STANDARD NOTE

FOR
PRODUCTION UNIT
CLW
AS ON 31.03.17
 Contents

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

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

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

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

1.4 Production of Traction Motors and control equipment commenced in April 1967. In the year 2016-17, upto
31.3.17, 1385 TM were produced.

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

1.6 CLW has in house facilities for machining and assembly of wheel sets, fabrication and machining bogies.
The facilities include modern CNG machines, Plasma Cutting machines, Inert Gas Welding etc.

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

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

1.9 CLW has been sanctioned “Creation of additional facilities for enhancement of production capacity” .
The major works are:
1.Additional Bay of Loco Fabrication &Loco Assembly Shops.
2.Extension of Traction Motor Shops.
3.Additional Machinery &plant, Tools, jigs &fixture.
4.control Information Management System.
5.Augmentation to various Ancillary Shops.
1.10 CLW has acquired the ISO-14001 certificate on 26.4.2002 both for its works and township for a neat and
clean environment. CLW has been awarded ISO 9001:2008 certificate for Quality Management System and
OHSAS 18001:2007 for occupational health and safety management system.
1.11 Chittaranjan is a true example of Environment preservation and consciousness. Its lush green ambience talks
of the efforts of the Administration as well as the residents of the township in the conservation of
Environment, as well as using of all the existing natural resources in an eco-friendly manner. The concerted
and unending efforts have been rewarded immensely by the World Environment Foundation and the
Golden Peacock award for Environment Management 2006 had been conferred on 9th June 2006.

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

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

1.14 During the year 2015-16, CLW has completely switched over from GTO to IGBT technology. The 1 st
WAG-9 class freight loco No.31215 fitter with IGBT based Power Converter was commissioned on 18th
December, 2009. Currently more than 600 CLW produced IGBT locomotives are running with IGBT
based Power Converter on Indian Railways.

1.15 The first electric locomotive (WAP-7 type no. 30277) with Head on Generation (HOG) scheme was
flagged off on 30th June ,2010. Up to March 2017, More than 50 such locomotives have been
commissioned. TFP 7775 with double hotel load wining has been provided with Hotel Load Converter.
The modified arrangement eliminates need of Autotransformer (used earlier to boost 750V to 960 V) and
also reduces line to earth voltage from 2.4 kV to 750V, improving the overall reliability of HOG system.
1.16 High Reach Pantograph: Action has been taken for provision of one High Reach Pantograph in
locomotives required for Dedicated Freight Corridor. Order for 100 Nos have been placed and two
locomotives of BRC electric shed are being equipped.

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

1.19 Indigenous Wheel Discs for 3-Phase locomotives have been developed by SAIL and complete
requirement of material is sourced on SAIL Durgapur.

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

1.21 VISIT OF MEMBER ELECTRICAL , RAILWAY BOARD TO CLW

Shri A.K. Kapoor, Member Electrical, Railway Board and Ex-Officio Secretary to Govt. of India visited
Chittaranjan Locomotive Works (CLW) on 1st July 2016. He inspected various shops especially, traction
motor shop, loco assembly shop & shell fabrication shop of CLW. He also reviewed the Electric loco
production in CLW.

Shri Kapoor held detailed discussions with senior officers and discussed relevant issues in the Conference
Hall. In his brief address he appreciated the good work being done by CLW.
1.22 VISIT OF MEMBER ELECTRICAL , RAILWAY BOARD TO ELAAU AT DANKUNI UNIT OF
CLW

Shri A.K. Kapoor, Member Electrical, Railway Board and Ex-Officio Secretary to Govt. of India visited
Electric Locomotive Assembly & Ancillary Unit (ELAAU) at Dankuni of Chittaranjan Locomotive Works
(CLW) on 2nd July 2016 . He inspected the Dankuni unit of CLW and also reviewed the Electric loco
production from Dankuni unit of CLW.

The first loco of the year 2016-17, WAG-9H type ( 31751 ) was ceremonially flagged off by Shri
A. K. Kapoor . Shri C. P. Tayal , General Manager along with other senior officers of CLW were present
during this programme inside the workshop.

1.23 VISIT OF MEMBER MECHANICAL , RAILWAY BOARD TO CLW

Shri Hemant Kumar, Member Mechanical, Railway Board and Ex-Officio Secretary to Govt. of India
visited Chittaranjan Locomotive Works (CLW) on 25th July 2016 . He inspected various shops especially,
Loco Assembly Shop, Traction Motor Shop, Shell Fabrication Shop, Bogie Shop, Wheel Shop & Steel
Foundry shop of CLW. He also reviewed the electric loco production in CLW.

Shri Kumar held detailed discussions with senior officers and discussed relevant issues in the Conference
Hall. In his brief address he appreciated the good work being done by CLW and wished a prosperous
future. CLW Staff Council members presented a memorandum to the visiting dignitary to represent about
current issues.

750th WAG-9H freight locomotive (31763) was ceremonially flagged off by Shri Hemant Kumar. Shri
C. P. Tayal , General Manager , CLW along with other senior officers of CLW, were present during this
programme inside the workshop.

