1.1. Brief history...is thrown out of bearing. For manual cleaning of Roller bearing, it takes...

MRS’s Inspection LGDS 22/06/2018 of 62

1.0 General:

1.1. Brief history:

The Carriage Workshop of SCR located at Lallaguda was established in 1893 as the

Locomotive, Carriage and Wagon Workshop of the Nizam State Railway (NSR). The

Government of Hyderabad took over direct control of the Railways in 1930 and

renamed it as the Nizam Guaranteed State Railways (NGSR).

The Lallaguda Workshop complex is one of the oldest surviving examples of modern

Industrial Architecture in the Twin Cities. It signaled the beginning of major industry in

the state. A few structures in use today date from the time of the workshop’s initial

commissioning. The precinct provides us with a glimpse of not only the industrial

advances made over more than a century but is also a repository of heritages from a

bygone era. Restored wagons, coaches and a variety of artifacts relating to railway

history have been preserved and quite a few are displayed at the site. Notable among

these one finds a meticulously restored coach of 1886 vintage.

South Central Railway was carved out on 2nd October 1966, and Lallaguda Workshop

went on to become a major workshop of the zone. It continued to be a composite

workshop for MG/BG rolling stock till 1973. As a result of phasing out of steam locos,

the Workshop took up POH of all types of BG coaches and hence rechristened as

“Carriage Workshop” during 1997.


INTACH Heritage award 2015:

This Workshop was bestowed with the prestigious Heritage Award of Indian National Trust for Art and Cultural Heritage (INTACH), Hyderabad Chapter on the occasion of the World Heritage Day celebrations held at Salarjung Museum, Hyderabad on 18th April, 2015. The award was presented to the Carriage Workshop under the Modern Industrial Heritage category.

1.2. Heritage preservation:

1.2.1. 1886 NIZAM’S SALOON- NGSR: Restored 1886 built Nizam’s Guaranteed

State Railway’s wooden bodied

4-wheeler inspection carriage (Saloon)

during December 2006.

1.2.2. 1920 BUILT WAGON:

Restored 1920 built wagon, by Birmingham Railway Carriage & Wagon Company (BRC&W), Smethwick, England, during May 2007.

1.2.3. HERITAGE MG AC SALOON

(SC CTAC-150):

Restored dilapidated 1970 ICF built

meter gauge coach (saloon) stabled at

“Purna” and hitherto utilized by General

Manager, South Central Railway.


1.2.4. HERITAGE MG STEAM CRANE 35 TONNES: Restored 1976 North Eastern Railway

Workshop, Izzatnagar manufactured 35

ton MG Steam Crane (SCR – S-3508),

with a tare weight of 70 ton and

equivalent to match truck of 15 ton,

during August 2010.

1.2.5. FIRE EXTINGUISHER – NIZAM STATE RAILWAY:

Restored Nizam era’s Vintage fire

extinguisher.

1.2.6. JOHN MORRIS FIRE ENGINE

(1914 MAKE): John Morris Fire engine, housed at

National Rail Museum/ New Delhi, is

maintained by Carriage Workshop,

Lallaguda.

1.2.7. MAHATMA GANDHI STATUE (BRONZE):

Restored Bronze Mahatma Gandhi Statue manufactured by foundry staff of Lallaguda during 1955 and placed adjacent to the main gate (inside).


1.2.8. FIRE ALARM BELL – 1925:

Bronze bell 1925 manufactured and weighing 83 Kg used as mass alert during exigencies.

1.2.9. RESTORATION OF LIBRARY COACH – (WPCTLAC- NWR -91565 – 1991 built

used in Palace on wheels). Restored 1991 ICF built library coach used on Palace on wheels.


1.3. प्रमखु उपलब्धिय ां Major milestones:

1893 “निज म ग रांटीड स्टेट रेलवे” के अांतगगत यह लोको, कैरेज और वगैि क रख िे के रूप में अब्स्तत्व में आय

Established as Loco, Carriage and Wagon workshops under “NIZAM’S GUARANTEED STATE RAILWAY”.

1951 यह मध्य रेलवे के अांतगगत आ गय . Brought under Central Railway.

1966 यह दक्षिण मध्य रेलवे के अांतगगत आ गय Carved out as South Central Railway.

1975 बीजी भ प के्रिों की आवनिक ओवर ह लल ांग

POH of BG steam cranes.

1981 व त िकूुललत सव री डडधबों की आवनिक ओवर ह लल ांग

POH of AC coach.

1988 िए लमिी कां प्यटूर क आरांभ ककय गय Commissioned mini- computer.

1997 क रख िे क ि म बदल कर “सव री डडधब क रख ि ” के रूप में रख गय . Rechristened as CARRIAGE WORKSHOP.

2000 आईएसओ – 9002 – 1994 प्रम णीकरण प्र प्त हुआ. Awarded ISO-9002: 1994 Certification.

2003 डीएचएमय ूकी टे्रलर क रों की आवनिक ओवर ह लल ांग आरांभ हुई. Commenced POH of DHMUs trailer cars.

2006 ईएमय ूटीसी और ट वर वगैिों की आवनिक ओवर ह लल ांग आरांभ की गई. Commenced POH of EMU TCs and Tower wagons.

2007 आईएसओ – 9001 – 2000 प्रम णि प्र प्त ककय गय . Awarded ISO-9001: 2000 Certification.

2007 बोगगयों की आईओएच (18 महीिे) आरांभ हुई.

Commenced 18 months POH.

2008 बोगगयों की आईओएच (9 महीिे) आरांभ हुई. Commenced IOH of bogies (9 months).

2009 कोचों क िवीिीकरण Commenced Refurbishment of coaches.

2009 क रख िे क आिनुिकीकरण क यग िवांबर’09 से आरांभ हुआ. Commenced modernization of workshop (from November 2009).

2011 डीएचएमय,ू डीईएमय ूकी प वर क रों की आवनिक ओवर ह लल ांग आरांभ की गई .


Commenced POH of power cars of DHMU and DEMU.

2012 आईएसओ 9001 : 2008 प्रम णि प्र प्त ककय गय . Awarded ISO 9001:2008 Certification.

2012 एलएचबी कोच एसएस-1 शडे्यलू आरांभ हुआ. Commenced LHB Coach SS1 Schedule.

2013 एलएचबी कोच एसएस-2 शडे्यलू आरांभ हुआ. Commenced LHB Coach SS2 Schedule.

2015 ईएमय ूऔर मेम ूमोटर कोचों की आवनिक ओवर ह लल ांग आरांभ की गई

Commenced POH of EMU & MEMU Motor coach.

2015 डबल डकेर कोचों क SS1 आरांभ ककय गय Commenced SS1 of Double Decker coaches.

2015 व इस – II आरांभ ककय गय . Implemented WISE-II.

2016 एलएचबी कोचों क SS3 शडे्यूल आरांभ ककय गय . Commencement of LHB Coach SS3 Schedule.

2016 आईप स को कक्रय ब्ववत ककय गय . Implemented IPAS.

2016 सीबीसी हेडस्ट क क रे

Retro-fitment CBC Headstocks.

2016 Accredited with 5S Workplace Management System (WMS).

2016 Accredited with IMS, Containing QMS (ISO 9001:2015);

EMS (ISO 14001:2015); OSHAS (180001:2007) &

EnMS (ISO 50001:2011).

2017 Awarded Green-Co Silver Rating by CII/Hyderabad.

2017 Accreditation of NABL certificate to CMT Laboratory.

2017 Received best innovation award for “automated single car test rig”.


1.4. मखु्य ववशषेत एां Salient features:

1. Total area of Workshop 13.97 hectares

2. Covered area 4.25 hectares 3. Rail track length 8.25 kms

4. M&P 509 nos.

5. Railway quarters 556 nos. 6. WMS budget 2018-19 Rs.297.32 crores

(Mech. - Rs.230.32 crores; Elect. - Rs.66.99 crores)

7. Monthly outturn target for 2018-19 a) 136.4 VUs POH. b) 200 IOH of bogies, c) Fiat Bogies

8. Average power consumption/month during 2018-19

1.41 lakh units.

