STANDARD NOTE FOR PRODUCTION UNIT CLW AS ON 31.03.17

Contents

1. INTRODUCTION 2. SALIENT FEATURES 3. ORGANISATIONAL CHART 4. PRODUCTION PERFORMANCE 5. DESIGN&DEVELOPMENTINCLUDING TOT 6. QUALITY ASSURANCE 7. MARKETING INCLUDING EXPORT 8. STATUS OF M&P 8A. STEEL FOUNDRY 9. STAFF POSITION 10. UNIT COST OF THE PRODUCT 11. INDUSTRIAL SAFETY 12. FUTURE PLANS 13. OTHER ISSUES

INTRODUCTION

1

1. INTRODUCTION :

1.1 The Works and Administrative office of Chittaranjan Locomotive Works (CLW) are located at Chittaranjan, Dist. Burdwan in West Bengal. In addition, a Stores Purchase office in Kolkata and CLW’s inspection cells in New Delhi, Mumbai, Kolkata and Bangalore.

1.2 Chittaranjan Locomotive Works (CLW), is the first industrial gift to free India by the planners of the nation. The issue of setting up a locomotive building unit continued to be under active consideration of the Central legislature and in the late thirties, a committee consisting of M/s Humphries and Srinivasan was appointed to investigate the possibility of establishing a locomotive manufacturing unit and to consider its economic viability. The initial project at Chandmari, a place near Kanchrapara in the state of West Bengal, could not mature due to partition, which inevitably necessitated a change of site. The present site of Chittaranjan was selected after a fresh survey and Railway Board’s approval was obtained in the year 1947. The locoworks was initially established for production of 120 average sized steam locomotives with the capacity to manufacture 50 spare boilers. Production of steam loco commenced on 26th January, 1950. The first President of India, Dr. Rajendra Prasad dedicated the first steam locomotive to the nation on 1st November, 1950 and on the same day the factory which was called Locomotive Manufacturing Works, was named after the great Patriot, Deshbandhu Chittaranjan Das. Production of Diesel Locomotive was taken up during 1968. After manufacturing 2351 Steam Locomotives of 5 types and 842 Diesel Locomotives of 7 types, production of Steam and Diesel Locos were discontinued from 1971-72 and 1993-94 respectively. CLW is now manufacturing main line Electric Locomotives only. Upto 31.03.17, 6002 Electric Locomotives have been produced of different class (AC/DC, AC, DC & 3- phase).

1.3 CLW has augmented its production capacity for Electric Locos in phases besides absorbing 3-phase technology i.e from 60 to 80 Locomotives, 80 to 100, 100 to 130, 130 to 150, 150 to 180, 180 to 200, 200 to 230, 230 to 250, 250 to 280 and now up to 300.

1.4 Production of Traction Motors and control equipment commenced in April 1967. In the year 2016-17, upto

31.3.17, 1385 TM were produced.

1.5 Steel Foundry was set up in 1962-63 for production of steel castings for Steam Locomotives produced in CLW. It took up production of castings with the State of the Art technology provided M/S Rockwell International Corporation, USA in the year 1990-91. Steel Foundry/CLW has been accredited with CLASS- ‘A’ FOUNDRY certificate by RDSO on 9th August 2012.

1.6 CLW has in house facilities for machining and assembly of wheel sets, fabrication and machining bogies.

The facilities include modern CNG machines, Plasma Cutting machines, Inert Gas Welding etc.

1.7 CLW has an exclusive Centre for Design and Development with CAD/CAM facilities.

1.8 There is a well-established quality assurance/inspection for incoming material and stage inspection and final inspection of the CLW manufactured items.

1.9 CLW has been sanctioned “Creation of additional facilities for enhancement of production capacity” . The major works are:

1.Additional Bay of Loco Fabrication &Loco Assembly Shops. 2.Extension of Traction Motor Shops. 3.Additional Machinery &plant, Tools, jigs &fixture. 4.control Information Management System. 5.Augmentation to various Ancillary Shops.

1.10 CLW has acquired the ISO-14001 certificate on 26.4.2002 both for its works and township for a neat and clean environment. CLW has been awarded ISO 9001:2008 certificate for Quality Management System and OHSAS 18001:2007 for occupational health and safety management system.

1.11 Chittaranjan is a true example of Environment preservation and consciousness. Its lush green ambience talks of the efforts of the Administration as well as the residents of the township in the conservation of Environment, as well as using of all the existing natural resources in an eco-friendly manner. The concerted and unending efforts have been rewarded immensely by the World Environment Foundation and the Golden Peacock award for Environment Management 2006 had been conferred on 9th June 2006.

1.12 CLW has complied fully with the provisions of the Industrial Safety Act, 1948. CLW in its safety policy aims to ensure 100% safety for all workers working in Chittaranjan Locomotive Works. CLW is the proud recipient of the Safety innovation award 2006. The award was conferred on CLW on 6th September, 2006 by the Safety and Quality forum of the Institute of Engineers (India).

1.13 During the year 2015-16, CLW has moved towards toward complete switchover to 3-phase and started producing only 3-phase locomotives from year 2016-17.

1.14 During the year 2015-16, CLW has completely switched over from GTO to IGBT technology. The 1st

WAG-9 class freight loco No.31215 fitter with IGBT based Power Converter was commissioned on 18th December, 2009. Currently more than 600 CLW produced IGBT locomotives are running with IGBT based Power Converter on Indian Railways.

1.15 The first electric locomotive (WAP-7 type no. 30277) with Head on Generation (HOG) scheme was flagged off on 30th June ,2010. Up to March 2017, More than 50 such locomotives have been commissioned. TFP 7775 with double hotel load wining has been provided with Hotel Load Converter. The modified arrangement eliminates need of Autotransformer (used earlier to boost 750V to 960 V) and also reduces line to earth voltage from 2.4 kV to 750V, improving the overall reliability of HOG system.

1.16 High Reach Pantograph: Action has been taken for provision of one High Reach Pantograph in locomotives required for Dedicated Freight Corridor. Order for 100 Nos have been placed and two locomotives of BRC electric shed are being equipped.

1.17 Complete VCU redundancy: 5 locomotives have ben turned out with feature of complete VCU redundancy for avoiding necessity of cab changing in case of processor card.

1.19 Indigenous Wheel Discs for 3-Phase locomotives have been developed by SAIL and complete

requirement of material is sourced on SAIL Durgapur. 1.20 An automated new paint booth has been commissioned under AP-50 Project. In the paint booth PU

paining is being carried out in a controlled atmosphere. 1.21 VISIT OF MEMBER ELECTRICAL , RAILWAY BOARD TO CLW

Shri A.K. Kapoor, Member Electrical, Railway Board and Ex-Officio Secretary to Govt. of India visited Chittaranjan Locomotive Works (CLW) on 1st July 2016. He inspected various shops especially, traction motor shop, loco assembly shop & shell fabrication shop of CLW. He also reviewed the Electric loco production in CLW. Shri Kapoor held detailed discussions with senior officers and discussed relevant issues in the Conference Hall. In his brief address he appreciated the good work being done by CLW.

1.22 VISIT OF MEMBER ELECTRICAL , RAILWAY BOARD TO ELAAU AT DANKUNI UNIT OF CLW Shri A.K. Kapoor, Member Electrical, Railway Board and Ex-Officio Secretary to Govt. of India visited Electric Locomotive Assembly & Ancillary Unit (ELAAU) at Dankuni of Chittaranjan Locomotive Works (CLW) on 2nd July 2016 . He inspected the Dankuni unit of CLW and also reviewed the Electric loco production from Dankuni unit of CLW. The first loco of the year 2016-17, WAG-9H type ( 31751 ) was ceremonially flagged off by Shri A. K. Kapoor . Shri C. P. Tayal , General Manager along with other senior officers of CLW were present during this programme inside the workshop.

1.23 VISIT OF MEMBER MECHANICAL , RAILWAY BOARD TO CLW

Shri Hemant Kumar, Member Mechanical, Railway Board and Ex-Officio Secretary to Govt. of India visited Chittaranjan Locomotive Works (CLW) on 25th July 2016 . He inspected various shops especially, Loco Assembly Shop, Traction Motor Shop, Shell Fabrication Shop, Bogie Shop, Wheel Shop & Steel Foundry shop of CLW. He also reviewed the electric loco production in CLW. Shri Kumar held detailed discussions with senior officers and discussed relevant issues in the Conference Hall. In his brief address he appreciated the good work being done by CLW and wished a prosperous future. CLW Staff Council members presented a memorandum to the visiting dignitary to represent about current issues. 750th WAG-9H freight locomotive (31763) was ceremonially flagged off by Shri Hemant Kumar. Shri C. P. Tayal , General Manager , CLW along with other senior officers of CLW, were present during this programme inside the workshop.

1.24 Hon’ble MOSR dedicates CLW’s Electric Locomotive Ancillary & Assembly Unit at Dankuni to the

Nation Shri Rajen Gohain, Hon’ble Minister of State for Railways, Govt of India , dedicated the Electric Locomotive Assembly & Ancillary Unit at Dankuni (ELAAU-Dankuni) of Chittaranjan Locomotive Works(CLW) to the Nation by remote through video conference on 9th September 2016. Speaking on the occasion, from the inauguration site of New Jubilee Bridge of Eastern Railway, Hon’ble Minister of State for Railways dedicated this unit and appreciated the efforts for such successful endeavour and hoped that this unit will cater to the requirements of High Horse Power Electric Locomotives for Indian Railways. Shri C. P. Tayal, GM, CLW was also present at the site of inauguration alongwith General Managers of E.R, S.E.R & Metro Railway. A plaque was unveiled by Hon’ble Minister of State for Railways through remote .

1.25 “IROCON 2016 ” - 17TH CME & 10TH ANNUAL CONFERNCE OF IROPA HELD IN CLW

K.G. Hospital of Chittaranjan Locomotive Works (CLW) organised “IROCON 2016 ” - its 17th Annual CME along with 10th Annual Conference of Indian Railway Ophthalmic Physician Association (IROPA) at Chittaranjan Club from 21st to 23rd October, 2016. The programme was inaugurated by Dr. Anil Kumar , Director General, Railway Health Services/Railway Board as Chief Guest along with Shri C.P. Tayal , General Manager /CLW as President of the conference by lighting the lamp at Chittaranjan Club on 21st October, 2016. Delegates comprising Chief Medical Directors, Medical Directors, Chief Medical Officers, Chief Medical Superintendents, Ophthalmologists and other Doctors of various zones of Indian Railways and production units attended the programme. Smt. Amita Tayal , President , CLW-WWO along with members of CLW-WWO, Sr.Officers of CLW were also present on this occasion.

1.26 JUNIOR VIKAS SHIVIR ORGANISED IN CLW Junior Vikas Shivir was organised in Chittaranjan Locomotive Works (CLW) on 21st Oct.,2016 afternoon in Badhwar Hall of TTC, as part of the Rail Vikas Shivir scheduled on 18-20 Nov., 2016 at national level. The purpose of this Vikas Shivir was to generate new innovative ideas amongst the Railway employees to take the Indian Railways to next higher level. Shri C.P.Tayal, General Manager, Principal HODs, Senior Officers and Senior Supervisors of CLW were present in the Shivir. Among the 8 themes indicated by the Railway Board. The theme “LOOKING BEYOND FARE” was assigned to CLW to come up with ideas which can dramatically improve non-fare revenues through advertising and real estate developments.

1.27 73rd ALL INDIA RAILWAY FOOTBALL CHAMPIONSHIP IN CLW

73rd All India Railway Football Championship was successfully held at Chittaranjan Locomotive Works (CLW) from 7th Nov. 2016 to 12th Nov. 2016. Eight teams from South-Eastern Railway/ Kolkata, Central Railway/ Mumbai, Rail Coach Factory/ Kapurthala, Diesel Locomotive Works/ Varanasi, Integrated Coach Factory / Perambur, Metro Railway/ Kolkata, Western Railway/ Mumbai & Northern Frontier Railways/ Guwahati participated in the knock out championship.

1.28 BADMINTON CHAMPIONSHIP AT CLW

A badminton championship was organized by Chittaranjan Locomotive Works Sports Association (CLW-SA) from 24th to 26th January,2017 at the Badminton Hall of Chittaranjan. Officers of CLW and their family members participated in this keenly contested championship. Apart from this, Burdwan District Badminton Championship was also organized at the same venue from 20 to 23rd January. Chittaranjan Badminton Association in association with CLW-SA organized this district level competition in which a total of 148 matches were played.

1.29 CLW GYMNASTS SHINE IN ALL INDIA RAILWAY GYMNASTICS CHAMPIONSHIP

Kumari Pranati Nayak of Chittaranjan Locomotive Works Sports Association (CLW-SA) has emerged as the overall champion among girls in 46th All India Railway Gymnastics Championship held at Goghat Railway Colony from 19th January to 21st January, 2017. A three-member team of CLW took part in this championship, organized by Western Railway Sports Association. Kumari Pranati Nayak secured first position in Floor Exercise and Vault Table. She became runner up in Uneven Bars and got third position in Balance Beam. Her compatriots Kumari Sangita Biswas and Arpita Malik were joint second in Vault Table.Shri V.P.Pathak, GM, CLW has expressed his satisfaction for this achievement and congratulated all the members of the team.

1.30 HINDUSTANI SANGEET SAMAGAM BY CLW CULTURAL ASSOCIATION

A Hindustani Sangeet Samagam by Chittaranjan Locomotive Works (CLW) Cultural Association was organised on 28-01-2017 in the afternoon. The sangeet samagam was organised on classical singing, sitar & tabla playing. Shri V.P.Pathak, General Manager/CLW along with other Sr.Officers of CLW, Dr.Rekha Pathak, President/CLW Women’s Welfare Organisation, Shri G.Sreenivasa Rao, President/CLW Cultural Association were present on the occasion. All the artists were felicitated by presenting Uttariya by Shri V.P.Pathak, General Manager/CLW & Dr.Rekha Pathak, President,CLW Womens Welfare Organisation. Shri V.P.Pathak, General Manager appreciated the Sangeet Samagam by CLW Cultural Association and expressed the importance of classical sangeet. He urged the Cultural Association to organise such type of Cultural programmes in the future so that the classical music, which is the cultural heritage of the country should groom among the CLW employees.