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

Shri Rajen Gohain, Hon’ble Minister of State for Railways, Govt of India , dedicated the Electric
Locomotive Assembly & Ancillary Unit at Dankuni (ELAAU-Dankuni) of Chittaranjan Locomotive
Works(CLW) to the Nation by remote through video conference on 9th September 2016.

Speaking on the occasion, from the inauguration site of New Jubilee Bridge of Eastern Railway, Hon’ble
Minister of State for Railways dedicated this unit and appreciated the efforts for such successful endeavour
and hoped that this unit will cater to the requirements of High Horse Power Electric Locomotives for Indian
Railways. Shri C. P. Tayal, GM, CLW was also present at the site of inauguration alongwith General
Managers of E.R, S.E.R & Metro Railway. A plaque was unveiled by Hon’ble Minister of State for
Railways through remote .

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

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

Junior Vikas Shivir was organised in Chittaranjan Locomotive Works (CLW) on 21st Oct.,2016
afternoon in Badhwar Hall of TTC, as part of the Rail Vikas Shivir scheduled on 18-20 Nov., 2016
at national level. The purpose of this Vikas Shivir was to generate new innovative ideas amongst the
Railway employees to take the Indian Railways to next higher level. Shri C.P.Tayal, General Manager,
Principal HODs, Senior Officers and Senior Supervisors of CLW were present in the Shivir.

Among the 8 themes indicated by the Railway Board. The theme “LOOKING BEYOND FARE” was
assigned to CLW to come up with ideas which can dramatically improve non-fare revenues through
advertising and real estate developments.

1.27 73rd ALL INDIA RAILWAY FOOTBALL CHAMPIONSHIP IN CLW

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

1.28 BADMINTON CHAMPIONSHIP AT CLW

A badminton championship was organized by Chittaranjan Locomotive Works Sports Association (CLW-
SA) from 24th to 26th January,2017 at the Badminton Hall of Chittaranjan. Officers of CLW and their
family members participated in this keenly contested championship.

Apart from this, Burdwan District Badminton Championship was also organized at the same venue from
20 to 23rd January. Chittaranjan Badminton Association in association with CLW-SA organized this
district level competition in which a total of 148 matches were played.

1.29 CLW GYMNASTS SHINE IN ALL INDIA RAILWAY GYMNASTICS CHAMPIONSHIP

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

1.30 HINDUSTANI SANGEET SAMAGAM BY CLW CULTURAL ASSOCIATION

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

The Golf team of Chittaranjan Locomotive Works Sports Association has won the team event of 61 st All
India Railway Golf Championship , held at Patna Golf Club from 2nd Feb – 4th Feb,2017. A total of 16
teams participated in this championship which was organized by East Central Railway Sports
Association. The CLW Golf team displayed superlative skill to clinch the title. Shri D.K.Gayan, GM/
E.C.Railway handed over individual trophies to each member of the team at the end of the championship.

Shri V.P.Pathak, GM/CLW, has expressed his satisfaction for this achievement and encouraged all the
members of the team to do better in future events.

1.32 INTER RAILWAY CULTURAL MUSIC COMPETITION IN CLW

A Three day Inter Railway Cultural Music Competition on Classical vocal, Light classical vocal &
Instrumental was conducted by the Chittaranjan Locomotive Works Cultural Association (CLWCA) in
Chittaranjan Locomotive Works (CLW) from 2nd to 4th March 2017. Shri V.P.Pathak, General Manager
inaugurated the competition on 2nd March 2017 in Ranjan auditorium, as Chief Guest by lighting the
ceremonial lamp.

In this competition 19 teams from various railways participated & competed in the Classical vocal, light
classical vocal & instrumental categories.

On the Second day, that is, on 3rd March, 2017of the competition, Classical vocal event was organized,
wherein 17 teams from different railways participated.

1.33 INTERNATIONAL WOMEN’S DAY CELEBRATED IN C L W

International Women’s Day was celebrated on 8th March, 2017 in the afternoon, at Ranjan Auditorium by
the Chittaranjan Locomotive Works (CLW) Administration. Shri V.P.Pathak, General Manager/CLW
graced the occasion as Chief Guest . Shri G. Srinivasa Rao, Chief Personnel Officer/CLW was also
present as Chairman/CLW-Staff Benefit Fund Management Committee (SBFMC), along with
Dr.(Mrs.)Tulu Chakraborty, Sr.DMO/ K.G.Hospital / Chittaranjan were also present on the occasion.
Almost all the lady employees of CLW were present on this occasion of International Women’s Day.

A cultural programme was also arranged to enthral the gathering followed by prize distribution to a
selected group of women employees of CLW and to the winners of various competitions organised by
CLW-SBF for this occasion.

1.34 NO SMOKING DAY OBSERVED IN CLW

In continuation to health education to railway employees and their families, No Smoking Day was
organized by K G Hospital, CLW at Steel Foundry workshop on 10th March 2017.