9. Manpower as on 01.06.2018. (All depts.)

Sanctioned Actual Vacancy

3528 3078 450

1.5. क यगश ल की वतगम ि गनतववगिय ां Present activities of the Workshop:

• POH of BG ICF/RCF/BEML coaches.

• SS-I, SS-II and SS-III schedules of LHB Coaches.

• POH of Duronto (Hybrid) coaches, Tower Cars, Double decker coaches.

• POH of Power & Trailer cars viz., DEMU, EMU, MEMU& SPART.

• POH (Shop schedule) of LHB coaches.

• IOH of bogies for divisions.

• Supply of FIAT bogies for SS-I schedule of LHB coaches

• POH of Defense owned coaches.

• Manufacturing of all types of locomotive filters at LOFP/SC.

• Works under Railway Board’s bulk RSP.

• Supply of wheel sets to divisions.

• Fitment of Bio-toilet tanks on coaches.

• Over hauling of DVs, BMBCs & other air brake components for division.

• Calibration of instruments/gauges.

• WISE-II functioning.

• Chemical and Metallurgical testing/analysis of components.

• Basic Training Centre offers:

a) Refresher courses to Artisan Staff

b) Imparting training to Apprentices engaged against Apprentice Act, 1961

c) Skill development programmes.

d) SAKSHAM Training


1.6. सांगठि च टग Organization chart:

M.Vijaya kumar

CWM

M.Ravi Kiran (WM-Co-Ord)

Prashant Kumar PE/LGDS

Kamal Kant WM/LGDS

N. Ganga Raju Dy. CEE/LGDS

M. Parthasaradhi

Dy. CMM

V. V. K. R. Verma Dy. FA&CAO/WS

C. Veeraiah DEE/Coaching

Dy.CME

DY.cme

DY

G. Seshadri AWM-II

A

S.Murali AWM-III

K.Venkat Ramana AWM-I

A

P. Raghavendra Sarma

AEE

T. Rajendra Kumar AMM/M&E

V.Harisha AWAO

S.Manivannan CMT

S.Laxman Rao WPO

Rabindranath Sabar DEN

R.Nageshwar Rao

AEME/LOFP

WM/RBK/YG Vacant S.V.S. Raju

AWM/RBK/YG

G.V.S.Rayudu

IPF/RPF


1.7. ल ल गुड क रख िे क लेआउट Layout of LGD Workshop:


2.0. प्रम णि Certifications – IMS, 50001, 5S, ISO 3834, NABL:

2.1. 5S – Work place Management System (WPS): Certificate awarded on 08.10.2016.

2.2. Integrated Management System (IMS): Certificate awarded on 31.3.2017

2.3. Green-Co rating system Certificate awarded on 26.04.2017

2.4. ISO 3834 – 2: 2005: Certificate awarded on 26.04.2017


2.5. EnMS: 50001: Certificate awarded on 07.04.2017

2.6. NABL Accreditation for CMT Lab: Certificate awarded on 6.10.2017


3.0.िवोवमेष Innovations:

Developments During the year 2018-19

3.1 Automated tensile testing machine for Screw coupling in machine shop.

The software programming for horizontal tensile testing machine have the advantages of hydraulic power pack for controlling the pressures, measurement of elongation to the respective load applied, measurement of load, sensing of the pressures, auto cut off of hydraulic pressure item tested, recording of elongation, load applied, pressures, date tested and name of the staff tested with print out.

3.2 Pre-cleaning plant for Roller Bearing in Wheel Shop

It works on the centrifugal force, on

rotating the roller bearing, an air pressure

of 8 kg/cm2 is applied on the roller

bearing. The grease on the roller bearing

is thrown out of bearing. For manual

cleaning of Roller bearing, it takes around

2 to 3 minutes/Roller bearing. By this

machine, we can clean two roller bearing

in 2 minutes; 15-20 sec for loading, 15-20

sec for unloading, 1 minute for cleaning.


3.3 . INTEGRATED TEST BENCH FOR WSP & BRAKE EQUIPMENT OF LHB COACHES

(FAIVELEY MAKE)

Brief of WSP test bench:

Integrated test bench with real time simulation of train speed, designed and

developed in-house at carriage workshop, Lallaguda, is a replica of Complete

Disc Brake System of FAIVELEY make fitted in LHB Coaches.It can check the

functional test of complete disc brake equipment and WSP equipment of a

LHB coach as a complete coach set.

The following Brake Equipment and Wheel slide protection equipment can be

checked integrally and individually on this test bench.

Distributor Valve; 2) Emergency Brake Valve ; 3) Emergency Alarm Pull Box; 4)

Emergency Brake Accelerator; 5) Pressure Switch; 6) K-5 Relay; 7) Filters; 8)

Check Valve; 9) Isolating Cocks; 10) Test Point Connectors; 11) Brake

Indicator; 12) Micro Controller Unit; 13) Electronic Cards of WSP System; 14)

Speed Sensors; 15) Dump Valves

ISOLATING COCK’S

TEST POINT BC

AIR STRAINER

TEST POINT BP

PRESSURE SWITCH

DISTRIBUTOR VALVE

TEST POINT FP


Developments During the year 2017-18:

3.4 Automatic Integrated test bench for Air Spring

control equipment

Developed in house, for testing Air spring Leveling

valve & Duplex valves which are used for controlling

secondary Air suspension of DEMU/EMU DPC and TC

coaches. This test ensures quality of above valves for

air suspension, before fitment on coach, thus ensuring

coach reliability

3.5 Automatic single car test rig for LHB:

Automatic Single Car Test Rig is used to perform Air

Brake testing on LHB coaches to ensure proper

functioning of Air Brake System. This testing procedure

is generally done during the POH of LHB coaches or

change of any Air Brake sub-assembly.

This machine is so designed that it can work in any

climate condition; robust and suitable for Railway

working system. This is a probable machine which

gives a power backup upto 6 hours. The Automatic

Single car test rig minimizes the time for testing, avoids

human errors, records the tested parameters and

stores the data in database. And it gives saving of

2 employees per shift and assures accuracy in the job.

3.6 Automatic Grease dispensing machine:

Automatic filling of grease into the roller bearing directly

from the grease drum. Quantity to be

filled is controlled by PLC embedded in the circuitry.


3.7 Automatic Single car test rig

Automatic Single car test rig designed and developed by Carriage Workshop Lallaguda on 15.11.2016 is used to perform Air Brake testing on coaches to ensure proper functioning of air brake

system. The Ministry of Railways awar ded "1st

Best Innovation Award" to South Central Railway in the category of Suggestion Scheme of Best Innovations by Indian Railways for the year 2016-17

on 20-10-2017.

3.8 Integrated Test Bench for WSP & brake equipment of LHB

Coaches )Knorr Make(

Integrated test bench with real time simulation of

train speed, designed and developed in-house on

02-08-2017, is a replica of Complete Disc Brake

System of Knorr make fitted in LHB Coaches.This

integrated test bench can check the functional test

of complete disc brake equipment and WSP

equipment of a LHB coach as a complete coach set.

3.9 Air spring test stand:

The Air Spring Test bench is

developed to check any air leakages

/rubber burst/ O-ring damages of the

air bellow during POH. The Air bellow

is tested with air pressure of

10kg/Cm2. It helps in reducing the

laborious work of finding out

leakages/damages in air bellow, so

that air bellow can be rectified or

replaced with new spares.


3.10 Automated Electro pneumatic Brake test

stand:

This EP brake system provided in EMU, DEMU,

MEMU PCs is for brake application, works in

conjunction of Electrical and pneumatic brake

control application.

