South Central Railway
Carriage Workshop Lallaguda
Brochure - 2020
1.0 General
1.1 संक्षिप्तइक्षिहास Brief History:
The Carriage Workshop / Lallaguda was established in 1893 as the Locomotive, Carriage and Wagon Workshop of the Nizam State Railway (NSR). The Government of Hyderabad took over direct control of the Railways in 1930 and renamed it as the Nizam Guaranteed State Railways (NGSR).
It is one of the oldest surviving examples of modern Industrial Architecture in the Twin Cities. It signaled the beginning of major industry in the state. A few structures in use today date from the time of the workshop’s initial commissioning.
The precinct provides us with a glimpse of not only the industrial advances made over more than a century but is also a repository of heritages from a bygone era. Restored wagons, coaches and a variety of artifacts relating to railway history have been preserved and quite a few are displayed at the site. Notable among these one finds a meticulously restored coach of 1886 vintage.
South Central Railway was carved out on 2nd October 1966, and Lallaguda Workshop went on to become a major workshop of the zone. It continued to be a composite workshop for MG/BG rolling stock till 1973. As a result of phasing out of steam locos, the Workshop took up POH of all types of BG coaches and hence rechristened as “Carriage Workshop” during 1997.
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1.2 प्रमुखउपलक्षधियां Major milestones:
1893 Established as Loco, Carriage and Wagon workshops under “NIZAM’S GUARANTEED STATE RAILWAY”. 1951 Brought under Central Railway. 1966 Carved out as South Central Railway. 1975 POH of BG steam cranes. 1981 POH of AC coach. 1997 Rechristened as CARRIAGE WORKSHOP. 2000 Awarded ISO-9002: 1994 Certification. 2003 Commenced POH of DHMUs trailer cars. 2006 Commenced POH of EMU TCs and Tower wagons. 2007 Awarded ISO-9001: 2000 Certification. 2007 Commenced 18 months POH. 2008 Commenced IOH of bogies (9 months). 2009 Commenced Refurbishment of coaches. 2009 Commenced modernization of workshop (from Nov’09). 2011 Commenced POH of power cars of DHMU and DEMU. 2012 Awarded ISO 9001:2008 Certification. 2012 Commenced LHB Coach SS1 Schedule. 2013 Commenced LHB Coach SS2 Schedule. 2015 Commenced POH of EMU & MEMU Motor coach. 2015 Commenced SS1 of Double Decker coaches. 2015 Implemented WISE-II. 2016 Commencement of LHB Coach SS3 Schedule. 2016 Implemented IPAS. 2016 Accredited with 5S Workplace Management System (WMS). 2016 Accredited with IMS, Containing QMS (ISO 9001:2015); EMS (ISO 14001:2015); OSHAS (180001:2007) & EnMS (ISO 50001:2011). 2017 Awarded Green-Co Silver Rating by CII/Hyderabad. 2017 Accreditation of NABL certificate to CMT Laboratory. 2017 Received best innovation award for “Automated single car test rig”. 2018 Received Railway Minister Shield (sharing) for “Best Workshop over IR”. 2019 Received “Best Establishment Award” for imparting training to 550 Trade Apprentices for the year 2018-19. 2019 Received “Gold Prize” for Energy conservation in 2018-19 from “Her Excellency Tamilisai Soundararjan , Honorable Governor of Telangana on 20-12-19. 2020 Received Certificate of “Best Energy Efficient unit” from Confederation of Indian Industry in August 2020.
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1.3 मु奍यक्षिशेषिाएं Salient features:
2. Total area of Workshop 13.97 hectares 3. Covered area 4.25 hectares Rail track length 8.25 kms 4. M&P 549 nos. 5. Railway quarters 584 nos. 6. WMS budget Grant 2020-21 Credits –322 Crores (Mech- 256.14 ; Elec – 65.86crores) Debits – 301.72crores (Mech – 240.67 ; Elec – 61.05)
7. Avg Monthly Target 2020-21 a) POH –133.64 VUs (RB) b) IOH of bogies – 230 nos c) IOH of Fiat Bogies (SS1)- 58 nos 8. Average power consumption/month 1.60 lakh units.(including Solar) 2020-21.
9. Manpower as on 01.01.2021. Sanctioned Actual Vacancies (Mech + Elec) 3256 2660 596
1.4 काययशालाकीिियमानगक्षिक्षिक्षियां Present activities of the Workshop:
• POH of AC & Non AC BG ICF/RCF/BEML coaches. • POH of LHB Coaches i.e. SS-II and SS-III schedules • POH of Duronto (Hybrid) coaches • POH of DEMU Power &Trailer cars & SPART coaches • POH of EMU/MEMU coaches • POH of Tower cars • IOH of ICF conventional bogies for divisions. • IOH of FIAT bogies for SS-I schedule of LHB coaches • POH of Defence owned coaches. • Supply of wheel sets to divisions. • Fitment of Bio-toilet tanks on coaches. • Over hauling of DVs, BMBCs & other air brake components for division. • Nodal workshop for implementation of WISE-II • Chemical and Metallurgical testing/analysis of components. • Manufacturing of all types of locomotive filters at LOFP/SC. • Rail Bogie Karkhana/Yadgir : Manufacturing of FIAT bogie frames • Basic Training Centre offers a) Refresher courses to Artisan Staff b) Imparting training to Apprentices engaged against Apprentice Act, 1961 c) Skill development programmes.
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1.5 संगठनचार्यOrganization chart: Sk. Salauddin AWM-I Sandeep Kumar
WM/LGDS G. Seshadri AWM-II Prashant Kumar Dy.CME/LGDS [Vacant] K. Krishna PE/LGDS Chaitanya AWM-III
N. Ganga Raju K. Srinivasa Rao Dy. CEE/LGDS ADEE
Ch. Eswaraiah K. Thavare Naik Prasun Chakraborty Dy. CMM SMM/M&E CWM
Y. V. S. Prakash Rao K.K. Subramani WAO AWAO
R. Papa Rao ACMT
S. Laxman Rao WPO
S. Rabindranath Sabar Sr.DEN S. Dakshna Murthy AEME/LOFP
S. V. S. Raju AWM/RBK/YG
B. S. Sarswati IPF/RPF
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1.6 लालागुडाकारखानेकालेआउर् Layout of LGD Workshop.
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1.7 प्रमाणनCertifications Achieved:
• 5S – Workplace Management System (WPS): 5S recertification done on Feb’20. Validity up to Feb’2023.
• Integrated Management System (IMS): (Four International standards). Awarded to M/s.IR Class/ Secunderabad on 31.05.2020. Agreement to be signed, delayed due to COVID-19 pandemic. Firm yet to respond.
• Green-Co rating system “Silver”Certificate awarded on 26.04.2017. Valid upto March’2020. Revaluation under process.