Dr. Alok Majumdar CMO/KGH presided over the function. Dr. Joydip Mitra, Sr. DMO, Dr. Rajarshi Kar,
ADMO, Mr. B. Chakraborty, Dy CME/Plant, Mr. K K Chowdhury, AWM/Safety were also present on
this occasion.

Dr. Joydip Mitra, Sr. DMO gave the audio visual presentation on the occasion. He explained about the
hazards of smoking tobacco, risk pattern of a smoker and a non smoker for various diseases. He told that
a smoker intake 4000 kind of chemicals which is carcinogenic and very harmful to human body. Dr.
Rajarshi Kar, ADMO in his speech discussed about the deadly effect of smoking related to ENT. He also
said that smokers are more prone to lung, facial, mouth cancer, and showed various pictures of cancer
patient.

There was also Pulmonary Function Test (PFT) conducted for smokers to test their lung function. 30
employees were tested.
1.35 44TH DISTRICT RALLY BY BHARAT SCOUTS & GUIDES OF C L W.

The 44th District Rally of Bharat Scouts & Guides of Chittaranjan Locomotive Works (CLW) was held
on 28-03-2017 & 29-03-2017 at Scouts Den in CLW. Dr. A. Majumdar, President, Bharat Scouts &
Guides/Chittaranjan District and Chief Medical Officer/CLW inaugurated the 44 th District Rally in the
morning on 28-03-2017.About 250 volunteers of Scouts & Guides participated in this rally. Parade was
presented by the Scouts & Guides and Scouts Anthem was sung .

Later in the evening, The Annual Arts & Crafts Exhibition was organized at the Scouts Den. Dr. Rekha
Pathak, President / CLW-Women’s Welfare Organisation ( CLW-WWO ) inaugurated the Exhibition. Dr
Rekha Pathak visited different stalls of state exposition and appreciated the arrangements made by the
volunteers . Different Cultural programmes were also organized on the occasion which were enjoyed by
all. Appreciating the efforts of Bharat Scout & Guides of Chittaranjan District for organizing the Art &
Craft Exhibition and Cultural programmes , Dr Rekha Pathak, President/ CLW-WWO had announced a
group award of Rs 10000 from WWO .

A Grand Camp Fire was organised at the “Circle of Joy” in scouts den in Chittaranjan in the evening
on 29-03-2017 in which the campers of Scouts & Guides presented various cultural programmes. Shri
V.P.Pathak, General Manager presided over the Grand Camp Fire. Shri V.P.Pathak, General Manager &
Dr. Rekha Pathak, President/ CLW-WWO gave away the prizes to the winning groups and individuals .

1.36 INAUGURATION OF BULK MESSAGING SYSTEM IN CLW

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

1.37 CLW GOLFER WINS ALL INDIA CHAMPIONSHIP 2017.

Shri Vinay Kumar Yadav of Chittaranjan Locomotive Works (CLW) won India Golf Union NCR Cup in
All India Championship 2017 organised in Delhi Golf Club from 13 th to 17th March,2017. Shri Yadav is
a Golf player of CLW and was recruited in CLW under Sports quota.

Shri V.P.Pathak, General Manager /CLW had congratulated Shri Vinay Yadav and appreciated the efforts
of CLW Sports Association in encouraging the talents in participation in different championship.
 2
SALIENT FEATURES
 2. SALIENT FEATURES
Salient features of CLW w.r.t the following :
2.1 Total turn over as on 31.03.17
a) For Indian Railways : Rs.3975.81 Crores
b) For others : -- Nil
Turn over ratio as on 31.03.17 –
Break up of Turnover as on 31.03.17
Supply of Locos Rs. 3571.78 Crore
Components manufactured for stock Rs. 387.06 Crore
Supply of Spares for Zonal Railways Rs. 16.97 Crore
……………………
TOTAL Rs: 3975.81 Crore

Turn over ratio of Store Deptt./CLW for 2016-17 (up to 31.03.17) Physical : 9.9%
2.2 Total assets : (as on 31.03.17) : Rs 407.25 crores
Fixed assets: (as on 31.03.17) : Rs 582.36 crores
a) Township : Rs 11.19 crores
b) Workshop with M&P : Rs 571.17 crores
Floating assets (as on 31.03.17) : Rs(-) 175.11 crores
a)Stores : Rs 18.19 crores
b)WMS : Rs.(-)215.39 crores
c)Misc Adv. : Rs. 22.09 crores
2.3 Sanctioned and on-roll position staff as on (31.03.2017) group of staff i.e. Group A, Group B, Group C
& Group D.