1.31 CLW GOLFERS WIN ALL INDIA GOLF TOURNAMENT The Golf team of Chittaranjan Locomotive Works Sports Association has won the team event of 61st All India Railway Golf Championship , held at Patna Golf Club from 2nd Feb – 4th Feb,2017. A total of 16 teams participated in this championship which was organized by East Central Railway Sports Association. The CLW Golf team displayed superlative skill to clinch the title. Shri D.K.Gayan, GM/ E.C.Railway handed over individual trophies to each member of the team at the end of the championship. Shri V.P.Pathak, GM/CLW, has expressed his satisfaction for this achievement and encouraged all the members of the team to do better in future events.

1.32 INTER RAILWAY CULTURAL MUSIC COMPETITION IN CLW

A Three day Inter Railway Cultural Music Competition on Classical vocal, Light classical vocal & Instrumental was conducted by the Chittaranjan Locomotive Works Cultural Association (CLWCA) in Chittaranjan Locomotive Works (CLW) from 2nd to 4th March 2017. Shri V.P.Pathak, General Manager inaugurated the competition on 2nd March 2017 in Ranjan auditorium, as Chief Guest by lighting the ceremonial lamp. In this competition 19 teams from various railways participated & competed in the Classical vocal, light classical vocal & instrumental categories. On the Second day, that is, on 3rd March, 2017of the competition, Classical vocal event was organized, wherein 17 teams from different railways participated.

1.33 INTERNATIONAL WOMEN’S DAY CELEBRATED IN C L W

International Women’s Day was celebrated on 8th March, 2017 in the afternoon, at Ranjan Auditorium by the Chittaranjan Locomotive Works (CLW) Administration. Shri V.P.Pathak, General Manager/CLW graced the occasion as Chief Guest . Shri G. Srinivasa Rao, Chief Personnel Officer/CLW was also present as Chairman/CLW-Staff Benefit Fund Management Committee (SBFMC), along with Dr.(Mrs.)Tulu Chakraborty, Sr.DMO/ K.G.Hospital / Chittaranjan were also present on the occasion. Almost all the lady employees of CLW were present on this occasion of International Women’s Day. A cultural programme was also arranged to enthral the gathering followed by prize distribution to a selected group of women employees of CLW and to the winners of various competitions organised by CLW-SBF for this occasion.

1.34 NO SMOKING DAY OBSERVED IN CLW

In continuation to health education to railway employees and their families, No Smoking Day was organized by K G Hospital, CLW at Steel Foundry workshop on 10th March 2017. Dr. Alok Majumdar CMO/KGH presided over the function. Dr. Joydip Mitra, Sr. DMO, Dr. Rajarshi Kar, ADMO, Mr. B. Chakraborty, Dy CME/Plant, Mr. K K Chowdhury, AWM/Safety were also present on this occasion. Dr. Joydip Mitra, Sr. DMO gave the audio visual presentation on the occasion. He explained about the hazards of smoking tobacco, risk pattern of a smoker and a non smoker for various diseases. He told that a smoker intake 4000 kind of chemicals which is carcinogenic and very harmful to human body. Dr. Rajarshi Kar, ADMO in his speech discussed about the deadly effect of smoking related to ENT. He also said that smokers are more prone to lung, facial, mouth cancer, and showed various pictures of cancer patient. There was also Pulmonary Function Test (PFT) conducted for smokers to test their lung function. 30 employees were tested.

1.35 44TH DISTRICT RALLY BY BHARAT SCOUTS & GUIDES OF C L W.

The 44th District Rally of Bharat Scouts & Guides of Chittaranjan Locomotive Works (CLW) was held on 28-03-2017 & 29-03-2017 at Scouts Den in CLW. Dr. A. Majumdar, President, Bharat Scouts & Guides/Chittaranjan District and Chief Medical Officer/CLW inaugurated the 44th District Rally in the morning on 28-03-2017.About 250 volunteers of Scouts & Guides participated in this rally. Parade was presented by the Scouts & Guides and Scouts Anthem was sung . Later in the evening, The Annual Arts & Crafts Exhibition was organized at the Scouts Den. Dr. Rekha Pathak, President / CLW-Women’s Welfare Organisation ( CLW-WWO ) inaugurated the Exhibition. Dr Rekha Pathak visited different stalls of state exposition and appreciated the arrangements made by the volunteers . Different Cultural programmes were also organized on the occasion which were enjoyed by all. Appreciating the efforts of Bharat Scout & Guides of Chittaranjan District for organizing the Art & Craft Exhibition and Cultural programmes , Dr Rekha Pathak, President/ CLW-WWO had announced a group award of Rs 10000 from WWO . A Grand Camp Fire was organised at the “Circle of Joy” in scouts den in Chittaranjan in the evening on 29-03-2017 in which the campers of Scouts & Guides presented various cultural programmes. Shri V.P.Pathak, General Manager presided over the Grand Camp Fire. Shri V.P.Pathak, General Manager & Dr. Rekha Pathak, President/ CLW-WWO gave away the prizes to the winning groups and individuals .

1.36 INAUGURATION OF BULK MESSAGING SYSTEM IN CLW

Shri V. P. Pathak, General Manager /CLW inaugurates a bulk messaging system on 25.03.17, for the benefit of CLW vendors who will be intimated through SMS regarding the clearance of their payments. This system has been developed by the Electronic Data Processing Center of CLW under Accounts Department of Chittaranjan Locomotive Works . This facility will benefit the registered vendors about their payments status through SMS. Inaugurating this facility, Shri Pathak appreciated the efforts of EDP/Accounts Department and hope this facility may be extended to all vendors of CLW.

1.37 CLW GOLFER WINS ALL INDIA CHAMPIONSHIP 2017.

Shri Vinay Kumar Yadav of Chittaranjan Locomotive Works (CLW) won India Golf Union NCR Cup in All India Championship 2017 organised in Delhi Golf Club from 13th to 17th March,2017. Shri Yadav is a Golf player of CLW and was recruited in CLW under Sports quota. Shri V.P.Pathak, General Manager /CLW had congratulated Shri Vinay Yadav and appreciated the efforts of CLW Sports Association in encouraging the talents in participation in different championship.

SALIENT FEATURES

2

2. SALIENT FEATURES Salient features of CLW w.r.t the following :

2.1 Total turn over as on 31.03.17 a) For Indian Railways : Rs.3975.81 Crores b) For others : -- Nil Turn over ratio as on 31.03.17 – Break up of Turnover as on 31.03.17

Supply of Locos Rs. 3571.78 Crore Components manufactured for stock Rs. 387.06 Crore Supply of Spares for Zonal Railways Rs. 16.97 Crore …………………… TOTAL Rs: 3975.81 Crore

Turn over ratio of Store Deptt./CLW for 2016-17 (up to 31.03.17) Physical : 9.9% 2.2 Total assets : (as on 31.03.17) : Rs 407.25 crores

Fixed assets: (as on 31.03.17) : Rs 582.36 crores a) Township : Rs 11.19 crores b) Workshop with M&P : Rs 571.17 crores

Floating assets (as on 31.03.17) : Rs(-) 175.11 crores a)Stores : Rs 18.19 crores b)WMS : Rs.(-)215.39 crores c)Misc Adv. : Rs. 22.09 crores

2.3 Sanctioned and on-roll position staff as on (31.03.2017) group of staff i.e. Group A, Group B, Group C & Group D.

Group Sanctioned Strength On Roll Group A Gr. A + B = 236 106 Group B + CMP Doctors - 71+09 (CMP Doctors) Group C 14455 11346 Group D 63 63 Total 14754 11595

2.4 Elec. Power requirement (maximum demand) : 11MVA 2.5 Electric energy consumption : (in lakh units/year) : 407 Lakh unit (from 1st Apr’2016 to

31st Mar’ 2017) 2.6 No. of H.T. Sub station: A) 33/11 KV : 01 no.

B) 11/3.3KV : 01no. C) 11/0.4KV : 57 nos. D) 11/0.4KV : 21 nos.- under main shop.

2.7 Stand by power generation capacity(in KW) : 4228.78 KWH(as on 31.03.17) 2.8 Water consumption : 0.157 Lakh Kilo liters per day 2.9 (a)Workshop Land : 101.26 Hectare (b) Covered area of other service building (in SQM) : 35,241 Sq.m 2.10 Township area : 1,834.441 Hectares. 2.11 (a) Covered area in shops : 4,73,268 Sq.m 2.12 (a) Total staff as on 01.4.17 : 11,655 (b) Total number of staff quarters : 9,346 Nos. 2.13 Hospital (no. of beds) : 197 Nos.

ORGANISATIONAL CHART

3

ORGANISATIONAL CHART (UPTO JAG) AS ON 31.03.17) GM

CPO CMO CME CEE Secy. to GM COS FA&CAO CVO CE

Dy.GM Dy.CVO

Dy.CPO(W) Dy.CPO(A) CEE/CLW CEE/LOCO CEE/TM CEE/L&S CEE/PL&I CME/Loco Dy.CE/con-I (DKAE/Con)* Dy.CME/ELB FA&CAO(P) Sr. EDPM

Dy.CEE/D-I Dy.CME/ELF DyCEE/D-II Dy.CEE/M

CEE/Loco Dy.CEE/EL Dy.CEE/TMM Dy.CEE/D&D Dy.CEE/Insp/SBC (DKAE)* Dy.CEE/ELA Dy.CEE/TMD Dy.CEE/I&D/DLI* Dy.CEE/Loco Dy.CEE/I&D/Mum Dy.FA&CAO(I)

(DKAE) Dy.CME/I&D/HWH* Dy. FA&CAO(Kol) CQAM

CME/Prod/SF CME(Mfg) Dy.CME/Proj/Con/SF* Dy.CME/Mfg Dy.CME/Plant/SF Dy.CME/Plant Dy.CME/MPP/CON * CMM(CRJ) CMM/Kol(E) CMM/Kol(M) Dy.CME/M&P/CON* Dy.CC&M Dy.CMM/HQ* Dy.CMM-III/Kol Dy.CMM/I/Kol Dy.CMM/Project Dy.CMM-IV/KOL Dy.CMM/Sys/Con* Dy.CMM/Depot

Addl CMS/A Sr.DMO(P) Addl.CMS/G Sr.DMO(S) SR. DMO/FW SR. DMO(HU) Sr.DMO Sr.DMO Sr.DMO (eye) Sr.DMO/Anaesthesia V-Vacant *-WC Post

PRODUCTION PERFORMANCE

4

4. PRODUCTION PERFORMANCE

CLW built 2351 Nos. of Steam Locomotives and 842 Nos. of Diesel locomotives before switching over completely to the production of Electric Locomotives. The last Steam Locomotive was built in the year 1971-72. The production of Diesel locomotives continued up-to 31st March 1993 when the last ZDM-5 Narrow Gauge Loco was turned out. The total No. of conventional locos produced in CLW is 2607 Nos. (WAG-7=1770 Nos. & WAP-4 Locos=837 Nos) which got discontinued after 31st December 2016. Now CLW is involved in the production of Three Phase Electric Locomotives and maintenance spares required by Zonal Railways It has produced 6002 Electric locomotives till 31st March, 2017 . The annual out turn of various types of Locomotives during preciding years is given at Annexure – I & II. 4.1 ELECTRIC LOCOMOTIVES :

The production of Electric Locomotives was started in the year 1961. Till 31st March 2017, 6002 nos Electric Locomotives of various classes and traction have been produced as shown in the Annexure-III in two sheets. The present production of electric locomotives consists of:

i) 3-Phase AC Thyristor controlled 6000 HP, 6-Axle Frieght WAG-9H (with an Axle load of 22.5 Ton).

ii) Passenger version of 3-phase loco viz, WAP-5 with an axle load of 19.5 Ton having Micro

Processor controlled brake system for hauling Mail/Express and other super fast trains. iii) Passenger version of 3-phase Loco viz. WAP-7 with an axle load of 20.5ton having

Microprocessor controlled Brake system suitable for hauling Mail/Express and other super fast trains.

During the year 2016-17 (till the end of March 2017) CLW has manufactured 190 Nos WAG-9, 23 Nos WAP-5 and 79 Nos WAP-7 Electric Locomotives i.e. total 292 agaainst planned yearly out turn of 300 Electric Locomotives (As per JPO-71, Dt. 31-01-2017). CLW has planned to produce 350 nos Electric Locomotives during the year 2017-18(As per JPO-71, dt. 31.01.17). 4.1.1 Year wise production from 2000-01 to 2016-2017 YEAR

WAP-4 (RAJ)

WAG-7 (HH)

WAP - 5 (TP)

WAP-7 (TPP)

WAG-9 (TG)

Total

2000-01 Target 45 67 2 1 5 120

Actual 50 62 2 1 5 120

2001-02 Target 37 50 - 1 2 90

Actual 34 40 - 2 6 82

2002-03 Target 20 24 4 9 12 69

Actual 28 27 1 6 7 69

2003-04 Target 32 39 - 9 6 86

Actual 32 36 - 9 9 86

2004-05 Target 30 35 - 13 12 90

Actual 32 36 2 9 11 90 2005-06 Target 39 56 4 2 27 128

Actual 40 60 1 4 24 129

2006-07 Target 37 77 1 - 35 150 Actual 37 77 - 1 35 150

2007-08 Target 47 98 3 3 49 200 Actual 47 98 3 3 49 200

2008-09 Target 51 115 4 20 30 220

Actual 51 115 3 20 31 220 2009-10 Target 40 120 5 20 45 230

Actual 40 120 3 18 39 220 2010-11 Target 35 95 15 30 55 230

Actual 40 120 12 18 40 230

2011-12 Target 30 100 15 30 55 230 Actual 44 126 12 19 45 246

2012-13 Target 20 100 15 40 75 250

Actual 37 123 13 40 57 270

2013-14 Target 20 80 30 50 95 275 Actual 27 100 13 31 93 264

2014-15 Target 35 70 07 40 98 250 Actual 35 70 07 40 98 250

2015-16 Target 30 35 17 58 140 280

Actual 30 35 17 58 140 280

2016-17 As per JPO-68, Dt.18.10.15 (As on 31.1032016)

Target 00 00 30 95 175 300 Actual 00 00 23 79 190 292

47 51 40 40 4437

2735 30

0

98

115 120 120 126 123

100

70

35

03 3 312 12 13 13 7

17 23

3

20 18 18 19

4031

40

58

79

49

3139 40 45

57

93 98

140

190200

220 220230

246

270 264250

280292

0

50

100

150

200

250

300

350

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (JPO-71 dt.31.01.17)

Year wise Electric Loco production from 2007-08 to 2016-17(As on 31.12.17)

WAP-4

WAG-7

WAP-5

WAP-7

WAG-9

Total

4.2 TRACTION MOTORS:

4.2.1. Cumulative production of Traction Motors during the year 2016-17 has been 1385 Nos. ( 1315Nos. Co-Co & 70Nos. Bo-Bo). Production of Hitachi Traction Motor type HS-15250A has been discontinued from the year 2016-17.