3.11 Hydraulic press fixture for Scragging of Draft Gear of Faively make

Hydraulic press fixture for Scragging of Draft Gear developed in-house for scragging of draft gear equipment during POH repairs. The main features of the equipment is to compress the draft gear to 430mm by using hydraulic press fixture and release the draft gear to 512mm,by releasing the hydraulic press fixture. Recording serial number of assembly and corresponding period value for future reference.

Developments During the year 2016-17:

3.12 Computerized Automated Distribution Valve

Testing System:

The Automated DV Testing System is developed

on 09-12-2015, to overcome the human errors

and laborious working for testing the distributor

valves specified parameters on the test rig before

passing the Distributor Valves of its and fitment

on coach. The existing system of testing of various

types requires high skilled operators to perform

the test types of Distributor valves, as each type

of Distributor valve has different testing

parameters, now with this test stand with any

operator DVs can be tested on this developed

computerized DV test stand.

Automated DV Test Bench

DV Test Screen Shot


3.13 Automated BMBC testing system:

Developed automated BMBC testing system.

Automation of Bogie Mounted Brake Cylinder test bench as it is a crucial and highly safety Air Brake Equipment which plays vital role in application and release of brakes in coaching stock during train operations and to avoid manual operations and errors.

3.14 Centre of excellence:

a. Air brake shop has been developed as “Centre of excellence”.

b. CBC shop & Roller Bearing sections are

also developed as “ Centre of Excellence during 2017-18.

Epoxy flooring at CBC section Hydraulic press fixture for Scragging

of Draft Gear


Pneumatic Balancer for handling Axle Box Pneumatic Balancer for handling roller

bearing

Air Gauge to measure Inside Diameter of Roller Bearing Automatic Grease dispensing machine

3.15 Self-learning kiosk and performance evaluation:

This application is developed as a part of centre of excellence

3.16 Pneumatic Balancer for handling roller bearings:

Facilitates mechanized handling of direct mounted roller bearing after it is heated to 120OC on induction heater, to mount on the axle during assembly.


3.17 Welding Manipulator for welding repairs of body side main door:

Developed a welding manipulator, in-house, for

accurate welding of new panels on doors, assist in

easy tilting of doors, which eliminates intensive

labour. This manipulator also eases down hand

welding.

3.18 Air Brake Hose Pipe test bench:

Developed a test bench for detection

of leakages in air brake hose pipe, in-

house. 5 hose pipes can be tested

concurrently. Process - Hose pipes

shall be connected to the pipelines

provided on the test bench and

immersed the

water. Thereafter, air pressure of 10 Kg/cm2 is allowed to pass through the pipes,

which throws air sound/bubbles, resulting in identification of leakages or

otherwise. Additionally, the same test bench is equipped with a fixture to allow

passage of light rays through hose pipes to identify physical blockages, if any.

3.19 Test Rig for axle drive run:

Developed a test rig, in-house,

to test axle drive of SPART PC

coaches.

Process – The axle drive is run on

bogie with the aid of power from

traction motor to detect defects

viz., oil leakages, etc., and to

attend to the same before

releasing the axle drive for

induction.


3.20 Sensors based Automatic air circulators for energy saving:

To reduce power consumption, infra-red human

sensors were fitted to 10 air circulators at shop

floor. The infra-red sensors shall switch the air

circulators on & off only on the detection of human

movement.

3.21 LED digital display boards:

Installed LED digital display boards operable by

LAN/WI-FI/Android App, at prominent locations, to

relay information.

3.22 Mechanized gate system:

Installed mechanized Main gate system to assist RPF in remote operation of gate.

3.23 Energy meters provided for compressors GD:

16 energy meters have been inducted to precisely

monitor the energy consumption by compressors

that would aid in analyzing variations, if any, to

arrest wastage of energy.

Sensor


3.24 Ring Main System for Sub Stations:

Developed a ring main system by linking all the

three sub-stations of Workshop, thus, creating

standby for power supply to one another, in

exigencies. This would not only enable energy

control but also aids in trouble shooting,

preventive maintenance schedules, etc. Also

resulted in savings of 4365 units per month

(Rs.34,920/month).

3.25 Power turn table:

A pneumatically operated coach brake cylinder is modified with thruster bearing arrangement to lift the bogie and amenable to rotate by 90o to place cross-wise to move bogie the next bay.

4.0 अच्छ क यग Good work done:

Conversion of DEMU DPC to Self-Propelled Inspection Car

4.1. A 700 HP DEMU Power Car was converted to Self-

Propelled Inspection Car (SPIC) No.015002. Dual driver

cabins with CCTV cameras, full AC inspection room with

16 air craft type seats, modern electrical/electronic

gadgets such as wireless PA system, internet router with

4G SIM, real time GPS based tracking system, full HD display units, are provided.

• A mini bed room with modern bathroom, kitchen and

attendant room are also provided.


4.2. Sunk in type Hydraulic Jack commissioned at

Corrosion shop to aid in precise lifting of coach body

during corrosion repairs.

4.3. De-clamping and Clamping device:

Commissioned for lifting and lowering of FIAT

bogie during POH of secondary suspension.

4.4. Axle box induction heater commissioned

for easy mounting to avoid manual

hammering

4.5. Control arm bracket of FIAT bogie

One of the LHB double decker coach no. 14158/C LWCZDAC was badly worn out and developed a crack. As it was non-standard FIAT bogie frame, sent to ICF for repairs to provide new bracket and machining of the part at axle seating area. Special efforts were taken to undertake repairs on top priority and after receipt of bogie, coach was sent.

4.6. 9 Marooned coaches due to heavy floods in Mumbai during September 2017 were attended for special repairs as per the instructions of headquarters vide lr.no. M.271/C&W/POH/BG/237.Vol.IV dated 07.09.2017.

4.7. Supply of IOH FIAT bogies: 62 coach sets i.e., 124 nos. of IOH Fiat bogies were supplied till 31.05.2018 to division (i.e., coach sets of 32 nos. to SC, 25 nos. to HYB & 5 nos. to BZA respectively).


4.8. AC duct cleaning activity started during

the year. As on date, 231 ducts were cleaned during POH of AC coaches from April-2017 to May-2018. which is 100% more over previous years outturn

4.9. 26 LHB coaches are modified to Twin Pipe Air Brake system. 25 coaches are converted from ferrule joint to threaded joints. (All LHB Coaches are converted during Shop Schedules)

4.10. All -SLR coaches are provided with 40mm working stroke BMBCs during POH. From Apr-2017 to May-2018, 88 coaches are fitted with single acting BMBC with 40mm stroke.

4.11. Controlled discharge flush cock For part flush- 1 litre/flush

For Full flush – 2 litre/flush.

16 coaches were provided on a trial measure.

Indent for further 200 nos , material is under

procurement.

4.12. Water meters:

11 water meters are installed during July/August 2016 to monitor the raw water consumption. Average consumption of raw water during May’18 was 1.80 lakhs liters/day.


4.13. Fitment of Bio-toilet tanks and ensuring hygiene I. LGDS Fitted Bio tanks from 2014-15 to 31.05.2018

A. To avoid bad odour in Toilets fitted with Bio-Tanks, following modifications are being carried out.

To avoid entering of foreign materials in lavatory of Indian commode with Bio-Tank one

Stainless Steel Restrictor is provided on pan neck.