• ISO 3834 – 2: 2005: (Quality requirements for fusion Welding of metallic materials) Certificate awarded on 26.04.2017 and valid upto 25-4-2020. Agreement for recertifcation to be issued to Firm. Firm yet to respond.
• NABL Accreditation for CMT Lab: Certificate awarded on 06.10.2017 and recertified for another two years in Sept’19. Valid upto 5-10-2021
• LEAN SIX SIGMA Certification Certificate awarded on 30.01.2019 A one time certification.
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2.0 क्षनष्पादन Performance: 2.1 POH Outturn - Target/Actuals (VUs):
Target Actual Prop actual up to Oct'20
1669 1733 1734 1637 1583 1247 1331 1111 1111
2018-19 2019-20 2020-21 (up to Dec'20) Note: a)Target for 2020–21 is 1583 coaches as per HQrs and 1605 as per RB. b) In 20-21, actual outturn less due to lock down in April’20 and May’20.
2.2 Type wise outturn –last 3 years in (VUs) Type wise 2018-19 2019-20 2020-21 (up to Dec’20) Tar Actual Target Actual Annual HQ Annual Target Actual Target target as (upto (upto (RB) per arising Dec’20) Dec’20)
AC coaches 300 326 324 312 288 288 200 200 Non AC 1008 1019 1080 1085 996 994 739 739 LHB 44 53 45 44 108 86 45 45 EMU/MEMU 82 101 101 65 76 74 54 54 ( incl of PC) DEMU 97 97 175 216 194 60 60 ( incl of PC) SPART 220 09 09 04 17 13 05 05 ( incl of PC) Tower car 16 12 12 06 08 08 08 Total 1637 1669 1776 1734 1605 1583 1111 1111
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2.3 Outturn of Power cars: EMU/ DEMU SPART Year MEMU 2017-18 26 47 6 2018-19 21 37 3 2019-20 21 40 7 2020-21 54 60 5 (up to Dec)
2.4 Ineffective Avg. Holding of coaches:
Year Avg.holdings 2017-18 74.42 2018-19 79.98 2019-20 74.97 2020-21 57.39 (up to Dec)
2.5 Average Cycle Time (in working days):
18-19 19-20 20-21(up to Dec)
17.12 14.54 15.29 13.64 14.51 13.06 12.5 12.35 11.6 10.69 11.67 10.01 9.16 8.28 8.05
Non-AC AC LHB EMU DEMU
2.6 Average POH Cost/VU ( in Lakhs):
18-19 19-20 20-21 (Q.E.Dec'20) 23.15
19.15 18.95
14.32 14.52 13.93 12.14 11.27 11.79 12.18 9.91 10.81
Non-AC AC EMU DEMU
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2.7 Average NTXR initial advice (in % age):
17-18 18-19 19-20 20-21(up to Dec)
2.04 1.90 1.81
1.50 % Initial advise Initial %
17-18 18-19 19-20 20-21(up to Dec)
2.8 Fitment of New Bio-Toilet tanks (No.of tanks):
17-18 18-19 19-20 20-21 ( up to Dec) 2339
1525 tanks
920 No.of
20
17-18 18-19 19-20 20-21 ( up to Dec)
Note: Bio toilets have been provided on all eligible PCV coaches.
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2.9 Scrap Disposal (in MT) (Mech. + Elect.): in MT
Ferrous Non-Ferrous & others 6124 5003
1374 1315 593 337
18-19 19-20 2020-21(up to Dec)
2.10 Support to Divisions (in nos)
18-19 19-20 20-21 ( up to Dec)
2442 2460 2241 1953 1794
564 430 421 258 354 110 147
IOHed Bogie Fiat Bogies BMBC Wheels
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2.11 Important modifications undertaken on coaches:
S.N Item Cumulative so far (upto Dec’20) 1. Conversion from ‘P’ trap to ‘S’ trap 938 (no .of coaches) 2. Controlled discharge flushing valve for Bio toilet 2490 coaches 3. SLR coaches modified to bogie bracket and chain with 470 trunions block in hand brake arrangement. 4 Retro fitment of coaches with threaded joints in lieu of ferrule joints near cut off angle cock in the FP & BP pipe 735 arrangement of ICF conventional mainline coaches. 5 Coaches modified from single pack to BDG in CBC 158 coaches. ICF coaches. 6 LHB toilet side window modification - AC 72
7 Retrofitment of LED lights in TL & AC coaches 544 8 AC Coaches modified with WRA Mono block type 26 compressor type during this month to improve reliability 9 Provision of Exhaust fans in Bio Toilet AC coaches (each 194 coach consists of 04 No’s)
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3.0 उ配कृष्टिा का कᴂद्र Centre of excellence:
3.1 Air brake shop (2017-18):
Housekeeping Test benches
BMBC-Overhauling section Air brake shop sub stores
3.2 CBC shop
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3.3 Roller Bearing section:
Pneumatic Balancer for Pneumatic Balancer for
handling Axle Box handling roller bearing
Air Gauge to measure Inside Automatic Grease dispensing Diameter of Roller Bearing machine
3.4 Welding laboratory (BTC) (2019-20)
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Welding laboratory equipped with Digital intelligent microprocessor inverter digital intelligent microprocessor based synergic pulse MIG/MAG welding inverter based synergic pulse systemWith down draft fume extraction system MIG/MAG, and TIG welding systems.
3.5 RMPU Section (19-20)
RMPU - Layout AC-Stores
Dispatch section Motors Overhauling
Assembling section Cleaning section.
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4.0 Innovations
4.1 Innovations done by the Workshop in 2017-18
S.no. Description Photograph
Automatic single car test rig for LHB: Automatic Single Car Test Rig is used to perform Air Brake testing on LHB coaches to ensure proper functioning of Air Brake System. This testing procedure is generally done during the POH of LHB coaches or change of any Air Brake sub-assembly.The Automatic Single car test rig minimizes the time for testing, avoids human errors, and records the tested 1. parameters and stores the data in database. And it gives saving of 2 employees per shift and assures accuracy in the job.
Automatic Grease dispensing machine: Automatic filling of grease into the roller bearing 2. directly from the grease drum. Quantity to be filled is controlled by PLC embedded in the circuitry
Integrated Test Bench for WSP & brake equipment of LHB Coaches )Knorr Make: Integrated test bench with real time simulation of train speed, designed and developed in-house on 02-08-2017, is a replica of Complete Disc Brake 3. System of Knorr make fitted in LHB Coaches. This integrated test bench can check the functional test of complete disc brake equipment and WSP equipment of a LHB coach as a complete coach set.