4.2.2 3-PHASE TRACTION MOTORS TYPE 6FRA 6068 & 6FXA 7059: 3-Phase Traction Motor type 6FRA 6068 for WAG-9 and WAP-7 Locomotives and 6FXA 7059 for WAP-5 Locomotive are being manufactured indigenously by CLW since 1998-99 and 1999-2000 respectively. Upto March ’17, CLW has manufactured 7120 nos. 6FRA-6068 (Co-Co) and 383 nos. 6FXA-7059 (Bo-Bo). During the current fiscal, a total of 1385 Nos. three-phase Traction Motors (1315 nos. 6FRA 6068 and 70 Nos. 6FXA 7059) have been manufactured at CLW. These Traction Motors, due to absence of Commutator and Commutator peripherals like carbon brushes, brush holders etc., need minimal maintenance and are free from problems associated with DC Traction Motors.

Following Bar chart shows the production trend of Traction Motor at CLW with emphasis of 3-phase Traction Motors:

YEARWISE PRODUCTION OF TRACTION MOTORS

4.2.3 STATIC EQUIPMENTS: Static Equipments were required for manufacture of conventional locomotives (WAG7 / WAP4). Due to the closing of conventional loco production, Static Equipment’s manufacturing have also been discontinued from 2016-17.

4.2.4 SUPPLY OF SPARES : The following materials were supplied to zonal Railways as spares during the year 2016-17 against their sanctioned RSPs / vetted indents :

4 0 4 8 5 24 44 43 60 42 19 30 70128

205276 321 316

390 373 332

564

844759

1019

1315

417

726 761

896 881815

1000900 913

676 672

465549

9311041

1225 1202 1229

1417

1275

1537 15621450

15141385

0

200

400

600

800

1000

1200

1400

1600

1800

04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 2016-17

6FXA 7059 6 FRA 6068 HS 15250 A Total

I T E M

3 Phase Traction Motor (Co-Co)

Smoothing Reactor (SL)

Complete Rotor (Co-Co)

4.2.5 IMPROVEMENTS TO ENHANCE RELIABILITY To improve reliability and performance of 3 Phase Traction Motors, modifications as listed below have been

implemented :

To arrest the failure of Bearing seizures, dimension of End Frame (DE) has been revised w.e.f. 03.11.16 as per RDSO’s Amendment No. 1 of Modification Sheet No. RDSO/2012/EL/MS/0415 (Rev ‘0’) dated 24.12.13

To drain out the excess gear case oil, three cuts in Outer Bearing Cap (DE) has been implemented vide

RDSO’s Modification Sheet No. RDSO/2016/EL/MS/0439 . 4.2.6 INNOVATIONS & DEVELOPMENTAL WORK IN T.M . SHOPS

One Coil spreading machine has been shifted to Hitachi Field coil insulation section and 31 surplus staff have been engaged for 3-Phase coil manufacturing.

One new bay for stacking of 3infrastructure of Hitachi TM which were lying idle with certain modifications.

One new CNC Turnmill centre in TM/Shop 20 was inaugurated by Hon’ble GM on 23.11.16. The macwill augment the outturn of Rotor Shaft.

One V.M.C. machine in TM/Shop 20 was modified and programming done for keyway milling of Rotor Shafts. The machine was idle after discontinuation of Hitachi TM production.

Production Performance of Manufactur

Sl.No.

Name of Item

1 Wheel Set Assembly

2 Stator 3 Phase (G9/P7/P5)

3 WAP-7 Head Stock

4.3 Production Performance of Steel Foundry :4.4.1 Production & Despatch of Steel Castings over last five years

2976 2770

4094

0

1000

2000

3000

4000

5000

2012-13 2013

Qty. I T E M Qty.

Co) 06 Hitachi Traction Motor

25 Hitachi Armature Shaft

01 Complete Stator (Co-Co)

MENTS TO ENHANCE RELIABILITY: To improve reliability and performance of 3 Phase Traction Motors, modifications as listed below have been

To arrest the failure of Bearing seizures, dimension of End Frame (DE) has been revised w.e.f. 03.11.16 as per RDSO’s Amendment No. 1 of Modification Sheet No. RDSO/2012/EL/MS/0415 (Rev ‘0’) dated

To drain out the excess gear case oil, three cuts in Outer Bearing Cap (DE) has been implemented vide RDSO’s Modification Sheet No. RDSO/2016/EL/MS/0439 (Rev ‘0’) dated 23.11.16

INNOVATIONS & DEVELOPMENTAL WORK IN T.M . SHOPS : One Coil spreading machine has been shifted to Hitachi Field coil insulation section and 31 surplus staff

Phase coil manufacturing. or stacking of 3-Phase Stator and Rotors have been started by utilizing the existing

infrastructure of Hitachi TM which were lying idle with certain modifications. One new CNC Turnmill centre in TM/Shop 20 was inaugurated by Hon’ble GM on 23.11.16. The macwill augment the outturn of Rotor Shaft. One V.M.C. machine in TM/Shop 20 was modified and programming done for keyway milling of Rotor Shafts. The machine was idle after discontinuation of Hitachi TM production.

Production Performance of Manufacturing Shops

2015-16 2016-17

Comparison of Prod.2016-17 with2015-16

265 L/S 300-3/6 L/S +13.2%

502 Nos. 583 Nos. (+) 13.9%.

34-5 L/S 40 L/S (+) 15.5%

roduction Performance of Steel Foundry :

Production & Despatch of Steel Castings over last five years—

2770 2500 22852632

2018 2010

2013-14 2014-15 2015-16

Production Despatch

Qty.

109

98

06

To improve reliability and performance of 3 Phase Traction Motors, modifications as listed below have been

To arrest the failure of Bearing seizures, dimension of End Frame (DE) has been revised w.e.f. 03.11.16 as per RDSO’s Amendment No. 1 of Modification Sheet No. RDSO/2012/EL/MS/0415 (Rev ‘0’) dated

To drain out the excess gear case oil, three cuts in Outer Bearing Cap (DE) has been implemented vide (Rev ‘0’) dated 23.11.16

One Coil spreading machine has been shifted to Hitachi Field coil insulation section and 31 surplus staff

Phase Stator and Rotors have been started by utilizing the existing

One new CNC Turnmill centre in TM/Shop 20 was inaugurated by Hon’ble GM on 23.11.16. The machine

One V.M.C. machine in TM/Shop 20 was modified and programming done for keyway milling of Rotor

Comparison of Prod. 17 with

23791899

2016-17

4.4.2 Production of Despatch of FC Bogies over last Five years

4.4.3 Production & Desp. Of RIC Bogie Castings over last five years

YEARLY OUTTURN OF ELECTRIC LOCOMOTIVES FROM CLW

Year

WCM-5

DC WCG-2

ACMT WAG-1 WAG-4

ACMT (WK) WAM-4B

WAG-5A

ACMTWAP-1,3,4

1961-62 05

1962-63 14

1963-64 2 2

1964-65 27

1965-66 32

1966-67 57

1967-68 50

1968-69 28

1969-70 31

1970-71 3 41

1971-72 6

66

9895

67

0

20

40

60

80

100

120

2012-13 2013-14

51

120

4633

0

20

40

60

80

100

120

140

2012-13 2013-14

Production of Despatch of FC Bogies over last Five years—

Production & Desp. Of RIC Bogie Castings over last five years—

AnnexureYEARLY OUTTURN OF ELECTRIC LOCOMOTIVES FROM CLW

ACMT WAP1,3,4

ACMT WCAM-4

WAG-7

DC WCM-6 WCG-3

ACMT WAM -4

WAG- 9

WAP -5

WAP-7

06

40

112

30

6756

65

14 2014-15 2015-16

Production Despatch

54

3

33

14

50

14 2014-15 2015-16

Production Despatch

Annexure – I

WAP

Grand Total

5

14

4

27

32

57

50

28

31

50

46

0 2

2016-17

2032

2016-17

1972-73 14 41 55

1973-74 14 36 50

1974-75 13 1 32 46 1975-76 4 4 46 54

1976-77 3 13 28 44 1977-78 18 41 59

1978-79 5 11 40 56 1979-80 2 6 43 51

1980-81 11 4 54 69

1981-82 17 33 50 1982-83 2 51 53

1983-84 17 21 9 47 1984-85 49 1 50

1985-86 54 54 1986-87 70 1 71

1987-88 65 1 66

1988-89 98 2 100

1989-90 100 5 105

1990-91 102 8 110

1991-92 104 10 1 115

1992-93 108 12 5 125

1993-94 105 15 20 140

1994-95 105 15 30 150

1995-96 61 14 59 1 135 1996-97 25 18 111 1 155

1997-98 28 137 165 1998-99 45 112 8 165

1999-00 60 50 8 1 1 120

2000-01 50 62 5 2 1 120

2001-02 34 40 6 - 2 82

2002-03 28 27 7 1 6 69 2003-04 32 36 9 - 9 86

2004-05 32 36 11 2 9 90 2005-06 40 60 24 1 4 129

2006-07 37 77 35 - 1 150 2007-08 47 98 49 3 3 200

2008-09 51 115 31 3 20 220

2009-10 40 120 39 3 18 220

2010-11 40 120 40 12 18 230

2011-12 44 126 45 12 19 246

2012-13 37 123 57 13 40 270

2013-14 27 100 93 13 31 264

2014-15 35 70 98 07 40 250

2015-16 30 35 140 17 58 280 2016-17 0 0 190 23 79 292

TOTAL 21 57 268 54 1067 843 53 1770 02 500 895 113 359 9195

Summary as on 31.03.2017

Steam locos – 2351 nos. Diesel locos – 842 nos.

Electric locos – 6002 nos. Total -- 9195 nos.

Annexure - II

ANNUAL PRODUCTION OF TRACTION MOTORS AT CLW

Year MG-1580 TAO-659 HS15250A 6FRA6068 6FXA7059 TOTAL 1969-70 92 - - - - 92 1970-71 92 - - - - 92 1971-72 18 129 - - - 147 1972-73 - 75 - - - 75 1973-74 - 195 - - - 195 1974-75 - 255 - - - 255 1975-76 4 349 - - - 353 1976-77 12 233 - - - 245 1977-78 12 425 - - - 437 1978-79 8 425 - - - 433 1979-80 8 385 - - - 393 1980-81 10 432 - - - 442 1981-82 5 430 - - - 435 1982-83 8 420 - - - 428 1983-84 4 361 - - - 365 1984-85 1 305 - - - 306 1985-86 3 325 - - - 328 1986-87 12 440 - - - 452 1987-88 6 380 - - - 386 1988-89 8 350 79 - - 437 1989-90 14 350 - - - 364 1990-91 9 450 21 - - 480 1991-92 5 500 80 - - 585 1992-93 6 500 95 - - 601 1993-94 2 400 250 - - 652 1994-95 - 220 422 - - 642 1995-96 - 92 630 - - 722 1996-97 - 36 701 - - 737 1997-98 - 4 750 - - 754 1998-99 - - 755 6 - 761 1999-00 - - 600 6 4 610 2000-01 - - 528 30 - 558 2001-02 - - 400 36 4 440 2002-03 - - 320 76 14 410 2003-04 - - 392 124 8 524 2004-05 - - 417 128 4 549 2005-06 - - 726 205 - 931 2006-07 - - 761 276 4 1041 2007-08 - - 896 321 8 1225 2008-09 - - 881 316 5 1202 2009-10 - - 815 390 24 1229 2010-11 - - 1000 373 44 1417 2011-12 - - 900 332 43 1275 2012-13 - - 913 564 60 1537 2013-14 - - 676 844 42 1562 2014-15 - - 672 759 19 1450 2015-16 - - 465 1019 30 1514 2016-17 - - - 1315 70 1385 Total 339 8466 15145 7120 383 31453

DESIGN & DEVELOPMENT

INCLUDING TOT

5

5. CENTRE FOR DESIGN & DEVELOPMENT

5.1. Dual Mode Locomotive:

Development of Multi Traction Hybrid passenger Locomotives (MTHPL) is aimed at bridging gap between electrified and non-electrified routes of Indian Railways. MTHPL shall enable operational flexibility for operating same locomotives on main line as well as in goods yards, sidings and in shunting sheds, which are non-electrified.

Status: A total 05 (five) Locomotives sanctioned by Railway Board (vide RSP 2016-17, Item No.1161). Functional requirement Specification (FRS) prepared by RDSO. CLW has also prepared salient design features giving emphasis on weight reduction techniques, use of state-of-art

technology etc. Pre-application conference held in March’16 to facilitate the prospective manufacturers. Expression of Interest (EOI) floated on CLW website. Specification and Special Conditions of Contact finalized. Tender floated and scheduled to be open on 26.05.2017

5.2. Upgradation of WAG-9H locomotive to 9000 HP:

The project for upgradation of the existing 6000 hp WAG-9H locomotives to 9000 hp with suitable modifications in propulsion equipment has been taken up by CLW. It shall lead to higher traffic throughput, better line capacity, reduced stalling, increased reliability and improved overall performance.