S.No. Year Tanks fitted

1 2014-15 74

2 2015-16 140

3 2016-17 1279

4 2017-18 2339

5 2018-19 (up to May’18) 494

Total 4326

Inside view of toilet with low level ventilator (BLDC-brushless DC exhaust fan)

Provision of dust bins to avoid

choking of bio toilets

Exhaust fan provided at End wall


4.14. 8 Garibrath EOG coaches have been fitted with bio-tanks duly relocating the

electrical cables, as per RDSO drawing no. 14053

5.0. डडधबों के अांदरूिीहहस्सों में सिु र Improvement in coach interiors/Passenger

amenities:

a. 530 no. of coaches’ exterior painting is carried out inside the paint booth. b. In 176 coaches (629 toilets) are renewed with complete flooring of PVC. c. 1221 litter bins are provided in 629 coaches below the outside wash basins.

d. 1545 stainless steel bins are provided in 500 coaches fitted with Bio toilets.

e. 140 no. of coaches painted with Anti-graffiti coating.

f. 70 AC coaches fitted with double acting inter communicable doors.

g. 5048 berths in 130 coaches are fitted with jute felt for improving the repair

quality of the berths.

h. 271 no. of coaches are fitted with curtain frills.

i. 198 no. of coaches are fitted with health faucets

5.1. Wooden fixed type footsteps in FAC:

As per the directives of Railway Board, All first AC

coaches are provided with fixed type footsteps using

Compreg sheets during POH.

5.2. To improve general appearance of berth upholstery

fitment stiff and tight, repair is done by providing jute felt along the corners and double stitching of rexine to prepare wrinkle free berths.


5.3 Window curtains are stitched with six frills and

twelve rings to maintain uniform height when hung so as to avoid sunlight ingress, and when curtain is closed it enormously improved the internal aesthetics in POH of AC coaches.

5.4. Fitment of health faucets: As per Rly Boards instructions, all

reserved coaches are to be provided with health faucets in

toilets. 198 coaches are provided upto May’18.


6.0. Mechanical Department:

6.1. निष्प दि Performance:

6.1.1. POH outturn - Target/Actuals (VUs):

*Target for 2018-19-- 1637. 6.1.2. Type-wise POH Outturn 2018-19 (up to May):

Type CN GS SLR Other

conventional ACCN

Other AC

DEMU EMU/

MEMU Total

Qty 116 39 16 18 37 26 22 15 289

% 40 13 6 6 13 9 8 5 100

40%

13%6%6%

13%

9%

8% 5%

CN GS

SLR Other Conventional

ACCN Other AC

DEMU EMU/MEMU

16801566

289

16871578

289

16-17 17-18 18-19 (up to May)

Target Actual

Target 18-19 = 1637 coaches (136.4/month)


6.1.3. Average Cycle Time (in working days):

6.1.4. Average POH Cost/VU ( in Lakhs):

6.1.5. Average NTXR initial advice (in % age):

3.35

1.81

2.60

16-17 17-18 18-19 ( up to May)

% In

itia

l ad

vise

16-17 17-18 18-19 ( up to May)

6.4

11.4

8.35

13.2

6.97

12.63 12.44 12.73

8.16

18.39

12.4111.26

Non-AC AC EMU DEMU

16-17 17-18 18-19 (up to May)

8.38

16.3

10.3912.12

8.52

16.23

10.5612.01

10.08

18.33

12.6313.62

Non-AC AC EMU DEMU

15-16 16-17 17-18

In % age


6.1.6. Fitment of Bio-Toilet tanks:

6.1.7. Scrap Disposal (in MT) (Mech. + Elect.):

6.1.8. Support to divisions:

5488 6009

948516 486 265

16-17 17-18 18-19(up to May)

Ferrous Non-Ferrous & others

74 140

1279

2339

494

14-15 15-16 16-17 17-18 18-19 (up toMay)

No

.of

tan

ks

14-15 15-16 16-17 17-18 18-19 (up to May)

23142056

2344 2230

428 490

IOHed Bogie Wheels

16-17 17-18 18-19 (up to May)

Target 16-17: Ferrous-4500 MT; NF-400 MT

Bolted & welded design tanks


6.2. RSP Works:

Sl Work Target Actual Remarks

1 Fitment of Balanced draft gear - 2017-18

80 coaches 5 coaches work in progress.

2 Upgradation of coach toilets 2017-18

60 coaches 11 coaches work in progress.

3 Dustbins at outside wash(new acquisition): 2017-18

800 bins (400 coaches)

Nil Material awaited

4 Fire detection & suppression system in Pantry cars

10 coaches full quantity completed

NIL

5 Fire detection system in AC coaches

100 coaches NIL Detailed estimates are forwarded to FA & CAO and sanction of GM.

6 Anti-graffiti coating to

coach exteriors

180 coaches Nil Material awaited from M/s.Verma Engineers and contracts and DD 11.7.18


7.0 ववद्यतु Electrical

Dy. CEE/S/LGDS Electrical Department is assisted by EEE and ADEE. EEE work

charged post to look after POH works of AC, TL, DEMU, EMU/MMTS Power cars,

ART, SPART, SPIC, TRCs, Saloons, etc.. ADEE looks after the Electrical Maintenance

of Four workshops viz., CWS/LGD, EWS /LGD, FBWP/MLY and S&T Workshop

/G&S/MFT and STC/SC. Principal/ESTC post is vacant since Feb, 2013. To

strengthen and to improve training activities, it is requested to post Principal to

ESTC/LGD.

7.1. Electrical energy consumption variation Vs Vehicle units (VUs): S.No. Description 2015-16 2016-17 2017-18 2018-19 1. Electrical Energy

consumption in ‘000 units.

2090.19 1928.03 2014.58 283.05

2. VUs 1576 1687 1733 310 3. Consumption/VUs 1264 1114 1162 913

7.2. POH Quality Improvement Efforts:

• Cleaning of evaporator and condenser coils with water jet and compressed air.

• 100 % replacement of filters, AVM pads, duct canvas etc.,

• Working of OHPs including shifting is ensured. 232 coaches completed so far in RMPU and in all 44 under slung coaches.

• Working of vane relays and OLRs’ ensured.

• Replacement of must change items like FRP cleats, grommets, Gaskets and fasteners is ensured.

• Overhauling of RRU/ERRU with proper setting of OVP working and load setting is ensured in all coaches including DEMUs.

• 100% load testing of Alternators & RRU/ERRUs.

• Ultrasonic testing on 25 KW Alternator shafts is done in 548 (Cum. upto May’18) AC alternators during POH .

• Overhauling of 18/25 KW alternators with good practices like DPT of shafts, replacement of bearings with approved makes, insertion of bearings with induction heater, testing of bearings condition with SPM, greasing of bearings in IOH, crimping of winding leads with proper lugs etc.,

• Overhauling and load testing of pre-cooling battery chargers, 50,60,3KVA transformers, RBCR, EBCR, SBCR is being done for all AC coaches.

• ELUs are being repaired by replacing PCB, Cluster units and batteries and 100 % working is ensured in all coaches.


• 40 Amps HRC fuse for batteries are provided with enclosure in under frame of all non- AC coaches, 400 Amps fuses for all AC coaches.

• Provision of Push button arrangement in RJB for testing of ELUs is ensured in all coaches.

• Provision of LED based tail lamps in all eligible SLRs is ensured(material available and work is carried out departmentally)

• Use of standard rated HRC fuses procured from RDSO approved sources in all coaches.

• C-5 Rate of discharging is implemented in batteries during POH to filter out weak batteries of AC and non- AC coaches.

• Provision of connectors for Light fittings and fans is being ensured.

• All Non-AC Coaches are being provided with CFL/LED fittings in place of incandescent lamp Fittings at doorways/washbasins.

• Provision of 100 % BLDC fans in place of conventional DC fans for improved reliability(Cumulative for 2017-18 : 2746 Nos, 2018-19: 760 Nos (upto May’18).

• Overhauling of Traction motors is being done of 700HP & 1400 HP capacity of DEMU,MEMU and MMTS Coaches.

7.3. Energy Consumption (till May. 18):

Year Connected Load in KW Consumption in

‘000 units

2012-13 7759 2270.10

2013-14 10250 2065.70

2014-15 10610 1971.70

2015-16 11048 2090.20

2016-17 11672 2631.70

2017-18 11923 2014.58

2018-19

(upto May 18)

11923 283.05

Note :- The increased consumption in 2017-18, is due to introduction of new

plant loads such as ATL machine (65KW), Induction heater (20KW), TM Test

bench (40KW), Hydraulic jacks(18KVA), Automated Paint booth of

coaches(243KW) and Grit blasting plant for cleaning of coach bogies (243KW)

during 16-17 and 17-18.


