Standard Note for Production Unit Clw As on 31.03.20

STANDARD NOTE FOR PRODUCTION UNIT CLW AS ON 31.03.20

Contents SN CHAPTER PAGE NO. 1. INTRODUCTION 3

2. SALIENT FEATURES 10

3. ORGANISATIONAL CHART 12

4. PRODUCTION PERFORMANCE 14

4A. ELAAU/Dankuni 23

5. DESIGN&DEVELOPMENT INCLUDING TOT 25

6. QUALITY ASSURANCE 31

7. MARKETING INCLUDING EXPORT 36

8. STATUS OF M&P 39

8A. STEEL FOUNDRY 44

9. STAFF POSITION 49

10. UNIT COST OF THE PRODUCT 51

11. INDUSTRIAL SAFETY 57

12. FUTURE PLANS 56

13. OTHER ISSUES 58

INTRODUCTION

1. INTRODUCTION :

1.1 The Works and Administrative office of Chittaranjan Locomotive Works (CLW) are located at Chittaranjan, Distt. Paschim Barddhaman in West Bengal. In addition, it has a Stores Purchase office in Kolkata and inspection cells in New Delhi, Mumbai, Kolkata and Bangalore.

1.2 CLW is the first industrial gift to free India by the planners of the nation. The issue of setting up a locomotive manufacturing unit had been 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 into the possibility of establishing a locomotive manufacturing unit along 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. Railway Board’s approval was obtained in the year 1947. The locoworks was initially established for production of 120 average sized Steam Locomotives along 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. Production of Electric Locomotives commenced in 1961. However after producing 4635 nos of Conventional Electric Locomotives ( DC, AC/DC and AC) of 14 variants, its production was discontinued from 2016-17. At present CLW is manufacturing only 3-phase Electric Locomotives. Upto 31.03.20, 7185 nos. of Electric Locomotives of different variants including 2550 nos of 3-phase Electric Locomotives have been produced by CLW.

1.3 CLW has augmented its production capacity for Electric Locos in phases besides absorbing 3-phase technology. It has also set up additional manufacturing facility at (ELAAU) Dankuni which started its production during March 2016.

1.4 Production of Traction Motors and control equipment commenced in April 1967. During the year 2019-20, upto 31.03.20, 2330 TMs were produced.

1.5 Steel Foundry was set up in F.Y. 1962-63 for production of steel castings for Steam Locomotives. 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 ISO-14001 certificate both for its works and township for a neat and clean environment, ISO 9001:2008 certificate for Quality Management System and OHSAS 18001:2007 for occupational health and safety management system, 5S certification for Workplace Management System, ISO-3834-2:2005 (Manufacturing of Shell body of Electric Locomotive) certificate, ISO-50001 (Energy Management System) certificate for commitment for

reducing operating cost, significant financial savings through increased energy conservation & improved energy efficiency. ELAAU/Dankuni of CLW has acquired IMS certificate and 5S Certification.

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 to CLW 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 to CLW on 6th September, 2006 by the Safety and Quality forum of the Institute of Engineers (India).

1.13 During the F.Y. 2015-16, CLW has moved towards complete switchover to 3-phase and started producing only 3- phase locomotives from December 2015.

1.14 During the F.Y. 2015-16, CLW has completely switched over from GTO to IGBT technology. The 1st WAG-9 class freight loco No.31215 fitted with IGBT based Power Converter was commissioned on 18th December,2009.

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 Feb 2017, 46 such locomotives have been commissioned. TFP 7775 with double hotel load winding 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 also been taken for provision of one High Reach Pantograph in locomotives required for Dedicated Freight Corridor.

1.17 Complete VCU redundancy: 5 locomotives have been turned out with feature of complete VCU redundancy for avoiding necessity of cab changing.

1.18 Indigenous Wheel Discs for WAP-5 locomotives have been developed by SAIL and complete requirement of material is sourced on SAIL Durgapur.

1.19 An automated new paint booth has been commissioned under AP-50 Project. In the paint booth, PU painting is being carried out in a controlled atmosphere.

1.20 CLW PRODUCES RECORD 431 ELECTRIC LOCOMOTIVES OF 2019-20: CLW has produced 431 locomotives in FY 2019-20. With this CLW has become largest manufacturer of locomotives in the world. In last FY 2018-19, CLW turned out 402 locomotives. CLW has been inducted in LIMCA BOOK OF RECORDS for producing 402 Locomotives during FY 2018-19.

1.21 PRODUCTION OF FIRST EVER 9000 HP LOCO: Under "Make in India" initiative, CLW has successfully produced IR's first 9000HP locomotive and turned out on 31.03.2019. With this IR joins the elite club of manufacturer capable of producing 9000HP locomotives. The locomotive will facilitate in improving through-put by delivering better acceleration reserve at higher balancing speed.

1.22 CLW WON FIRST PLACE IN SOLO DANCE FORM IN ALL INDIA RAILWAY CULTURAL COMPETITION 2019: In the All India Railway Cultural Competition held on 08-10 April, 2019 in DLW auditorium, Varanasi organised by North Eastern Railway , Varanasi Division , Km. Mousami Saha of Chittaranjan Locomotive Works (CLW) got First position in the Classical Solo Dance Recital. It is a matter of great pride for the CLW.

1.23 VENDORS MEET BY CLW:

a. VENDORS MEET BY CLW AT KOLKATA ON 2ND MAY 2019; As per directives of Railway Board, a Vendors Meet was organized by Chittaranjan Locomotive Works (CLW) in association with ER, SER & METRO Rly in the Belvedere Club at Kolkata on 2nd May 2019. The objective was development of new vendors as well as

enhancing product range of existing vendors. High purchase value items as well as items for which very few approved sources are available were showcased. Emphasis was given on indigenization of imported items.

b. QUARTERLY VENDORS MEET BY CLW: Quarterly Vendors Meet was organized by Chittaranjan Locomotive Works (CLW) in Administrative office meeting room at Chittaranjan on 5th Dec 2019 . The objective of this quarterly vendors meet was discussions on supplies of mechanical items to be made during December 2019 to March 2020 for steady production of locomotives.

c. VENDOR MEET BY CLW: A vendor meet was organized by Chittaranjan locomotive Works (CLW) in Chittaranjan Club on 05.02.2020 for educating domestic vendors on facility of payment through “Letter of Credit” LOC mode. This vendor meet was organized jointly by the Stores deptt of Chittaranjan locomotive Works and State Bank of India.

1.24 SCOUTS & GUIDES PROVIDES DRINKING WATER AT CHITTARANJAN RAILWAY STATION: In this peak summer, the volunteers of Scouts & Guides team of CLW carried out a philanthropic services by providing drinking water to the passengers to all the trains stopping at Chittaranjan Railway station from 11.30 hrs to 16.00 hrs daily. This service is taken up every year in summers by the volunteers of Chittaranjan unit of Bharat Scouts & Guides. This service was started from 14th May and will continue till second week of June 2019. About 20 volunteers took part in this activity for the service to the train passengers .

1.25 WORLD ENVIRONMENT DAY OBSERVED IN CLW: The World Environment Day was observed on 5th June 2019 in Chittaranjan Locomotive Works (CLW). On this World Environment Day, an awareness rally was organized by Bharat Scout & Guides/ Chittaranjan unit in various places in Chittaranjan township in which volunteers of Scouts & Guides participated with awareness placards on Environment conservation. A tree plantation was organized in the Environment Park in Chittaranjan Golf Course, yesterday, in which Sr. Officers of CLW actively participated in the plantation drive.

1.26 INTERNATIONAL DAY OF YOGA OBSERVED IN CLW; “International Day of Yoga” was observed in Chittaranjan Locomotive Works (CLW) on 21 June, 2019, in a befitting manner to spread the awareness regarding usefulness of Yoga . Sr. Officers, Staffs, supervisors and member of CLW-WWO attended the yoga demonstration at several places places of CLW in early morning.

1.27 E-OFFICE INAUGURATED IN CLW: E-Office in Chittaranjan Locomotives Works (CLW) was inaugurated by Shri Praveen Kumar Mishra, General Manager/CLW in presence of other Senior Officials and GM/RailTel, Kolkata On 27.06.2019. CLW becomes first production unit in Indian Railways who adopted E-Office for official working. This has been implemented by Railtel, a Miniratna PSU under the Ministry of Railways. E-Office is a cloud enabled software that is deployed/hosted from RailTel’s Tier-III certified data centres at Secunderabad and Gurugram.

1.28 IP BASED CCTV SURVEILLANCE SYSTEM INAUGURATED IN KG HOSPITAL/ CLW: An IP based CCTV surveillance system was inaugurated by Shri Praveen Kumar Mishra, General Manager in the Kasturba Gandhi Hospital of Chittaranjan Locomotive Works(CLW),on 02-07-19. It is hoped that by this system security arrangements in the hospital can be beefed up in order to provide safety and security to all.

1.29 AADHAAR BASED AEBAS INAUGURATED IN CLW WORKSHOP: Aadhar Enabled Biometric Attendance System(AEBAS) is implemented in the shop floor of CLW/Chittaranjan on 03rd July, 2019. Shri Praveen Kumar Mishra, GM inaugurated the AEBAS for shop floor initially in HMS shop today amongst the presence of staff and supervisors.

1.30 ASTRONOMICAL TIMER BASED STREET LIGHT AUTOMATION STARTED IN CLW; Shri Praveen Kumar Mishra, General Manager inaugurated the Automated timer based street light monitoring system in presence of senior officers on , 12th July 2019. . This will be operational from all the 57 sub stations of Chittaranjan Township. This user friendly system will not only provides timely switching ON & OFF of street lights in all the areas of Chittaranjan but will also save considerable amount of electricity due to manual process.

1.31 SAIL OFFICIALS VISITED CLW, 20-07-2019; Dr. G Viswakarma , Director, Projects & Business Planning, SAIL and Shri T. B. Singh, ED, Project, Durgapur, SAIL visited the CLW yesterday dated 19.07.2019,afternoon and viewed the manufacturing process of electric locomotives Dr. Viswakarma had a formal meeting with Shri Praveen Kumar Mishra, General Manager/CLW.

1.32 MEMBERS OF RAILWAY BOARD VISITED CLW: Smt. Manju Gupta, Addl. Member (Electrical), Rly. Bd. and Shri Kishore Kumar, EDEE (RS), Rly Bd visited CLW on 25 July 2019 .Shri Ramprakash, PCEE, CLW accompanied them during their workshop visit.

1.33 CLW EMPLOYEES AWARDED IN 64TH RAILWAY NATIONAL AWARD CEREMONY AT MUMBAI: 64th Railway National Award ceremony cum Rail Exhibition was organized in Mumbai at Jamshedji Bhabha Theatre on 30th July 2019. Exhibition stalls of CR, WR, SCR, SWR, SR, CORE, ICF, DFCCIL, KRCL, CONCOR, MRVC & others showcased their activities . Large numbers of spectators visited the Exhibition stalls. Shri Piyush Goyal, Hon'ble MR; addressed the award distribution ceremony through video link from Delhi . During the prize distribution ceremony, Shri Ankit Kumar Verma, SSE and Dr Joydip Mitra, Sr.DMO of CLW, were awarded by Shri Vinod Kumar Yadav, CRB.