Status: Functional requirement Specification (FRS) prepared. Expression of Interest (EOI) uploaded on CLW website. Pre-application conferences held in Sept’16 and October’16 at CLW for better appreciation and clarification. Estimate finalized. Meeting held with manufacturers on 10.03.2017 at Railway Board. Specification under finalization by RDSO.

5.3. Centre of Excellence at CLW:

The rationale to set-up Centre of Excellence at CLW is as follows:

To become self reliant in the field of design of Electric Locomotive equipment. To cater to domestic requirement of adoption of new technology in locomotives. To become technology exporter. To come in a position to cater to the emerging world market as per the customized requirement.

Project details: Total 04 projects have been envisaged under Centre of Excellence at CLW:

Project-1: (a) Center for Simulation and Evaluation of Suspension/ Bogie & Traction System.

(b) Electric loco modeling, virtual modeling and simulation.

Project-2: Laboratory for Development and evaluation of Power Electronics Applications (Setting up of PCB Lab). Project-3: Software development Lab. Project-4: Laboratory for development and evaluation of Electrical Insulation Materials

Status:

Specifications for all projects finalized. Detailed estimated sanctioned by GM/CLW. NSR approved by Finance.

Special Conditions for Contract & Eligibility Criteria for all 04 projects prepared and approved by competent authority.

Tender opening for all projects scheduled on: 21.5.17. Pre-bid conference for all projects to be held on 24.04.17.

5.4. Development of Hotel load Converter:

This is for utilizing OHE power for supply of hotel load requirements of Shatabdi/Rajdhani trains through HOG Scheme by providing Hotel Load converter in the locomotive. Order placed on M/s Siemens, BHEL, ABB, AAL, Medha and Hind rectifier. Status: Siemens: 1st Hotel load converter fitted in 30277 (WAP-7) and dispatched to GZB on 30.06.2010. Commercial service of the

loco started on 21.02.2011. Presently 37 locomotives with Siemens supplied Hotel load converters are running. 6 more sets have been received at CLW. Under installation at CLW.

MEDHA: Ist HLC Loco No. 30375 (WAP-7) dispatched to ELS/GZB. Presently 15 locomotives with Medha supplied Hotel load converters are running. 32 sets are in the process of installation

BHEL: 1st set commissioned on loco No. 30426 and dispatched to ELS/RPM in Aug.’15. Supply of balance quantity to commence after successful completion of field trial of the prototype set by RDSO. 35 more sets are yet to be received at CLW. AAL: 1st set commissioned on loco No. 30502 and dispatched to ELS/HWH in Nov.’16. Supply of balance quantity to commence after successful completion of field trial of first unit..

ABB: 1st set commissioned on loco No. 30510 and dispatched to ELS/BRCY in Dec.’16. Supply of balance quantity to commence after successful completion of field trial. 03 more sets are yet to be received at CLW. Status: Tender No. 70/18/1125 as per Specification No. CLW/ES/3/IGBT/0490 Alt. D upload on CLW website for 99

Loco/sets. Tender scheduled to open on 21.4.2017.

5.5. Indigenous development of TCN compliant vehicle control system through C-DAC

This project has been undertaken through C-DAC for development of TCN compatible vehicle control system which will ensure compatibility between open standard equipments of different makes. MoU is for developing 02 sets of TCN compliant vehicle control system. Firms have been approached through EOI for transfer of technology from C-DAC for development of new vendors. Status: 1st unit commissioned on loco No. 31356 (WAG-9H). Loco dispatched to ELS/TKD. Performance is satisfactory. 2nd unit commissioned in loco No. 31778 and dispatched to ELS/WAT in August’16. Agreement for Transfer of Technology of TCN compliant vehicle control system signed between CGL, ABB & BHEL

with C-DAC. Tender for 50 Locosets opened on 25.07.2016. PO placed for 24 sets Remaining 26 sets decided for retender. 50 sets sanctioned in RSP for 2017-18.

Tender No. 70/17/1142 for 76(26+50) Loco/sets to be open on 28.4.2017.

5.6. Development of Wireless remote control for control of slave locomotives on a train.

This project has been taken up as per RSP provision. The project shall help in development of wireless communication amongst locomotives in a train formation leading to better adhesion and other operational advantages. 2 sets of this system have been ordered on M/s ARC Bangalore for 3-phase locomotives.

Status: The prototype has been installed in loco nos. 31282 (WAG-9) & 31284 (WAG-9). Loco has been put into commercial

service w.e.f. 18.05.2012. 2nd set has been installed on Loco No. 31525 & 31526 and dispatched to ELS/TATA. Field trials completed. Tender for 75 sets have been opened on 27/10/2016 PO placed on M/s ARC- 45 nos., M/s Lotus-20 sets, M/s GE-10 sets.

5.7. Provision of Crew voice & video recording system on 3-ph passenger locomotives:

The project for provision of Crew voice & video recording system on 3-ph passenger locomotives has been taken up for effective and tamperproof video and voice recording of locomotive cab/EMUs driver’s cab and track view for post event analysis. Status: System to be provided on 3-ph passenger locomotives. Specification has been prepared by RDSO. Expression of Interest (EOI) floated on CLW website and 6 offers were received. Category amendment has been done. Tendering under process.

5.8. Development of Alternate Drive Gear Assembly for WAP5 AC Electric Locos (160 Kmph)

This project will address the reliability issues of the presently used Hurth coupling by way of improved design of the transmission system. P.O. of 5 loco sets (20 Nos.) of new type of Drive Gear system placed on M/s Arihant Electricals.

Status: One locoset commissioned in Loco No. 30056 (WAP-5). Loco sent to ELS/Vadodara on 15.11.2012. Presently 03 locomotives with above Drive Gear system suitable for 160 kmph are running under ELS/BRCY and 01

locomotive under ELS/GZB. Expression of interest (EOI) for development of Alternate Gear Drive System for WAP-5 locomotives called for the

proliferation of the system. 08 Nos. offers received. Pre-application meeting with above firms and RDSO held in April’16 at CLW. Technical specification finalized by RDSO. Tender floated for the procurement of 20 locosets scheduled to open 31.05.2017.

5.9. Development of Alternate Drive Gear Assembly for WAP5 AC Electric Locos (200 Kmph).

This project will address the reliability issues of the presently used Hurth coupling by way of improved design of the transmission system. P.O. of 2 loco sets (08 Nos.) of new type of Drive Gear system placed on M/s Arihant Electricals.

Status: Prototype unit commissioned on loco No. 30086. Loco dispatched to ELS/GZB in Oct’15. Balance set to be supplied after successful field trial.

5.10. Indigenous development of propulsion system:

IGBT based 3-phase propulsion system consists of traction converter, auxiliary converter, and control electronics (Vehicle control unit).

Orders have been placed on M/s BHEL, M/s MEDHA, M/s ABB, M/s AAL, M/s SIEMENS & M/s CGL, M/s BTIPL.

Status:

BHEL: 1st locoset installed on Loco no. 31347 (WAG-9) dispatched to ELS/LGD on 11.7.2012. 20 more locomotives have been commissioned and running in field. MEDHA: 1st set installed on loco No. 31427 (WAP-7) dispatched to ELS/LGD on 31.10.2013. Presently 29 locomotives with M/s Medha supplied propulsion system are running under different shed. Further, P.O. has been placed for 48 L/sets. 02 L/set supplied to DLW. 08 L/sets supplied at CLW are under commissioning

ABB: P.O. has been placed for 04 L/sets. Design document approved Inspection under process.

AAL (THOSHIBA): P.O. has been placed for 16 L/sets. Supply yet to commence.

SIEMENS: P.O. has been placed for 01 L/set. Supply yet to commence.

CGL: P.O. has been placed for 01 L/set. Design document approved Supply yet to commence. BTIPL: P.O. has been placed for 01 L/set. Design document submitted

5.11. Remote Monitoring System:

To develop interface equipments for real time monitoring of performance of key equipments. To improve the utilization by taking corrective measures at right occasion.Online monitoring of 3-phase locomotive for better reliability.

Status: Specification C_D&D/ES/3/0546 finalized by CLW. Tender No. 72/16/1268 for 150 locosets scheduled to be open on 10.05.2017.

5.12. Composite Converter:

IGBT based Composite Converter with Traction Converter and Hotel Load Converter for 3-ph WAP-5 locomotives.

Status: Specification CLW/ES/IGBT/ 0518 Alt. B.finalized by CLW P.O. placed on M/s ABB- 10 sets (supply yet to commence). P.O. place on M/s BHEL- 05 sets (supply yet to commence). P.O. Place on M/s ABB- 05 sets (supply yet to commence).

5.13. Other activities:

(a) To address the problem of failure of locomotive due to increased temperature of SR oil, the following modifications have been implemented in software:

(i) Increase in temperature settings of SR oil from 64˚/66˚ C to 65˚/67˚ C. (ii) Increase in trigger range of temperature disturbance from 10˚ C to 25˚C.

(b) Integration/ Modification of software for incorporation of water closet in WAG-9 Locomotive no.31952.

(c) Filter cubicle has been modified in TPP-339, duly ensuring adequate clearances for enhanced reliability of operator of locomotive.

(d) VCU Redundancy to eliminate need of cab changing by crew in case of STB/HBB cards failure. Tested on all versions of 3-phase locomotives. Regular Cut-in for all WAG-9 locomotives from CLW is under process. Accordingly software version R1450 and modified schematics/cable layout diagram have been uploaded on CLW website. RDSO advised for issuing MS.

Type of Locomotive Status of VCU redundancy

WAP-5 Implemented on loco no. 30083(BRC) with additional I/O cards to achieve full functionalities in June’15.

WAP-7

Implemented on loco no. 30451 (TKD) with additional I/O cards to achieve full functionalities in Feb’16. Implemented on loco no. 30533 (BRC) with additional I/O cards to achieve full functionalities in Feb’16.

WAG-9H

Implemented on loco no. 3176 9(AQ) with 4 additional I/O cards to achieve full functionalities in Sept’16. Implemented on loco no. 31791 (WAT) with 4 additional I/O cards to achieve full functionalities in Dec’16.

3.14 Action Taken to improve Roof Sealing of 3-Phase Locomotives.

(a) Provision of Roof Hatch Retainer There are reports of water leakage in 3 phase Locomotives. Therefore provsionof Roof Hatch Retainers has been made for 3 phase locomotives. Advantages of Roof Hatch Retainers are i. Holds roof together tightly. ii. Avoid air & Water ingress from outside. iii. Less dust in machine room.

(b) Design Change of Rubber Gasket of OCU Filter Assembly.

Zonal Railways reported water leakage from OCU top panel. To strengthen the sealing between OCU Top Panel and roof, design of rubber gasket has been modified. The material specification of the gasket has been changed to EDPM sponge type. Further thickness of gasket reduced to 15 mm from 25 mm and hardness has been reduced to 25S to 50 S for better sealing.

QUALITY ASSURANCE

6

5 QUALITY ASSURANCE

6.1 QUALITY OBJECTIVES: 6.1.1. Inspection of locomotives and its components in the Inspection Shops to be done 100% on the basis of Work

Instruction and their related Design, Drawings, Specifications and relevant Standards to meet Quality requirement on continuing basis.

6.1.2. Inspection within fortnight from date of receipt of call letter for inspection of Purchase Items. 6.1.3. 5% or minimum 5 nos. of inspection of materials offered by the Venders per month, are to be personally

inspected by the Outstation Officer in-charge. (N.B. SL. No. 1.2.2 & 1.2.3 above are applicable only for Out Side Inspection Wings of CLW i.e.

DyCEE/I&D/NDLS, DyCEE/I&D/Mumbai, DyCEE/I&D/Bangalore & DyCME/I&D/HWH) 6.2 OTHER OBJECTIVES:

6.2.1. Constant endeavor for Quality improvement of the products at all stages of manufacturing which are turned out

from different shops of CLW. 6.2.2. To carry out inspection of various assembly and sub-assembly at TM Shops, Static Equipment Shops, HMS,

LMS, Loco Fabrication & Assembly Shops and also Steel Foundry Shops. 6.2.3. To certify the Material Movement Slip for movement of products conforming to the drawings/WI/Specification

from one shop to other and consequently clearing Job Cards related to that product. 6.2.4. To prepare Loco Inspection Certificates and sent the same to User Railways. As per previous year’s

commitment, 100% Scanned Inspection Data are used to make the Soft Copy of Loco Inspection Certificates of locomotive produced since the financial year 2014-2015 and onwards.

6.3 ACHIEVEMENTS:

6.3.1. Modified Vertical damper bracket ensured by repetitive booking on that issue. 6.3.2. Modified platform assembly ensured for WAP-7 loco fitted with hotel load by repetitive booking on that item. 6.3.3. Tail lamp bracket provision is ensured. 6.3.4. Provision of Checker Plate between SR & Oil Expansion Tank in BT Converter ensured. 6.3.5. Grommet provision over Cables while tightening under cable cleat near TM Junction Box has been ensured. 6.3.6. Trial implementation of modified lifting hook for IGBT ballast block done. 6.3.7. 100% radiography of Hitachi suspension tube (Spares) ensured. 6.3.8. 100% testing for rain water leakage from locomotive roof is implemented by providing high pressure jet water

taking facilities in order to arrest water leakage. 6.3.9. Inspection check points for three phase loco fabrication have been introduced for the bend portion of L-shaped

metal piece welded with Compressor bracket on which compressor is tightened to eliminate it’s shearing problem.

6.3.10. On trial basis the camber of 15 mm in place of earlier 10 mm has been introduced for roof girder/channel to minimize the gap between roof and girder which were causing roof leakage.