Group Sanctioned Strength On Roll

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

2.4 Elec. Power requirement (maximum demand) : 11MVA

2.5 Electric energy consumption : (in lakh units/year) : 407 Lakh unit (from 1st Apr’2016 to
31st Mar’ 2017)
2.6 No. of H.T. Sub station: A) 33/11 KV : 01 no.
B) 11/3.3KV : 01no.
C) 11/0.4KV : 57 nos.
D) 11/0.4KV : 21 nos.- under main shop.
2.7 Stand by power generation capacity(in KW) : 4228.78 KWH(as on 31.03.17)
2.8 Water consumption : 0.157 Lakh Kilo liters per day
2.9 (a)Workshop Land : 101.26 Hectare
(b) Covered area of other service building (in SQM) : 35,241 Sq.m
2.10 Township area : 1,834.441 Hectares.
2.11 (a) Covered area in shops : 4,73,268 Sq.m
2.12 (a) Total staff as on 01.4.17 : 11,655
(b) Total number of staff quarters : 9,346 Nos.
2.13 Hospital (no. of beds) : 197 Nos.
 3

ORGANISATIONAL CHART
 ORGANISATIONAL CHART (UPTO JAG) AS ON 31.03.17)
GM

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

Dy.GM Dy.CVO
Dy.CPO(W) Dy.CPO(A) CEE/CLW CEE/LOCO CEE/TM CEE/L&S CEE/PL&I CME/Loco Dy.CE/con-I
(DKAE/Con)*
Dy.CME/ELB FA&CAO(P) Sr. EDPM
Dy.CEE/D-I Dy.CME/ELF
DyCEE/D-II Dy.CEE/M
CEE/Loco Dy.CEE/EL Dy.CEE/TMM Dy.CEE/D&D Dy.CEE/Insp/SBC
(DKAE)* Dy.CEE/ELA Dy.CEE/TMD Dy.CEE/I&D/DLI*
Dy.CEE/Loco Dy.CEE/I&D/Mum Dy.FA&CAO(I)
(DKAE) Dy.CME/I&D/HWH* Dy. FA&CAO(Kol)
CQAM

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

Addl CMS/A Sr.DMO(P) Addl.CMS/G Sr.DMO(S) SR. DMO/FW SR. DMO(HU)

Sr.DMO Sr.DMO Sr.DMO (eye) Sr.DMO/Anaesthesia
V-Vacant
*-WC Post
 4

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 Locomotive was built in the year 1971-72.
The production of Diesel locomotives continued up-to 31 st March 1993 when the last ZDM-5 Narrow Gauge
Loco was turned out. The total No. of conventional locos produced in CLW is 2607 Nos. (WAG-7=1770 Nos. &
WAP-4 Locos=837 Nos) which got discontinued after 31st December 2016. Now CLW is involved in the
production of Three Phase Electric Locomotives and maintenance spares required by Zonal Railways It has
produced 6002 Electric locomotives till 31st March, 2017 .

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

4.1 ELECTRIC LOCOMOTIVES :

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

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

ii) Passenger version of 3-phase loco viz, WAP-5 with an axle load of 19.5 Ton having Micro
Processor controlled brake system for hauling Mail/Express and other super fast trains.

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

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

4.1.1 Year wise production from 2000-01 to 2016-2017

YEAR WAP-4 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
2016-17 Target 00 00 30 95 175 300
As per JPO-68, Actual 00 00 23 79 190 292
Dt.18.10.15
(As on 31.1032016)
 Year wise Electric Loco production from 2007-08 to 2016-17(As on 31.12.17)
350

300 292
280
270
264
246 250
250
230
220 220
200 WAP-4
200 190
WAG-7
WAP-5
150 140 WAP-7
126 123
115 120 120 WAG-9

98 100 98 Total
100 93
79
70
57 58
47 49 51 44 45
50 40 39 40 40 37 40 35 40
31 27 31 3035
20 18 18 19 23
12 12 13 13 17
33 3 3 7
00
0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (JPO-
71 dt.31.01.17)
4.2 TRACTION MOTORS:
4.2.1. Cumulative production of Traction Motors during the year 2016-17 has been 1385 Nos. ( 1315Nos. Co-Co &
70Nos. Bo-Bo). Production of Hitachi Traction Motor type HS-15250A has been discontinued from the year
2016-17.

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

Following Bar chart shows the production trend of Traction Motor at CLW with emphasis of 3-phase
Traction Motors:
YEARWISE PRODUCTION OF TRACTION MOTORS

1800

1537 1562
1600 1514
1417 1450
1385
1400 1275 1315
1225 1202 1229
1200
1041 1000 1019
1000 931 896 900 913
881 844
815
726 761 759
800 676 672
549 564
600
465
417 390 373 332
400 321 316
276
205
200 128
44 43 60 42 30 70
4 0 4 8 5 24 19
0
04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 2016-17

6FXA 7059 6 FRA 6068 HS 15250 A Total

4.2.3 STATIC EQUIPMENTS:

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

4.2.4 SUPPLY OF SPARES :

The following materials were supplied to zonal Railways as spares during the year 2016-17 against their
sanctioned RSPs / vetted indents :
 ITEM Qty. ITEM Qty.