1.34 100TH ELECTRIC LOCOMOTIVE FLAGGED OFF FROM DANKUNI: Chittaranjan locomotive Works (CLW) scripted yet another history on 12-08-2019, by rolling out the 100th Electric locomotive of the year 2019-20 from its Electric Loco Assembly & Ancillary Unit at Dankuni near Kolkata. On this occasion, a Press Conference was organized at Dankuni, wherein Shri Praveen Kumar Mishra, GM addressed the Television and Print Media representatives of Kolkata region. More than 50 media representatives participated in that Press Conference.

1.35 UNIQUE MEDICAL IDENTIFICATION CARD (UMID) IN CLW: Indian Railways has decided to issue Unique Medical Identification card (UMID) to all its employees for providing medical services. The medical card generated through UMID are accepted for availing medical facility w.e.f. 31-08-2019.

1.36 NEW “CHITRAVAN” COMPLEX INAUGURATED IN CLW: The Newly built 214 type-II quarters in Simjuri area in Street NO 66 end was inaugurated on 73rd Independence Day 2019. Ample modern living facilities have been provided in these quarters. The construction of these quarters were recently completed at a total cost of Rs.20 Cr and subsequently some allotted among the eligible employees on 15.08.2019.

1.37 SADBHAVANA DIVAS in CLW; Sadbhavana Divas was observed in Chittaranjan Locomotive Works in the Administrative office foyer on 20th Aug. 2019 . Shri Praveen Kumar Mishra, GM /CLW read out the Sadbhavana Divas pledge before a gathering of Principal HODs, Sr. Officers and employees.

1.38 NATION WIDE PENSION ADALAT IN CHITTARANJAN; Nation Wide Pension Adalat in CLW was organized in Vivekananda Auditorium on 23rd August 2019 . About 55 cases of grievances received from the retired railway employees and 48 cases were settled on the spot by a panel of judges

1.39 CENTRALIZED INTEGRATED PAYMENT SOLUTION (CIPS) SYSTEM STARTED IN CLW; The Centralized Integrated Payment Solution (CIPS) by Accounts Deptt. of Chittaranjan Locomotive Works(CLW) is under implementation and made operational from 9-9-2019. The CIPS has been developed as part of IPAS system, which facilitates digital signing of payment files and its automatic & safe transfer from IPAS server to SBI server. These payment files are verified for its authenticity and then processed by SBI’s system. The reconciliation of transactions are made automatically by this CIPS system from SBI Server to IPAS server.

1.40 SWACHCHATA HI SEVA SHRAMDAAN IN CLW:: “Swachchata Hi Seva” observed in Chittaranjan Locomotive Works(CLW) on 11th Sept.,2019,a campaign being launched by Hon’ble Prime Minister of India from today. Under this, “Swachchata Hi Seva” programme, a massive Shramdaan on plastic waste collection was organized at the surrounding areas of administrative office canteen, in CLW today. Sr. Officers, supervisors and staff in large nos. actively participated in the Shramdaan.

1.41 SWACHCHTA PAKHWARA STARTED IN CLW: Chittaranjan, 16th SEPT’ 2019;As per the direction received from Railway Board, Swachchta Pakhwara is being organized at various locations in CLW premises from 16th to 30th Sept.,2019.

1.42 CLW PRODUCED 7000 LOCOMOTIVES: Chittaranjan Locomotive Works (CLW) has produced 7000 electric locomotives (32597) upto 25th October of the current financial year 2019-20. In CLW, the production of electric locomotives started in 1961 . Since 1961, CLW produced about 17 types of locomotives of various capacity . During a splendid journey of almost 58 yrs, CLW moved from DC to AC and to then migrated to IGBT based technology locomotives.

1.43 HAEMO DIALYSIS TREATMENT FACILITY COMMISSIONED IN CLW: For the First time Haemodialysis treatment started in K. G. Hospital / Chittaranjan on 1st November 2019. Shri Praveen Kumar Mishra, General Manager inaugurated this dialysis facility amidst senior officers.

1.44 SEMINAR ON “INTEGRITY-A WAY OF LIFE” ORGANIZED IN CLW; A Vigilance Awareness week is being observed in Chittaranjan Locomotive Works (CLW) from 28th October to 2ndNovember, 2019,under this a Vigilance Seminar on “Integrity-a way of life” was inaugurated by Shri Praveen Kumar Mishra, General Manager along with Shri Boyjayanta Upadhyay, Dy Director & Scientist-D of CFSL/Kolkata; Shri Sanjoy Singh, DySP/CBI/Kolkata ; Swami Dibyanisthanandaji of Ramakrishna Mission Ashram/Asansol and Shri R.Yadav, CVO in Chittaranjan Club premises on 1st Nevember,2019 by lighting the lamp.

1.45 CLW ORGANISED 10th ALL INDIA RAILWAY ARCHERY CHAMPIONSHIP 2019-20: The 10th All India Railway Archery (M&W) Championship started in Chittaranjan Locomotive Works (CLW) from 7th to 9th November 2019 in the newly built Archery Range near Indoor Stadium.

1.46 TRAINING PROGRAMME ON PUBLIC PROCUREMENT IN CLW: A three day long training on "Public procurement" for Group C staff of CLW stores department in Chittaranjan Locomotive Works concluded on 16th November 2019.The programme, commenced on 14th November 2019, and was attended by 30 staff. It was organised by CLW in Association with Indian Railway Institute of Logistics and Material management (I R I L MM), New Delhi.

1.47 CLW WON THE FIRST PRIZE IN CLASSICAL SOLO DANCE: Km Soumi Das of CLW cultural team won First prize in Classical Solo Dance category in the recently concluded Inter Railway Cultural Competition held at Bilaspur on 28th and 29th Nov 2019. Another Special Prerna Award was also given in Group Folk Dance category to CLW dance team.

1.48 CLW Won 64TH ALL INDIA RAILWAY GOLF CHAMPIONSHIP 2019-20: Sri Ram Prakash, PCEE & President/CLWSA as team leader along with Shri Vinay Kumar Yadav, Shri Sahil Kumar Singh & Shri Ajit Rawat had won the Winner’s Trophy in the 64th All India Railway Golf Championship held at DLW/Varanasi on 3rd& 4th Dec 2019. Individually, all of them secured Gold Medals in the championship.

1.49 CLW PRODUCES 446 LOCOS IN ONE CALENDER YEAR 2019: Chittaranjan Locomotive Works (CLW) created world record by producing 446 locomotives in a calendar year 2019 (Jan-Dec). CLW is having an installed capacity to produce 200 locomotives per year and has produced 446 locomotives in one year. With a focus on diligence & efficiency , production almost doubled from 242 in 2014 to 446 in 2019 over the last 5 years. This remarkable production has been achieved with the adroit planning and execution. 223% Asset utilization against Installed capacity to achieve this record figure of 446 locomotives.

1.50 CELEBRATION OF 70 GLORIOUS YEARS: During this FY 2019-20, CLW has completed 70 glorious years of its service to the nation and various programmes were organised to commemorate this up-to 26th Jan 2020. Seventy retired railway employees of CLW were honoured & felicitated on 26th Jan 2020. Other programmes were also organised on this occasion, such as Drawing , Essay & Debate competitions by Railway schools; Inter Unit competitions organised by Scout & Guides wing of CLW; Annual cultural competitions by Basanti & Srilata Institutes; Photography competition & Exhibition organised by the Public Relations Deptt.; Inter Area cultural competitions organised by the Cultural Association & Inter Departmental Athletics championship organized Sports Association.

151. NEW DIGITAL CASH COLLECTION SYSTEM INTRODUCED IN CLW: New digital cash collection system introduced in CLW by the Accounts department in association with SBI, Chittaranjan on 06.01.2020. In this new system the outsiders do not have to come to the cash counter in Administrative Building to deposit the cash instead they can remit the amount from the Point of Sale (POS) machines in which ATM cards/Debit cards/ Credit cards can be swiped to pay the requisite amount / pay by transferring to CLW account. This new POS system introduced in the pay office, officers rest house & the Kasturba Gandhi Hospital in first phase and being planned for other places

1.52 CANCER AWARENESS PROGRAMME ORGANIZED BY KGH IN CLW; A Cancer Awareness programme was organized by Chittaranjan Locomotive Works (CLW) on 04.02.2020 in Conference Hall of K.G Hospital.

1.53 HON’BLE CHAIRPERSON OF NATIONAL COMMISSION FOR ST VISITED CLW: Hon’ble Chairperson of National Commission for Scheduled Tribe, Dr. Nand Kumar Sai, visited Chittaranjan Locomotive Works (CLW) along with seven members delegation on 7th February 2020.

1.46 PUBLIC HEALTH SERVICES THROUGH WHATSAPP IN CLW: K.G.Hospital of Chittaranjan Locomotive Works is providing various Public Health services to the inhabitants of CLW, through its Public Health Section. In order to streamline the complaint system, an additional mode of receiving complaints through WHATSAPP is being introduced. The complaints may be sent to the WHATSAPP group “CLW Public Health” by registering themselves with their Name, Control No. & Address on mobile no.9163340528 & 7365027453.

1.47 EMPOWERING WOMEN & DESPATCH OF 400th LOCO FROM CLW; On International Women's Week celebration in CLW, 400th loco,WAG-9HC. (32803) of FY 2019-20 was flagged off by the senior most woman employee, Smt Annamma Varghese, Matron in KGH and in presence of President of CLWWWO, Smt. Sunita Mishra , other lady staff and other ladies, on 4-3-20. The loco was driven by female loco pilots named Mrs. Surachi Kumari, loco pilot/goods/ASN and Miss Anupriya Kumari, Asst loco pilot/ASN of ER.

1.48 CLW GYMNASTIC TEAM WON FOUR GOLD AWARD: In 49th All India Railway Gymnastics Championship 2019-20 held at AGRA from 4th to 6th March 2020 organised by NCR, Km Pranati Nayak of CLW won Four Gold medals in Individual, Balancing Beam, Uneven Bar & Table Vault and One Bronze medal in Floor Exercise events. On the other hand , Km Swastika Ganguly of CLW also won one Silver medal in Floor Exercise and Three Bronze medals in Individual, Uneven Bars & Table Vault.

1.49 PRECAUTION TAKEN BY CLW AGAINST NOVEL CORONA VIRUS: On taking precautionary measure against spreading of NOVEL CORONA VIRUS(COVID-19) and its quarantine, the Chittaranjan Locomotive Works(CLW) authority has mobilized various activities with assistance from K. G. Hospital. Posters on DOs & DONTs on CORONA VIRUS are being displayed in different parts of Chittaranjan including K. G. Hospital & offices . To further quarantine the suspected patients, an isolation ward of 18 beds has been organised in K G Hospital.

1.50 DESPATCH OF 2500th 3-PHASE LOCO FROM CLW:; The 2500th 3-phase passenger locomotive, WAP-5 bearing no. 35007 with hauling capacity of 6000HP was dedicated to the nation today by Chittaranjan Locomotive Works(CLW) on 13-3-20.

1.51 AWARENESS PROGRAMME FOR PREVENTION OF COVID-19 IN CLW; Chittaranjan Locomotive Works(CLW) has been taking proactive measures to stop the spread of CORONA VIRUS in Chittaranjan. A weeklong awareness & sensitization programme is being organised against spreading / prevention of CORONA VIRUS (COVID- 19) infection in various places in CLW by the Public Health wing of K. G. Hospital. Two teams of para medical staff started conducting awareness & sensitization programmes at different time slots in Chittaranjan township, beginning with Service buildings, K. G. Hospital premises, shop floor and all Health units of CLW, assisted by volunteers of Scouts & Guides, Civil defence and St. John’s Ambulance brigade.