6.3.11. Tail lamp bracket has been ensured to be fitted after introducing new check points and repeated NC arisen. 6.3.12. Safety sealing of Traction Motors at the loco under-frame have been provided by constant booking and

monitoring to ensure safety. 6.3.13. Fitment of Leather Bellow in place of Rubber Bellow has been mostly ensured by repetitive booking and

constant monitoring to ensure durability and flexibility. 6.3.14. 100% NDT test implemented on different types of Axle and Wheels for better quality control. 6.3.15. To overcome the bearing cease problem during MSU fitment in three phase locomotives, new check points at

X-clearance and D-clearance have been introduced on Wheel Set Assembly. 6.3.16. To improve the performance of power transmission drive in Traction Motors, proper matching of the gear with pinion has been ensured by colour coating procedure. . 6.3.17. To improve the quality of Flexi-coil Bogie rectification is restricted up to the R-2 stage of Radiography Test. 6.3.18. On the basis of customer feedback received in the past, fresh inspection check points have been introduced in the fitment of the following items during shell fabrication for quality improvement. a) Floor Ventilation Ducting and Machine Room Entrance Door on shell of WAP 5 locos. b) Under Slung Compressor and Battery Box Stools on WAP-4 Shell at USD Stage. c) Compressor Leg at USD Stage on both WAG-9 & WAP-7 locos. d) CBC on all types of locos. 6.3.19. Keeping in view the recently received customer complaint on welding joint failure of WAG-9 loco, 100% DP

Test has been introduced for the four joints between Cross Box and Transformer rod pillar mounting base of Central Under-frame.

6.3.20. The huge back log (due to newly adopted Soft copy of loco ICs and other unavoidable reason) of preparation

of Loco Inspection Certificate and issue the same to user shed have been reduced a lot by clearing a record 1280 numbers of loco ICs in last Three years and six months (w.e.f. 1st July 2013 to December 2016).

6.3.21. Recently, in-spite of acute shortage of Staff and Supervisors in various Inspection Shops, up-gradation of Loco

Inspection Certificate in to 100% soft copy along with reduction of back log as stated above have been achieved.

6.4 METALLURGICAL & CHEMICAL LABORATORY

Metallurgical & Chemical Laboratory under control of Dy. CC & M and assisted by 01 Sr. Scale & 03 Jr. Scale officers are responsible for quality assurance of Electric Loco components and miscellaneous mechanical items by conducting metallurgical, chemical and non-destructive test of casting, forging & fabricated components as well as physical-chemical test of non-metals, rubber items, paints & oil & lubricants. It consists of three units i.e. main Lab., NDT Lab, loco works and Steel Foundry.

The M & C Laboratory ensures quality control of inputs and finished products of Steel Foundry including

stage wise process control. The M&C wing of Steel Foundry ensures quality control of castings like CO – CO Bogie, FC bogie, Bolster, Casnub bogie, Suspension tube etc. It also ensures quality control of different raw material of Steel Foundry like Ferro – manganese, Silico – Manganese, Ferro-silicon, Ferro - molly, iron ore, silica sand, core binders, bentonite power etc. It also ensures quality control of furnace consumables like basic lining bricks, high alumina bricks, ladle bricks etc.

NDT Lab./SF arranges radiography of various casting to ensure casting quality as per specification. Main activities of M&C organization is as under:-

i) Chemical analysis of Ferrous & non-ferrous alloys using spectrometer. ii) Review of specification from time to time for quality improvement. iii) Internal & external ISO: 9001 & ISO: 14001, OHSAS-18001 audit as per ISO requirements. iv) All Lab. IMTE’s calibration in time both in Main Lab & SF. v) Testing of Loco items as per Loco production target to meet the requirement. vi) Testing of water samples and controlling various parameters of drinking water requirements.

Metallurgical & Chemical Lab conducts metallurgical investigations of in-service failures of components of

CLW built Locomotives. It maintains liaison with RDSO, BIS & other Non-Railway institutions on M&C matters.

6.5 PERFORMANCE w.e.f. 2014, 2015, 31-03-2016 to 31.12.2016 and 1.1.17 to 31.3.17 6.5.1 METALLURGICAL & CHEMICAL LAB/LOCO:

Sl.

No. Name of Lab.

No. of Sample Tested

Nos. of Tests No. of Sample

Accepted % of Rejection

2014 2015

2016 & 1.1.17

to 31.3.17

2014 2015 2016 & 1.1.17

to 31.3.17

2014 2015 2016 & 1.1.17

to 31.3.17

2014 2015 2016 & 1.1.17

to 31.3.17

1. Metallurgical/ Mechanical Lab.

3480 4013 3254 1040

7116 8038 6858 2155

3406 3631 3198 1015 2.12 9.52

1.72 2.40

2. Chemical Lab. 3125 3172

2159 596

18220 17483 12386 3584

3054 3144 2116 590 2.27 0.89

1.99 1.01

3. Filter House Lab.

2020 3649 2291 503

16821 17336 12706 3158

2020 3649 2291 503 Nil Nil

Nil Nil

4. Rubber , DMC, I. M. & Lubricant

221 216 181 65

445 964 963 352

208 201 172 63 5.88 6.94

4.97 1.49

TOTAL

8846 11050 7885 2204

42602 43821 32913 9249

8688 10625 7777 2171

6.5.2 NDT LABORATORY (LOCO):

Sl. No. Name of Lab.

No. of Sample Tested Nos. of Location/

Component Tested Nos. of

Component Accepted % of Rejection

2014 2015

2016 & 1.1.17

to 31.3.17

2014 2015

2016 & 1.1.17

to 31.3.17

2014 2015

2016 & 1.1.17

to 31.3.17

2014 2015

2016 & 1.1.17

to 31.3.17

1. Ultrasonic Testing

8785 9958 7096 2797

26129 31458 22648 7744

8720 9820 7047 2787

0.73 1.57 0.56

0.69 0.36

2. M P T 4864 5746 4733 1481

12257 14988 7937 2531

4864 5746 4733 1481

Nil - -

Nil Nil

3. Radiographic Test

359 302 165 02

359 201 165 02

294 273 125 01

18.38

10.9 -

24.24 50.00

4. Misc. 1207 1641 1471 682

3374 4790 7543 2197

1207 1638 1461 670

Nil 0.23

- 0.68 1.76

TOTAL

15215 17647 13465 4962

42119 51437 38293 4939

15085 17477 13366 4939

- -

6.5.3 METALLURGICAL & CHEMICAL LABORATORY /STEEL FOUNDRY: CHEMICAL LABORATORIES:

Sl. No. Name of Lab.

No. of Sample Tested Nos. of Tests

2014 2015 2016 &

1.1.17 to 31.3.17

2014 2015 2016 &

1.1.17 to 31.3.17

1. Chemical Lab. 3024 2556 1652 334

16898 10,310 8682 1389

2. Chemical Misc. 149 41 23 15

972 208 136 78

TOTAL 3173 2597 1675 349

17870 10,518 8818 1467

6.5.4 FIELD LABORATORY/S. F. :

Sample Test Physical & Radiographic Tests

Sl. No. Name of Test

No. of Tests Name of Test

No. of Tests

2014 2015 2016 &

1.1.17 to 31.3.17

2014 2015 2016 &

1.1.17 to 31.3.17

1. Zircon Wash 66 80

35 15

Tensile Strength 1318 497

325 116

2. Green Sand 5726 5586 3858 594 Microstructure 525 355

233 59

3. Permeability 972 2021 1656 129 Charpy 0 0

0 0

4. No-bake Sand 992 6059 3581 1320 Hardness 926 6393

1012 135

5. Silica Sand 78 2718 1472 416

Radiography Exposures

11478 10220 5756 1430

Total 7834 16464 10602 2474

Total 14247 14465 7326 1740

Marketing including export ( Supply of spares to Zonal Railways )

7

7.Supply of spares

7.1 LIAISON & SERVICES WING:

Electric Loco Sheds and POH/Repair shops over Indian Railways are engaged in maintenance of Locomotives. The Liaison and Service (L&S) Wing of CLW is to perform the task of meeting the requirements of Capital spares allotted by Railway Board & Railways’ own needs of Spares for maintenance. Broadly Liaison and service wing performs the following functions.

7.2 FUNCTIONS:

Consolidating the demands in the form of Requisitions/indents from Railways for purchased and Shop manufactured including imported items.

Co-ordination with Stores department for the procurement of such spares and to issue work orders for the shop manufactured item.

Supplying spares to the railways through stores/shops taking as per demand and availability and to maintain accountal of such supplies.

7.3 SPARES TO RAILWAYS: The supply of spares to various user Railways is one of the most important function of L&S wing. All-out

efforts are made to fulfill the demands of Capital spares as well as the requirement of spares by the Railways. In the year 2016-17 spares worth Rs 11127.8 lakhs (as on 31.03.17) were supplied to the Railways. The break up of the same may be seen at Annexure -B.

CLW / CHITTARANJAN

SUPPLY OF SPARES TO ZONAL RAILWAYS AGAINST RLY BOARD’S RSP & REQUITIONS OF ZONAL RAILWAYS IN APRIL 2016 TO March 2017 ANNEXURE- A (All Costs are in Rs. Lakh)

Sl.

Item description QUANTITY SUPPLIED UPTO MARCH 2017 Total qty.

Total cost of supply

CR B/ Req

ECoR B/ Req

ECR B/ Req

ER B/ Req

NCR B/ Req

NR B/ Req

SCR B/ Req

SECR B/ Req

SER B/ Req

SR B/ Req

WCR B/ Req

WR B/ Req.

Other ZR

1. TM for G-9/P-7 (3Ф) 3 1 2 6 159.35 2. TM for P-5 (3Ф) 3. Stator of TM for G-9 (3Ф) 3 1 2 6 2 1 15 142.54 4. Rotor of TM for G-9 (3Ф) 1 1 5.52 5. Transformer of G-9/P-7 (3Ф) 1

6 696.53 6. Transformer of P-5 (3Ф)(7775 Kva) 2 2 1 7. Auxiliary Converter (3Ф) 2 1 1 1 1 1 3 1 1 2 1 15 589.13 8. Central Electronics (3Ф) 9. Traction Converter (3Ф) 1 2 1 4 770.66 10. O.C.B. Unit (3Ф) 11. E-70 Brake System (3Ф) 1 2 3 110.45 12. Driver’s Display Unit (3Ф) 27 8 4 8 6 14 2 8 4 1 82 347.83 13. TM (Hitachi) 17 48 5 3 17 2 5 12 109 3997.05 14. TM (H)-Armature 12 3 15 264.79 15. Transformer 5400 KVA 16. High Speed Pantograph 20 10 27 15 20 15 10 15 2 134 669.81 17. Oil free Compressor 4 4 8 128.56 18. VCB 19. DBR (Roof Mounted) 1 1 7.57 20. Shunting Contactor 199 20 219 36.58 21. Co-Co Bogie Machined

WAP-4 2 2 57.01 WAP-5 WAP-7 WAG-9

22 Bogie with Brake Rigging WAP-5 WAP-7 2 2

26.09 WAG-9 2 2

23 Wheel and Axle Assly. WAG-7 2 2 17.84 WAP-5 WAP-7 6 6 94.39 WAG-9 2 5 7 64.09

24 Fabricated Bolster 2 2 10.00 25 Fire Detection Unit 3 3 3.18 26 Oil Cooler Radiator 8 7 1 16 68.59 27 Oil Cooling Unit 2 2 5.96 28 Pantograph AM-92 2 2 1.88 29 SL-30 4 5 2 11 119.75 30 Diagnostics System 4 1 3 3 1 4 4 3 3 3 4 3 36 450.00 31 CTF 1 & 2 10 10 17.48 Cost of Misc Items in Rs. Lakh 825.41 34.90 154.10 495.62 47.68 99.19 43.41 12.26 75.47 85.08 80.22 311.84 2265.18 Total Cost in Rs. Lakh 1961.87 403.80 1997.82 1165.59 557.36 703.91 660.92 216.06 1086.56 537.57 686.46 1149.89 11127.8

STATUS OF M&P

8

8. MACHINARY AND PLANT

Manufacturing, M&P Maintenance, Transport, Machinery & Plant Procurement

Manufacturing group of shops consists of Heavy machine shop, Wheel shop, Light machine shop, Smithy & Forge shop, Heat Treatment shop and Tool Room. Millwright and Electrical Maintenance shops look after maintenance of all M&Ps of loco works, power supply and distribution inside loco works. M&P cell deals with planning and process for procurement & commissioning of machines sanctioned by Rly.Board & GM/CLW under M&P Plan Head-4100 & 4200. It also looks after TPT shop including Road and Industrial vehicle maintenance work and shunting work.

Manufacturing shops: (i) Wheel Shop: Wheel shop manufactures wheel sets for loco production as well as spares to Zonal Railways. Presently wheel sets for WAP5, WAP7 and WAG9 locos are manufactured. (ii) Heavy Machine shop: Heavy machine shop undertakes machining of components for loco production of 3 Phase Stators, Transom, Support, Torque Support, Motor support etc. Machining work of Steel Castings from Steel Foundry like Hitachi Suspension tube, DMW Suspension Tube and CBC Yokes are also done in HMS. In addition to this, 68 Loco sets, tested Motorized Wheel set assembly were supplied upto March’2017. It has helped the Bogie Shop and in turn CLW in manufacturing 1002 motorized bogie in house. (iii) Smithy & Forge shop: SFS undertakes fabrication of Head Stock of WAP7 loco, forging of small components of loco assembly such as Resting hook, operating handle of CBC. (iv) Light Machine Shop: Light Machine Shop manufactures 308 small loco components and different kinds of scheduled work to meet requirement of loco production. (v) Tool Room: Tool room supplies tooling, gauges, jigs & fixtures for production requirements of various shops. It also carries out calibration of various gauges, fixtures, instruments etc to meet the ISO requirements. (vi) Heat Treatment Shop: Heat Treatment Shop undertakes heat treatment of WAP7/WAG9 bogies manufactured in Loco Shop and other items e.g. Axle Holder, Motor support, Torque support. manufactured in Mfg Shop. Performance of Manufacturing Shop is furnished in the Annexure-‘A’

BRIEF REGARDING PLANT MAINTENANCE ORGANISATION(LOCO WORKS) CLW has more than 860 M&Ps various CNC/Non-CNC Machines including 123 Cranes utilised for

production of Electric Loco Components. Breakdown as well as preventive maintenance of M&Ps including 47 critical machines (Enclosed as Annexure B) is carried out by the Plant Maintenance Organisation consisting of Millwright Shop(MTS-56), Electrical Repair Shop(Shop-59) and CNC Wing. Plant Maintenance Organisation deals with repairing, reconditioning, re-engineering, retro-fitment of machinery and plant & electrical maintenance of lighting inside shops. Installation of new small machineries and plants, condemnation & uprooting of old M&Ps are also carried out by the Maintenance Shops-56 & 59.

