61INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Rolling Stock

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

Type of Rolling Stock Units placed on lineReplacement

accountAdditional account

Year B.G. M.G. N.G. B.G. M.G. N.G.Diesel Locos 2012-13 68 - - 225 - -

2013-14 64 - - 271 - -Electric Locos 2012-13 30 - - 300 - -

2013-14 - - - 302 - -Wagons 2012-13 1,070 - - 11,810 - -(in vehicle units) 2013-14 1,826 - - 6,488 - -Electric Multiple UnitsMotor Coaches 2012-13 20 - - 88 - -

2013-14 13 - - 24 - -Trailer Coaches 2012-13 18 - - 286 - -

2013-14 12 - - 42 - -Main line Electric Multiple UnitsMotor Coaches 2012-13 - - - 28 - -

2013-14 - - - 24 - -Trailer Coaches 2012-13 - - - 84 - -

2013-14 - - - 72 - -Passenger Carriages 2012-13 1,037 - - 2,253 - -

2013-14 222 - - 3,265 - -Other Coaching 2012-13 10 - - 183 - -Vehicles 2013-14 2 - - 113 - -

Stock condemned during the year was as under:

Type of Rolling Stock (in units)

B.G. M.G. N.G.2012-13 2013-14 2012-13 2013-14 2012-13 2013-14

Diesel Locos 106 106 19 03 05 -

Electric Locos 49 63 - - - -

Wagons(in Vehicle Units)

3,319 3,022 365 150 - -

Electric Multiple Units

Motor Coaches 41 48 - - - -

Trailer Coaches 48 128 - - - -

Passenger Carriages 686 788 107 217 17 16

Other Coaching Vehicles 103 110 21 22 - -

Electronic Fuel Injection (EFI) System Fitted In Alco Loco By DLmw

Auxilliary Power Unit (APU) Fitted In Loco By DLmw

62 INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Traction

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

The traction-wise fleet as on March 31, 2014, was as follows:

(in units)Locomotive As on

March 31, 2013As on

March 31, 2014Steam 43 43Diesel 5,345 5,633Electric 4,568 4,823Total 9,956 10,499

Manufacturing of Rolling Stock

The performance of Production Units during 2013-14 was as under:

y Chittaranjan Locomotive Works (CLW), Chittaranjan manufactured 264 BG electric locomotives including 137 state-of-the-art 3-phase 6000 HP electric locos (72 equipped with IGBT technology based propulsion system & auxiliary converters).

y Diesel Locomotive Works (DLW), Varanasi manufactured 304 BG diesel locomotives including 266 indigenous high HP locomotives. Out of these, 14 diesel locomotives were manufactured for Non-Railway Customers (NRCs) and 19 locomotives for export. Value of sales for export and NRC locomotives from DLW during 2013-14 was `321.59 crore.

y Integral Coach Factory (ICF), Chennai manufactured 1,604 coaches including 21 Electric Multiple Units (EMUs), 92 Diesel Electric Multiple Units (DEMUs), 33 self propelled high speed accident relief trains (SPART) and 25 LHB coaches.

y Rail Coach Factory (RCF), Kapurthala manufactured 1550 coaches including 102 Main line Electric Multiple Units (MEMUs) and 388 light weight LHB coaches with higher passenger comfort and amenities

NDM6 loco on DHR

MG Steam Loco

63INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Auxilliary Power Unit (APU)-closer look

In side view of a Diesel Shed - North East Frontier Railway

y Rail Wheel Factory (RWF), Bengaluru produced 45,233 wheel-sets. It also manufactured 1,88,188 wheels and 77,406 axles. RWF executed orders worth `24.43 lakhs for NRCs .

y Diesel Loco Modernisation Works (DLMW), Patiala successfully upgraded 75 nos. of 2600 HP WDM 2 diesel electric locomotives to 3100 HP, thus increasing the hauling capacity to the extent of 3 to 4 additional coaches. DMW also manufactured 81 new locomotives for IR and exported spares worth `24.12 lakhs to Malaysia and Mozambique.