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Air spring test stand: The Air Spring Test bench is developed to check any air leakages /rubber burst/ O-ring damages of the air bellow during POH. The Air bellow is tested with air 4. pressure of 10kg/Cm2. It helps in reducing the laborious work of finding out leakages/damages in air bellow, so that air bellow can be rectified or replaced with new spares
Automated Electro pneumatic Brake test stand. This EP brake system provided in EMU, DEMU, MEMU PCs is for brake application, works in conjunction of Electrical and pneumatic brake control 5. application
Hydraulic press fixture for Scragging of Draft Gear of Faively make Hydraulic press fixture for Scragging of Draft Gear developed in-house for scragging of draft gear equipment during POH repairs. The main features of the equipment is to compress the draft gear to 6. 430mm by using hydraulic press fixture and release the draft gear to 512mm,by releasing the hydraulic pressure. Recording serial number of assembly and corresponding period value for future reference.
Automatic Integrated test bench for Air Spring control equipment. Automatic Integrated test bench for Air Spring control equipment developed in house, for testing Air spring Levelling valve & Duplex valves which are 7. used for controlling secondary Air suspension of DEMU/EMU DPC and TC coaches. This test ensures quality of above valves for air suspension, before fitment on coach, thus ensuring coach reliability
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Horizontal Tensile Testing Machine for screw coupling and draw hook The software programming for horizontal tensile testing machine have the advantages of hydraulic power pack for controlling the pressures, 8. measurement of elongation to the respective load applied measurement of load, sensing of the pressures, auto cut off of hydraulic pressure item tested, recording of elongation, load applied, pressures, date tested and name of the staff tested with print out.
Sunk in type Hydraulic Jack commissioned: Sunk in type Hydraulic Jack commissioned at Corrosion shop to aid in precise lifting of coach 9. bodies during the corrosion repairs.
De-clamping and Re-clamping device De-clamping and Re-clamping device Commissioned for lifting and lowering of FIAT 10. bogie during POH of secondary suspension.
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4.2 Innovations done by the Workshop in 2018-19
S.no. Description Photograph
Pre-cleaning machine for Roller Bearing of Coach wheels: Pre-cleaning machine for roller bearing of wheels is developed In-house by Millwright staff of LGDS. It works on the centrifugal force, on rotating the roller bearing, an air pressure of 8kg/cm2 is 1. applied on the roller bearing. The grease on the roller bearing is thrown out of bearing. For manual cleaning of Roller bearing, it takes around 2 to 3 minutes/Roller bearing. By this machine, we can clean two roller bearing in 2 minutes; 15-20 sec for loading, 15-20 sec for unloading, 1 minute for cleaning.
Computerized Automatic DV test bench for testing Distributive valves of Faiveley make in LHB coach Distributor 2. Valve Testing is performed whenever during SS-II and SS-III of coach to ensure proper functioning Automatic DV test bench is utilised to test each distributor valve as per test procedure/parameters of OEM manuals Software on wheel shop Data recording system software on wheel shop Data recording system has been developed in house with various 3. parameters like Receipt of wheels, wheel tread profile, Roller bearing inspection, ultrasonic test of wheel assembly, Wheel and Axle press-in and press out particulars
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Exhaust Muffler Cleaner – DEMU Dust chamber for cleaning of exhaust mufflers, exhaust pipes and panel filters of DEMU 4. coaches is developed in-house at power car shed
Press-in and Press-out Fixture for Silent block of Control arm for FIAT Bogies
Special Team of LGDS Developed Press-in and Press-out Fixture for Silent block of Control arm for FIAT Bogies. Earlier, the 5. fixture available at LHB bogie section served the purpose of only press-in operation of silent block of Control arm of FIAT bogie. It was very challenging to press-out silent block from control arm. To overcome this problem, Fixture for press-in and press-out the silent block from control arm was developed in-house, which is very useful.
6. Primary Spring clamping & De-clamping machine- LHB Coaches
CBC functional test fixture A CBC functional test fixture was commissioned in the CBC shop which is inaugurated by PCME on 04-01-19. According to RDSO quality audit check 7. sheet, overhauled CBCs are to be checked for Functional test. This was demonstrated to PCME.
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4.3 Innovations done by the Workshop in 2019-20
S.no. Month Description Photograph
1. April’19 A Helical Spring muck cleaning machine: A Helical Spring muck cleaning machine:
i.Semi-automatic machine. ii.Fabricated in house. iii.Human effort has come down and effective. iv.4 springs are cleaned in one cycle i.e degreasing and cleaning in a cycle of 6 to 7 minutes.
2. Jun’19 A Kiosk was developed in house and installed in wheel shop for Self- learning: A Kiosk was developed in house and installed in wheel shop for Self-learning and Performance evaluation of Wheel & RB Sections. This enhances the technical knowledge of the workforce. 3. Aug’19 Automatic Grease Dispensing Unit : Automatic Grease Dispensing Unit for direct mounted roller bearings at both ends of wheel set simultaneously.
4. Aug’19 Development of Wheel Data Base Management System: A Wheel shop Data base management system was developed in house Details of roller bearings & axles mounted on wheels sets are computerized, thereby facilitating easy traceability
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Photograph S.no. Month Description
5. Aug’19 Kiosk for self-learning and performance evaluation application for welding training.`
6. Aug’19 Website of BTC under scr.indianrailways.gov.in
7. Aug’19 Centre of Excellence in RMPU.
Computerized RMPU cooling test facility.
8. Dec’19 CBC lifting gadget (500kg).
Facilitates lifting and transportation of CBCs.
9. Jan’20 LHB bogie work station with Manipulator for LHB coaches
LHB bogie work station with Manipulator for LHB coaches Disassembly and assembly of LHB bogie components by moving up/down and rotating the bogie frame to 1800 for attention.
10. Jan’20 Dynamic wheel balancing machine for LHB wheel sets.
It is Used for correction of unbalanced new LHB wheel sets.
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11. Jan’20 Industry 4.0 in roller bearing section.
▪ 9 machines connected against 11 ordered. Report generation under development. ▪ 2 machines under break down .i.e. One VTL and one AJTB.
12. Jan’20
LHB shock absorber testing machine Testing of yaw damper and other dampers of LHB coaches
13. Jan’20
Helical spring load deflection testing machine for LHB coaches
14. Jan’20 Computer Controlled Direct Reading Optical Emission Spectrometer for Analysis of Metal & Alloy Compositions
15. Jan’20
Computerized Universal Testing Machine (CUTM) a CMT Lab.
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4.4 Innovation during 2020-21
S.no. Month Description Photograph
1 July Testing gadget for DEMU ventilation pump - In order to ensure the proper functioning of the ventilation pump before fitment on coach, this test gadget was developed in house to test the performance of the pump. If any malfunction of the hydraulic motor is detected, it would be attended immediately. Grouping of new ‘C’ groove belts is also possible with this gadget 2 July Mobile test gadget for radiators/ heat exchangers. A Hydraulic mobile pressure testing gadget was fabricated in-house for testing of radiators and transmission oil heat exchangers. This mobile gadget has facilitated pressure testing of radiators and heat exchangers at site, which hitherto was not available 3 Oct Automatic thermal scanner cum sanitizer Dispenser machine was developed in an eye-catching robot shaped design and other sanitising machines of 10 nos. also provided for the use of staff.