I. SPECIAL WORK DONE 1. HEC Wheel Lathe of Shop-09 was under breakdown due to problem with PCB. The same has been

rectified in-house successfully and the machine has been put in service within a very short period. 2. 85 Nos. Energy efficient LED Bridge light have been commissioned in different EOT Cranes.

3. Premier CNC Vertical Turret Lathe No. 09/1789/02 was under breakdown due to critical hydraulic leakage problem at ram head. The leakage problem was set right by the maintenance staff.

4. Danovat CNC Axle Turning Lathe No. 09/1115/01 was under breakdown due to defect in telescopic cover. The staff of MTS opened the cover & repaired the cover thoroughly.. .

5. Shigiya Grinding M/c No. 09/4625/01 was under breakdown due to table movement defect. Hydraulic locking gear and spring of the machine have been changed and the problem was set right.

6. Premier TC Milling Machine of Shop-08 was under breakdown as the universal tool head of the machine was defective. The same has been dismantled and repaired by the maintenance wing staff and set right the machine.

7. EOT Crane 4C was under breakdown due to damage of LT bearing and wheel. The wheel with coupling and shaft assembly has been replaced with new one.

8. Crane No. 23/E/15 was under breakdown due to defect in wheel bearing. The bearing has been replaced by dismantling of wheel.

9. Premier make Plano Milling M/c No. 08/2463/02 was under breakdown due to spindle head movement defect. Spindle head gear box of the machine has been dismantled. Power shifting gears along with shaft keys have been rectified in-house and the machine has been put in service.

10. Unique-2(19/E/09) 50/5T Crane of Shop-19 was under breakdown due to problem in damaged bearing of LT Idle Wheel.. The Wheel was dismantled and new bearings was fitted.

11. Crane No. 23/E/13, 5T of Shop-23 was under breakdown due to LT Wheel, Axle and bearing damaged. The total assembly was replaced by new set with new bearings. The crane is now running with full load.

12. 1 No. old Oil Filtration Plant brought from TATA Loco Shed with fault in control unit, PCBs and set of filters. These are repaired in-house successfully by the Maintenance Wing and the Plant was put in service.

13. Crane No. 396 of Jessop make at AIF Store was under long breakdown due to problem in resistance, limit switches, power line, brash collector shoe and drum controller. The crane has been successfully put in service by repairing the above mentioned items and complete rewiring by ERS staff.

14. SBCNC 30(Rotor Shaft Turning Lathe) was under breakdown due to problem in steady rest. The problem has been rectified successfully by modifying the steady rest with provision of non-wearing rollers by In-house maintenance staff and put into service.

15. HEC Surface Wheel Lathe of Shop-09 which was under breakdown due to underground conveyor

system not working. Safety device of the conveyor crasher got damaged. The gear arrangement was completely dismantled and rectified.

16. Crane No. 20/E/01(5A) was under breakdown due to LT gear box damaged. New gear box has been fitted in the crane and the crane set right.

17. Fortuna Cylindrical Grinding M/c No. 20/4671/01 was under breakdown due to failure of hydraulic system. The same has been repaired and put in service in-house by the maintenance wing of CLW. .

18. Zayer CNC Universal M/c (Mini Zayer) No. 08/2595/03 was under breakdown due to universal tool head movement defects. Universal head locking device was damaged and the same has been replaced with new one by in-house staff of maintenance wing.

19. BBM Wheel Press 09/7537/01 of Wheel Shop was under breakdown due to defect in head trolley

movement.. The same has been repaired in-house by the maintenance wing of CLW and put in service. .

20. HMT Universal Grinding Machine No. 20/4680/01 was under breakdown. Rewinding of motor of the machine was done and wiring cable thoroughly changed.

21. Tantus Turret Punch, M/c No. 15/6951/01 which was under long breakdown due to defect in encorder. The encorder has been procured & fitted & and the machine made functional..

22. 6 Nos. Feeder Pillar and 21 Nos. Distribution Box have been replaced/newly installed at Main Assembly Shop.

23. HEC Surface Wheel Lathe No. 09/1042/01 was under breakdown due to damage of ball screw. The same has been repaired and fitted in the machine. The machine is now running satisfactorily.

24. Wheel Parking area of Wheel Shop was without any light. Illumination of the Wheel Park was done with provision of energy efficient .

25. Maintenance free earthing was provided in 5 CNC M/c

26. Rewiring of Sutripti Canteen was carried out near TM Gate. 27. Repairing of Induction Puller at TM shop was done. 28. 3 Phase Motor testing Plant at TM Shop which was under long breakdown has been rectified with

inhouse effort. . 29. Thorough renovation of Coach and Bogie of 1/4th Steam Loco(Fairy Princes) at Loco Park was done 30. Repairing of Pro-Arc M/c. No. 17/6093/03 at ELS-17 Corta Section was done 31. Rectification of Kellen Berger M/c. at Tool Room/Shop-52 was carried out 32. HMT HCG grinding Machine NO. 09/4626/01 was under breakdown due to breakage of shaft. The

same was made inhouse and the machine was rectified. 8.3.1 UPTIME AVAILABILITY OF CRITICAL MACHINES

The availability of 47 critical machines in Loco Works was 95.10% during the year 2016-17 against the target of 90%.

8.3.2 CONDEMNATION OF M&Ps

During the year 2016-17, 23 Nos. of machines have been condemned.

Annexure ‘A’ 8.4 Production Performance of manufacturing shop

Sl.No.

Name of Item 2015-16 2016-17

Comparison of Prod. 2016-17 with 2015-16

1 Wheel Set Assembly 265 L/S 300-3/6 L/S +13.2%

2 Stator 3 Phase (G9/P7/P5)

502 Nos. 583 Nos. (+) 13.9%.

3 WAP-7 Head Stock 34-5 L/S 40 L/S (+) 15.5%

8.5 M&P Wing is engaged with planning and procurement of machinery & plants through M&P Programme & GM’s ‘out of turn’. Installation , commissioning, and warranty issues of Machinery plants is also planned.

Procurement status of various M&Ps during last year(2016-17) is as follows: 1. INDENTS PENDING WITH COFMOW (as on 31.03.17 ) :- SN

Sanction under

Allocation

Description of machine/Qty.

Sanc.. Cost

Consignee Status

1 M&P 16-17

CAP 16 Wheellabrator Grit Blast Plant, 01 no.

865 lakh

Dy.CME/ ELA

Spec. sent to COFMOW on 17.03.2017.

2 M&P 16-17

CAP EOT Crane, 30T, Qty.02 nos

156 lakh

Dy.CME/ ELA

Tender due on 11.04.2017.

3 PH-42 CAP CNC Machining Centre, 01 no.

1382 lakh

Dy.CME/Mfg .

Tender due on 26.04.2017.

2. Progress of work by M&P Deptt. during the year 2016

Particulars Received

M&P Programme items sanctioned by Rly. Board GM’s Out of turn items sanctioned by GM/CLW

Project items ( 200 Loco Project & 50 Loco Project & 275 Loco Project )

Total

(a) Machines Commissioned –20 Nos.

(i) M&P Programme Items :- 5 Nos. S/ No

Item No. & Yr. of san.

Description, Qty. & allocation

1 M&P 11-12

Portable Radial Drilling Machine, DRF Qty.01 no., cost 35,99,958.

2 M&P 13-14

CNC Vertical Turret Lathe. (Swing dia. 1400 mm), PO Cost – 1.57 Cr. DRF

3 M&P 13-14

Induction Brazing Equipment. (Qty. – 2 nos.), CAP

84 Lakh

4 M&P/ 16-17

Utility Vehicle 587598.59 , DRF

5 M&P 13-14

CNC Axle Turning Lathe.(Length 3000 mm)., 7.93Cr. Key No. 214101.

(ii) GM’s Out of Turn Item : 13 Nos. S/ No

Item No. & Yr. of san.

Description, Qty. & allocation

1 GM OT 12-13

Magnetic Particle Inspection Equipment

Progress of work by M&P Deptt. during the year 2016-17

( Position from April’16 to Mar’17)

M&Ps Received

M&Ps Commissioned.

M&Ps Under

commissioning

04 05 02

17 13 04

- 02 -

21 20 06

20 Nos.

5 Nos.

Description, Qty. & MT No Supplier & AT/PO No

Portable Radial Drilling Machine, DRF Qty.01 no.,

MT/ 2131

M/s. Energy Machine Tools, Jamnagar, COFMOW/IR/S-4757/P-I/OP-2219 dt 04.01.14.

CNC Vertical Turret the. (Swing dia. 1400

1.57 Cr.

MT/ 2163

M/s. HYT Engg. Co. Pvt. Ltd., New Delhi, OP – 2309 dated – 10.09.14.

MT/ 2165

M/s. EFD Induction Pvt. Ltd., Karnataka, P.O no. 05/2014/ 7114 /05862 dated – 20.08.15.

MT/ 2201

M/s. Mahindra & Mahindra Ltd, Mumbai, P.O no. 05/2016/ 7115/08050 dated- 04.11.16

e Turning Lathe. (Length 3000 mm)., 7.93Cr. Key No. 214101.

MT/ 2164

M/s. Askar Microns, Mysore. G – 600 841,

GM’s Out of Turn Item : 13 Nos.

Description, Qty. & MT No Supplier & AT/PO No

Inspection Equipment MT/ 2160

M/s. K. Electronics, Gujrat, P.O.No.05/2014/7107/

tion from April’16 to Mar’17)

commissioning

P.O Placed

03

-

-

03

Consignee/Location

Dy.CME/ ELF, shop-26 new shed

Dy.CME/ Mfg., WS-09

Dy.CEE/ TMM, shop-21

SC/RPF

Dy.CME /Mfg.

Consignee/ Location

Dy. CC& M, shop-09

(Qty. – 01 No.) CAP, 27.25 Lakhs

2 GM OT 13-14

Horizontal High PressSterilizer, 01 no., Cost 8.20 lakhs

3 GM OT 14 – 15

Hydraulic Motorised Pipe Bender with Power Pack.(Qty. – 02 Nos.) DRF.

5.41 lakh 4 OT

15-16 Mobile X-Ray Machine, DRF 4.76 lakh

5 GM OT 13-14

Mig Welding sets. (Qty. – 2 nos.)

16.05 lakhs, DRF

6 OT 15-16

ICU Ventilator Qty. 01, Cost- 22,84,800

7 OT 15-16

Defibrillator with facility of external pacing, 9,98,901/- DRF

8 OT 15-16

TMT machine, Qty.01, DRF Cost Cost-2,99,985.00

9 OT 15-16

Micro convex Probe for Diagnosis of Dieses related to Cardiovascular System, cost- 4.23, WMS

10 GM OT 13 – 14

Dimmer Stat Variable Auto Transformer 200 KVA. (Qty.–1no.)CAP13.13lak

11 OT 15-16

Ultrasonic Flaw Detector with a scan Storage.(Qty. – 03 nos.) 07.33 lakhs CAP

12 OT 15-16

Air Plasma cutting Machine with air compressor- 03 nos, Cost Rs.7,87,000/- CAP

13 OT 15-16

Digital Rockwell Hardness Testing M/c. Qty. – 01 No. 275000/DRF

01 No.) CAP, 05093 dated – 17.04.15

Horizontal High Pressure Sterilizer, 01 no., Cost

MT/ 2173

M/s. Shri Hari International, Kolkata, P.O no. 05/2015/ 7106/06510 dated- 25.05.16.

Hydraulic Motorised Pipe Bender with Power Pack.

02 Nos.) DRF.

MT/ 2181

M/s. VANKOS & Co., Patna. P.O no.02/2015/7108 /06408 dtd-14.12.15.

Ray Machine, MT/ 2186

M/s. Sigma Medical Systems, Kolkata, P.O no.05/2016/ 7107/07635 dated-22.07.16

MT/ 2178

M/s. Metal Care, Burdwan P.O no.05/2015/7104/ 07293 dated – 13.06.2016.

ICU Ventilator Qty. 01, MT/ 2184

M/s. Sigma Medical Systems, Kolkata, P.O no.05/2015/7110/07864 dated-19.09.2016

Defibrillator with facility

MT/2193

M/s. Shir Hari International, Kolkata, P.O no. 05/2016/ 7108/07745 dated- 05.09.2016

Qty.01, MT/2194

M/s. The Medi Power, Kolkata, P.O no. 05/2016/7110/07962 Dated - 14.10.2016.

Micro convex Probe for

related to Cardiovascular 4.23,

MT/2196

M/s. Sigma Medical Systems, Kol, PO no.05/2016/7112/ 08068 dated-10.11.2016

Dimmer Stat Variable Auto Transformer 200

1no.)CAP

MT/2177 M/s. Deswetch Engineers, Thane, P.O no.05/2015/ 7107/ 06505 dtd 22.01.16.

Ultrasonic Flaw Detector with a scan Storage.(Qty.