1.52 CLW ENTERS LIMCA BOOK OF RECORDS: The record production of 402 electric locomotives in FY 2018-19 from Chittaranjan Locomotive Works (CLW) has got recognition from the Limca Book of Records as World Record. The certificate has been published by the Limca Book of Records from their Delhi office on 28.02.2020 and was formally handed over to CLW authority. This is a moment of pride for CLW fraternity for achieving this recognition from Limca Book of Records for World Record .

1.53 RECORD 431 LOCOMOTIVES PRODUCED IN CLW: World’s biggest Locomotive Manufacture Chitatranjan Locomotive Works (CLW) produced record 431 Locomotives in FY2019-20 (despite COVID-19 restrictions coming in force on 21.3.2020) surpassing its own world record of FY 2018-19. In last FY 2018-19, CLW produced 402 locos in FY 2018-19 which has been recognised by Limca Book of Records as World Record.

1.54 The production has witnessed a jump of 75% over the last 6 yrs from 250 in 2014-15 to 431 in 2019-20 to support 100% Electrification and Make in India. CLW production of 431 locomotives in this FY is 2.16 times the installed capacity of 200 locomotives per year. With improved by supply chain management, hard work & dedication of staff & officers of Team CLW has been able to achieve this ever best record production in FY 2019-20 by consistently producing average 40+ locomotives since July 2019.

2 SALIENT FEATURES

2. SALIENT FEATURES Salient features of CLW w.r.t the following : 2.1 Total turn over as on 31.03.20 a) For Indian Railways : Rs. 4564.95Crores b) For others : -- Nil Turn over ratio as on 31.03.20: 6.05% (Approx) Break up of Turnover as on 31.03.20 Supply of Locos Rs. 3938.82 Crores Components manufactured for stock Rs. 563.88 Crores Supply of Spares for Zonal Railways Rs. 62.25 Crores …………………… TOTAL Rs: 4564.95 Crores

Turn over ratio of Store Deptt./CLW for 2019-20 (up to 31.03.20) Physical : 16.06%

2.2Total assets : (as on 31.03.20) : Rs. 960.40 crores Fixed assets: (as on 31.03.20) :Rs. 662.16 crores a) Township : Rs. 29.34 crores b) Workshop with M&P : Rs. 632.82 crores Floating assets (as on 31.03.20) : Rs. 298.24 crores a) Stores : Rs 21.29 crores b) WMS : Rs. 276.47 crores c) Misc. Adv : Rs. 0.48 crores 2.3 Sanctioned and on-roll position of staff as on (31.03.20) group of staff wise i.e Group A, Group B, Group C & Group D. Group Sanctioned Strength On Roll Group A 176 103 Group B 71 65 Total 247 169 Group C 10914 8138 Group D 2931 2512 Total 13845 10650 Grand Total 14092 10819

2.4Elec. Power requirement (average maximum demand) : 10MVA (CLW/CRJ) 2.5 Electric energy consumption : (in lakh units/year) : 394.57 lakh KWH 2.6 No. of H.T. Sub station: Location Power Transformer Details No. of Transformers Main Sub. Station a. 33 KV / 11 KV – 12.5 MVA 01 b. 33 KV / 11 KV – 10 MVA 03 c. 33 KV /11KV – 6 MVA 01

Location Details of Distribution Transformer No. of Transformer a. Main works & steel Foundry 11 KV / 440 V 25 Nos. b. Township 11 KV / 440V 45 Nos. c. Pumping Station 05 Nos. 2.7 Water consumption : 159.49 lakh litre per day 2.8 (a)Workshop Land : 101.26 Hectares (b) Covered area of other service building (in SQM) : 35,241 Sq.m 2.9 Township area : 1,834.441 Hectares. 2.10(a) Covered area in shops : 4,73,268Sq.m (b) Covered area of other service buildings : 35,241 Sq.m 2.11 (a) Total staff as on 31.03.20 : 10,650 (b) Total number of staff quarters : 9,650 Nos. 2.12Hospital (no. of beds) : 197 Nos.

ORGANISATIONAL CHART

ORGANISATIONAL CHART (UPTO JAG) AS ON 31.03.20)

PRODUCTION PERFORMANCE

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 Locomotives 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=1770Nos. & WAP-4=837Nos.) which got discontinued after 31st December ,2015.Now,CLW is involved in the production of Three Phase Electric Locomotives and maintenance spares required by Zonal Railways. It has produced 7185 Electric Locomotives till 31st March,2020.

The annual out turn of various types of Locomotives during preceding years is given at Annexure – I & II.

4.1 ELECTRIC LOCOMOTIVES :

The production of Electric Locomotives started in the year 1961. Till 31stMarch 2020, 7185 nos. Electric Locomotives of various classes and traction have been produced as shown in the Annexure-I. The present production of electric locomotives consists of:

(a) 3-phase AC Thyristor controlled 6000 H.P.6-Axle Freight WAG-9HC (with an Axle load of 22.5 Ton) (b) 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. (c) Passenger version of 3-phase loco viz. WAP-7 with an axle load of 20.5 ton having Micro processor controlled brake system for hauling mail/Express and other super fast trains.

During the year 2019-20 CLW has manufactured 364 Nos. WAG-9H (Including 01 Loco of WAG-9HH),28Nos. WAP-5 and 39 Nos.WAP-7 Electric Locomotives i.e, Total 431 Nos. against planned yearly out turn of 430 Electric Locomotives(No.-GB/7/RSP/2019-20,Dt:03-01-2020). CLW has planned to produce 400 Nos. Electric Locomotives, including DKAE, during the year2020-21(As per PCEE’s letter no.CEE/21,dated-25/12/2019 &Dy.CEE/D/Conv’s letter no. ELDD/1725, dated-23/01/2020).

4.1.1 Year wise production from 2000-01 to 2019-20 YEAR WAP-4 WAG-7 WAP - 5 WAP-7 WAG-9 Total (RAJ) (HH) (TP) (TPP) (TG) Target 45 67 2 1 5 120 2000-01 Actual 50 62 2 1 5 120 Target 37 50 - 1 2 90 2001-02 Actual 34 40 - 2 6 82 Target 20 24 4 9 12 69 2002-03 Actual 28 27 1 6 7 69 Target 32 39 - 9 6 86 2003-04 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 Target 30 100 15 30 55 230 2011-12 Actual 44 126 12 19 45 246 2012-13 Target 20 100 15 40 75 250 Actual 37 123 13 40 57 270 Target 20 80 30 50 95 275 2013-14 Actual 27 100 13 31 93 264 Target 35 70 07 40 98 250 2014-15 Actual 35 70 07 40 98 250 Target 30 35 17 58 140 280 2015-16 Actual 30 35 17 58 140 280 Target 00 00 30 95 175 300 2016-17 Actual 00 00 23 79 190 292 2017-18 Target 00 00 30 110 210 352 Actual 00 00 21 107 222 350 2018-19 Target 00 00 30 70 400 500 Actual 00 00 30 73 299 402 2019-20 Target 00 00 25 45 360 430 (No.GB/7/RSP/2019-20) Actual 00 00 28 39 364 431 dt. 03.01.2020

Year wise Electric Loco production from 2010-11 to 2019-20(As on 31.03.20) 500

450 431 402 400 377 364 350

292 299 300 280 WAP-4 270 264 WAG-7 246 250 250 230 WAP-5 222 WAP-7 200 190 WAG-9 Total 150 140 134 120 126 123 100 93 98 100 79 70 73 57 58 40 45 40 40 39 50 40 44 37 31 35 3035 30 27 23 21 28 1218 1219 13 13 17 7 00 0 0 0 0 0 0 0 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

4.2 TRACTION MOTORS: 4.2.1. Cumulative production of Three Phase Traction Motors during the year 2019-20 has been 2330 Nos. (2234 Nos. of type 6FRA-6068 & 96 Nos. of type 6FXA-7059) till 21.03.2020 (Production has been stopped from 22.03.2020 due to outbreak of COVID-19).

For the first time TM shop has manufactured 2330 nos. Three Phase Traction Motors which is a record and has crossed the stipulated annual target of 2220 TMs.

This is 35.45% higher production than previous year.

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 21/03/2020, CLW has manufactured a total of 12661 nos. 6FRA-6068 (Co-Co) and 629 nos. 6FXA-7059 (Bo- Bo).

Following Bar chart shows the production trend of Traction Motors at CLW for last Five years:

YEARWISE PRODUCTION OF TRACTION MOTORS

2330 2500 2234

2000 1741 1720 1688 1619 1514 1500 1315 1385 1019 1000 465 500 30 70 53 101 96 0 2015-16 2016-17 2017-18 2018-19 2019-20

6FXA 7059 6FRA 6068 HS 15250A Total

4.2.3SUPPLY OF SPARES : The following materials were supplied to zonal Railways as spares during the year 2019-20against their sanctioned RSPs / vetted indents:

I T E M Qty. 3 Phase Traction Motor (Co-Co) 6FRA-6068 53Nosto Zonal Rlys Complete Stator (Bo-Bo) 01Nos Complete Rotor (Bo-Bo) 06Nos

4.2.4IMPROVEMENTS TO ENHANCE RELIABILITY: To improve reliability and performance of 3 Phase Traction Motors, modifications as listed below have been implemented :

 To drain out the excess gear case oil, three cuts in Outer Bearing Cap (DE) had been implemented vide RDSO’s Modification Sheet No. RDSO/2016/EL/MS/0439 (Rev ‘0’) dtd. 23.11.16. However, as per RDSO’s recommendation original design and dimensions given by ABB for various Labyrinths are now being used.  Procedure of measurement of Axial clearance as per RDSO SMI-323 are being followed.  Snap Gauge / out Side Micro Meters are used for measurement of Shaft Diameters.

 Dimension of Matching Components i.e. Labyrinths are being made.  Besides, to minimize failures due to Temperature Sensors, a new design and specification of Temperature Sensor has 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’) dtd. 24.12.13.

 CLW has implemented by alteration of Drg. in Bearing Cap(NDE) vide MS-460 & in Bearing Cap(DE) vide MS-466 to ensure adequate lateral thrust in Bearing.

 CLW has started 100% measurement & record of dimension of DE & NDE Bearing Bore housing and outer dimension of Bearing.

 100% measurement of critical dimensions of Stator Bore, Concentricity of Stator, distance between centre of bore to MSU face are being carried out by CMM machine.

4.2.6 INNOVATIONS & DEVELOPMENTAL WORK IN T.M . SHOPS :

The following M&P items have been installed during 2019-20.  Three nos. O.H. Crane have been installed.  One No. Variation Analyser Tester have been introduced for Testing of TM.