4 Oct Virtual Welding Simulator is procured to impart virtual training at BTC to welders to experience efficient welding techniques on a simulation environment to feel a real welding process before attempting on a real welding machine.
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5 Nov Winch With Pulley Arrangement: this arrangement is developed at D1 & D2 lines in new DEMU shed for smooth movement and exact placement of coaches. This arrangement enhances safe working environment and also helps the staff in saving time.
6 Dec Laser Engraving Machine - It is used to engrave the POH date and Station on Roller bearing in standard pattern and all the data is stored in computer.
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5.0 Good Works 5.1 Good works done 2019-20
S.no Description Photograph
To reduce the gap between backrest in DEMU coaches. 1 • Modification is under trial. • Use of LP sheet to secure and fill-up the gap between two seats in DEMU coaches. Before After
Jute Felt on Corners of Berths: Providing Felt on side surfaces of seats and 2 berth metal frames to give cushioning effect at sides also. This will prevent tearing of rexine at sharp edges of seats and berth Frames
PVC Soft Sleeve: 3 Providing PVC soft sleeve for all berth chains which will give soft feel and aesthetic look
Spring pallets for handling LHB Springs: A new pallet has been made for transporting LHB Springs between shops and also to 4 prevent damage to them.
Rexine Moulding: Bed cum backrest, where staples were provided previously now is being provided with 5 a rexine moulding to prevent giving up of rexine and improve aesthetics
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Pasting Rexine before Stapling: Pasting rexine on back side of seats and 6 berths compreg sheet before securing with staples to give extra strength
Reducing the length of flap from 14 “ to 8” 7
Before After
TC Backrests provided with metal strip 8 back side to prevent rexine giving up
Fitment of Fire-Extinguisher: Workshop has started fitment by using bolt & nut instead of screws. Work started since 4-2- 9 20. Divisions are advised to watch the performance.Fitted in 112 coaches as on date.
Repair of Body Bolster at location away from 10 Centre pivot and side bearer of Coach No.12063
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Isolation coaches: One Isolation coach prototype (coach no.SC GSCN 00205) was made ready on 31-3-20 which was inspected by PCME on 31-3-20. The second Cabin at each end of the coach 11 i.e. 2 nos were converted for keeping COVID- 19 patients under isolation/ quarantine (Details at PPT enclosed).
A set of new synchronised lifting Jacks were collected from Jamalpur workshop These are utilised in corrosion shop line no.6 for facilitating lifting of coaches and keeping them on trestles for undertaking heavy corrosion. 12 Lowering of the coach on overhauled bogies is done here itself, thus avoiding multiple movements of coaches to Lift lower shop crossing the two traverser lines. This is found very helpful as it has reduced considerable time on shunting of coaches also.
A Central Railway coach no. CR LWCZ 18632 was received for special repairs. This was found with all the window frames missing. This was made good in addition to the Special repairs attended on the coach. A total of 9 nos 13 of new full body window frame arrangement were provided by taking material assistance from RCF.
Provision of 8 additional window bars at 2nd window from main doors in GSCN coaches is 15 ensured. Work commenced from May’19. 100 % provision ensured during POH.
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Improving bio toilet ventilation system to avoid bad odour
17
Exhaust bellow in 1600 HP DPC fitted in DPC 18 No. 15083. Designed and supplied by OEM as per LGDS advise
Exhaust Mufflers were getting cracked. Same were replaced in 6 DPCs duly claiming warranty and also made a trail of 19 Manufacturing exhaust muffler with available SS: 301 which is being used for trough floor manufacturing which was done in-house fabrication. Same was fitted in DPC No. 15083
Developed in-house.Eliminate the spreading 20 of dust during cleaning of Traction motor using pressurized air. Environment friendly
21 A safety ladder for coach Roof painting was developed in house
Corrosion Attentionof outer head stock in 2017 built ICF coaches: Five coaches (2017 built) which were received for first POH had corrosion of outer head stock 22 thickness below the permissioble level.these coaches ICF had sent representative for inspection.as the firms have not attended. LGDS has given strenghthing arrangement along with ribs for the head stock and turned them out with due intimation to ICF.
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13th International Railway Equipment exhibition (IREE) was held from 22.10.19 to 23 24.10.19 at AERO city/NDLS. This was led by Shri. Prasanth Kumar Dy.CME/LGDS along with Supervisors and staff were represented SCR for the exhibition. .
24 Inauguration of Bio toilet maintenance shed for POH on 07.06.2019 by PCME/SC.
A Contractors performance review meeting 25 was conducted on 16.05.2019
Mock Drills/Civil Defence Demo/Elect Shop Drill Demo by CR & SCR Civil Defence Team on-Rescue Management Fire 26 Fitting/First Aid &Evacuation from High-rise Buildings during Emergencies
World Environment Day was celebrated on 06/06/2019 Theme was ‘Air Pollution’. An awareness program was conducted on the 27 Causes & Effects of Air Pollution with an audio/visual presentation. Banners and posters were displayed across the workshop for spreading awareness
A water balance study was conducted in workshop through outside agency for the following: 28 1. Improve ground water level by rain harvesting pits at 5 locations. 2. Recycling of sewage water by means of constructing wet land of feasible capacity at low lying area.
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Cornicorpus plantation 29 Total plants: 200 nos were planted near Bio- tank Maintenance Shed.
Miyawaki plantation 30 Total Plants: 475 nos were planted near Sand Blasting Machine
31 Green toilets for women employees: • Developed In-house.
E-toilet as a part of Green-Co initiative is under commissioning • IT Enabled toilet. 32 • Automatic self-cleaning, washing/flushing mechanism. • Procured through GeM. • Water tank Capacity: 225 Ltrs
Model toilet. Sensor based flushing system for toilets. 33 Proper Ventilation and Natural light is developed to reduce energy consumption.
Effluent Treatment Plant (ETP). Power car shop-20KL/day. For treating the effluents released from Cleaning of Power car components and 34 cleaning of IOH bogie frames Wheel shop-10KL/day. For treating the effluents released from Roller Bearing Cleaning Plant.And also, Effluents released from nearby Shops are diverted to these ETPs for treatment.
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“BEST ESTABLISHMENT AWARD” was
given to BTC/Lallaguda by Sri.Ch Malla Reddy, Hon’ble Minister for labour, 35 Employment, Women & Child Development Government of Telangana for imparting training to 550 Trade Apprentices for the year 2018-19 on 15.10.19.