3 Phase Traction Motor (Co-Co)

Co) 06 Hitachi Traction Motor 109

Smoothing Reactor (SL) 25 Hitachi Armature Shaft 98

Complete Rotor (Co-Co) 01 Complete Stator (Co-Co) 06

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

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

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

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

 One Coil spreading machine has been shifted to Hitachi Field coil insulation section and 31 surplus staff
have been engaged for 3-Phase
Phase coil manufacturing.
 One new bay for or stacking of 3-Phase
3 Phase Stator and Rotors have been started by utilizing the existing
infrastructure of Hitachi TM which were lying idle with certain modifications.
 One new CNC Turnmill centre in TM/Shop 20 was inaugurated by Hon’ble GM on 23.11.16. The mac machine
will augment the outturn of Rotor Shaft.
One V.M.C. machine in TM/Shop 20 was modified and programming done for keyway milling of Rotor
Shafts. The machine was idle after discontinuation of Hitachi TM production.

Production Performance of Manufacturing

Manufactur Shops

Sl.N Name of Item 2015-16 2016-17 Comparison of Prod.

o. 2016-17
17 with
2015-16
1 Wheel Set Assembly 265 L/S 300-3/6 L/S +13.2%

2 Stator 3 Phase 502 Nos. 583 Nos. (+) 13.9%.

(G9/P7/P5)
3 WAP-7 Head Stock 34-5 L/S 40 L/S (+) 15.5%

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

5000
4094
4000
2976 2770 2632
3000 2500 2285 2010 2379
2018 1899
2000
1000
0
2012-13 2013-14
2013 2014-15 2015-16 2016-17
4.4.2 Production of Despatch of FC Bogies over last Five years—
years

Production Despatch

120 112
95 98
100

80 66 67 65
56
60

40 30

20
0 2
0
2012-13 2013-14
14 2014-15 2015-16 2016-17

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

Production Despatch

140
120
120
100
80
60 51 54 50
46
40 33 32
20
20 14
3
0
2012-13 2013-14
14 2014-15 2015-16 2016-17

Annexure – I
YEARLY OUTTURN OF ELECTRIC LOCOMOTIVES FROM CLW

AC
Year DC
DC MT ACMT ACMT
ACMT WC ACMT
WC
WC WA (WK) WAG WAP WCA WAG M-6 WAM WAG WAP WAP Grand
M-5
G-2 G-1 WAM -5A -1,3,4
1,3,4
M-4
-7
WC -4
-9 -5 -7 Total
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
TOTAL 21 57 268 54 1067 843 53 1770 02 500 895 113 359 9195
Steam locos – 2351 nos.
Diesel locos – 842 nos.
Summary as on 31.03.2017 Electric locos – 6002 nos.
Total -- 9195 nos.
 Annexure - II

ANNUAL PRODUCTION OF TRACTION MOTORS AT CLW

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

DESIGN & DEVELOPMENT

INCLUDING TOT
 5. CENTRE FOR DESIGN & DEVELOPMENT

5.1. Dual Mode Locomotive:

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

Status:
 A total 05 (five) Locomotives sanctioned by Railway Board (vide RSP 2016-17, Item No.1161).
 Functional requirement Specification (FRS) prepared by RDSO.
 CLW has also prepared salient design features giving emphasis on weight reduction techniques, use of state-of-art
technology etc.
 Pre-application conference held in March’16 to facilitate the prospective manufacturers.
 Expression of Interest (EOI) floated on CLW website. Specification and Special Conditions of Contact finalized.
 Tender floated and scheduled to be open on 26.05.2017

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

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

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

5.3. Centre of Excellence at CLW:

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

 To become self reliant in the field of design of Electric Locomotive equipment.

 To cater to domestic requirement of adoption of new technology in locomotives.
 To become technology exporter.
 To come in a position to cater to the emerging world market as per the customized requirement.

Project details:

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

Project-1: (a) Center for Simulation and Evaluation of Suspension/ Bogie & Traction System.
(b) Electric loco modeling, virtual modeling and simulation.

Project-2: Laboratory for Development and evaluation of Power Electronics Applications (Setting up of PCB Lab).

Project-3: Software development Lab.

Project-4: Laboratory for development and evaluation of Electrical Insulation Materials

Status:

 Specifications for all projects finalized. Detailed estimated sanctioned by GM/CLW.

 NSR approved by Finance.
  Special Conditions for Contract & Eligibility Criteria for all 04 projects prepared and approved by competent
authority.
 Tender opening for all projects scheduled on: 21.5.17.
 Pre-bid conference for all projects to be held on 24.04.17.

5.4. Development of Hotel load Converter:

This is for utilizing OHE power for supply of hotel load requirements of Shatabdi/Rajdhani trains through HOG Scheme
by providing Hotel Load converter in the locomotive. Order placed on M/s Siemens, BHEL, ABB, AAL, Medha and
Hind rectifier.

Status:

Siemens:
 1st Hotel load converter fitted in 30277 (WAP-7) and dispatched to GZB on 30.06.2010. Commercial service of the
loco started on 21.02.2011.
 Presently 37 locomotives with Siemens supplied Hotel load converters are running.
 6 more sets have been received at CLW. Under installation at CLW.