Production Performance of Manufacturing Shops

4.3 Production Performance of Steel Foundry : 4.4.1 Yearwise Cast & Supply (In MT)

Production Supply

4000 3398 3064 3088 3000 2694 2285 2379 2412 2226 2010 1899 2000

1000

0 2015-16 2016-17 2017-18 2018-19 2019-20

4.4.2 Year Wise Cast & Supply of Casnub Bogies (In Nos)

Production Supply 280 280 269 269 300 239 204 200 140 100 73 37 0 0 2015-16 2016-17 2017-18 2018-19 2019-20

Annexure – I YEARLY OUTTURN OF ELECTRIC LOCOMOTIVES FROM CLW

AC Year DC MT ACMT DC ACMT ACMT WC ACMT WC WA (WK) WAG WAP WAG WAG WAG WAP WAP Grand WC WCA M-6 WAM M-5 G-1 WAM -5A -1,3,4 -7 - 9 -9HH -5 -7 Total G-2 M-4 WC -4 WA -4B G-3 G-4 1961-62 05 5 1962-63 14 14 1963-64 2 2 4 1964-65 27 27 1965-66 32 32 1966-67 57 57 1967-68 50 50 1968-69 28 28 1969-70 31 31 1970-71 3 41 06 50 1971-72 6 40 46 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 2017-18 0 0 222 21 107 350 2018-19 0 0 298 1 30 73 402 2019-20 0 0 363 1 28 39 431 TOTAL 21 57 268 54 1067 843 53 1770 02 500 1778 2 192 578 10378 Steam locos – 2351 nos.

Diesel locos – 842 nos. Summary as on 31.03.2020 Electric locos – 7185 nos. Total -- 10378 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 2017-18 - - - 1688 53 1741 2018-19 - - - 1619 101 1720 2019-20 - - - 2234 96 2330 Total 339 8466 15145 12661 629 37244

ELAAU/Dankuni

4A.1 Electric Loco Assembly & Ancillary Unit of CLW at Dankuni (ELAAU/Dankuni) has been established to augment the production of Freight Locomotives. This unit has started production from March-2016. Upto 31.03.2020 total 140 Nos. WAG-9 Locomotives have been produced at ELAAU/Dankuni since its inception.

4A.2 Salient Features pertaining to ELAAU/DKAE

4A.2.1 Sanctioned and on-roll position of staff at ELAAU/DKAE is as on 31.03.20 is as under

Group Sanctioned Strength On-roll Shop staff including supervisors 405 337 Other than shop staff (Ministerial, Personnel, 106 75 Accounts, Medical, Store Engg.) Total 511 412 4A.2.2 Elect. Power Requirement (Average maximum demand): 0.336 MVA

4A.2.3 Electric Energy Consumption (in lakh units/year): 13.34 (from Apr’19 to Mar’20)

4A.2.4. No. of HT Sub-station: 33kV/415V : 03 Nos

4A.2.5 Workshop land: : 70 Acres (1180 X 140 m2+1180 X 100 m2)

4A.2.6 Total No. of Staff Quarter : 34

4A.3 Organizational Chart (upto JAG) as on 31.03.2020

4A.4 Production Performance

4A.4.1 The production of 3-phase AC IGBT, 6000 HP, 6-Axle Freight WAG-9H locomotive started from March-2016. During the year 2019-20, ELAAU/DKAE has turned out 52 WAG-9H locomotive. Upto 31-03-20 total 88 nos. WAG-9H locomotives have been produced at ELAAU/Dankuni since its inception.

Year wise production of WAG-9H locomotive at ELAAU/DKAE: Year Production 2015-16 1 2016-17 12 2017-18 25 2018-19 50 2019-20 52 Total 140 24

DESIGN & DEVELOPMENT INCLUDING TOT

5. CENTRE FOR DESIGN & DEVELOPMENT

5.1 Up gradation of WAG-9H locomotive to 9000 HP: As per Specification No. RDSO/2017/EL/SPEC/0217Rev ’0’.The Project for up gradation 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 throughout, better line capacity, reduced stalling, increased reliability and improved overall performance. Status: Siemens: As per P.O.No.70/18/1145/01152 dated.04.12.2017:  Loco No.90002 turned out from CLW in December 2019.  EBD and Oscillation trails completed in February 2020.  CRS inspection is under process.

As per P.O.No.70/18/1145/01152 dated.04.12.2017:  Supply yet to commence.  Firm yet to submit design document and test protocol as per Stage-II document. Medha: As per P.O.No.70/18/1145/01220 dated.12.04.2018:  Bogie frame and traction motor are yet to be supplied.  Other equipment commissioned in Loco No.90001 BHEL As per P.O.No.70/18/1145/01226 dated.12.04.2018:  All material supplied except Bogie Frame and Radiator  Other equipment commissioned in Loco No.90003. Railway Board has further advised to manufacture 50 nos. of 9000HP locomotives. The same is being processed.

5.2 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 Electric Locomotive equipments.  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.

Status of projects under COE is as follows

1) Centre for Simulation and Evaluation of Suspension/Bogie and Traction System and Electric loco modeling, virtual modeling and simulation has been set up.TCS team has been giving onsite support since May 2019. 2) Dedicated cadre of SSE/JE comprising of 19 post has been sanctioned for COE, posting order for three SSE/JE’s issued out of that one joined. 3) Software development lab is under retendering.

5.3 IGBT based Composite Converter with Traction Converter and Hotel Load Converter: This is for utilizing OHE power for supply of hotel load requirements of Shatabadi/Rajdhani trains through HOG Scheme by providing Hotel Load converter in the locomotive. Order placed on M/s BHEL, ABB and CGL.

Status: M/s.ABB:  10Units are supplied out of which 8 units are commissioned. o Seven Units have been commissioned in WAP-5 locomotive

o One Unit have been commissioned in WAP-7 locomotive no.30750  02 units are under commissioning at CLW in loco no.35012 and 35013 with aerodynamics structure.

M/s.CGL:  Design document submitted, under scrutiny. M/s.BHEL:  Design document approval accorded.  First unit supplied in May’19, remaining under manufacturing.  First prototype unit commissioned and currently under field trail.

5.4 Development of Distributed Power Wireless Control System (DPWCS) for 3-phase electric loco: In DPWCS, more than one MU consist are provided in a train ,the master locomotive is provided with crew but slave locomotives(s) are operated based on commands from master locomotive through wireless communication. The rear MU consist shall be distributed at any point in the train for example.

Status: M/s.ARC/Bengaluru: As per LOA No. OT/C-D&D/01/07/2007-08 dated: 03.06.2008:  The prototype pairs have 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/TATAin Nov’14. As per P.O.No.70/16/1140/01088 dated: 28.06.2017,Qty: 45 sets:  45 set received at CLW and spared to loco sheds against RSP. As per P.O.No.70191140100178 date 29.07.2019  76 set orders placed. supply yet not commenced

M/s.GE  P.O.No.70/16/1140/01090 dated: 28.06.2017. Qty.10 sets  Design document approval accorded.

M/s.Lotus As per P.O.No.70/16/1140/01089 dated: 28.06.2017.  Till dated 20 sets have been received at CLW and 14 sets have been spared to Electric Loco shed against RSP.  Prototype unit commissioned in loco no.32196 & 31879 at ELS/WAT. Final field trial planned in July 2020. As per P.O.No.70191140100218 date 14.08.2019  183 set orders placed. Supply yet not commenced. Final Interface Control Document (ICD) and FUPLA logic has been circulated to propulsion manufacturer for modification in VCU for DPWCS operation.

5.5 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: P.O of 5 loco sets (20 nos.) placed on M/s Arihant Electricals  All sets are supplied. Tender for further 20 loco sets opened on 31.05.2017. P.O. placed on 3 firms.  M/s Involute Technologies -10 sets  Type test done and prototype unit rejected.

 M/s Mackeil and Compant Pvt.Ltd.-04sets  Type test protocol yet to be submitted.

 M/s River Engineering (counter offer) – 06 sets  Type test protocol under scrutiny.

5.6 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: P.O of 2 loco sets (08 nos.) placed on M/s Arihant Electricals  All units are supplied and commissioned in loco no.30086 and 30164

5.7 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: M/s ARC  P.O.no.72/16/1268(NS)/11321 dated:31.01.2018  Order for 54 sets placed and till date 41 sets have been supplied  Prototype unit commissioned in loco no 30715 and loco dispatched to ELS/GZB.

M/s. LOTUS

 P.O. No. 72/16/1268(NS)/11320 dated: 31.01.2018 Qty. 83 Sets  Prototype units fitted in loco no. 32165 and dispatched to ELS/BIA.  Prototype unit is commissioned  Prototype clearance accorded after satisfactory field performance.

5.8 Twin BO-BO Locomotive with speed up to 200 KMPH:

Indian Railways intends to upgrade the existing 5440HP WAP-5 locomotives by joining two 5440 HP WAP- 5 loco as twin BO-BO with minimal suitable modifications in propulsion equipments to achieve higher speed, higher power , increased continuous power , better acceleration reserve, more reliability and improved overall performance of the locomotive. Status:  A total 05 (Five) locomotives sanctioned by Railway Board.  Technical specification prepared by RDSO.  Based on RDSO specification tender done twice but no bonafied offer received for bulk ordering.  Case has been referred to Railway Board for reviewing procurement /development of Twin BO-BO with a speed potential of 200 KMPH in view of recent development of push pull operation.

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

Indian Railways in association with C-DAC(T) developed indigenously, using state- of-the –art hardware and software , an open architecture technology for functional equivalent of vehicle control unit. The design is based on Train Communication Network(TCN) as per IEC 61375. Status:  Transfer of Technology (TOT) provided to CGL, ABB, AAL, BHEL and Delta.  CGL and ABB are supplying CDAC based VCD regularly with their propulsion system.

Development Status

M/s. ABB As per P.O. No. 70/16/1142/11003 dated : 07.03.2017, 70/18/1142/11195 dated : 15.09.2017 AND P.O. No. 70/18/1142/01/11286 dated : 27.11.2017  All sets received at CLW M/s. BHEL As per P.O. No. 70/16/1142/11002 dated : 07.03.2017  One set received at CLW.  Prototype and routine test protocol approved for remaining sets.  Type test report yet to be submitted. As per P.O. No. 70/17/1142/11077 dated : 17.06.2017  Supply of 42 sets is yet to commence. As per P.O. No. 70/18/1142/11230 dated : 09.10.2017  Supply of 23 sets is yet to commence. M/s. CGL: As per P.O. No. 70/16/1142/11003 dated:07.03.2017, P.O. No. 70/17/1142/11078 dtd:17.06.2017, P.O. No. 70/18/1142/11287 dated : 27.11.2017  All sets received at CLW M/s. AAL As per P.O. No. 70/16/1142/11008 dated:14.08.2018, Qty: 2 sets:  First set ( manufactured by M/s C-DAC) offered for routine inspection.

5.10 Fault diagnostic tool for 3-Phase locomotive:

Fault diagnostic tool is used for the purpose of downloading the loco software and troubleshooting the locomotive is a DOS based network device which can communicate with MVB. Once fault diagnostic tool is connected to MVB network of a locomotive, it becomes an extension of an MVB node and can access all the processors on the MVB network.

Status:

M/s. BTIL: As per P.O. No. 91/17/1007/01229, dated:06.03.2018, Qty: 40 sets:  All sets received at CLW and distributed to sheds as per RSP. M/s. ARC As per P.O. No. 91/17/1007/01228, dated:06.03.2018, Qty: 10 sets:  Prototype clearance accorded.  All sets received at CLW and distributed to sheds as per RSP.

5.11 Up-gradation of speed of WAP-7 locomotive from 140 kmph to 160 kmph (WAP-7HS).

Status:  First prototype WAP-7HS locomotive 30750 dispatched to ELS/GZB on 27/02/2019.  COCR trial to be conducted by RDSO.  Final clearance given by RB in march ’20 for operation after CRS inspection.  EIG is under process by Northern Railway.