Innovations in EMU/MEMU rakes and Kolkata Metro

Introduction of new state-of-the-art technology AC/DC EMU rakes in Mumbai area: So far a total of 130 AC/DC EMU Rakes (114 rakes of 12 car & 16 rakes of 9 car) with new state-of-the-art IGBT technology have been manufactured by ICF. Out of these rakes, 128 rakes have already been inducted into services which generated 35% additional carrying capacity. These rakes are energy efficient having regenerative features and also provided with forced ventilation system. With regenerative braking feature, about Rs.1 crore/rake is saved per annum in energy consumption.

In addition to the above, two prototype AC EMU rakes of 12 car with new state-of-the-art IGBT technology have also been manufactured by ICF against MUTP-Phase II Project. Tests on trials on these rakes have been completed by RDSO and these rakes will be inducted into passenger services shortly.

15 car EMU services have also been introduced in Mumbai area.

Introduction of stainless steel EMU rakes: M/s Bharat Earth Movers Ltd., Bengaluru has already manufactured two stainless steel EMU rakes against a developmental order placed on them. First two stainless steel EMU rakes are already in operation in Eastern Railway and four more rakes will be manufactured in due course.

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

64 INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Kolkata Metro: With the construction of elevated corridor, it has been decided to induct air conditioned rake. Thirteen air-conditioned rakes with indigenous technology have been introduced. The new rakes have higher acceleration and deceleration besides improved riding characteristics with air suspension arrangement.

Imports

Import content of raw material/components, in terms of percentages of total production cost (excluding proforma charges) for different types of rolling stock manufactured in Indian Railway Production Units for the year 2013-14 is furnished below:

Production Unit Locomotives Import content (%)

2012-13 2013-14

DLW WDG-3A* 1.92 1.87

WDG-4 31.08 32.82

WDP-4D 29.79 31.89

WDG-4D 30.72 30.19

WDP-4B 31.08 31.72

CLW WAG-9 1.78 0.63

WAP-7 1.70 0.62

WAP-5 2.38 0.61

Coaches

ICF AC DC EMU B MRVC - 0.51

AC DC EMU C MRVC - -

AC DC EMU D MRVC - -

AC DC EMU D/HC MRVC - -

SPART DPC I 0.83 0.48

SPART DPC II 0.83 1.91

SPART TC 2.19 -

DEMU DPC HHP 0.74 0.70

DEMU TC HHP (GEN) - -

DEMU TC HHP (VEN) - -

DMU TC HHP (GEN) HALDIA 4.05 -

DMU TC HHP (VEN) HALDIA 4.05 -

ACCW LHB - -

SCN LHB - -

FACCW - -

FACCW CBC - -

DHR Steam Loco

SGUJ Diesel Shed

65INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Jagadhri Workshop With Monthly ACPOH Increased From 18 To 30 Coaches

Man at work of a engineering workshop

Production Unit Locomotives Import content (%)

ACCW - -

ACCN - -

FAC - -

SCZ AC - -

SCZ AC JS - -

SCN - -

GS - -

CB - -

SCZ - -

SCZ JS - -

SR JS - -

SLRD - -

RCF ACCB/EOG/LHB 4.25 4.20

ACCN/EOG/LHB 4.36 4.36

ACCW/EOG/LHB 4.27 4.21

FAC/EOG/LHB 4.30 4.20

WLRRM/EOG/LHB 2.53 3.36

FCZAC/LHB 4.28 4.23

SCZAC/LHB 4.45 4.20

LFCWAC 3.83 3.78

LWCZDAC 2.54 2.52

LWSCN 7.97 7.89

LWSCZ 5.65 5.58

LGS 7.29 7.32

*NRC

IR’s bulk requirement of wagons is met by wagon manufacturing units both in public and private sectors as well as PSUs under the administrative control of Ministry of Railways. During the year 2013-14, 9,326 wagons were inducted in Indian Railway System. Out of these, 1,168 wagons (including 210 BLC wagons) were manufactured by railway workshops and the remaining 8,158 wagons including 80 BLC wagons were manufactured by wagon industry.

During April-September, 2014, 3,400 wagons were inducted in Indian Railway system. Out of these, 632 wagons (including 260 BLC wagons) were manufactured at railway workshops under the administrative control of Ministry of Railways. The balance 2,768 wagons were manufactured by wagon industry.