7.4. The following energy conservation steps initiated:

• 25 No’s of EOT cranes, 01 No. of air compressor, 05 No’s of pumps, 6Nos of Test benches are provided with VVVF drives.

• LOA issued to M/S. CSR Engg. Services, Hyderabad on 19.04.18 to install new VVVF drive for Traverser No.1. Work under progress.

• PO issued to M/S. A.K. Electricals and Automation, Tadipatri, on 25.4.18, to install a new 4.5KW test bench with VVVF drive for testing of alternators and RRUs.

• Estimate sanctioned for new VVVF drives for Traverser No.2 and for 30/5 EOT crane of lift lower shop. Work Order under process.

• NS Indents sent to Dy. CMM/M&E/LGD for 5Nos of VVVF drives.Waiting for PO

• 37No’s of natural light pipe system provided at store wards of DY.CMM/M&E/LGD and scrap depot.

Provision of Natural Solar light pipe system in M&E/LGD Stores depots

• 3 more light pipes provided at CMT lab.

• 25 Nos. of lights pipes and 9 Nos. NoriKool lighting system (proposed to provide in M&E Stores) estimate sanctioned, NS Indents sent. Awaiting for PO

Provision of solar street light with timer

• 09 No’s of high mast light fittings are provided with 100W LED lights and 16

Nos 400 W MH type replaced with 150W LED for better illumination and

energy conservation

• 48 nos. of timers for air circulators, 20 nos. of timers for water coolers and 20

nos. for lighting circuits are provided for energy conservation.


• As per RB instructions 100% LED lights are provided in service buildings and

entire workshop. Total fittings including office and street lights: 4205, 100%

LED completed on 26.03.18. 2144 (Departmentally), 2061 no’s (provided by

M/s. EESL).

Renovated CWM conference hall with LED lights

• Energy savers have been provided to all arc welding plants(68 no’s). New

indent sent for 25nos.

• Solar water heater plant of 1000 LPD

capacity provided at staff canteen.

• 12000 LPD solar water heating plant is

planned for axle box & roller bearing

plants to save electrical energy. As on

date 4000 LPD plant commissioned on

the roof top of new wheel shop.

Thereby an average of 5200 units of

electrical energy is being saved per

month.

• 4 KWp installed during November 2014,

which generates 500 units/month

approximately

• 4.5 KWp solar panel commissioned in

Sept. 16 on roof top of RPF Post, which

generates 550 units/month approx.

• Energy auditing of Corrosion shop and ER

shop completed for the year 2017-18.

• Energy auditing proposed for Wheel shop

and Carriage shop during 2018-19.

• IGBT type battery charge/ discharge panels - for AC / Non AC battery / charging /

discharging with feedback to mains has been provided. GBT type VVVF drive with


regenerative energy system was commissioned for testing of 25KW Alternators and

ERRUs on 13.12.14 - energy saved: 2014-15: 3385, 2015-16:11836, 2016-17: 9886,

2017-18 : 8385 units, 2018-19 : 1372 units.

a. Solar Works under progress:

S.No Description Qty Reference 1 750KWp Solar

power project 450KWp finalized for CWS

Work allotted to M/S. Mytrah Energy systems to provide Solar project on Galvolume sheets, survey completed. Civil work under progress

Installation of Solar PV Panels on A Sub-Station (60KWp)

b. Solar PV panels Existing:

Description Location Capacity/ commis-sioned

Units generated

2014-15 2015-16 2016-17 2017-18

2018-19

18.5 KWp solar power plant

Ä Switch board

4 KWp (Nov,14)

2795 6001 5046 5086 978

CMT Lab 10 KWp (Apr,17)

-- -- -- 11693 2499

RPF Out-post

4.5 KWp (Sep,16)

-- -- 3125 4828 1032

solar power plant

Main Sub-station

18.2KW (Feb,18)

-- -- -- 3167 4027

Total (Dept) 36.7KWp 2795 6001 8171 18,353 8536

Renew

CMT 26.3.18/60 -- -- -- 4076 15413

Ward-7 26.3.18/150 -- -- -- 8898 36057

Ward-11 26.3.18/200 -- -- -- 7664 39744

Before After


solar 530KWp

ESTC 26.3.18/60 -- -- -- 3392 11906

ASB 26.3.18/60 -- -- -- 8412 16116

Total (Renew) -- -- -- 32442 119236 Total 2795 6001 8171 50795 127772

7.5 Infra structure improvements:

Test bench for EBCR (230 / 24 V )and RBCRs Test bench for EBCR (230 / 24 V )and RBCRs

Final testing and fixing of Axle pulleys of TL and AC Coaches with suitable gadgets is 100% ensured

Renovated Battery Section for TL & AC Sections


100% Replacement of Fire retardant canvas in AC coaches during POH

Cleaning of RMPU unit with forced water jet after removal of electrical appliances

7.6 IGBT based inverter:

During load testing of 25 kW alternators/RRUs at ER shop with resistive load there is loss of energy which is replaced by connecting an IGBT based inverter to back feed the generated supply of alternators to system mains.

During load testing of 25 kW alternators / RRU’s saving at about 40 units per day on average. Cumulative savings till May 18: 34864 units.

This type of arrangement is introduced for the first time on Indian railways

7.7. Solar street light fittings:

Automatic solar street light fittings are provided at various places in the workshop to save electricity.

Provision of Emergency lights:

All AC coaches are provided with LED emergency lights and all non-AC coaches

with more than 10 years residual life have been provided with emergency

lights.


7.8. Provision of mobile charging sockets:

All AC and CN coaches are provided with mobile charging facility. As per the directives of Railway Board, CN, GS, CZ & SLR coaches are provided with 18 mobile charging sockets.

Type of Coach

No. of coaches 2016-17



Charging Points Charging Points Charging Points

GS 362 60 0 SLR 119 51 0

WGSCN 491 44 0

WGSCZ 90 39 0 Total 1062 191 0

Note: New Work order for provision of lap top charging points is under preparation 7.9 Provision of CFL fitting in lieu of incandescent lights at gangways/wash basins:

CFL fittings are fitted in all AC coaches and in non-AC coaches at gangways & wash

basins. Till date 1524 AC coaches and 1143 non-AC coaches have been fitted.

7.10. Buffing of Stainless Steel items -wash basin & toilet pans:

Buffing of all stainless steel items like

wash basins & toilet pans are carried out

to improve aesthetics.


7.11. Berth Indication Light & Night Lamp:

All AC coaches are provided with berth indication light & night lamp for easy

identification of bay and berth and till date 168 coaches have been completed. All

coaches are provided with 100% LED night lights.

7.12. LED Berth Reading Light-cum-

Mobile/Laptop charging point:

Installed LED berth reading light-cum-mobile/laptop charging point in 63 1AC & 2AC coaches for 2017-18 and 5 in 2018-19 (upto May, 18).

7.13. Street lights provided with timers

7.14. Natural Day light piping system installed in

M&E/LGD stores for conservation of energy


8.0 Housekeeping:

6 (six) contracts exist for housekeeping. Details

1. Collection, transportation and disposal of hazardous waste accumulation

2. Collection, segregation and transportation of metallic scrap.

3. Cleaning of toilets viz., water closets, urinal cubicles, wash basins &drinking

water sources.

4. Daily housekeeping, cleaning of bogie and axle box components.

5. Daily cleaning of roads, housekeeping of administrative buildings, cleaning of

canteen, maintenance of gardens and indoor potted plants.

Disposal through sale of non-metallic scrap mixed with embedded metallic

contents.