5.12 Aerodynamic model of WAP-5 cab for High speed loco  Aerodynamic re-profiling of WAP-5 locomotive done.  Loco no. 30164 manufactured and dispatched to ELS/GZB  On concept of train set operation, Two Locomotive 35012 and 35013 modified for aerodynamic and under commissioning at CLW for Push Pull Operation.

5.13 Push Pull Operation  Speed Certificate issued for push pull Operation after trails in Jan 2019.  Train No. 22221/22222(Special Rajdhani ( CSTM-NDLS Express) on commercial service since Feb 2019  Software of Push Pull Validated for BTIPL and BHEL  Software of CDAC tested and being validated 29

 Software of MEDHA need to be validated at ELS/BRC  Two locomotive 35012 and 35013 under commissioning at CLW for push Pull operation.  Further interface Control Document (ICD) finalized and distributed to propulsion manufactures for interoperability and push pull operation.

5.14 Source Development for Aluminum tank of Transformer:

In order to broaden the vendor for Aluminum tank of 6531 KVA & 7775 KVA transformer development tenders were floated and purchase order issued for the transformer tank and active parts separately.

Status of development source for Aluminum tank of 6531 KVA(15 L/s) & 7775 KVA (10 L/s) of Main Transformer are as follows:

High Volt  As per 70190049100176 , dated 28-Feb-20  Prototype completed Final IC issued.

Apollo  As per 70190049100177 , dated 28-Feb-20  Prototype completed.

Hind Rectifier  As per 70190049100174 , dated 28-Feb-20  Prototype completed.

M/s. BHEL, M/s. Electro Auto, M/s. ADROIT are under Capacity cum capability Assessment and prototype inspection stage.

QUALITY ASSURANCE

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 CLWlocated at NDLS, Mumbai, Bangalore and Howrah.)

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, Wheel Shop, 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 send the same to User Railways. To fulfil the previous years commitment, 100% scan of Inspection Data are used to make the Soft Copy of Loco Inspection Certificates of locomotives manufactured since the financial year 2014-2015 and onwards.

6.2.5 To upload the preliminary loco details in website after the despatch of locomotive, for the purpose of viewing the same through a Mobile App.

6.3 ACHIEVEMENTS:

6.3.1. The Mobile App namely “CLW IGBT Loco Information”, has been introduced from April 2018 by which important loco data for CLW built locomotives can be searched by entering the serial number of locomotives according to the numbering plan. The validity of Domain Name, Cloud Server Space and necessary software maintenance has been suitably extended for the next two years with effect from April’2020.

6.3.2. Inspection of imported loco items through in-house inspection team has been introduced.

6.3.3. IC0 feed-back system from sheds through online mode is newly introduced.

6.3.4. Inspection formats have been modified according to IGBT based locos in place of earlier GTO locos.

6.3.5. Measurement of temperature rise during running of motorized wheel set has been implemented in bogie assembly stage.

6.3.6.Anti vibration bracket for TFP expansion tank is provided and ensured in all locos.

6.3.7. Newly Modified Compressor Safety Sling has been provided on trial basis.

6.3.8. Air flow measurement in Machine Room has been ensured.

6.3.9. 100% Eccentricity measurement by CMM, for Stator has been ensured and maintained.

6.3.10. Modified platform assembly ensured for WAP-7 loco fitted with hotel load by repetitive booking on that item.

6.3.11. Tail lamp bracket provision is ensured. 32

6.3.12. Grommet provision over Cables while tightening under cable cleat near TM Junction Box has been ensured.

6.3.13. 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 its shearing problem.

6.3.14. The camber of 15 mm in place of earlier 10 mm is ensured for roof girder/channel to minimize the gap between roof and girder which were causing roof leakage.

6.3.15. Safety sling of Traction Motors at the loco under-frame have been constantly monitored to ensure safety.

6.3.16. 100% NDT test conducted on different types of Axle and Wheels for better quality control.

6.3.17. To overcome the bearing cease problem during MSU fitment in three phase locomotives, checks for X-clearance, D- clearance and C-clearance have been ensured and maintained on Wheel Set Assembly.

6.3.18. On the basis of customer feedback received in the past, inspection checks which were introduced earlier are now ensured for 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 WAG-9, WAP-7 and WAP-5 loco 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. Trial implementation of modified lifting hook of ballast block for WAG-9H (T-shaped) has been ensured and maintained.

6.3.20. Inter-stage coil testing for stator have been ensured to increase reliability of Traction Motor.

6.3.21. Rain water testing for possible leakage has been introduced with newly modified facilities.

6.3.22. Machine Room spare holes have been plugged and maintained after raising NC regularly.

6.3.23. For Scheme-II Rotors measurement of gap between Resistance Ring & End Ring is ensured to maintain proper gap between them.

6.3.24. Up-gradation of Loco Inspection Certificate in to 100% soft copy has been ensured and maintained.

6.4 METALLURGICAL & CHEMICAL LABORATORY

Chemical & Metallurgical Laboratory under control of CMT and assisted by 02 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 consist of three units i.e. main Lab, loco works and steel foundry. The C & M Laboratory ensures quality control of inputs and finished products of steel Foundry including stage wise process control. The C & M wing of steel Foundry ensures quality control of castings like Narrow Gauge Wheel, IGBT Block 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 powder etc. It also ensures quality control of furnace consumables like basic lining bricks, high alumina bricks, ladle bricks etc.

Main activities of C & M 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.

Chemical and Metallurgical 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 C & M matters.

6.5 PERFORMANCE w.e.f 01.04.2019 to 31.03.2020 6.5.1 METALLURGICAL & CHEMICAL LAB/LOCO:

No. of Sample No. of Sample Tested Nos. of Tests % of Rejection Accepted Sl. Name of Lab. 2017 2018 2019-20 2017 2018 2019-20 2017 2018 2019- 2017 2018 2019-20 No. 20

Metallurgical/ 3757 3170 4083 8305 6677 8038 3675 3090 3695 2.18 2.52 9.50 1. Mechanical Lab. 2. Chemical Lab. 2416 1981 2177 13654 11266 12564 2399 1914 2086 0.70 3.82 4.18

Rubber , DMC, 411 589 653 3347 4274 5745 401 568 617 2.43 3.67 5.51 3. I.M. & Lubricant TOTAL 6584 5740 6913 25306 22217 26347 6475 5572 6398 - -

6.5.2 NDT LABORATORY (LOCO):

Nos. of Location/ Nos. of No. of Sample Tested % of Rejection Sl. Component Tested Component Accepted Name of Lab. No. 2017 2018 2019-20 2017 2018 2019-20 2017 2018 2019- 2017 2018 2019- 20 20 9621 10646 12410 28930 31778 38730 9568 10567 12371 0.551 0.742 0.341 1. Ultrasonic Testing

5852 5858 7222 9272 7236 7526 5851 5857 7222 0.017 0.000 - 2. M P T 2 121 133 182 121 133 182 98 125 182 19.00 6.015 - 3. Radiographic Test

4. Misc. 2566 3581 1911 7766 12229 12758 2517 3542 1911 1.90 1.089 - TOTAL 18160 20198 21725 46089 51376 59196 18034 20091 21686 - -

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

No. of Sample Tested Nos. of Tests Sl. No. Name of Lab. 2017 2018 2019-20 2017 2018 2019-20 1. Chemical Lab. 1505 1533 1197 7190 5785 5271

2. Chemical Misc. 16 28 66 96 167 373

TOTAL 1521 1561 1263 7286 5952

6.5.4 FIELD LABORATORY/S. F. : Sample Test Physical & Radiographic /UT Tests Sl.no. Name of Test No.of Tests Name of Test No.of Tests 2017 2018 2019-20 2017 2018 2019-20 1. Zircon Wash 85 60 6 Tensile strength 160 12 20 2. Green Sand 3000 3657 4987 Microstructure 210 270 116 3. Permeability 881 1346 1614 Charpy 0 0 0 4. No-bake 4542 702 408 Hardness 225 36 24 Sand Radiography 4215 898 199 Exposures UT -- 153 94 5. Silica sand 1828 1136 1032 DPT - - 6 Total 10336 6901 8047 Total 4810 1369 459

6.5.5. PLAN EXECUTED DURING 2019-20:

1. Installed & Commissioned of Flash Point Apparatus (for low temperature) for testing of Oil and Thinner. 2. Installed & commissioned of Notch Cutting Machine.

Marketing including export

( Supply of spares to Zonal Railways )

7.Supply of spares

7.1LIAISON & SERVICES WING: 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 against bulk RSP & Railways’ own needs of Spares against Indent/PO/Requisition for maintenance of locomotive at Electric Loco Sheds and POH/ Repair Shops over Indian Railways. Broadly, Liaison and Service Wing perform the following functions:-

7.2FUNCTIONS:

 Consolidating the demands in the form of RSP from Railway Board & Requisitions/Indents/PO from Railways for purchase and Shop manufactured 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 as per demand receipt and availability.

 Co-Ordination with Railway Board for timely provision of fund for RSP items.

 To maintain accountal of such supplies.

7.3SPARES TO RAILWAYS:

In the year 2019-2020 spares worth Rs.19526.44 Lakh (as on 31.03.20) were supplied to the Railways. The breakup of the same may be seen at Annexure-A.

CLW/CHITTARANJAN ANNEXURE- 1

SUPPLY OF SPARES TO ZONAL RAILWAYS AGAINST RLY BOARD’S RSP & REQUISITIONS OF ZONAL RAILWAYS UPTO March'2020 (All Costs are in Rs. Lakh)

Sl. CR ECoR ECR ER NCR NR SCR SECR SER SR WCR WR Total Total cost of Item description Oth /ZR qty. supply RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ RSP REQ 1 TM for G-9/P-7 6 3 7 2 4 4 7 7 3 3 6 52 1021.21 2 TM for P-5 3 Stator of TM for G-9 1 1 18.45 4 Rotor of TM for G-9 12 12 83.31 5 Transformer of G-9/P-7 (7775KVA) 1 1 95.68 6 Transformer of P-5(6531 KVA) 7 Potential Transformer 8 Auxiliary Converter 9 Traction Converter 3 1 1 1 1 7 1268.55 10 Propulsion Equipment 2 2 5 5 2 4 1 3 2 1 27 5859.50 11 E-70 Brake System 2 1 1 2 1 2 1 2 1 1 14 479.72 12 Vehicle Control Unit 2 1 3 164.94 13 Driver’s Display Unit 1 10 11 46.42 14 Bogie Frame WAP-5 2 2 13.86 15 Bogie Frame WAP-7 2 2 4 2 10 87.90 16 Bogie Frame WAG-9 2 6 2 2 6 6 2 26 210.99 17 Brake Rigging WAP-5 18 Brake Rigging WAP-7 19 Brake Rigging WAG-9 1 1 1 20.93 20 Wheel & Axle Assly. WAP-5 2 2 4 211.24 21 Wheel & Axle Assly.WAP-7 2 13 1 3 19 188.68 22 Wheel & Axle Assly. WAG-9 3 2 6 4 2 17 156.16 23 Gear Case Assly. WAP5 24 Acess Tool / Diag System 2 2 4 50.00 25 High Reach Pantograph 4 30 2 86 24 50 194 2 392 1802.89 26 High Speed Panto AM92 6 10 10 6 9 5 8 2 2 58 92.47 27 Remote Monitoring 25 30 11 5 71 426.00 28 DPWCS 7 7 14 532.00 29 2x500 Kva Hotel load Converter 3 3 432.03 30 Oil Free Compressor 31 VCB 1 1 3.04 32 Oil Cooler Radiator 9 1 1 2 6 4 2 2 2 2 3 34 175.48 33 Main Compressor 13 4 4 24 6 18 16 14 24 123 584.04 34 Primary Volage Transformer 4 2 1 1 5 2 4 2 1 22 101.88 35 HB1 & HB2 PANEL 2 1 02 1 1 1 1 3 1 1 1 3 18 279.83 36 SB1 & SB2 PANEL 2 2 4 18.98 37 Pivot Housing 8 4 4 4 20 4.60 38 30 KW Oil Cooling Blower 6 9 7 7 8 10 8 4 6 10 8 3 1 87 212.84 Cost of items from row 1-38 14643.62 Cost of Misc. items in Rs. Lakh 1175.48 153.79 135.26 420.46 89.83 374.68 267.96 96.85 1131.45 468.78 122.65 363.54 82.09 4882.82 Total cost in Rs. Lakh 2574.80 230.80 693.00 732.73 180.18 3216.67 2334.11 1032.89 3394.04 1461.29 1039.60 2219.00 119.68 19526.44