“JOHN MORRIS FIRE ENGINE-1914 built” has won the “53rd Statesman Vintage and Classic car rally” held at Delhi on 10th Feb’2019. The Fire Engine is maintained by LGDS staff at NRM/NDLS. 36
Buffing of all stainless steel items like wash basins, toilet pans & wall protectors are carried out to improve aesthetics 37
To improve general appearance of berth upholstery fitment:Stiff and tight fitment ensured. Jute felt along the corners provided Double stitching of rexine to avoid wrinkles. 38
Window curtains are stitched with six frills and twelve rings to maintain uniform height when hung so as to avoid sunlight ingress, and 39 when curtain is closed it enormously improved the internal aesthetics in POH of AC coaches. 229 coaches provided in current year
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Provision of Emergency lights: All AC coaches are provided with LED emergency lights and in all non-AC coaches 40 with more than 10 years residual life have been provided with emergency lights.
Provision of mobile charging sockets: All AC and CN coaches are provided with mobile charging facility. As per the directives 41 of Railway Board, CN, GS, CZ & SLR coaches are provided with 18 mobile charging sockets.
Berth Indication Light & Night Lamp: All AC coaches are provided with berth indication light & night lamp for easy 42 identification of bay and berth. All coaches are provided with 100% LED night lights
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5.2 Good work done during 2020-21
S.No. Month Description Photograph 1 Isolation coaches: 76 coaches were converted to COVID-19 Isolation wards as per Railway Board instructions during April & May’20. The second Cabin at each end of the coach i.e. 2 nos were converted for keeping COVID- 19 patients under isolation. One toilet was converted to bath room at one end. Middle berths were removed.
2 2000 nos of Coverall were
manufactured and supplied to Central Hospital / LGDS on 20-5- 20 as part of PPE manufacture for COVID-19 pandemic.
3 17295 face masks were manufactured and distributed to HQrs, Divisions and LGDS staff.
4 Project Utkristh phase II 202-21: • Target 23 rakes. • 14 Rakes turned out.(upto Dec’20) • Bal – 9 rakes
5. May’20 Coach No. SC VPH 99843 of Train No. 07258 special express of HYB Division was taken for special repairs “Near Body sole bar crack at SC End Trolley” at LGDS in view of demand for parcel vans for transportation of essentials during lockdown period
6. May’20 LGDS has taken a step forward for welfare of contract staff by providing groceries during COVID-19 pandemic crisis. Staff of LGDS contributed voluntarily an amount of
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Rs 1,17,000/- . Groceries i.e. Wheat powder, Tur Dal, Sugar, Upma rava, Tea powder, Tooth paste, Toilet soap, Vim liquid, Rin washing powder were packed in suitable bags and then distributed to 252 contract staff at the canteen on 30- 5-20.
37. Aug’20 LGDS secured “Energy efficient Unit award” at 21st CII National award for Excellence in Energy Management 2020: Virtual event held on 25th-28th Aug 2020.
8. Aug’20 First e-pass issued through HRMS by the Workshop on 27-8-20.
9. Sept’20 Mass covid-19 RT-PCR testing was organized for employees of LGDS, EWS/LGD, Scrap depot & FBWP/Mly at New Car parking area of the workshop from 22.09.2020 to 26.09.2020. All staff, supervisors and officers had undergone the testing at the centre. A total of 3300 staff have undergone the COVID test. 151 staff of LGDS have been tested positive. These staff have been advised to consult the Four nominated Doctors of Railway Hospital / LGD for further treatment.
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10. Sept’20 Thavare Naik Karmathota, SMM/M&E/LGD has been GOLD CERTIFIED for completing the online assessment that covered ADVANCED functionality of the Government e-Marketplace (GeM) portal.
11. Nov’20 As per Railway Board instructions vide lr.no.2002/M©/137/7 dt.07.10.2020, LGDS planned to convert four VPRs into NMGs. In this regard one VPR is converted into VPU and shop out done on 30.11.2020.
12. Dec’20 As per modification the material required and operation involved was managed in –house to complete the modification job. By implementing lock pin arrangement on Dellner Coupler, lock lift safety can be ensured.
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5.3 क्षडधबⴂमᴂसंरिासुक्षनक्षििकरनेकीप्रणाली Systems to ensure safety in coaches:
Grit blasting of bogies are undertaken to clean the bogies to the bare metal to detect damages/cracks, if any.
Cleaned bogies after grit blasting are subjected to chalk testing to detect damage/cracks in bogies. About 8.0 % is the rejection.
Tests on springs: Springs are subjected to shot blasting for thorough cleaning and detection of crack followed by Magna-flux test to detect sub- crack, if any and finally tested for tensile strength on computerized Shot blasting for MAGNAFLUX Computeri thorough testing to detect zed load load testing machine. cleaning sub cracks testing
Digital bore gauge for measuring bore of Wheel disc: Digital bore gauge is used to accurately measure the bore diameters of Wheel discs
Zyglow& DPT tests of critical components: Axle box, LHB brake discs, bogie frames & roller bearings are subjected to Zyglow & DPT tests to detect cracks.
Overhauling and testing of Alarm- chain: Alarm chain setting is certified by NTXR for all the coaches under POH.
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6.0 स्िचालनप्रक्रियािीन Automation under process.
S.No Innovations Details 1. Industry 4.0 • Being installed by M/s Parivartan Automation – RaiBareli UP. • Total 11 machines are covered. 2. LHB Manipulator. Machine commissioned on 29.07.2020
3. Automation of • Ultra-Model Facilities at Spring Shop (Centre of Spring shop Excellence of Spring Shop): o Load deflection testing machine with lateral measurement for flexi coil springs o Renovation of existing conveyor system of springs shop proposed under umbrella works o Automation of Spring Testing Machine o Magnetic Crack detector for coil spring for LHB coaches 4 Integrated Station o Umbrella Works 2019-20 sanction: Cost Rs. 15,15,25,000/- for LHB FIAT Bogie Assembly o Automation in working, inspection, record keeping & record and Disassembly transmission in workshops” for both Lallaguda &Tirupati workshops. Allocation for SC Rly under Umbrella Work PB No. 660 of 2020-21.
o Detailed Estimate vetted by unit finance for Rs. 15,39,83,895 and the same along with Technical specification/Scope of work is sent to HQRS on 09.10.2020 for onward submission to COFMOW for procurement
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7.0 एम&पी, काययऔरआिुक्षनकीकरण M&P, works & modernization:
7.1 Works Programme (2020-21): (Rs. in crores)
Expenditure
Expenditure Revised Grant 2020-21 Name of work & (upto 19-20) 2020-21 (Upto Sanctioned Cost 27.01.2021) LHB Shed (19.1crores) 7.16 3.03 1.7206 sanctioned : 12-13 Special Coaching Stock Shed (11.91crores) 2.03 2.32 1.4737 sanctioned : 12-13
7.2. Modernization: Objectives : a) Augmentation of POH capacity viz., from 100 to 120 coaches/month b) Improve the layout leading to decongestion of Workshop and c) Provide infrastructure for expansion activities.