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

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

AAL:
 1st set commissioned on loco No. 30502 and dispatched to ELS/HWH in Nov.’16.
 Supply of balance quantity to commence after successful completion of field trial of first unit..

ABB:
 1st set commissioned on loco No. 30510 and dispatched to ELS/BRCY in Dec.’16.
 Supply of balance quantity to commence after successful completion of field trial.
 03 more sets are yet to be received at CLW.

Status:
 Tender No. 70/18/1125 as per Specification No. CLW/ES/3/IGBT/0490 Alt. D upload on CLW website for 99
Loco/sets. Tender scheduled to open on 21.4.2017.

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

This project has been undertaken through C-DAC for development of TCN compatible vehicle control system which will
ensure compatibility between open standard equipments of different makes. MoU is for developing 02 sets of TCN compliant
vehicle control system.

Firms have been approached through EOI for transfer of technology from C-DAC for development of new vendors.

Status:
 1st unit commissioned on loco No. 31356 (WAG-9H). Loco dispatched to ELS/TKD. Performance is satisfactory.
 2nd unit commissioned in loco No. 31778 and dispatched to ELS/WAT in August’16.
 Agreement for Transfer of Technology of TCN compliant vehicle control system signed between CGL, ABB & BHEL
with C-DAC.
 Tender for 50 Locosets opened on 25.07.2016.
 PO placed for 24 sets
 Remaining 26 sets decided for retender.
 50 sets sanctioned in RSP for 2017-18.
  Tender No. 70/17/1142 for 76(26+50) Loco/sets to be open on 28.4.2017.

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

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

Status:
 The prototype has been installed in loco nos. 31282 (WAG-9) & 31284 (WAG-9). Loco has been put into commercial
service w.e.f. 18.05.2012.
 2nd set has been installed on Loco No. 31525 & 31526 and dispatched to ELS/TATA.
 Field trials completed.
 Tender for 75 sets have been opened on 27/10/2016
 PO placed on M/s ARC- 45 nos., M/s Lotus-20 sets, M/s GE-10 sets.

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

The project for provision of Crew voice & video recording system on 3-ph passenger locomotives has been taken up for
effective and tamperproof video and voice recording of locomotive cab/EMUs driver’s cab and track view for post event
analysis.

Status:
 System to be provided on 3-ph passenger locomotives.
 Specification has been prepared by RDSO.
 Expression of Interest (EOI) floated on CLW website and 6 offers were received.
 Category amendment has been done.
 Tendering under process.

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

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

Status:
 One locoset commissioned in Loco No. 30056 (WAP-5). Loco sent to ELS/Vadodara on 15.11.2012.
 Presently 03 locomotives with above Drive Gear system suitable for 160 kmph are running under ELS/BRCY and 01
locomotive under ELS/GZB.
 Expression of interest (EOI) for development of Alternate Gear Drive System for WAP-5 locomotives called for the
proliferation of the system.
 08 Nos. offers received.
 Pre-application meeting with above firms and RDSO held in April’16 at CLW.
 Technical specification finalized by RDSO.
 Tender floated for the procurement of 20 locosets scheduled to open 31.05.2017.

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

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

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

5.10. Indigenous development of propulsion system:

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

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

BHEL:
 1st locoset installed on Loco no. 31347 (WAG-9) dispatched to ELS/LGD on 11.7.2012.
 20 more locomotives have been commissioned and running in field.

MEDHA:
 1st set installed on loco No. 31427 (WAP-7) dispatched to ELS/LGD on 31.10.2013.
 Presently 29 locomotives with M/s Medha supplied propulsion system are running under different shed.
 Further, P.O. has been placed for 48 L/sets.
 02 L/set supplied to DLW.
 08 L/sets supplied at CLW are under commissioning

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

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

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

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

BTIPL:
 P.O. has been placed for 01 L/set.
 Design document submitted

5.11. Remote Monitoring System:

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

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

5.12. Composite Converter:

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

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

5.13. Other activities:

(a) To address the problem of failure of locomotive due to increased temperature of SR oil, the following modifications
have been implemented in software:
(i) Increase in temperature settings of SR oil from 64˚/66˚ C to 65˚/67˚ C.
(ii) Increase in trigger range of temperature disturbance from 10˚ C to 25˚C.
(b) Integration/ Modification of software for incorporation of water closet in WAG-9 Locomotive no.31952.
 (c) Filter cubicle has been modified in TPP-339, duly ensuring adequate clearances for enhanced reliability of operator of
locomotive.
(d) VCU Redundancy to eliminate need of cab changing by crew in case of STB/HBB cards failure. Tested on all versions
of 3-phase locomotives. Regular Cut-in for all WAG-9 locomotives from CLW is under process. Accordingly software
version R1450 and modified schematics/cable layout diagram have been uploaded on CLW website. RDSO advised for
issuing MS.