STATUS OF M&P

8. MACHINERY 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 its distribution network inside loco works. Plant organisation looks after TPT shop and yard section, which looks after maintenance of passenger and Industrial and shunting activities. M&P cell deals with planning and processes for procurement & commissioning of machines sanctioned by Rly. Board & GM/CLW under M&P Plan Head-4100 & 4200.

MANUFACTURING SHOPS:

a) Wheel Shop: Wheel shop manufactures wheel sets for loco production as well as spares to Zonal Railways sanctioned under RSP. Presently wheel sets for WAP5, WAP7 and WAG9 locos are manufactured.

b) Heavy Machine shop: Heavy machine shop undertakes machining of components for loco production of 3 Phase Stators, Transom, support, Torque Support, Motor support etc. In addition to that, HMS has undertaken manufacturing Head stock of WAG9 and Bolster for WAG9H locos.

c) Smithy & Forge shop: Smithy & Forge shop undertakes fabrication of Head Stock of WAG9 locos, forging of small components of loco assembly such as Resting hook, Operating handle of CBC etc.

d) Light Machine Shop: Light Machine Shop manufactures various small components of locos and different kind of scheduled works to meet the requirement of loco production.

e) Tool Room: Tool room supplies toolings, 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. In addition to above, Tool Room is regularly supplying Axle Guide Bearings.

f) Heat Treatment Shop: Heat Treatment Shop undertakes heat treatment of WAG9 locomotive 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 504 M&Ps including 116 Nos. Cranes in Loco Works. Breakdown as well as preventive maintenance of M&Ps including 48 critical machines (list attached) is carried out by the Plant Maintenance Organization consisting of Millwright Shop (MTS-56), Electrical Repair Shop (Shop-59) and CNC Wing. Plant Maintenance Organization deals with repairing, reconditioning, re-engineering, retro-fitment of machineries and plant, maintenance of Heritage Locomotives & electrical maintenance of lighting inside shops. Installation of small machineries and plants, condemnation & uprooting of old M&Ps are also carried out by the Maintenance Shops-56 & 59.

I. SPECIAL WORK DONE

a) Renovation of 04 Nos. EOT Cranes have been done for the year 2019-20. b) Reconditioning of CNC M/cs.:- Wire DSL to Shrouded DSL conversion, Plasma Cutting Machine. c) One time repairing and system modification work has been done of these M/cs. such as Wheel Press- 09, Hoesh Press Machine, Takisawa CNC ATL, Premier VTL, Danobat CNC ATL. d) Out of 300 Chain slings, 231 Nos. have been tested within 21.03.2020, 40 Nos. Pressure Vessels(external) tested within 21.03.2020. e) One Heritage NG Coach renovated completely and installed at Deshbandhu Loco Park for exhibition. f) The Boiler Pipe of 1/4th Steam Loco was damaged for prolong running. The staff of Heritage maintenance section set right the Boiler with their dedicated effort within very short time and put the loco in operation. g) Inaugural Lathe Machine has been fully renovated and commissioned and installed in the loco park for display of public.

II.UPTIME AVAILABILITY OF CRITICAL MACHINES

 Plant wing of CLW has been entrusted with the maintenance of all M&P items which are more than 504 Nos. of all the shops.  Out of the above M&Ps, 48 Nos. of M&Ps have been identified as critical machines. The breakdown of any of these critical machines directly affected the production of Locomotive. Hence, these critical machines are being monitored very closely.  The availability percentage of various categories of machines in CLW during 2019-20 are given below: :

Target and Achievement Availability Target Achievement Cumulative 48 Nos. of critical M&Ps Up To 90% 95.08% 95.00% Non Critical M&Ps Up To 90% 98.74% 98.97% EOT Cranes Up To 90% 99.51% 99.51% Position of LED light fitting Up To 90% 99.09% 99.09%

8.3.1 CONDEMNATION OF M&Ps During the year 2019-20, 178 Nos. of machines have been condemned upto March’2020 out of which 142 No. of Machines have been disposed off. Annexure ‘A’ PRODUCTION PERFORMANCE OF MANUFACTURING SHOP

SN Name of Item 2018-19 2019-20 Remarks (Achieved) (Achieved) 1 Wheel Set Assembly 402 L/S 435 L/S (+) 33 L/S 2 Stator3 Phase(G9/P7/P5) 774 Nos. 878 Nos. (+) 104 Nos. 3 Head Stock 40 L/S 45.5 L/S (+)5.5 L/S 4 Bolster 48 L/S 48 L/S -- 8.4 M&P 8.4.1 M&P Wing is engaged with planning and procurement of machinery & plants through M&P Programme, sanctioned by Railway Board and GM’s ‘out of turn’ Powers and Project items under 275 loco Project, Installation, commissioning, and warranty issues of Machinery plants is also planned.

8.4.2 Procurement status of various M&Ps during last year (2019-2020) is as follows:

1. INDENTS PENDING WITH COFMOW/COS (as on 31.03.2020 )

i) COFMOW: 03 Nos. ii) COS : Nil 2. Progress of work by M&P Deptt. during the year 2019-20 Particulars P.O Placed M&Ps M&P Under M&Ps Received commissioning Commissioned M&P Programme items 01 no. 04 nos. 02 nos. 04 nos. sanctioned by Rly. Board GM’s Out of turn items 11 nos. 09 nos. 04 nos. 10 nos. sanctioned by GM/CLW Project items 03 nos. 01 no. Nil 01 no. (275 Loco Project ) Total 15 nos. 14 nos. 06 nos. 15 nos.

8.4.3 The following M&P items for medical deptt. have been procured, for the period from 1.04.19 to 31.03.20 :

1. ICU Monitoring System of 08 monitors with Central station. 2. Ventilator 3. Automated CPR Machine 4. ECG Machine 5. High end BIPAP machine 6. ICU Electrical bed- 2 nos. 7. ICU bed with Mattress – 4 nos. 8. Semi-Fowler bed – 6 Nos. 9. Electrolyte Analyzer 10. Semi-Automated Clinical Chemistry Analyser 11. Autoclave Machine for Blood Bank 12. Blood Bag sealer 13. Blood Donor Couch 14. Blood Collection monitor 15. Digital Dental X-ray 16. Cervical cum Lumber Traction Machine 17. Combination therapy unit 18. Short wave Diathermy 19. High/Low Electrical Treatment Couch

8.4.3. LIST OF CRITICAL M & P’s IN LOCO WORKS FOR THE YEAR 2019-2020

SI.No. SHOP DESCRIPTION OF THE MACHINE M/C .No. LOCATION YEAR OF COMM. 1. ELA NENCKI LOCO LIFTING JACK 16/3820/4A-4E SHOP-16 2. ELA GRIT BLAST PLANT 16/9020/01 SHOP-16 202 3. ELA EOT CRANE NO.0A 16/E/01 SHOP-16 1995 4. ELA EOT CRANE NO.2A 16/E/03 SHOP-16 1995 5. ELA EOT CRANE NO.2B 16/E/04 SHOP-16 1967 6. ELA EOT CRANE NO.1B 16/E/07 SHOP-16 1999 7. ELA EOT CRANE NO.1C 16/E/08 SHOP-16 1999 8. ELA EOT CRANE NO.2C 16/E/05 SHOP-16 1994 9. ELA EOT CRANE UNIQUE-I(50/5T) 19/E/08 SHOP-19 2011 10. ELA EOT CRANE NO.3B 19/E/02 SHOP-19 1964 11. ELA EOT CRANE NO.3A 19/E/01 SHOP-19 1964 12. ELA EOT CRANE NO.4C 19/E/07 SHOP-19 1987 13. ELA EOT CRANE UNIQUE-II(50/5T) 19/E/09 SHOP-19 2011 14. ELB HIMALAYA PLATE STRAGHTENING M/C 05/6030/02 SHOP-05 2009 15. ELB ZAYER CNC BOGIE MACHINE CENTRE 18/2463/01 SHOP-18 2010 16. ELB ZAYER CNC BOGIE MACHINE CENTRE 18/2463/02 SHOP-18 2012 17. ELB EOT CRANE NO.365 18/E/02 SHOP-18 1951 18. ELB HMT PROFILE MILLING M/C 05/2598/01 SHOP-05 2008 19. ELB EOT CRANE JESSOP-359 05/E/02 SHOP-05 1951 20. ELB PRO ARC OXY CUTTING 05/6025/02 SHOP-05 2009 21. ELF EOT CRANE NO.369(65/5T) 12/E/01 SHOP-12 1951 22. ELF EOT CRANE NO.368(65/5T) 12/E/02 SHOP-12 1951 23. ELF H.H.SHEARING 15/7064/03 SHOP-15 1993 24. ELF CNC PRESS BRAKE -200T 15/5743/02 SHOP-15 2012 25. ELF CNC PRESS BRAKE-400T 15/5743/01 SHOP-15 2006 26. ELF CNC TURRET PUNCH PRESS 15/6951/02 SHOP-15 2008 27. ELF PRO-ARC PLASMA CUTTINGM/C 17/6095/01 SHOP-17 2011 28. ELF EOT CRANE-UNIQUE 17/E/09 SHOP-17 2010 29. ELF EOT CRANE-367 17/E/05 SHOP-17 1951 30. ELF EOT CRANE -366 26/E/04 SHOP-26 1951 31. ELF EOT CRANE NO – 361 JESSOP 26/E/05 SHOP-26 1951 32. ELF JORDING SHEARING 15/7065/01 SHOP-15 2009 33. MFG UNIVERSAL CNC MACHINING 08/1833/01 SHOP-08 2013 CENTRE(MAG) 34. MFG CNC SURFACE WHEEL LATHE (HEC) 09/1042/01 SHOP-09 2012 35. MFG CNC CTLINDRICAL EXTERNAL 09/4626/02 SHOP-09 2014 GRINDING M/C(MORARA) 36. MFG AXLE GRINDING M/C(HMT) 09/4626/01 SHOP-09 2007 37. MFG 500T WHEEL PRESS (BBM) 09/7537/01 SHOP-09 2013 38. MFG PREMIER CNC VTL 09/1789/02 SHOP-09 2012 39. MFG PREMIER CNC VTL 09/1789/01 SHOP-09 2010 40. TM SB CNC LATHE 20/0687/01 SHOP-20 2003 41. TM MICROMATIC GRINDING 20/4673/01 SHOP-20 1999 42. TM HMT CYLINDRICAL GRINDING M/C 20/4680/01 SHOP-20 2010 43. TM FORTUNA EXTERNAL GRINDING 20/4671/01 SHOP-20 1983 44. TM HYD PRESS -300T NUCHEM 21/7581/04A SHOP-21 1993 45. TM EFD INDUCTION BRAZING M/C 21/1002/06 SHOP-21 2005 46. TM VEL 21/1002/01 SHOP-21 2013 47. TM MOTOR TESTING PLANT 21/9550/01 SHOP-21 2000 48. TM PROTEC BALANCING 23/100706 SHOP-23 2010 New Summary ELA 13 ELB 7 ELF 12 MFG 7 TM 9 TOTAL→ 48

STEEL FOUNDRY

8A.1 OVERVIEW Location of the Factory: Steel Foundry, Chittaranjan Locomotive Works P.O. & P.S. : Chittaranjan Dist : Paschim Barddhaman, Pin – 713331

The Factory is located at Chittaranjan, Dist: Paschim Barddhaman, West Bengal, approx. 240 km. from Kolkata. The location is well connected by road and rail from Howrah Station.