8.1. Swach Bharat Mission:

Under Swach Bharat Mission intensive cleanliness programme has been organized at all work places at LGDS. During 2018-19, up to May-18 206 MTs i.e., 259MT truckloads of rubbish removed from shops during Swachh Bharatabhiyan.


8.2. Clearance of old engineering debris from shops:

Over the years, engineering debris containing concrete mix slabs RCC

material, earth etc., dumped all along the workshop and vacant area has

occupied considerable space. An initiative has been made to gradually

remove this debris, which is being cleared out of workshop to generate

space. In this process good amount of old building material near shot

blasting area and south west of Air Brake shops were also cleared.

8.3. Material management:

i. i. Every year AACs are reviewed by three man committee of JAG grade

officers comprising of stores & Finance.

a. During 2015-16 Rs. 99,69,064/- savings achieved.

b. During 2016-17 Rs. 7,18,71,106/- savings achieved.

c. During 2017-18 Rs. 1,55,75,642/- savings achieved.

Net savings- Rs. 9,74,15,812.

ii. Due to the increased population of LHB coaches, items required for POH of LHB

are reviewed. 166 items are stocked and it is also proposed to stock 134

additional items to carry out POH repairs of LHB coaches.


9.0 डडधबों में सांरि सनुिब्चचत करिकेी प्रण ली Systems to ensure safety in coaches:

9.1. Cleaning of bogies by sand blasting:

Sand blasting of bogies are undertaken to clean the bogies to the bare metal to

detect damages/cracks, if any.

9.2. Chalk testing of bogie frames:

Sand blasted coaches are subjected to chalk testing to detect and rule out the damage/cracks to bogies that escape physical examination after sand blasting. This year 1725 bogies have been subjected to the said test and 8 nos. of bogies have been rejected due to crack, amounts to 0.46%.

9.3. Tests on springs:

Springs are subjected to shot blasting for thorough cleaning and detection of

crack followed by Magna-flux test to detect sub-crack, if any and finally tested for

tensile strength on computerized load testing machine.

MAGNAFLUX testing to detect sub cracks

Shot blasting for thorough cleaning

Computerized load testing


9.4. Ultrasonic testing of axles:

Axles are subjected to ultrasonic testing to detect cracks, if any that are not visible on physical examination.

9.5. Digital bore gauge for measuring bore of Wheel disc:

Digital bore gauge has been inducted to

accurately measure the bore diameters of

Wheel discs.

9.6. Zyglow & DPT tests of critical components:

Axle box, LHB brake discs, bogie frames & roller bearings are subjected to Zyglow

& DPT tests to detect cracks, if any.


9.7. Overhauling and testing of Alarm-chain:

Alarm chain setting is certified by NTXR

for all the coaches under POH.

9.8. Use of Co2 welding:

.

MMAW = 60%; CO2 =38%; TIG=2%

Avg 18-19 (upto May-18)


10.0 एम&पी, क यग और आिनुिकीकरण M&P, works & modernization:

10.1 Works Programme (2018-19): (Rs. in crores)

Name of work & Sanctioned Cost

Expenditure (upto 2017-18)

Budget Grant 2018-

19

Expenditure 2018-19

(Upto May’18)

IOH shed. (extension of MW - 14.68 crores) sanctioned :10-11

12.94 Work

Completed Work

Completed

LHB shop (19.1 crores) sanctioned : 12-13

1.05 1.5840 0

Infra for special stock (11.91 crores) sanctioned : 12-13

0.44 1.32 0

10.2. Modernization:

Modernization programme shall help in a) Augmentation of POH capacity viz., to 120 coaches/month from 100

coaches/month.

b) Improve the layout leading to decongestion of Workshop and c) provide

infrastructure for expansion activities.

(Rs. in Crores)

Department Detailed estimate

Grant till March ‘18

Expenditure till March ’18

Balance (DE Expend)

Mechanical 40.39 14.33 15.33 25.06

Civil 42.23 37.16 35.04 7.19

Electrical 8.23 6.83 7.99 0.24

S&T 0.69 0.70 0.21 0.48

Total 91.54 59.01 58.56 32.97


Modernisation (2018-19)

Fig. in ‘000

Name of the

department

Budget Grant

2018-19

Approx. Expenditure to

end of 31.05.2018

CAP DRF TOTAL CAP DRF TOTAL

Mechanical 0 50000 50000 3605 0 3605

Civil 5000 120000 125000 741 15250 15991

Electrical 0 10000 10000 0 0 0

S&T 0 0 0 0 0 0

TOTAL 5000 180000 185000 4346 15250 19596

10.2.1. Works under Progress:

S.No Description of the work Status

a. Construction of Bogie stripping shed

Columns, track work, flooring completed. Roofing work and gantry work under progress. Track connecting to main line is under progress

b. Axle box cleaning plant shed Columns, track work, flooring completed. Roofing under progress.

10.2.2. Works under Tendering process:

S.No Description of the work Alloc Status Cost (lakhs)

a. Pre-inspection shop CAP Work yet to be started

163.35


10.2.3. Works planned for 2018-19:

S.No.

Description of the work Alloc

Status Cost (lakhs)

a. Hostel for BTC CAP These works are prioritized for the year 2018-19 and

the same have been communicated to CME/PLG

vide this office letter dt: 16.02.2018 for advising the Construction department

accordingly.

114.42

b. Two wheeler parking

facilities. DRF

110.77

10.2.4. Works to be planned:

S.No. Description of the work Alloc Status Cost (lakhs)

a. Industrial effluent and sewerage line

DRF

To be planned

131.23

b. Laying of internal service roads DRF 4.07

c. Land scaping and drain for nallah at low lying area

CAP 44.04

d. Renovation of drinking and raw water pipe lines

DRF 131.23

e. Retaining wall and road along boundary wall towards scrap depot

CAP 98.58


10.2.5.SANCTIONED ITEMS PENDING WITH COFMOW AT VARIOUS STAGES

S. No

Item

Description

Alloc. Qty. LOA/ Indent Cost

Remarks

1 Hot Phosphating plant

1 188.39 96.71

One no. of Bogie components cleaning plant is proposed against this sanction under Change of description.

Draft specification sent by COFMOW to LGDS for comments/confirmation on 16.04.2018. Draft specification sent to consignee for verification on 17.04.2018 Reply awaited

2 Vertical milling machine

1 16.40 30.97

One no. of EOT crane 10 Ton capacity is proposed against this sanction under Change of description/Qty.

GA drawings received for Technical scrutiny Firm requested for alterations in GA drawings and re-submission on 12.03.2018 & 04.04.2018 3

Radial drilling machine

2 33.72

4 OT-107 4 19,65,980 MIG welding Plants 450 amps

Vetted indent received by Mechanical department of COFMOW on 05.03.2018 GT under approval of C/A from 01/05/18 (Sent to Stores)

5 OT-108 1 14,67,932 Digital microprocessor based MIG/MAG welding plants 400 A

E-Mail received from COFMOW on 11.05.2018 for confirmation of specification. Confirmation of specification communicated to COFMOW on 25.05.2018

6 OT-215 1 47,19,990 Welding simulator

1. Draft specification received from COFMOW for finalization Specification finalized and sent to COFMOW on 13.04.2018 G-104132. Tender floated on 17.04.2018. Tender due for opening on 04.06.2018

7 OT-216 1 43,77,969

Gas profile cutting Machine against LGD plant No. 1490

Specification received from COFMOW for clarification on 09.04.2018. Reply on specification sent to COFMOW on 24.04.2018 OP No. 905540. Tender floated on 21.05.2018. Tender due for opening on 21.06.2018

8 OT-217 1 25,41,592

Supply, Installation and commissioning of Dual platform Pit less Static Rail Weigh Bridge of 100Ton Capacity

COFMOW forwarded generalized specification prepared on weigh bridges for scrutiny at this end on 25.04.2018 Remarks for the specification sent to COFMOW on 25.05.2018 & 29.05.2018 COFMOW further sought clarifications vide their letter dt: 01.06.2018 Draft reply to COFMOW put up to PE/LGDS