Type of Locomotive Status of VCU redundancy

Implemented on loco no. 30083(BRC) with additional I/O cards to achieve
WAP-5
full functionalities in June’15.
Implemented on loco no. 30451 (TKD) with additional I/O cards to achieve
full functionalities in Feb’16.
WAP-7
Implemented on loco no. 30533 (BRC) with additional I/O cards to achieve
full functionalities in Feb’16.
Implemented on loco no. 3176 9(AQ) with 4 additional I/O cards to achieve
full functionalities in Sept’16.
WAG-9H Implemented on loco no. 31791 (WAT) with 4 additional I/O cards to achieve
full functionalities in Dec’16.

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

(a) Provision of Roof Hatch Retainer

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

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

Zonal Railways reported water leakage from OCU top panel. To strengthen the sealing between OCU Top Panel and
roof, design of rubber gasket has been modified. The material specification of the gasket has been changed to EDPM
sponge type. Further thickness of gasket reduced to 15 mm from 25 mm and hardness has been reduced to 25S to 50
S for better sealing.
 6

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 CLW i.e.
DyCEE/I&D/NDLS, DyCEE/I&D/Mumbai, DyCEE/I&D/Bangalore & DyCME/I&D/HWH)

6.2 OTHER OBJECTIVES:

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

6.2.2. To carry out inspection of various assembly and sub-assembly at TM Shops, Static Equipment Shops, HMS,
LMS, Loco Fabrication & Assembly Shops and also Steel Foundry Shops.

6.2.3. To certify the Material Movement Slip for movement of products conforming to the drawings/WI/Specification
from one shop to other and consequently clearing Job Cards related to that product.

6.2.4. To prepare Loco Inspection Certificates and sent the same to User Railways. As per previous year’s
commitment, 100% Scanned Inspection Data are used to make the Soft Copy of Loco Inspection Certificates
of locomotive produced since the financial year 2014-2015 and onwards.

6.3 ACHIEVEMENTS:

6.3.1. Modified Vertical damper bracket ensured by repetitive booking on that issue.

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

6.3.3. Tail lamp bracket provision is ensured.

6.3.4. Provision of Checker Plate between SR & Oil Expansion Tank in BT Converter ensured.

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

6.3.6. Trial implementation of modified lifting hook for IGBT ballast block done.

6.3.7. 100% radiography of Hitachi suspension tube (Spares) ensured.

6.3.8. 100% testing for rain water leakage from locomotive roof is implemented by providing high pressure jet water
taking facilities in order to arrest water leakage.

6.3.9. Inspection check points for three phase loco fabrication have been introduced for the bend portion of L-shaped
metal piece welded with Compressor bracket on which compressor is tightened to eliminate it’s shearing
problem.
6.3.10. On trial basis the camber of 15 mm in place of earlier 10 mm has been introduced for roof girder/channel to
minimize the gap between roof and girder which were causing roof leakage.

6.3.11. Tail lamp bracket has been ensured to be fitted after introducing new check points and repeated NC arisen.

6.3.12. Safety sealing of Traction Motors at the loco under-frame have been provided by constant booking and
monitoring to ensure safety.

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

6.3.14. 100% NDT test implemented on different types of Axle and Wheels for better quality control.

6.3.15. To overcome the bearing cease problem during MSU fitment in three phase locomotives, new check points at
X-clearance and D-clearance have been introduced on Wheel Set Assembly.

6.3.16. To improve the performance of power transmission drive in Traction Motors, proper matching
of the gear with pinion has been ensured by colour coating procedure.
.
6.3.17. To improve the quality of Flexi-coil Bogie rectification is restricted up to the R-2 stage of
Radiography Test.

6.3.18. On the basis of customer feedback received in the past, fresh inspection check points have been
introduced in the fitment of the following items during shell fabrication for quality improvement.
a) Floor Ventilation Ducting and Machine Room Entrance Door on shell of WAP 5 locos.
b) Under Slung Compressor and Battery Box Stools on WAP-4 Shell at USD Stage.
c) Compressor Leg at USD Stage on both WAG-9 & WAP-7 locos.
d) CBC on all types of locos.

6.3.19. Keeping in view the recently received customer complaint on welding joint failure of WAG-9 loco, 100% DP
Test has been introduced for the four joints between Cross Box and Transformer rod pillar mounting base of
Central Under-frame.

6.3.20. The huge back log (due to newly adopted Soft copy of loco ICs and other unavoidable reason) of preparation
of Loco Inspection Certificate and issue the same to user shed have been reduced a lot by clearing a record
1280 numbers of loco ICs in last Three years and six months (w.e.f. 1 st July 2013 to December 2016).

6.3.21. Recently, in-spite of acute shortage of Staff and Supervisors in various Inspection Shops, up-gradation of Loco
Inspection Certificate in to 100% soft copy along with reduction of back log as stated above have been
achieved.

6.4 METALLURGICAL & CHEMICAL LABORATORY

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

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

NDT Lab./SF arranges radiography of various casting to ensure casting quality as per specification.

