. In addition to ensuring safe travel, these coaches are designed for higher passenger capacity with operating speed up to 160 km/hr.

At present the production capacity of the LHB Coaches is 2800 LHB Coaches per year at the different Railway Coach manufacturing facilities i.e. Rail Coach Factory, Kapurthala, Integral Coach Factory, Perambur and Modern Coach Factory, Raebareli.

One LHB coach requires two FIAT Bogies. The bogie manufacturing capacity however, in the above manufacturing units is only for 1600 coach sets per year.

In order to fill the demand gap, two new Bogie production units were sanctioned at Budge-Budge (Bengal) and Yadgir (Karnataka, South Central Railway) to manufacture FIAT bogie frames.  Thus the Karkhana will serve the purpose of enhancing the fleet strength of Indian Railways.

Inside View of Rail Bogie Karkhana at Yadgir

Salient Features of Rail Bogie Karkhana:-

Ø     This factory will comprise of manpower strength of around 470 personnel including Railway Employees, Outsourced Employees and local people on Indirect Employment.

Ø     The Karkhana is set up with Pre-Engineered Building (PEB) technology. The PEB sheds offer several advantages including superior architectural features and excellent aesthetics. They are fully fabricated in the factory premises after designing and shipped to site in CKD (completely knocked down) condition; and are assembled and erected at site with nut-bolts, thereby reducing the time of completion.

Ø     Further, most advanced methods of production processes have been established at Rail bogie Karkhana by installing sophisticated machinery and equipment to meet the requirements of high dimensional accuracy and reliability.

Ø     The Karkhana exemplifies a green and environment friendly approach with the use of initiatives such as –

  • Ensuring zero effluent discharge.
  • Solar electricity by setting solar panels on roof tops of the workshop shed and buildings up to 232 KVA.
  • Water harvesting mechanism and Water pond to collect run-off water
  • Plantation of 25000 trees in the open area of the project.

Ø     The Civic Infrastructure includes Service Buildings, Boundary Walls, Roads, Staff Quarters, Water Supply, Drainage, Sewerage, Earth Work, Horticulture and Two Wheeler Parking Shed etc., besides the main production unit which is made of PEB Shed.

Ø     Power Supply arrangements comprises of 11 KV Power Supply drawn from State Electricity authority with Electrical Sub-station and standby power production. A 232 kWp Grid connected Solar Plant is also set up.

Production Process

Ø     The side bogie frames are set on jigs & fixtures and initial welding is done manually. The bogie frames are then transferred to Robotic Welding line for full welding. The welded frames are then subjected to Shot blasting and painting. The painted bogie frames are fed to 5-Axis CNC machine centre for machining. The finished bogie frames are transported to Production Units at ICF/PER, RCF/Kapurthala as per demand.

Important Production Machinery

Ø     5-Axis CNC Machining Centre with ATC (Automatic tool changes) (Cost- Rs.25 cr approx)

  • 5 Axis CNC machine is used for machining of Bogie frames. The machine is capable of undertaking different rough and finish machining operations such as , Pre-milling, Milling, Chamfering, Drilling, Boring, Counter boring, Reaming, Threading, Tapping, Spot face milling etc using Automatic tooling selection transfer /exchange.  ATC has 48 tools with tool change time of 30 secs.
  • Capacity – One bogie per shift.

Ø     Robotic Welding Machine (Cost- Rs. 6 Cr approx)

  • The Six Axis Robotic Machine with articulated long arm type construction is used for welding of bogie. It can cover entire length of the side frame. It has tactile gas nozzle sensor, for seam tracking and uses tandem wire technology (twin wire).
  • Capacity – Two Bogie frames per shift.

Ø     Bogie Frame shot blasting Machine (Cost:  Rs.2.4 Crs Approx.)

  • The fabricated bogie frames are shot blasted with spinner hanger type shot blasting system for proper surface finish before painting. The plant has a blasting chamber, abrasive and dust collection system, bucket elevator and abrasive separator. The flow of shots to the blasting turbine wheels is controlled by the shot controller and the plant conforms to applicable PCB norms.
  • Capacity: 3 Bogie frames per shift.

Ø     Bogie Frame Painting Booth (Cost: Rs.3 Crs Approx.)

  • After shot blasting, the bogie frames are painted with high performance anti corrosive EPOXY 1st coat of primer and top coat of DFT 60 micron. The paint booth has overall length 6 mtrs, width 3.6 mtrs and height 6.1 metres for air less painting of bogie frame. The painted bogie frames are finally fed to 5 – Axis CNC machine for final machining. The plant conforms to applicable PCB norms.
  • Capacity: 2 Bogie frames per shift.
Solar Panels set up at Rail Bogie Karkhana in Yadgir towards Green Energy norms

Pre-engineered building

Constructed with pre-engineered building technology, the Karkhana’s sheds were fully fabricated on the factory premises and were shipped to the site in completely knocked down condition before assuming and erecting them.

It has most advanced methods of production with sophisticated machinery. The Karkhana has adopted several green measures including zero effluent discharge, water harvesting, and solar power.

The side bogie frames are set on jigs and fixtures and initial welding is done manually. The bogie frames are then transferred to Robotic Welding line for full welding. The welded frames are then subjected to shot blasting and painting before feeding to 5-Axis CNC machine centre for machining. The finished bogie frames are transported to production units at Integral Coach Factories, Perambur or Kapurtala as per demand.