07.33 lakhs

MT/2189 M/s. Electronic Engineering Company India Pvt. Ltd., Mumbai, P.O no.05/2016/ 7102/07283 dated – 30.05.16

MT/ 2185

M/s. Nextgen Plasma Pvt. Ltd., Kolkata,P.O no.05/2016/7104 /07756 dated-23.08.16.

Hardness Testing M/c. 275000/--

MT/ 2190

M/s. Shiv Trading Corporation, Kolkata. P.O. No. 05/2016/ 7101/08006 dated 26.10.2016

CMO/ KGH Dy.CME /ELA, shop-16

CMO/ KGH

Dy.CME/ Mfg., HMS-08 CMO/KGH

CMO/ KGH

CMO/KGH

CMO/ KGH

Dy.CME/ Mfg

Dy. CC&M

Dy.CME/ ELF

Dy. CC&M

(iii) Under PH-42 : 2 Nos. S/ No

Item No. & Yr. of san.

Description, Qty. & allocation

1 PH 42, 275 Loco

EOT crane 5T (Qty. – 01 No.) PO Cost - 2469472/-

2 275 Loco Project

CNC Axle Turning M/C (for Shaft), 1.69 Cr,

(b) Machines under Installation & Commissioning (i) M&P Programme items - 2 Nos..

SN M&P Ref.

Description of machine

1 MT/ 2166,

Double Ended Facing, Centering and Drilling M/c. 1.04 Cr.,

2 MT/ 2182

EOT Crane 30T (Qty. 01). Key No. 215347. 60.96 Lakh DRF

(ii) GM’s Out of Turn Items :- 04nos.

SN M&P Ref.

Description of machine

1 MT/ 2188

X-Ray Machine – 01 No. DRF . 690000/-

2 MT/ 2191

Induction Heater (Micro processor controlled) – 02 nos, CAP 9.46 lakhs

3 MT/ 2183

Audio Conference System,Qty.01 no., DRF 11.14lakhs

SN M&P Ref.

Description of machine

4 MT/ 2204

20 ton Tensile Machine, Qty. 01. CAP 4 lakhs

Description, Qty. & MT /No Supplier & AT/PO No

-

MT/AP – 275/18

M/s. Saico Cranes Pvt. Ltd, Nasik, OP-2235/13

CNC Axle Turning M/C 1.69 Cr,

MT/AP – 275/08

M/s. Askar Microns, Mysore. OP – 2130 Dt. 23.04.12

Machines under Installation & Commissioning – 06 Nos. 2 Nos..

Received on

Suppliers name with PO no.

Double Ended Facing, Centering and Drilling M/c.

07.06.16

M/s. Geeta Machine Tools Pvt. Ltd. Jamnagar. OP– 2134 Amendment no. 2 Dated – 09.07.15.

18.02.17 M/s. Alpha Services, New Delhi. OP – 20 061,

04nos.

Received on

Suppliers name with PO no.

25.01.17 M/s. Rainbow Enterprises, Lucknow. P.O. 05/2016/7103/07768 dated 206.10.2016.

06.03.17. M/s. Unitech Instruments, P.O no.05/2016/ 7111/08024 dated-17.11.2016

11.03.17 M/s. Sandeep Tradex Pvt. Ltd., Kolkata, P.O no. 05/2015/7109/08246 dated- 12.01.2017.

Received on

Suppliers name with PO no.

20 ton Tensile Machine, Qty. 27.03.17 M/s. Ashian Engineers Company India, Delhi. P.O.no. 05/2016/7116/08365 dated 16.01.2017.

Consignee/Location

Dy.CME/ ELA, new paint shop-16 Dy.CEE /TMM

Consignee

Dy.CME /Mfg.

Dy.CME /ELF

Consignee

CMO/ KGH

Dy.CME / Mfg.

ASTE

Consignee

Dy. CC&M

(C ) P.O Placed, but machine not received- 03 nos.

SL No.

Item No. & year of sanction

Description Supplier name & AT/PO No. DP

1 M&P 13-14

CNC Press Brake Hydraulic 650T

M/s. Maanshan Hudong Heavy Industry Machinery Manufacturing Co. Ltd., China,

31.08.17

2 M&P 16-17

Hydraulic System for Pinion Mounting & Extraction

M/s. Crimpwell Services, COFMOW AT no. COFMOW /IR/S-4970/P-I/OP-402450 dated- 28.02.2017

30.09.17

3. M&P 14-15

EOT Crane 5T, 02 nos.

M/s. Meeka Machinery Pvt. Ltd,, Ahmedabad, OP – 501 010

31.07.17

8.6 Transport Shop :-

Transport Shop maintains all road vehicles consisting of passenger vehicles like cars, jeeps, mini buses etc. for movement of officials and industrial vehicles like forklifts, dumpers, tractors, platform trucks/listers for movement of material inside and outside the shops. Shunting of rolling stocks is also the responsibility of Transport Shop.

Availability of Material handling equipments (as on 31.03.17 ):-

FLT : 32 Nos. PLT : 26 Nos. Tractor : 02 Nos. Truck: 07 Nos., Tripper- 03 Nos. Bus: 02 Nos. Shunting Locos : 03 Nos. Sky Lifter : 05 Nos. Passenger Vehicles : 23 Nos. - Maintained through in-house and outside agencies

8.7 Yard Organization

For movement of traffic wagons, inward & outward departmental wagon and locomotives shell on dummy bogies, two shunting engines have been deployed. These locomotives are maintained and operated by Yard staff. Shunting requirement is met in three shifts. Yard organization also keeps liasion with the Asansol Division of Eastern Railway for movement of Traffic Wagons.

STEEL FOUNDRY

8A

8A.1 OVERVIEW

Location of the Factory: P.O. & P.S. : Chittaranjan Dist : Burdwan, Pin – 713331 The Factory is located at Chittaranjan, Dist: Burdwan, West Bengal, approx. 305 km. from Kolkata. The location is well connected by road and rail from Howrah Station. Chittaranjan Locomotive Works, Steel Foundry, a unit of Ministry of Railway is set up for supplying Steel casting products of locomotives. It has two Arc furnace of 15T and 7T capacity. The 7T Furnace is being replaced by a 10T Direct Arc Furnace, CLW follows stringent quality processes, duly certified with

ISO : ISO 9001::2008, ISO 14001:: 2004, ISO 18001 certified, Total Area of the Plant : 45 acres (182108.70 sq. m.) Covered Area : 12.4 Acres (50181.064 sq. m.) Product : Steel casting for rolling stocks

8A.2 IMPORTANT MILESTONES

ISO-9002 CERTIFICATE- In August 1996 Steel Foundry was awarded with the ISO-9002 Certificate for its Quality Standards.

ISO-9001:: 2008 CERTIFICATE- In October 2009 Steel Foundry was awarded with the ISO-9001 Certificate for its Quality Standards.

ISO-14001 CERTIFICATE- Steel Foundry was accredited with Environment Management System (EMS 14001:: 2004) in the year 2006 with the objective to regularly educate the staff, encouraging them to preserve the environment and conserve the environment as well as utilizing all the existing natural resources in a eco-friendly manner.

CLASS-A CERTIFICATE- Steel Foundry/CLW has been certified as CLASS-‘A’ FOUNDRY by RDSO on 9th August 2012 vide RDSO Vendor No. 419.

LOCO COUPLER- Production of Loco Coupler for Electric Loco has been started from August 2012 vide RDSO Vendor No. 419.

E- TYPE COUPLER- Production of E-type Coupler for Diesel Loco has been started from May 2013 vide RDSO Vendor No. 419.

8A.3 PRODUCT RANGE

8A.3.1 STEEL CASTINGS:

Loco-items—

Flexi coil Bogie for WAP-4 loco. Flexi coil Bolster for WAP-4 loco. Co-Co Bogie BG for WAG-5 & WDM-2 Loco. Suspension Tube for Hitachi TM. Suspension Tube for 3phase TM. Rotor Clamp for Hitachi TM. Commutator Spider for Hitachi TM.

Centre Pivot for WAP-4 loco. Ballast Blocks for WAG-9 loco. Ballast Block for IGBT loco. Ballast Weights for WAG-7 loco. Loco Couplers for Electric loco (Assly. with Yoke, Knuckle also) Striker Castings for Electric loco. ‘E’ type Couplers for Diesel loco

Wagon Items—

Casnub Bogie for BOXNHL wagons Casnub Bolster for 22HS/BOXNHL wagons Casnub Side Frame 22HS/BOXNHL wagons. Bogie Centre Pivot Top 22HS/BOXNHL wagons Bogie Centre Pivot Bottom 22HS/BOXNHL wagons

C.B.Coupler Items (Wagon) —

Knuckle for CB Coupler. Coupler Body for CB Coupler. Yoke for CB Coupler. Striker Castings for CB Coupler.

Spares for Zonal Railways—

Suspension Tube for WDM-3D loco. Wheels for Tower Car. Wheels for Power Car Wheels for Narrow Gauge Coaches. Wheels for Narrow Gauge loco. Wheels for Kalka. Wheels for Gwalior.

8A.3.2 DEVELOPMENT OF NEW STEEL CASTING ITEMS:

(a) DEVELOPED & SUPPLIED REQUIRED TO RAILWAYS-

Clevis for coupler items N.G. Wheel for N.F. Rly N.G. Wheel for Kalka N.G. Wheel for Gwalior

8A.3.3 FABRICATED ITEMS for LOCO:

Side Sill Centre Sill Head Stock Assembly Casnub Dummy Bogie(TG/TPP) Conversion of HH Dummy Bogie into TP Dummy Bogie Under frame Assembly for WAG-9H Loco Piping at LW.

8A.3.4 New Development

BLC wagon bogie: it is under project. An order of 63 Nos of BLC Wagon Bogie has been received from Rly. Board. The same casting has been cast and two bogie are ready for inspection by competent authority.

A. Under frame for WAG-9H: under Frame of WAG-9H Loco was started at Steel foundry in Bay No. 11 w.e.f. 22.07.2016. Fixture for under frame was manufactured. Two Complete Under Frame for WAG-9H Loco are ready for dispatch for Loco are ready for dispatch for Loco Workshop for Loco No. TG-859,TG-860. Letter has been given to CME/Loco for lifting two Loco sheds of under frame assly, Vide letter No. SFM-16/53/LW dt. 07.12.2016.

B. Loco Piping: Loco piping work has been started at loco works /CLW (shop No. 16) w.e.f. March-2016 by the staff of Steel Foundry. Upto Dec-2016 loco Nos. (TG-707, TG-714, TG-753, TG-766, TG-763, TG-764, TG-773, TG-771, TG-772, TG-790, 792, TG-800, TG-817, & TG-819, TG-826, TG-827, TG814, TG-850 & TG-861 has been completed upto March-2017.

8A.4 QUALITY:

Steel Foundry/CLW, despite following Green Sand moulding system, is endeavoring to contain the rejection level within 3%. Rejection percentage for the last 5 years is produced below which show that they are contained within the targeted limit.

8A.4.1 QUALITY ASSURANCE MEASURES: (a) Switching over to Metal Patterns/Core-boxes-

With an objective to eliminate the casting defects owing to over-aged wooden patterns/core-boxes, induction of metallic patterns/core-boxes has been introduced. In this regard, Hitachi Suspension Tube, Knuckle, Coupler Body etc. for locos & wagons, metallic patterns and core boxes have been procured from out agencies. The quality of the relevant castings pertaining to dimension and surface finish has been improved.

(b) Mechanization of Foundry Process—

Steel Foundry/CLW is in the process to adopt the Synthetic Sand Moulding System to overcome the casting defects like- sand inclusion, poor surface finish, blow holes etc. being induced by the existing Green Sand Moulding Practice.

(c) Other Steps— In addition, following actions are being taken to improve upon quality/reduction in rejections—

Periodical checking of patterns & core boxes on quarterly basis. Use of exothermic sleeves to eliminate chances of shrinkage and cavities & to increase

yield%. Use of branded Zircon based mould washes to improve surface finish. Use of pouring ponds and tiles of high refractoriness in metal flow areas. Strict control over carbon boiling during melting to avoid pouring of gassy metals.

Years Total Cast

(in MT)

Rejection

(in MT)

Target Rejection

Percentage

2012-13 2976 64 3 % 2.15 %

2013-14 2770 52 3 % 1.88 %

2014-15 2500 55 3% 2.20%

2015-16 2285 64 3% 2.80 %

2016-17 2379 54.3 2.35% 2.28%

Use of quick lime has been introduced to bring down phosphorous content of melt. Strict control on heat cycle during heat treatment of castings to achieve prescribed physical

properties. 100% load testing of Bogies & Bolsters to improve reliability in service.