66 INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

Maintenance of Rolling Stock

The number of units of rolling stock given periodic overhaul (POH) in railway workshops during the year and the percentage of stock overdue periodic overhaul at the end of the year are given in the following table:

Type of Rolling Stock(BG + MG)

Periodic overhaul (nos.) undertaken during the year

2012-13 2013-14Diesel Locos 509 560Electric Locos 377 380Coaches 27,205 28,504Wagons 42,896 45,025

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

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

B.G. M.G.2012-13 2013-14 2012-13 2013-14

Steam Locos - - 17.10 25.30Diesel Locos 8.90 8.71 11.27 11.94Electric Locos 7.25 7.56 - -EMU Coaches 10.40 10.20 - -Passenger Carriages 6.19 6.24 8.11 6.07Other Coaching Vehicles 6.81 6.36 1.89 1.32Wagons 4.06 3.99 7.57 8.28*revised

Export Order

The total value of exports of rolling stock during 2013-14 was `379.03 crore. The cumulative value of export of rolling stock/spares up to the end of March 2013 and March, 2014 was `1,798 crore and `2,177.03 crore, respectively. The value of export of rolling stock/spares during April-September, 2013 was `165.24 crore.

The exports during 2013-14 include locomotives, DMUs, coaches, lease and maintenance services etc. to developing countries like Myanmar, Sri Lanka, Bangladesh and Malayasia.

Modernization of Workshops

Central Organisation for Modernisation of Workshops (COFMOW) working under Ministry of Railways is situated at Railway Offices Complex, Tilak Bridge, New Delhi.

CNC Spot Welding Machine

800 Ton Press Brake

67INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

In side view of a Diesel Shed - North East Frontier Railway

Operation & Maintenance of locomotives

It was set up in 1979 for providing consultancy and engineering inputs for technology up-gradation and improving productivity of manufacturing units. It continues its endeavor to provide crucial technical support to the various manufacturing & maintenance units of Indian Railways with bare minimum staff strength of 181 personnel.

Salient Features

Imbibing latest state of the art technologies available yworldwide in the field of M&P.

Developing/ retaining professional expertise by training in yrequired field and interaction with firms.

Supports not only Mechanical units, but all the departments yof Indian Railways vis-à-vis their M&P requirements.

Up-gradation and compilation of specifications of all ymachines used in various workshops, maintenance sheds and Production Units.

E-tendering is being done for all M&P items. y

Reverse Auction has been introduced on IREPS website. y

Sole window for Industrial Engineering expertise in Indian yRailway

Successive efforts for indigenization have led to FOREX ysavings.

Key Milestones

S. No. Year Fund Utilization (` in crores)

Value of Orders (` in crores)

1 2012-13 408.7 6592 2013-14 460.0 601

Turnkey Projects

COFMOW has recently embarked upon the journey of handling Turnkey works including construction of Civil and Electrical infrastructure besides procurement, installation and commissioning of machines.

ICF Expansion Project:

Works contracts for composite work of augmentation of yproduction capacity at ICF for manufacturing of advanced LHB coaches (Cost `127 Crores.) nearing completion.

Shell manufacturing has started. y

68 INDIAN RAILWAYS ANNUAL REPORT AND ACCOUNTS 2013-14

RWF Axle Line Project:

A Works tender with estimated value of y `202 crores for setting up a process line facility for manufacturing of Axles at RWF/Bangalore is under process.

ICF Spring Line Project:

Setting up of a dedicated spring manufacturing facility at yICF/ Chennai is under process.

Pit Wheel Lathe turnkey Project:

A number of turnkey projects for Underfloor Pit wheel ylathes with shed have already been successfully executed and many more to follow.

Rate contracts

COFMOW has entered into Rate contracts for items purchased regularly. Rate contracts finalized are

Electric Driven Rotary Screw Air Compressors y

Road Mobile Cranes(Articulating type) y

Diesel Generating Sets. y

Robotic Spot welding Machine at ICF

Provision of Utilities in ICF LHB shed