(Rs. in Crores) Sanctioned Expenditure (Upto Departments Grant cost 27.01.2021) Civil 42.23 48.54 43.15 Mechanical 40.39 20.41 18.76 Electrical 8.23 7.89 9.40 S&T 0.69 0.70 0.21 Total 91.54 77.53 71.52
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7.3 Modernization works under Progress:
Description Cost Status of the work (lakhs) a) Location - Infront of existing Lift & Lower shop b) 31m X16.16 m covered shed completed. Laying of Surface track completed and pitline work Pre-inspection completed 163.35 shop c) For 34mx8m Shed completed and pit line work completed d) Final stage of completion e) PDC – Feb, 2021
7.4 Umbrella Works:
S.no. Name of Work and Sanction Year Sanc. Cost Status of Work Sanction of 2018-19 : Up gradation of Critical Work Centres of Rolling Stock Works Shops, PB No. 655 of 2020-21 Renovation of existing 2.26Cr Indent forwarded by conveyor system of spring HQRS to COFMOW on 1. shop at LGDS 15.06.2020. Specification under finalization at COFMOW Sanction of 2019-20: Up gradation/Improvement in Infrastructure and Augmentation of Maintenance and Manufacturing Capacity (PB No. 661 of 2020-21) Augmentation CCTV a) Specification and drawing surveillance system in LGD finalized at LGDS. b) Proposal for processing 1 shop 0.39Cr the work through works tender is with unit finance. c) Reply awaited. Bogie Frame Painting shed Detailed Estimate under vetting at unit finance 2 1.6Cr
Construction of new shed 3 2.0Cr Work dropped for stacking stores items Sanction of 2019-20: Automation in working, Inspection, record keeping and record transmission in
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workshops (PB No. 660 of 2020-21)
Integrated bogie assembly i. Item under procurement at line and disassembly line COFMOW. Draft COFMOW specification for item has been received for 1. comments/confirmation on 07.12.2020, the same is scrutinized and sent to COFMOW on 11.01.2021. 15.39 Cr Real time feeding and i. Item is returned by backup of shop level data COFMOW for with hand held devices procurement at LGDS. through mobile CRIS consent regarding 2. app/web/cloud this item has been received on 05.12.2020 and is under scrutiny at SSE/IT.
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8.0 गृह व्यिस्था Housekeeping:
03 (three) contracts exist for housekeeping: 1. Daily Housekeeping, Canteen Cleaning, Roads Cleaning, Toilets Cleaning and Scrap Disposal at nominated place at Carriage Workshop, Lallaguda, Secunderabad.
2. Collection, Segregation and disposal of Hazardous waste accumulation.
3. Disposal through sale of non-metallic scrap mixed with embedded metallic contents.
9.0 सामग्री प्रबंिन Material management:
i. Every year AACs are reviewed by three member committee of JAG grade officers comprising of Dy.CME, DY.CMM && DY.FA&CAO/WAO. S.No. Year Saving Achieved 1 2015-16 Rs. 99,69,064/- 2 2016-17 Rs. 7,18,71,106/ 3 2017-18 Rs. 1,55,75,642/- 4 2018-19 Rs 3,20,759/- increase in AAC value 5 2019-20 Rs 3,42,72,619/- 6 2020-21 Rs 2,10,60,097/-
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10.0 क्षिद्युि Electrical:
Dy. CEE/S/LGDS Electrical Department is assisted by ADEE to look after POH works of AC, TL, DEMU, EMU/MMTS Power cars, ART, SPART, SPIC, TRCs, Inspection carriages , etc.. and the Electrical Maintenance of Four workshops viz., CWS/LGD, EWS /LGD, FBWP/MLY and S&T Workshop /G&S/MFT and STC/SC.
10.1 Electrical energy consumption of CWS/LGD V/S Vehicle units (VUs):
S.No Description 2018-19 2019-20 2020-21 (up to Dec) 1. Electrical Energy 2257699 2367557 1441232 consumption(KWh) 2. Connected load(KW) 11996 11996 11996 3. VUs (Nos) 1804.4 1853 1222 4. Consumption/VUs 1251 1278 1179 (SEC)
10.2 Electrical Assets of LGDS:
S/No Workshop Capacity Qty 1 CMD 1000 KVA - 2 Major Sub-Stations(11KV) 3 3 Transformers 1000 KVA 6 4 DG sets 250 KVA 2 320 KVA 1 5 Solar Power Capacity 566.7 KWp 9 locations
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A. Solar Power plants installed at different locations:
Capacity Installed Units Remarks location generated till date 60 kWP CMT 152554 150 kWP Ward-7 365035 530 KW solar power plants 200 KWP Ward-11 424309 installed on 16.03.18 60 KWp ESTC 131844 60 Kwp ASB ward -9 157803 4 KWp A sub - station 25668 Commissioned on Nov -14 4.5 KWp RPF out post 17274 Commissioned on Sep-16 CMT/LGD roof 10 KWp 33719 Commissioned on18.04.17 top Main sub- 18.2 KWp 34840 Commissioned on 28.02.18 station TOTAL 1343046
A. Solar power generated 2019-20: 782190 KWH. (Average /month =65182.2units)
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10.3 Good works done (Electrical):
S No Description Photograph 01 Carriage Workshop Lallaguda received GoldPrize from Telangana State for Energy Conservation for the year 2019 from Honorable Governor of Telangana on 20.12.19:
02 Provision of energy meters for air compressors to monitor energy consumption pattern resulted energy Savings: 2180 units/month
03 Commissioning of ring main system resulted in savings of energy
Savings: 4365 units/month
04 Installation of Solar day light pipe system in M&E Stores and CMT lab
Savings: 1060 units/month
05 Installation of Solar Street lights with timers Savings: 650 units/month
06 Provision of Star rated BLDC fans resulted in 50% power saving.
07 Provision of Energy savers to all welding plants
Savings: 8500 units/month
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S No Description Photograph 08 1000LPD solar water heater at Canteen
Savings: 1500 units/month
09 Installation and commissioning of new Charge/Discharge Panel: for saving of power during testing of POHed/IOHed Alternators and RRUs/ERRUs. Earlier resistive loading arrangement was being used. New Smart Energy savers were installed on 22.06.2019. The units saved are 6199 (June 19-Dec,19)
10 Automated test bench for testing of RBCR, EBCR & SBCR: A new automated test bench for testing of RBCR, EBCR and SBCR of LBH AC coaches was procured and commissioned on 03.10.18 for testing the equipment as per the required parameters and the test results are compiled minute to minute and is saved in the in built computer. Till date 24 nos. of RBCRs, 135 nos. of EBCRs and 18 nos. of SBCRs have been tested on the panel since the date of commissioning
11 Fabrication and installation of new test bench for testing of ventilator fan motors: A new testing stand was developed for testing of various ventilation fan motors of EOG type Power Cars During POH
12 Provision of meta aramid fabric with silica rubber coating duct canvas in LHB coaches
13 Modified Anti-rotating clamps: To avoid the rotation of Suspension Hanger Pins of 25KW Alternators. It was developed by ER Shop/LGD and later approved by recently held MSG meeting as per drawing no. RDSO/PE/SK/AC/0164-2016 (Rev.1)
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S No Description Photograph 14 Belt transmission alignment tool: Axle Pulley to Alternator Pulley alignment is being tested using Belt transmission alignment tool during POH to avoid the dropping of V Belt.