8A.5 PRODUCTIVITY:

Load Lifted per Direct Worker— The Allowed Time Discharged per Direct Worker per Month for the last 5 years has been as follows:

Years 2012-13 2013-14 2014-15 2015-16 2016-17

AT Discharged 253 hrs. 255 hrs. 232.56 hrs. 218.40 hrs 214.22 hrs

8A.5 PLANT & SAFETY: 8A.5.1Action taken to ensure Safety 2016-17

a) Plant Safety inspection carried out at Sand Plant (61) on 07-04-16 and Pattern repair Shop (65) on 23.04.16.

b) 48 Nos safety posters has been displayed to increase safety awareness among the staff of SF/CLW/CRJ.

c) Stack emission test carried out on 12-05-2016 by Asst. Environment Engineer, WBPCB/ASN to maintain the pollution level within permissible limit.

d) Plant safety inspection carried out at Moulding Shop (32) on 09-05-2016 by external agency and as per their report no NC raised in SF.

e) Surveillacne Audit on ISO & OHSAS wre conducted in Steel Foundry on 12-05-2016 and test report received on 21-06-2016 and found within level.

f) Stack emission test report of GAD furnace conducted by WBPCB/Asansol on 12.05.2016 and test report received on 21-06-2016 and found within level.

g) Plant safety inspection carrid out at patter shop (65) on 01-06-2016 and melting Shop (34) on 24-06-16.

h) Internal-9001:2008 (Audit No. IQA-01/16), ISO-14001:2004 (Audit No. IEA-01/16) & OHSAS-18001:2007 (Audit No. OHSAS-01/16) were conducted in Steel Foundry on 20-07-2016 to 22-07-2016 and no NCR raised in the Audit.

i) Stack emission test report of GAD furnace conducted by WBPCB/Asansol on 12-05-2016 and test report received on 21-06-2016 and found within permissible limit.

j) Plant Safety inspection carried out at Core Shop (31) on 19-072016 and Moulding Shop-32 (Bay3&4) /SF on 20-07-16.

k) Departmental Safety Committee meeting was held on 13-07-2016 in th4 meeting room of SF and discussed about different safety aspects of SF/CLW.

l) Plant safety Inspection carried out at Fettling Shop on 22.08.2016 and Sand Plant Shop/SF on 27-08-2016.

m) Inspector of Factories /Asansol visited Steel Foundry on 06-08-2016 and discussed about safe practices to be followed.

n) Submitted Quarterly REtu4rn form No. 23A to inspector of Factories/ASansol on 26.08.2016 as it is statutory requirement.

o) Proposal of Safety Audit of Steel Foundry initiated on 19-08-2016 for safety of staff to comply the legal obligation.

p) Proposal for Work Environment Monitoring in Steel Foundry initiated on 25-08-2016 as it is statutory requirement.

q) Plant Safety Inspection carried out at Pattern Repair Shop on 14-09-2016 and moulding Shop/SF/Bay-10&11) on 27/09/2016.

r) Inspector of Factories /Asansol visited Steel Foundry on 06-08-2016 and discussed safe practices to be followed.

s) Submitted Quarterly Return Form No. 23A to inspector of factories/Asansol on 26-08-2016 as it is statutory Requirement.

t) Stack emission test carried out on 25-10-2016 by Asstt. Environment Engineer WBPCB/ASN and collected the sample to maintain the pollution level within permissible limit.

u) Modified Plant lay out drawing of Steel Foundry approval by Chief inspector of Factories; Govt of West Bengal has been received. Thus it complies the issue raised by Inspector of Factories/Asansol.

v) Modified Plant lay out drawing of Steel Foundry approved by Chief inspector of Factories; Govt of West Bengal has been receivewd. Thus it complies the issue raised by Inspector of Factories/Asansol. Plant safety Inspection carried out at MTS Shop on 10/11/2016 & Pattern Shop-65/SF on 24-11-2016.

w) Stack emission test carried out on 15-12-2016 by Asstt. Environment Engineer, WBPCB/ASN and collected the samples to maintain the pollution level within permissible limit.

x) Copy of Change of factory Manager in Form No. 3A submitted to I.O.F./ASansol on 23-12-2016.

y) Renewal of NOC for consent to operate Form submitted on 23-02-16 to S.O./CLW/CRJ for further action by them

z) Special cleaning drive taken on 22-03-2017 in view of GM’s visit.

8A.6 Machinery & Plant—

i. Synthetic Sand Moulding Plant of 10 MT capacities — Civil foundation work has been completed. Erecting work will be started by firm after joint inspection.

ii. Megatherm 10T Direct Arc Furnace — Complete material received. Civil work is under progress.

PDC- April 2017. A. Supplier : M/s Megatherm Electronics Pvt. Ltd. B. P.O. No. : 05/2009/7003/91381 dated 10-08-2011. C. P. O Cost : ` 6,16,45,113.00 D. Present Status as on 31.12.2017 :

i. Transformer Room :Completed. (All components are placed) ii. Cooling Tower :Civil work in water complex of 10T EAF is completed

Placement of component has been done. Cooling Water Circulation testing to be done within 03-04-2017..

iii. Fume Extraction System Civil Work is completed. Placement of components has been done. Duck line and Cable Termination in anel are under process.

iv. Furnace Area Civil Foundation work including placement of Components has been completed.

v. Pipe Line Work Water, pneumatic & hydraulic pipe line are under process. vi. Control Panel Room Civil work has been completed. placement of components

have been done. Electrical work is under process.

STAFF POSITION

9

9. STAFF BREAK UP

STAFF BREAK UP DEPARTMENT WISE Gr. C & D (AS ON 31.03.17)

DEPARTMENT SANCTIONED STRENGTH

STAFF ON ROLL VACANCY

ACCOUNTS

GROUP –C 535 348 187 GROUP –D 01 01 00 Total 536 349 187

ADMINISTRATION GROUP –C 834 691 143 GROUP –D 05 05 00

Total 839 696 143

CIVIL

GROUP –C 827 701 126

GROUP –D 39 39 00 Total 866 740 126

ELECTRICAL

GROUP –C 3123 2377 746 GROUP –D 02 02 00

Total 3125 2379 746

MECHANICAL GROUP –C 6688 5512 1176

GROUP –D 10 10 00

Total 6698 5522 1176

MEDICAL GROUP –C 612 361 251

GROUP –D 05 05 00

Total 617 366 251

PERSONNEL

GROUP –C 299 278 21

GROUP –D Nil Nil Nil Total 299 278 21

RPF

GROUP –C 509 430 79 GROUP –D Nil Nil Nil

Total 509 430 79

S & T GROUP –C 58 48 10

GROUP –D Nil Nil Nil

Total 58 48 10

STORES

GROUP –C 970 600 370

GROUP –D 01 01 00 Total 971 601 370

TOTAL

GROUP - C 14455 11346 3109

GROUP - D 63 63 00 GRAND TOTAL 14518 11409 3109

UNIT COST OF THE PRODUCT

10

10. UNIT COST OF THE PRODUCTS

(Figures in thousands of Rs.)

a. Financial Year 2013 – 14

Type of Loco

Direct Labour

Direct Materials

Over heads

Total(ex. Pro. Chgs.)

Pro. Charges

Total(in pro. charges)

ED Total (including ED)

WAP-4 3914 52800 11886 68600 1029 69629 1400 71029

WAG-7 4413 51856 12331 68600 1029 69629 1400 71029

WAG-9 5642 101094 18064 124800 1810 126610 2800 129410

WAP-7 5225 104136 16039 125400 1881 127281 2800 130081

WAP-5 5310 112428 16462 134200 2013 136213 2800 139013

b. Financial Year 2014-15

Type of Loco

Direct Labour

Direct Materials

Over heads

Total(ex. Pro. Chgs.)

Pro. Charges

Total(in pro.charges)

ED Total (in.ED)

WAP - 4 4347 52800 14853 72000 1800 73800 1400 75200

WAG-7 4901 51856 15543 72300 1843 74143 1400 75543

WAG-9 6265 101094 23241 130600 1959 132559 2800 135359 WAP-7 5802 104136 21062 131000 1965 132965 2800 135765

WAP-5 5896 112428 21476 139800 2097 141897 2800 144697

c. Financial Year 2015-16

Type of Loco

Direct Labour

Direct Materials

Over heads

Total(ex. Pro. Chgs.)

Pro. Charges

Total(in pro.charges)

ED Total (in.ED)

WAP - 4 4315 60539 12746 77600 1400 79000 1940 80940

WAG-7 3898 56476 11526 71900 1400 73300 1790 75090

WAG-9 3920 100207 11873 116600 2800 119400 1749 121149

WAP-7 4778 101405 14817 121000 2800 123800 1815 125615

WAP-5 6490 104059 19451 130000 2800 132800 1950 134750

c. Financial Year 2016-17

Type of Loco

Direct Labour

Direct Materials

Over heads

Total(ex. & Pro. Chgs.)

ED Total (in.ED)

Pro. Charges

Total(in pro.charges)

WAG -9 5917 90329 18566 114812 688 115500 1722 117222

WAP-7* 7910 89165 24197 131373 728 122000 1819 123819

WAP-7** 7910 105663 24599 138172 828 139000 2072 141072 WAP-5 9274 99712 28191 137177 823 138000 2058 140058

INDUSTRIAL SAFETY

11

11. SAFETY ORGANISATION

11.1 Safety Officer & Safety Inspectors regularly check the safety aspect in the shop floor such as use of Personal Protective Equipment, proper use of Material Handling Equipment, unsafe working practices etc. They also conduct safety inspections, investigations of accidents and recommended remedial measures. They also formulate plans for motivating staff for safety consciousness, use of safety equipment and compliance of statutory act and regulations. To monitor Occupational Health Hazards, periodical Medical Check-up is done by Medical Department as per statutory regulation. Safety department in co-ordination with Medical Department frames the programme and maintain the records of the tests. It also maintains liaison with State Pollution Control Board. Environmental Engineers of WBPCB from Asansol & Kolkata regularly visits Steel Foundry/ CLW/Chittaranjan. Safety department with the help of approved agencies of WBPCB conducts regular tests of air and sound to provide proper work environment.

11.2 Measures taken for Improvement:

i. All Shops and work sides are regularly inspected for “Plant Safety Inspection”. All plants using flammable substances like acetylene and LPG etc. are inspected regularly and plant maintenance/operation units follow fire proof working procedures for safe operation and maintenance of these plants. Contractors engaged for maintenance of acetylene/oxygen/LPG plants are monitored regularly by Safety Units. Fire Prevention measures - like use of Flash back arrestor in acetylene cylinder and declaration of fire prone area as “NO SMOKING ZONE”, rigorous training of staff by fire inspectors, demonstration of fire- fighting equipment at the work sites, regularly re-filling/repair of fire extinguishers and being followed for vulnerable zones. All accident/dangerous occurrences are investigated and remedial measures are suggested to prevent recurrence of such incidents.

ii. Regular check is conducted at shop floor regarding use of Personal Protective Equipments like Safety

Shoes, Goggles, Helmet, Nose mask etc. Staffs are continuously motivated to wear PPEs and also apprised of the adverse consequences associated with non use of such equipments.

iii. A proper vigil is regularly maintained to determine whether all critical equipments like Crane, chain,

Pressure Vessel etc. are tested as per Statutory Rules by the agencies approved by the State Inspectorate of factories. Do’s and Don’ts for safe operation of crane has been circulated to concerned shops.

iv. Crane Drivers, Riggers, staffs engaged for Spray Painting, Electroplating, Battery Charging, Foundry work,

operation and signaling to the cranes etc. are given regular medical check up to assess their vision, chest, lung function etc. in compliance with the statutory obligation.

v. Safety calendars, posters, retro-reflective boards containing safety slogans procured by safety deptt. are

displayed at shop floor for safety awareness among the workers. As per the relevant provision of Factory Rules’1958, Safety and Health Policy of CLW has been prepared duly signed by the CME and occupier and displayed the same in various locations through laminated boards. Staff are regularly counseled by the Chief Safety Inspectors / Safety Inspectors to adopt safe practices while they are at work.

vi. Work Area Monitoring and HIRA (Hazar Identification and Rist Assesment) have been conducted by the

expert agency approved by the Chief Inspector of Factories in different areas inside the Factory Premises. The deficiencies hound in course of the above work have been pointed out and the same have been brought to the notice of concerned authorities to make necessary rectification. Conducting of Plant Safety Audit is under process.

Accident Statistics of CLW during the following periods 2013, 2014, 2015, 2016 and upto 31.03.2017 Sl no. Year No. of Accident Type of Injury

Fatal Serious Minor 1 2013 10 01 07 02 2 2014 10 01 06 03 3 2015 03 -- 03 -- 4 2016 01 -- 01 -- 5 2017

upto 31-03-17 03 -- 02 01

FUTURE PLANS

12

Future Plan

CMO

o Proposal for tie up with HLG Hospital for emergency cases is in its final stages. Tie up with steriling

hospital/Asansol for dialysis is under process. Printing of Employees and their families health card

including those of Retired (RELHS) employees is under process.

CQAM

o 100% implementation of modified IGBT Ballast Block Assembly is to be ensured.

o 100% radiography test for DMW suspension tube (Spares) to be implemented.

Dy. CC&M

o Procurement of high power & high sensitive ultrasonic flaw detection machine under process.

o Procurement of 5 Ton UTM for rubber / polymer testing.

o Procurement of 2 Nos USFD on replacement A/c.

o Procurement of surface roughness tester.

o Procurement of XRF alloy analyser.

o Procurement of coating thickness gauge.

Dy. CEE/M

o Setting up of Solar PV Power Plant of 100 KW initially and subsequently augmentation of capacity for

10% captive consumption by renewable sources.

OTHER ISSUES

13

13. Other issues CMO

Medical Check up was conducted for 3220 workers of Locoworks, Steel Foundry and works office.

Cleanliness fortnight – 1st May to 15th May, in all the work places, 16th May to 31st May, in all officers, 1st Just to 15th July in all colony areas.

Swachh Bharat Mission – Cleanliness drives at Gate No. 1 and Kangoi Bhawan, with the active participation of the CLW unit of Bharat Scouts and Guides on 17th Septemper 2016. 30th September to 2nd October – special cleanliness drive and Swachchta Sapath.

Indian Railway Ophthalmic society conference was organized by the Scientific Association of Railway Medical Officers, CLW/Chittaranjan, from the 21st to 23rd of October 2016. The following M&P items were commissioned on 15th August 2016.

Mobile X-ray Difibrillator with facility of external pacing, 2 Nos. Horizontal high pressure sterilizer.

The following M&P items have been received and have been kindly inaugurated by GM/CLW on 26.01.2017.

o Computerised Tread Mill Test Machine o Biophasic Defibrillator with transthoracic pacine o Advanced ICU Ventilator.

School Health: 1075 students were examined in the year 2016. World cancer day was observed on 4th February 2017 by organizing awreness programme in

the Seminar hall of KG Hospital. Mental health awareness seminar at Locoworks (Shop No. 19) on 21st February 2017. No smoking day was organized at Steel Foundry workshop on 10th March 2017. CMO/CLW,

Sr. DMO/P and ADMO/ENT were present at the Function. An audio visual presentation was organized in the hazards of smoking was discussed in details.

Dy. CC&M

C&M post is lying vacant since last 1 year.

Two post of AC&M lying vacant since last 2 and ½ years.