Steel Foundry as a part of Chittaranjan Locomotive Works was set up for supplying Steel casting products of locomotives. It has an Arc furnace of 15T/12T. CLW follows stringent quality processes, duly certified with

ISO : ISO 9001:2008, ISO 14001: 2004, ISO 18001 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.

 OHSAS – 18001:2007: Steel Foundry was awarded on 05.05.2015, valid upto 11.02.2021.

 CLASS-A CERTIFICATE- Steel Foundry/CLW has been certified as CLASS-‘A’ FOUNDRY by RDSO on 9th August 2012 vide RDSO Vendor No. 419 and the certificate is renewed on 27.07.2018.

 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.3PRODUCT RANGE 8A.3.1 STEEL CASTINGS: a. Grade of Steel: Steel Foundry Manufactures steel castings generally compliant with grades IS- 1030 and AAR-201. To meet the requirements of different products, Steel Foundry had earlier been processing eight different grade of metal. Steel Foundry has been successful in rationalizing the same to five grades only without affecting any metallurgical, chemical or physical properties. This has resulted in improving productivity.

b. Different grades of steel castings are as follows: Grade Composition in Percentage Carbon Manganese Sulpher Phosphorus Silicon (Max.) (Max) (Max) Grade – I 0.22-0.26 0.08-1.00 0.025 0.025 0.50 Grade – II 0.18-0.22 0.70-0.90 0.040 0.040 0.50 Grade - III 0.20-0.32 1.40-1.85 0.030 0.030 0.065

c. Different Grades of steel castings products are as follows: Grade Products Grade-I Flexi Coil Bogie, Flexi Coil Bolster, RIC Bogie, GM Bogie, Casnub Side Frame, Casnub Bolster, Casnub Pivot, MG Bogie &Striker Casting. Grade-II Tower Wheel, Suspension Tube, Rajdhani Centre Pivot, GM Bogie, Suspension Tube (DCW), Centre Pivot (DLW), Hitachi Tube, Commutator Spider, Bearing Bracket (PE &CE), Rotor Clamp. Grade-E Knuckle, Yoke, Coupler body for Wagon & Loco.

8A.4 Product Mix of Steel Foundry 8A.4.1 Loco Items ITEMS UNIT WEIGHT  Flexi Coil Bogie for WAP-4 Loco 4.370 MT  Flexi Coil Bolster for WAP-4 Loco 1.720 MT  Co-Co Bogie BG for WAG-5 & WDM-2 Loco 4.370 MT  Suspension Tube for Hitachi TM 0.273 MT  Suspension Tube for 3Phase TM 0.435 MT  Rotor Clamp for Hitachi TM 0.043 MT  Commutator Spider for Hitachi TM 0.136 TM  Centre Pivot for WAP-4 Loco 5.000 MT  Ballast Block for IGBT Loco 5.500 MT  Ballast Weights for WAG-7 Loco 0.136 MT  Loco Coupler for Electric Loco 0.335 MT  Striker castings for Electric Loco 0.150 MT 8A.4.2 Wagon Items  Casnub Bogie for BOXNHL Wagons 2.250 MT  Casnub Bolster for 22HS/BOXNHL wagons 0.624 MT  Casnub Side Frame 22HS/BOXNHL wagons 0.436 MT  Bogie Centre Pivot Top 22HS/BOXNHL wagons 0.057 MT  Bogie Centre Pivot Bottom 22HS/BOXNHL wagons 0.061 MT 8A.4.3 C.B. Coupler (Wagon) Items  Knuckle for CB Coupler 0.039 MT  Coupler Body for CB Coupler 0.167 MT  Yoke for CB Coupler 0.094 MT  Striker Castings for CB Coupler 0.150 MT

8A.4.4 Spares to Zonal Railways  Suspension Tube for WDM-3D Loco 0.275 MT  Wheel for Tower Car 0.450 MT  Wheel for Power Car 0.300 MT  NG Wheel for DHR 0.115 MT  NG Wheel for Gwalior 0.140 MT  NG Wheel for Kalka 0.170 MT 8A.5 Outturn Performance 8A.5.1 Cast Outturn: Description Annual Target Cum. Actual upto March - 2020 Cast in MT 2755 MT 3088 MT

8A.5.2 Supply Position: Description Annual Target Cum. Actual upto Mar-2020 Supply (in MT) 2755 MT 3398 MT

8A.6 Production & Supply of Important Items: 8A.6.1 Casting Target & Achievement 2019-20 SN Item Target (Nos) Achievement ( Nos.) 01 Balalst Block IGBT 1240 nos. 1603 nos. 02 Casnub Side Frame 600 nos. 148 nos. 03 Casnub Bolster 300 nos. 79 nos. 04 NG Wheel for DHR/NFR 100 nos. 119 nos.

8A.7.2 Supply Target and Achievements 2019-20 SN Item Target Achievements 01 Ballast Block IGBT 1240 Nos. 1496 Nos. 02 Casnub Bogie 300 Sets. 230 Nos. 03 NG Wheel for DHR/NFR 100 Nos. 87 Nos. 04 NG Wheel for NCR/Gwalior 100 Nos. 64 Nos. 05 FC Bogie - 02 Nos. 06 Tower Wheel - 16 Nos.

8A.6.3 Fabricated items for CLW Loco Works (2019-20) Description Target Despatch in 2019-20 Side Sill TG/TPP 48 Loco Sets. 17 Loco Sets. Casnub Dummy Bogie (TG/TPP) NIL 04 Loco Sets. Centre Sill 36 Loco Sets. 08 Loco Sets. Cab Sill 48 Loco Sets. 28 Loco Sets. Head Stock 24 Loco Sets. 22.5 Loco Sets.

8A.8 8A.8.1 Action taken to ensure Safety 2019-20 Plant Safety Inspection carried out at fettling Shop (25.04.19 &26.04.19), PRS/SF (16.07.19), Sand Plant (12.07.19), Moulding shop Bay – 10 (22.06.19 & 09.08.19) MTS/SF (21.08.19), Pattern Shop (26.04.19, 20.05.19 & 14.11.19), Melting Shop /SF (22.05.19, 14.11.19) Moulding Shop/SF (17.11.19) Core Shop/SF (12.06.19, 14.12.19). a. Safety Posters has been displayed to increase safety awareness among the staff of SF/CLW/CRJ regarding COVID-19. b. Stack emission test carried out on 12.12.19 and Test Report received on 12.12.19 from Asst. Environment Engineer, WBPCB/ASN to check the pollution level which was found within permissible limit. c. Departmental Safety Committee meeting was held on 24.05.2019 & 27.01.2020 in the meeting room of SF and discussed about different safety aspect of SF/CLW. d. General Health Check up of the staff of SF started from 21.02.20.Total 413 staff attended the programme, Check up of Defaulter Staff done 14.03.2020. e. In January 2020 safety calendar has been distributed to all Offices of SF to increase Safety Awareness. f. International ‘YOGA DAY’ observed at Steel Foundry office of SF to increase Safety Awareness. g. Accident Prevention Committee meeting Held on 07.06.2019, 25.10.2019 & 27.02.2020 in CME/SF Chamber. h. Safety Posters has been displaced at important places. i. Work zone envornmental monitoring of SF/CLW by outside agencies was carried from 24.12.19 to 25.12.19 report received on 11.01.2020.

STAFF POSITION

9. STAFF BREAK UP

STAFF BREAK UP DEPARTMENT WISE Gr. C & D (AS ON 31.03.20) DEPARTMENT SANCTIONED STAFF ON ROLL VACANCY STRENGTH ACCOUNTS GROUP –C 460 251 209 GROUP –D 51 45 06 Total 511 296 215 ADMINISTRATION GROUP –C 580 505 75 GROUP –D 251 164 87 Total 831 669 162 CIVIL GROUP –C 311 233 78 GROUP –D 495 385 110 Total 806 618 188

ELECTRICAL

GROUP –C 2573 1921 652

GROUP –D 455 507 -52 Total 3028 2428 600 MECHANICAL GROUP –C 5415 4077 1338 GROUP –D 1036 955 81 Total 6451 5032 1419 MEDICAL GROUP –C 143 113 30 GROUP –D 275 199 76 Total 418 312 106 PERSONNEL GROUP –C 299 266 33 GROUP –D - - - Total 299 266 33 SECURITY GROUP –C 498 412 86 GROUP –D - - - Total 498 412 86 S & T GROUP –C 33 18 15 GROUP –D 12 14 -2 Total 45 32 13 STORES GROUP –C 602 342 260 GROUP –D 356 243 113 Total 958 585 373 TOTAL GROUP - C 10914 8138 2776 GROUP - D 2931 2512 419 GRAND TOTAL 13845 10650 3195

10 UNIT COST OF THE PRODUCT

10. UNIT COST OF THE PRODUCTS (Figures in thousands of Rs.) a. Financial Year 2016-17

Pro. Total(in Type of Direct Direct Total(ex. & Total Over ED Char pro.charg Loco Labour Materials heads Pro. Chgs.) (in.ED) ges es) 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 b. Financial Year 2017-18

Pro. Total(in Type of Direct Direct Total(ex. & Total Over GST Char pro.charg Loco Labour Materials heads Pro. Chgs.) (in.ED) ges es) WAG -9 4120 90147 12974 107241 5359 112600 733 113333 WAP-7* 7994 99021 23557 130572 6528 137100 1026 138126 WAP-7** 7994 86050 23290 117334 5866 123200 964 125615 WAP-5 9507 91322 27456 128285 6415 134700 1082 134750 c. Financial Year 2018-19

Total(ex. Total Pro. Total Type of Direct Direct Over Adjustment GST & GST (includi Charge (includingpr Loco Labour Materials heads of ITC Pro. Chgs.) ng .GST s o.charges) WAG -9 4607 85032 14187 -4944 98882 4944 103826 675 104501 WAP-7* 7198 99807 21501 -6119 122387 6119 128506 964 129470 WAP-7** 7198 84238 21190 -5363 107263 5363 112626 878 113504 WAP-5 8148 91813 23916 -5899 117978 5899 123877 991 124868

* With Hotel Load Converter ** Without Hotel Load Converter d. Financial Year 2019-20

Types of Loco Direct Labour Direct Materials Overheads Pro-forma Total Charges WAG-9 5248 78282 15178 267 98975 WAP-7 9357 93520 26483 970 130330 WAP-5 5572 87531 16168 929 110200

INDUSTRIAL SAFETY

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: Safety Department of loco works have carried out the following activities to ensure safety in the work shop area and to fulfill the objectives of zero accident during working hours.