9 OT-218 1 40,65,097 Magnetic Crack detector for coil spring for LHB coaches

Case sent to Dy CME-IV on 20/03/18 for confirmation of specs similarity with tender no. OP-903171. Draft specification received from COFMOW is finalized and sent back to COFMOW on 11.04.2018. OP-905170. Tender floated on 25.04.2018 Tender due for opening on 04.06.2018

10 OT-219 1 31,67,412 Dynamic Balancing Machine

OP-105030. Tender floated on 03.04.2018 Opened on 04.05.2018 Under Technical Evaluation

11 OT-220 4 19,65,980 MIG welding plants 450 Amps

Vetted indent received by Mechanical department of COFMOW on 05.03.2018 GT under approval of C/A from 01/05/18 (Sent to Stores)

12 OT-225 1 14,67,932 Digital microprocessor based MIG/MAG welding plants 400 A

E-Mail received from COFMOW on 11.05.2018 for confirmation of specification. Confirmation of specification communicated to COFMOW on 25.05.2018

13

IT-1263 of Railway Board M&P programme 2017-18

1 25600 Vertical Turret Lathe (VTL)

LOA released on M/s HYT/Pune, OP-104550, Probable date of supply: Nov 2018. GA drawings received from the firm are approved and sent back to the firm on 09.05.2018.

S. No

Item Description Alloc. Qty. LOA/ Indent Cost

Remarks

14 IT-285/ 15-16

Computer Direct reading optical spectrometer

DF-III 01 8972

Discharged cases G-603872, E-tender draft under preparation on 13.04.2018 Lr sent to CME/PLG/SC on 16.04.2018 to communicate COFMOW for grant of dispensation for procurement at zonal PCMM/SC. As per COFMOW portal, Case received back from mechanical dept at COFMOW & sent to finance dept at COFMOW on 01/06/18 for finance concurrence.

15

PB No. 619 of 17-18 (MOD)

Wheel set washing plant

DRF 01 18938

Draft specification sent by COFMOW to LGDS for comments/confirmation on 16.04.2018 Draft specification sent to consignee for verification on 17.04.2018 Remarks to specification sent to COFMOW on 21.05.2018 for clarification.

16

PB No. 619 of 17-18 (MOD)

Bogie components cleaning plant

CAP 01 9671

Draft specification sent by COFMOW to LGDS for comments/confirmation on 16.04.2018. Draft specification sent to consignee for verification on 17.04.2018 Reply awaited

17

PB No. 646 of 17-18 (LHB shed)

Load deflection testing machine with lateral measurement for flexi coil springs

DF-III 01 17000

At COFMOW, Global Tender no. G-801971 Tender floated on 04.11.2017 Tender opened on 29.01.2018 Under TC.


1.0 प्रलशिणव बी टी सी की गनतववगिय ां Training & BTC activities:

11.1. Courses Conducted at BTC/LGDS:

• Act apprentice

• Apprentice Graduates & Diploma

• Induction to skilled (RRB & CG)

• APP JE &SSE (RRB)

• Refresher Course for Technicians

• Welder Gradation

• Skill Development Programme for group ‘D’ staff & Diploma

• Special Courses

• Pre promotional courses for Group D to Group C staff and JE Ranker

• Awareness programme for IMS, Green co, ISO 3834

• Safety awareness for contract employees.

• Project Saksham training.

11.2. PROJECT SAKSHAM:

Concentrated Capsule of Training for All employees Vide letter

no.SCR/P_HQ/673/Trg/Saksham dated 17/11/2017.

Category Total Scheduled up

to Feb’18

STC BTC Under

training

Complete

d.

Supervisors 205 54 139 12 0 151

Technicians 1855 652 0 1203 7* 1203

Total 2050 696 55 372 7* 1354

Note- * under/training completing on 22.06.2018

11.3. “Project Saksham”-- CWM/LGDS Department wise comparison (up to 18.06.18)

DEPARTMENT TOTAL Target COMP COMP % ACCOUNTS 74 41.111 1 1.3 ELECTRICAL 558 310 109 19.5 ENGG. 194 107.78 0 0 GEN.ADMIN 1 0.5556 0 0 MECH. 2358 1310 1413 59.9 PERSONNEL 47 26.111 34 72.3 S&T 337 187.22 195 57.8 STORES 696 386.67 554 79.5

TOTAL 4265 2369.4 2306 53.2


11.5. CENTRE OF EXCELLENCE IN WELDING TRAINING - Action Plan:

1. Virtual Welding Simulator.

2. Welding Accessories set Consisting of 18 Items.

3. Inspection Gauges for Weld Quality Check consisting of 21Items.

4. Touch screen & Kiosk enclosure box with customized software application

5. Development of web designing for Centre of excellence in welding training

with android application.

6. Civil engineering works and Development of Garden in BTC.

7. Welding Booths, welding machines and its accessories for 5 Nos. along with

fume extractor

S.No Courses 2016-17 2017-18 2018-19

(up to 15.06.2018)

1 Act Apprentices 222

Reported-284 (Against

allotment for 2017-18 of 363)

Reported-284 (Against allotment for 2018-19 of 363)

2 Apprentice Graduates - 1 1

3 Apprentice Diploma - 6 6

4 Skilled Artisans (W/S + Divn.)

52 38 44

5 Apprentice SSE’s & JE’s 87 75 14

6 Refresher Course for Technicians

341 457 114

7 Welder Gradation (BTC+AWTI)

146 74 7

8 Promotional Courses - - -

9 Pre-Selection for JE rankers 25% quota

- - -

10 Skill Development for Group-D staff

134 362 279

12 Special Courses for shop floor technicians

25 5 -

13 Initial industrial training for contract employees

70 87 84

TOTAL 1077 1389 549

Staff Training:


11.6. Capacity utilization:

CAPACITY UTILISATION

year % utilisation

2016-17 184.93

2017-18 218.18

2018-19 322 (till 15.06.2018)

11.7. Models:

Basic Training Centre

Welding Laboratory Multimedia Class room

with surveillance

camera

Library

Air brake system working model Bio-toilet

Exploded view of BMBC WSP simulator


ICF Sperical Roller Bearing exploded view

CTRB Exploded view for LHB Coaches

EP BRAKE SYSTEM LED MODEL

AIR BELLOW DEMONSTRATION MODEL

Surveillance camera unit


12.0. औद्योगगक सांरि Industrial safety:

12.1. No. of Accidents/IOD cases:

12.2. Man days lost:

12.3. Analysis of IOD & Man days lost – Initiatives specific to IOD – 2017-18:

• IOD employees were counselled about the safety measures to be followed to avert bodily injuries while working and the importance of wearing “Personal Protective Equipment” (PPE) to avoid recurrence.

• SSEs of the shops were advised to educate employees’ about the safety procedure, proper working procedures and to create safe work environment by supplying adequate PPEs’ etc.

12.4. Steps taken to enhance safety of workmen:

• Ladders for EOT cranes - flat steps & ring cage provided.

• Rotating machinery parts -wire mesh guard / Fencing provided.

• Battery operated forklifts and trucks to control air pollution introduced.

• Periodic supply of soaps and cleaning agents (REINOL).

• Periodic supply of personal protective equipment.

• Safety jacket for shunting staff.

• Fire buckets with stands in all the shops.

• Safety nose mask during painting.

• Safety belt for working at heights.

• Safety mat at electrical mains.

9

3

0

16-17 17-18 18-19 (upto May'18)

16-17 17-18 18-19 (upto May'18)

225120.5

5

16-17 17-18 18-19(up to May)

16-17 17-18 18-19(up to May)

Type of injury Man day lost Hand Leg Eye Hand Leg Eye

1 2 0 27 93.5 0


’

13.0 पय गवरण प्रबांिि Environment management:

13.1. Green cover area of the workshop:

• 327 live trees exist at Workshop premises.