15 Provision of 36mobile chargers in GS/CN/CZ coaches:
16 Retrofitment of LED Lights: LED lights are providing in place of CFL lights for better illumination and power saving.
17 Robotic Duct Cleaning of AC coaches: 134 Coaches are completed Upto Dec 2019
18 Testing and fixing of Axle pulleys of TL and AC Coaches with suitable gadgets.
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11.0 प्रक्षशिणिबीर्ीसीकीगक्षिक्षिक्षियां Training & BTC activities 11.1 Courses Conducted at BTC/LGDS: ▪ Refresher Course for Technicians ▪ Welder Gradation ▪ Welding Basic Course for Beginners ▪ TIG Welding for Artisans ▪ Selection of Welding Consumables ▪ Welding Power Sources and its Selection ▪ Stainless Steel Welding for Welders ▪ Induction to skilled (RRB & CG) ▪ Special Courses on LHB ▪ APP JE &SSE (RRB) ▪ Pre promotional courses for Group D to Group C staff and JE Ranker ▪ Safety awareness for contract employees. ▪ Project Saksham training. ▪ Act apprentice ▪ Apprentice Graduates & Diploma ▪ Skill Development Program (Internship Mini and Major projects for B.tech students) ▪ Seminars
11.2. Project Saksham: Concentrated Capsule of Training for All employees Vide letter no.M.673/Pers/TrgMtg/42 dated 26/04/2019.
Category Total STC BTC Completed Due
Technicians 1817 0 1817 1817 0
Supervisors 202 0 202 202 0
11.3. Capacity Utilization:
Year Total Trainee Total Trainee days % Utilization* capacity given
2017-18 36604 79863 218.18 2018-19 36704 136847 372.80 2019-20 32398 123169 380.17
2020-21 14472 57375 396.45 (up to Dec’20)
*Note Total trainee days given/ Total trainee days capacity x 100 is % utilization.
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11.4. Staff Training:
2019-20 S.No Courses 2018-19 20-21 (upto Dec)
1 Act Apprentices 871 550 267
2 Apprentice Graduates 1 0 402 3 Apprentice Diploma 6 0 0 Skilled Artisans 0 4 63 170 (W/S + Divn.) 5 Apprentice SSE’s & JE’s 32 48 11 Refresher Course for 25 6 293 509 Technicians 0 7 Promotional Courses - 40 Pre-Selection for JE rankers 0 8 14 0 25% quota Skill Development for Group- 493 9 1009 742 D staff Special Courses for shop 117 10 0 170 floor technicians Initial industrial training for 16 12 151 48 contract employees Seminars (DEMU, Vacuum 0 13 0 138 Toilet, Roller Bearing) TOTAL 2440 2415 1331
11.5. Gradation of welders
S.No Courses 2018-19 2019-2020
1 Welder Gradation 70 84
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11.6. Model Room
11.6.1. Existing Models
• Working Model of Twin Pipe Air Brake System with PEASD. • AC Emergency window of WGACCZ. • Demonstration model of LHB Bogie. • Working Model of BMBC For Demonstration. • BMBC Exploded View Model For Demonstration. • Bio Toilet Model For Demonstration. • ICF Wheel & Axel Model for Demonstration. • ‘H’ Type CBC Cut Model For Demonstration. • Shaku coupler • CTRB exploded view for demonstration. • Spherical Roller Bearing Exploded View For Demonstration. • EP Brake System Demonstration Model. • Vacuum bio toilet. • Different types of welding joints. • LHB coach miniature model. • Welding position demonstration model. • LHB bogie for demonstration.
11.6.2. Proposed Models A. Digital Models 3D Animation. • Working of Disc Brake and Wheel Slide Protection System of LHB Coach. • Working of Conventional Twin Pipe Air Brake System of ICF coach. • Working system of DEMU Diesel engine. • Working of Air spring suspension with FIBA device. • Working of electro pneumatic system. • Use of safety equipment in welding shop.
B. Physical Models • Exploded view of AXLE MOUNTED DISC BRAKE CYLINDER with acrylic enclosure and LED lighting. • Exploded view of BOGIE MOUNTED DISC BRAKE CYLINDER with acrylic enclosure and LED lighting. • Exploded view of C3W of ICF AND KEO OF LHB DISTRIBUTOR VALVES of coaches with acrylic enclosure and LED lighting. • WATER FILLING AND PLUMBING ARRANGEMENT OF AC AND NON-AC (ICF&LHB) coaches with Acrylic enclosure and LED lighting.
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12.0 औद्योक्षगकसंरिा Industrial safety:
12.1. No. of Accidents/IOD cases:
IOD Cases
2018 20192 2020 (upto Dec) 5
3
1
IOD Cases
12.2. Man days lost:
2018 2019 2020(up to Dec) 168 134.5
23
2018 2019 2020(up to Dec)
12.3. Steps taken to enhance safety of workmen:
● Ladders for EOT cranes - flat steps & ring cage provided. ● Rotating machinery parts -wire mesh guard / Fencing provided. ● Battery operated forklifts and trucks to control air pollution introduced. ● Periodic supply of soaps and cleaning agents (REINOL). ● Periodic supply of personal protective equipment. ● Safety jacket for shunting staff. ● Fire buckets with stands in all the shops. ● Safety nose mask during painting. ● Safety belt for working at heights. ● Safety mat at electrical mains.
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13.00 का셍मयक Personnel branch Organization:
13.1 Staff Strength (All Departments)
Department Sanction Actual Vacancy Mechanical (Sup, Artisans) 2419 2018 401 Electrical (Sup, Artisans, Group- D) 606 493 113 Total 3025 2511 514 CMT Staff 36 22 14 Personnel 63 54 9 Mechanical – Others (non-Personnel, Group-D, Drawing, canteen, computer 110 90 20 centre) Electrical- Others (non-Personnel, Group- 26 13 13 D, Drawing) Stores 121 92 29 Accounts 100 63 37 Engineering 28 7 21 Total others 484 341 143 Grand Total 3509 2852 657
13.2 Grievance redressal: Year Received Disposed Balance 17-18 39 39 0 18-19 81 81 0 19-20 26 26 0 20-21 No camp was conducted due to COVID-19
13.3 Health camps:
Sl Year Month No.of staff screened 1. July 2018 268 2. 2018-19 Aug 2018 1138 3. Oct’2018 36 4. June’ 2019 1279 2019-20 17.06.19 to 28.06.2019 5. 01.07.19 to 10.07.19 529 6 2020-21 No camp was conducted due to COVID-19
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14.0 कमयचारी क쥍याणstaff welfare amenities
•
RO plant 3000 Ltrs Scooter parking
Water coolers provided in each shop Subsidized canteen
Reservation terminal Ladies rest /change room in each shop
Gents rest /change room in each shop
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15.0 쥍यूबिेलक्र쥍र्रपलांर् Lube oil filter plant:
Brief History:
Lube Oil Filter Plant (LOFP) commissioned during 1978 and the 1st filter was manufactured on 17.05.1978. Till recently, LOPF was only one of its kind on Indian Railways for manufacture of “Pleated Paper Type Long Life Lube Oil”, Fuel Oil and EMD Filter Elements required for DLW/ALCO/GM type diesel locomotives of Indian Railways.