01. All shops and work sites are regularly inspected through “plant safety inspection”. All plants using inflammable substance like Acetylene and LPG etc. are inspected regularly and plant maintenance operation units follow fire proof working procedure 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 proof area as “ NO SMOKING ZONE” Rigorous training of staff by the fire inspectors, demonstration of fire fighting equipments at work sites. Regularly re-filling /checking of the fire extinguisher are being followed for valuable zones. All accident dangerous occurrence are investigated and remedial measure are suggested to prevent recurrence of such incident. It is to be mentioned that licence has been obtained for storage of liquid Oxygen from PESO ( Petroleum and Explosive safety Organization ).

In 2019-20 plant safety inspection of GSD area of stores was given a special focus. A joint 04 inspection by senior Officer was also conducted on 25.02.2020 in GSD area and remedial measures have been suggested / recommended to encounter any fire incident in future because the area is vulnerable.

02. Regular check is conducted at shop floor regarding use personal protective equipment like Safety shoes, Safety Helmets, Safety Goggles, and Nose Mask etc. Staff are continuously motivated to wear PPEs and also apprised adverse consequence associated with non-use of such equipments. All sorts of PPEs procured mostly as stock items and some through non-stock indent have been provided to staff in adequate number.

In this regard safety awareness camping is organized regularly in different shop by the safety department. In 2019-20, 53 Nos. of such seminar awareness campaign has been organized in which 1140 nos. of employees (approx) participated.

The workers and supervisors have also been made aware of the legal provision existing under factories Act’1948 for not using personal protective equipment. Under Section 111(1)C and 111(2) of factories Act’1048 the employee not using safety gadgets PPEs provided by the administration are liable to be prosecuted. The contravention of the section leads to fine of Rs.e100/- or imprisonment for 03 months or with both. The contractors have also been issued caution notice to provide PPEs to the contract labourers like safety shoes, helmets and full body harness and also to use safety nets while working at height.

03. A proper vigil is regularly maintained to determine whether all critical equipment like crane , chain, pressure vessel etc. are tested as per statutory rules ( under section 29 and section 31 of Factories Act’1948) 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.

04. Crane Drivers, Rigger, staff engaged for spray painting, foundry work, Operation and signaling to the Crane etc. are given regular medical checkup of eye. Normal health checkup is also conducted at regular intervals for ascertaining the medical parameters such as B.P, Blood sugar and weight of the employee. About 4000 staff check-up have undergone health check-up till March -2020 in the year 2019-20.

05. Poster and safety calendars containing safety slogan procured by Safety department are displayed at shop floor for safety awareness among the workers. Training is also imparted to the supervisors and staff in Technical Training Centre of CLW in the course modules MS-015/A and MS-015 respectively pertaining to safety. As per the Course content /syllabus prescribed, the supervisors are made aware of important provisions laid down in Factories Act’1948 pertaining to safety, health and welfare Technical Training Centre.

In compliance to section 41(G) of Factories Act 1948 and Rule 63(C) of west Bengal Factories Rules 1958 there is an Apex body in CLW for safety. The body is called Accident prevention Committee (APC) comprising of elected representatives from the staff and nominated members (Officers) from the side of administration. APC meeting under the chairmanship of CME/LOCO is conducted once in a quarter where various issues pertaining to safety is discussed and action is taken thereafter.

06. In 2019-20 special emphasis given on dissemination of information to all levels of staff regarding Disaster Management plan of CLW which is a comprehensive one. This plan includes both On-site and Off-site Emergency plan (The disasters identified are Fire, Flood, Earthquake, wild animals staying and terrorist activity). With the initiative of safety department a small seminar was conducted on 27.02.2020 in the shop floor. Where a power point presentation was exhibited regarding the Disaster Management plan of CLW in brief, the roles and responsibilities of various departments were discussed. The objective was that the information should percolate to the bottom most level of the hierarchy.

Accidental statistic during the following periods 2015-16,2016-17,2017-18, 2018-19 and 2019-20 (as on 31.03.2020)

Sl Year No. of Accident Type of Injury no. Fatal Serious Minor 1 2015-16 01 - 01 - 2 2016-17 03 - 03 - 3 2017-18 04 01 02 01 4 2018-19 03 - 02 01 5 2019-20 01 - - 01 (as on31.03.2020)

FUTURE PLANS

12. Future Plans

Medical

 MOU signed between CRIS and CLW for implementing HMIS system in K.G. Hospital/CLW at an estimated cost of `2,48,66,674.00(Rupees Two crores forty eight lakhs sixty six thousand six hundred seventy four)only, including development of the software, procurement, supply, installation and commissioning of the hardware and software for execution of the work of “Commissioning, implementing of Hospital Management Information System(HMIS)” for Indian Railways of 2,49,47,415.00 (Rupees Two Crores Forty nine lakhs thirty seven thousand four hundred fifteen)only.

Chemist & Metallurgist Lab

 Procurement of Nephelo Turbidity Meter will be processed in the upcoming days.  Procurement of different types of Probes and Cables is under process.

OTHER ISSUES

13. Other issues

1.31 Medical  World health day was celebrated on the 7th of April 2019. This year the theme was “Universal Health coverage everyone everywhere”. On this occasion a seminar was organized at the Seminar hall.  World Tobacco day was organized on 31st May 2019 at ELS-19. Dr. T.S. Sangeet deliberated on the topic of “tobacco and lung health”. An audio visual presentation was also conducted. Elaborate posters on awareness about hazards of Tobacco were displayed at all the prominent places of the workshop, which means nearly 80% of the CLW’s man-force.  World Blood Donor day was celebrated on 14th June 2019. A voluntary Blood donation camp was organized. The Medical Officers deliberated on the subject for safe blood for all. They emphasized that Blood is an important resource, both for planned treatments and urgent interventions. It helps patients suffering from life threatening conditions and supports complex medical and surgical procedures.  International Day of Yoga was observed in K.G. Hospital. PCMO with other Medical Officers, Paramedical Staff and Ministerial staff participated.  Doctors’ day was observed on 1st July, 2019, in which the Medical Officers renewed their Hippocratic Oath.  World Breast Feeding week was observed from 1st August to 7th August, 2019. Mothers of newly born babies and would be mothers were told about the importance of Breast feeding.  Swachchta Bharat Pakhwara was observed from 17.9.2019 to 2.10.2019. A number of programmes were organized to create awareness to keep the environment clean and to avoid using plastic. Jute Bags were distributed by the Honourable General Manager to encourage people to use Jute bags.  School health check up for the session 2019-20 has been completed during the month of August Sept. 2019.  Medical Examination of RPF and RPSF Jawans were completed for the first phase.  A seminar on awareness on World Arthritis Day (12th October) & World Osteoporosis day(20th Oct0ber) was conducted simultaneously on 16th October 2019 on its outgoing IEC and Health Education to Railway Employees.  Intensified Pulse Polio Immunization Programme (IPPI) was organized by K.G.Hospital as per National Polio Programme on 19.1.2020. Eight nos. of Booths were organized in Chittaranjan Township in which a total of 1088 Nos. of children were immunized with pulse polio out of which 624 children were of Railway employees and 464 children were non-Railway. The campaign was followed by Home visit by Bharat Scouts and Guides for next 2 days to cover the defaulters and to ensure 100% immunization.  A seminar on health education cum mass awareness programme on the pandemic COVID 19 was arranged on 19.3.2020. There was an audio visual presentation on the same. The Sr.DMO/Physician emphasized to learn about the disease, its symptoms, complications, transmission, prevention, treatment etc. All other doctors, Paramedical Staff, /Nursing staff and other staff of the Medical department were present on the occasion.  ALL HEALTH UNITS BEING MANNED BY INDIVIDUAL DOCTORS Each individual health unit is being manned by a Doctor, so that patients do not have to reach the Kasturba Gandhi hospital for Medical treatment. Hospital Management information system has been initiated in all the health units. This has reduced crowding at the hospital and the patients are finding it easier to reach their own area Health unit.

 PUBLIC HEALTH ACTIVITIES The Working of the Public Health Department has been decentralized paving the way to a better grievance redressal mechanism with optimum use of the Public Health Staff. Every doctor of the Health unit has a separate set of Public health Staff with a dedicated Health & Malaria Inspector for each Area. This has resulted in faster complaints being received and redressed at the earliest time possible

 DEVELOPMENT OF 90 BEDDED COVID 19 WARD The right wing of the Kasturba Gandhi Hospital/CLW has been converted into a 90 Bedded COVID 19 ward . The facilities available are:  Each bed has an individual Oxygen supply either through the pipeline or through Oxygen Cylinders.  Amongst the 90 beds 16 are ICU beds .  Presently we have 4 ventilators and 8 more are expected to arrive.  All the beds are connected through a Central pipeline supply and have Cariac monitors.  We have sample testing in collaboration with the West Bengal State Government and Dr. Lal Path lab at CGHS approved rates  We have a separate kitchen & laundry system for the Covid wing  We have adequate numbers of PPE, Coveral & N-95 mask.

13.2 Electrical Maintenance Important Work Done :-  Commissioning of 4.24 MW Rooftop solar plant at shop floor.  Commissioning of 1 MW Rooftop Solar plant on service building.  CLW achieved National Energy Efficiency Award Conducted by BEE.  Air conditioning system at cable Harnessing and panel manufacturing section of shop – 19 has been completed.  88 nos. day light has been provided at ELA shop.  Two nos. package sub- station have been commissioned at Main shop.  Energy efficiency LED lights have been provided in all occupied railway residential quarters.  Wiring of 274 nos. newly constructed Type – II quarters in CLW.  Rewiring of 256 nos. residential quarters.  Installation of Astronomical Timer based switch for street light of township.  Green Building Certificate of Admin. Building ( West Block ).  Commissioning of elevator at Admin Building.  Replacement of HT Overhead line in to underground system in the northern ring over CLW Township.  Commissioning of 02 body Mortuary Machine at K.G. hospital.  Power supply system with UPS backup and new AC machine have been commissioned at new Dialysis Centre at KGH.  One no. High Mast installed at Children park.

Special Achievements:-  100% LED Lights Provided in all occupied Railway residential quarters of CLW/Chittaranjan.  4.24 MW (P) rooftop solar power plant has been commissioned in CLW work shop.  Installation of 88 nos. Day light system in CLW work shop.  100% street lights are now LED based.  100% Office Lights are now LED based.  16 nos. Split AC installed with environmental friendly gas R-290.  Reduction of no of maintenance complaints by 3% with respect to previous year.  Green Building Certification for GM Administration Building (West Block).  100% LED Light fitted in all service Building & Street Poles.  100% LED Lights has been fitted in 40% residential Rly. Qrs. At CLW/Chittaranjan.