• Workshop is spread over 13.97 hectares and coverage of trees per Sq.mt. is 0.0048.

• Coverage of live trees per unit area of 1000 Sq.mt. of Workshop is 2.34 nos.

Workshop area -- 13.97 hectares Covered area -- 05.4 hectares Traverser area I&II -- 0.677 hectares Roads -- 1.20 hectares Uncovered area -- 06.692 hectares Green area -- 2.50 hectares Green cover -- 37.36% (Green area developed

during 2017-18,corporate grass-100 SQM,600 saplings in 300sqm)

13.2. Water audit and recycling:

• 11 water meters are fitted during July/August 2016.

• Average consumption of raw water/day observed is 1.96 lakh liters/day during

May’18. This being watched to initiate necessary action to reduce

consumption, wherever possible.

• Drinking water received from division is recorded on daily basis, through meter

reading. Average consumption is 1.08 kl/day during May’18.

• Waste water from RO plant (1 lakh liters) capacity after recycling is used for

firefighting.


14.0. ल्यूब तेल क़िल्टर प्ल ांट Lube oil filter plant:

14.1. Brief History: Lube Oil Filter Plant (LOFP) commissioned during 1978 and the 1st filter was manufactured on 17.05.1978. Till recently, LOPF was only one of its kind on Indian Railways for manufacture of “Pleated Paper Type Long Life Lube Oil”, Fuel Oil and EMD Filter Elements required for DLW/ALCO/GM type diesel locomotives of Indian Railways.

14.2. Activities of the Plant:

• Manufacture and supply of Long Life Lube Oil, Fuel Oil and EMD Filters to Diesel sheds of Indian Railways as per RDSO Specifications.

• LOFP is equipped with laboratory with all the testing facilities required for testing filter paper, finished filters and other metallurgical properties of other components.

• Supply of filters to other than Indian Railways units like NTPC, IRCON, RITES etc. for diesel Locos operated for their sidings.

• 100% requirement of Long Life Lube oil filters & Low mean-pore size fuel oil filters like Large Primary, Large Secondary, Conventional Primary and Conventional Secondary for Indian Railways are being met by LOFP/SC.

• Manufacturing of 10” X 30” Long Life Lube Oil/Fuel Oil for EMD Locomotives commenced in January, 2011. As per Railway Board directives, 2/3rd requirement of EMD filters to be met by LOFP/SC.

14.3. Performance (Targets and Achievements):

Type/Year 2016-17 2017-18 2018-19

Target

(Rly.Bd.) Actual

Target

(Rly.Bd.) Actual

Annual Target

(Rly. Bd.)

Actual

(As on 13.06.18)

122 Days Lube Oil filter 50000 50015 50000 53025 50000 10180

EMD Filters 10000 10006 10000 10141 10000 2071

Large Primary (Fuel Oil) 1600 1616 3200 1970 3200 390

Large Secondary (Fuel Oil) 1600 2000 3200 1910 3200 975

Conventional Primary (Fuel Oil) 12000 12063 12000 13415 12000 2295

Conventional Secondary (Fuel Oil) 12000 12005 9000 9940 9000 2390

Total 87200 87705 87400 90401 87400 18301


17.0. क लमगक Personnel:

Personnel branch Organization: 17.1. Staff Strength (All Departments)

17.2. Settlement cases pending.18-19(up May’18)

Type No. of

cases

Pending

Normal

retirement

194 Nil

ONR 11 12

5*- legal, 7 under process

Department Sanction Actual Vacancy

Mechanical (Sup, Artisans) 2441 2127 314

Electrical (Sup, Artisans, Group- D) 604 525 79

Total 3045 2652 393

CMT Staff 30 19 11

Personnel 66 58 8

Mechanical – Others (non-Personnel, Group-D, Drawing, canteen, computer centre)

134 129 5

Electrical- Others (non-Personnel, Group-D,

Drawing) 28 21 7

Stores 150 135 15

Accounts 83 58 25

Engineering 29 22 7

Total others 520 442 78

Grand Total 3565 3094 471


17.3. Age Profile of Staff: (In Percentage)

17.4 Staff Matters –Attrition & Intake of Staff (Mech & Elec)

Year Attrition Intake

Mech Elec Mech Elec

13-14 187 26 307 44

14-15 155 12 247 4

15-16 138 20 89 3

16-17 139 32 84 12

17-18 225 38 101 14

Total 844 128 828 77

17.5. Retirement in next 5 years

10 9 2457

8 17 32 42

18-29 30-39 40-49 50-60

Mechanical Electrical

Year Mech Elec Total

2017-18 152 19 171

2018-19 171 32 203

2019-20 172 30 202

2020-21 124 37 161

2021-22 78 33 111

Total 697 151 848


17.6. Indents pending through RIMS on RRB/RRC

Catg Mech Elec Assessment up to

SSE & JE 12 1 31.12.2020

Tech III 194 36 31.12.2020

Grp ‘ D’ 427 126 31.12.2020

Jr.Clerk - - -

Total 633 163

17.7. Position of Compassionate appointments.

S.No Description No. of Cases

1 Referred to HQ 2

2 On hand 01

3 Party’s account 3

4 Minor 5

5 Total 11

17.8. DAR cases pending.

Year O.B cases

initiated

Cases

disposed

Balance

17-18 25 1 13 13

17.9. Court cases pending

Year O.B Accruals Disposed Pending

12-13 7 2 5

13-14 5 7 5 7

14-15 7 1 1 7

15-16 7 8 7 8

16-17 8 7 0 15

17-18

(upto Feb’18)

15 11 5 21


17.10. Surrender of posts.

Year Mech Elect Total

11-12 17 3 20

12-13 20 4 24

13-14 29 4 33

14-15 13+86* 0+26* 13+112*

15-16 0 0 0

16-17 151* 51* 202

17-18

(upto May’18)

-- 04 04

Total 316 92 408

17.11. Promotions ordered in 2018-19( 30.06.2018).

Assessment upto 01.02.2018

Category Mech Elect

Promoted Bal.inPa

nel Promoted

Bal.in Panel

SSE 10 04 0 0

JE 0 0 0 0

Sr. Tech. 362 14 61 2

Tech.-I 206 0 73 4

Tech.-II 328 0 38 5

Tech.-III 183 0 40 3

Sr.Clerk 0 0 1 0

Jr. Clerk 0 0 0 0

OS 6 0 0 0

Total 1095 18 213 14


17.12. Persons with disabilities

Description Accruals Filled up Balance

Backlog of PH quota

upto the year 2007 10 0 10

The accruals of PH

quota from 2008 to

2015

8 6 2

Fresh accruals as a

result of receipt of

286 RRC papers

46 46 0

Total 64 52 12

*As on roll 84 employees who are PWD are working in LGDS i.e. 2017.

17.13. Position of Rly. Quarters.

Type Nos Repair Bal Occup Vac

Type I 441 21 420 318 102

Type II 97 0 97 94 03

Type III 42 0 42 40 02

Type IV 04 0 04 04 0

Total 584 21 563 447 116

17.14. Grievance redressal:

Year Received Disposed Balance

13-14 37 37 0

14-15 47 47 0

15-16 4 04 0

16-17 156 156 0

17-18

39 39 0


17.15. Health camps:

Health Check-up camps were organized in the workshop on 12.10.2017 & 21.10.2017.

Total 140 & 158 employees were screened respectively.

a. Details of GRIEVANCE camps

S.no

Date Grievance Received

Grievance disposed

1. 15.07.17 01 01

2. 12.10.17 15 15

3. 21.10.17 23 23

4. 23.04.18

b. Details of HEALTH camps

S.n

o

Date No.of staff

screened

1. 18.7.17 276

2. 12.10.17 140

3. 21.10.17 158

4. 28.12.17 to 30.12.17

199

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