15.1 Staff position of Lube oil filter plant/ Secunderabad (As on 30.09.20) Sanc. Actual Vacancies. 1 Supervisors 02 02 - 2 Laboratory 02 02 -- 3 Ministerial 03 02 01 (Mech) 4 Liaison Inspector 01 01 -- 5 Technicians 18 17 01 6 Semi Skilled/ 22 08 14 Unskilled Total 48 32 16
Activities of the Plant:
● Manufacture and supply of Long Life Lube Oil, Fuel Oil and EMD Filters to Diesel sheds of Indian Railways as per RDSO Specifications. ● LOFP is equipped with laboratory with all the testing facilities required for testing filter paper, finished filters and other metallurgical properties of other components. ● Supply of filters to other than Indian Railways units like NTPC, IRCON, RITES etc. for diesel Locos operated for their sidings.
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● 100% requirement of Long Life Lube oil filters & Low mean-pore size fuel oil filters like Large Primary, Large Secondary, Conventional Primary and Conventional Secondary for Indian Railways are being met by LOFP/SC. ● Manufacturing of 10” X 30” Long Life Lube Oil/Fuel Oil for EMD Locomotives commenced in January, 2011. As per Railway Board directives, 2/3rd requirement of EMD filters to be met by LOFP/SC.
15.2 Performance (Targets and Achievements):
2018-19 2019-20 20-21 Target Actual Type/Year Target Target Actual Actual 2020- (upto (Rly Bd.) (Rly Bd.) 21 Sept-20) 122 Days Lube Oil 49417 47338 50000 43671 22482 13700 filter EMD Filters 10000 11582 16000 11908 11961 9950 Large Primary 3200 2953 4000 3396 2178 538 (Fuel Oil) Large Secondary 3200 2921 3700 2764 747 0 (Fuel Oil) Conventional 11789 12455 8000 5116 0 0 Primary (Fuel Oil) Conventional Secondary (Fuel 9000 10024 6000 3948 0 50 Oil) 86606 87273 87700 70803 37368 24238
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16.0 रेल बोगी कारखानाRAIL BOGIE KARKHANA, YADGIR:
(Under Administrative control of CWM/LGD) 16.1 Introduction: Railway Board has taken a decision to completely switch over to LHB coaches to ensure safe travel and higher passenger capacity with operating speed up to 160 km/hr. With the change in Scenario Railway Board sanctioned two projects for manufacture of Fiat Bogie frames at Budge Budge & Yadgir. The Plant is headed by an AWM.
S.No Category Staff on Roll 1 Supervisors 05 2 Artisans 20 Total 25
16.2 Salient Features of Rail Bogie Karkhana, Yadgir:
➢ Year of Sanction : 2013-14 ➢ Executing Agency : RVNL ➢ Sanctioned Cost : Rs. 75 Cr. ➢ Detailed Estimate cost : Rs. 80.92 Cr. ➢ Capacity : 600 FIAT Bogie Frames per annum ➢ Land : Located near Yadgir in Karnataka ➢ Inauguration of unit : On 18th August 2017.
16.3 Status of Production:
Sl Item Status 1 No. of Bogies made ready till Dec ’20 1171 2 No. of bogies dispatched 1104 3 Bogies ready at RBK for dispatch as on 70 29.01.2021 4 From August-2019 RBK has switched over 510 to manufacture of ASR Bogie frames (ASR Bogies have been suitable for Air Spring in Secondary completed. Suspension. till Dec’20)
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16.4 Year wise fabrication & Machining: (Target 20-21 : Fabrication 500 Nos. Machining 500 Nos.) In nos. Year Fabrication Machining Despatched 17-18 138 91 83 18-19 385 379 322 19-20 343 405 411 20-21 285 276 294 (upto Jan-2021)
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17.0 संरिण Heritage preservation: 17.1 This Workshop was bestowed with the prestigious Heritage Award of Indian National Trust for Art and Cultural Heritage (INTACH), Hyderabad Chapter on the occasion of the World Heritage Day celebrations held at SalarjungMusuem, Hyderabad on 18th April, 2015. The award was presented to the Carriage Workshop under the Modern Industrial Heritage category.
17.2 NIZAM’S SALOON-1886 built -NGSRly Restored 1886 builtNizam’s Guaranteed State Railway’s wooden bodied 4-wheeler inspection carriage (Saloon) during December 2006.
17.3 1920 BUILT WAGON: Restored 1920 built wagon, by Birmingham Railway Carriage & Wagon Company (BRC&W), Smethwick, England, during May 2007.
17.4 HERITAGE MG AC SALOON (SC CTAC-150): Restored dilapidated 1970 ICF built meter gauge coach (saloon) stabled at“Purna”and hitherto utilized by General Manager, South Central Railway.
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17.5 HERITAGE MG STEAM CRANE 35 TONNES: Restored 1976 North Eastern Railway Workshop, Izzatnagar manufactured 35 ton MG Steam Crane (SCR – S-3508), with a tare weight of 70 ton and equivalent to match truck of 15 ton, during August 2010.
17.6 FIRE EXTINGUISHER – NIZAM STATE RAILWAY: Restored Nizamera’s Vintage fire extinguisher.
17.7 JOHN MORRIS FIRE ENGINE (1914 MAKE): John Morris Fire engine, housed at National Rail Museum/ New Delhi, is maintained by Carriage Workshop, Lallaguda.
17.8 MAHATMA GANDHI STATUE (BRONZE):
Restored Bronze Mahatma Gandhi Statue manufactured by foundry staff of Lallaguda during 1955 and placed adjacent to the main gate (inside).
17.9 FIRE ALARM BELL – 1925: Bronze bell 1925 manufactured and weighing 83 Kg used as mass alert during exigencies.
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17.10 RESTORATION OF LIBRARY COACH – (WPCTLAC- NWR -91565 – 1991 built used in Palace on wheels).
Restored 1991 ICF built library coach used on Palace on wheels.
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