Main activities of M&C organization is as under:-

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

Metallurgical & Chemical Lab conducts metallurgical investigations of in-service failures of components of
CLW built Locomotives. It maintains liaison with RDSO, BIS & other Non-Railway institutions on M&C
matters.

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

No. of Sample No. of Sample

Nos. of Tests % of Rejection
Sl. Tested Accepted
Name of Lab.
No. 2016 & 2016 & 2016 & 2016 &
1.1.17 2014 2015 1.1.17 2014 2015 1.1.17 2014 2015 1.1.17
2014 2015
to to to to
31.3.17 31.3.17 31.3.17 31.3.17
Metallurgical/
1. 3254 6858 3198 1.72
Mechanical 3480 4013
1040
7116 8038
2155
3406 3631
1015
2.12 9.52
Lab. 2.40
2. 2159 12386 2116 1.99
Chemical Lab. 3125 3172
596
18220 17483
3584
3054 3144
590
2.27 0.89
1.01
3. Filter House 2291 12706 2291 Nil
Lab.
2020 3649
503
16821 17336
3158
2020 3649
503
Nil Nil
Nil
Rubber ,
4. 181 963 172 4.97
DMC, I. M. & 221 216
65
445 964
352
208 201
63
5.88 6.94
Lubricant 1.49
TOTAL 7885 32913 8688 10625 7777
8846 11050 42602 43821
2204 9249 2171

6.5.2 NDT LABORATORY (LOCO):

Nos. of Location/ Nos. of

No. of Sample Tested % of Rejection
Component Tested Component Accepted
Sl. 2016 & 2016 & 2016 & 2016 &
Name of Lab.
No. 1.1.17 1.1.17 1.1.17 1.1.17
2014 2015 2014 2015 2014 2015 2014 2015
to to to to
31.3.17 31.3.17 31.3.17 31.3.17
Ultrasonic 7096 22648 7047 1.57 0.69
1. 8785 9958 26129 31458 8720 9820 0.73
Testing 2797 7744 2787 0.56 0.36
4733 7937 4733 - Nil
2. MPT 4864 5746 12257 14988 4864 5746 Nil
1481 2531 1481 - Nil
Radiographic 165 165 125 18.3 10.9 24.24
3. 359 302 359 201 294 273
Test 02 02 01 8 - 50.00
1471 7543 1461 0.23 0.68
4. Misc. 1207 1641 3374 4790 1207 1638 Nil
682 2197 670 - 1.76
TOTAL 13465 38293 13366
15215 17647 42119 51437 15085 17477 - -
4962 4939 4939
6.5.3 METALLURGICAL & CHEMICAL LABORATORY /STEEL FOUNDRY:
CHEMICAL LABORATORIES:

No. of Sample Tested Nos. of Tests

2016 & 2016 &
Sl. No. Name of Lab.
2014 2015 1.1.17 to 2014 2015 1.1.17 to
31.3.17 31.3.17
1652 8682
1. Chemical Lab. 3024 2556 16898 10,310
334 1389
23 136
2. Chemical Misc. 149 41 972 208
15 78
1675 8818
TOTAL 3173 2597 17870 10,518
349 1467

6.5.4 FIELD LABORATORY/S. F. :

Sample Test Physical & Radiographic Tests

Sl. No. of Tests No. of Tests

No. 2016 & Name of Test 2016 &
Name of Test
2014 2015 1.1.17 to 2014 2015 1.1.17 to
31.3.17 31.3.17
1. 35 Tensile 325
Zircon Wash 66 80
15 Strength 1318 497 116
3858 233
2. Green Sand 5726 5586
594 Microstructure 525 355 59
1656 0
3. Permeability 972 2021
129
Charpy 0 0 0
3581 1012
4. No-bake Sand 992 6059 Hardness 926 6393 135
1320
1472 Radiography 5756
5. Silica Sand 78 2718 11478 10220 1430
416 Exposures
10602 7326
Total 7834 16464 Total 14247 14465
2474 1740
 7

Marketing including export

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

7.2 FUNCTIONS:

 Consolidating the demands in the form of Requisitions/indents from Railways for purchased and Shop
manufactured including imported items.
 Co-ordination with Stores department for the procurement of such spares and to issue work orders for the
shop manufactured item.
 Supplying spares to the railways through stores/shops taking as per demand and availability and to maintain
accountal of such supplies.

7.3 SPARES TO RAILWAYS:

The supply of spares to various user Railways is one of the most important function of L&S wing. All-out
efforts are made to fulfill the demands of Capital spares as well as the requirement of spares by the Railways. In the
year 2016-17 spares worth Rs 11127.8 lakhs (as on 31.03.17) were supplied to the Railways. The break up of the
same may be seen at Annexure -B.
 CLW / CHITTARANJAN
SUPPLY OF SPARES TO ZONAL RAILWAYS AGAINST RLY BOARD’S RSP & REQUITIONS OF ZONAL RAILWAYS IN APRIL 2016 TO March 2017 ANNEXURE- A
(All Costs are in Rs. Lakh)
QUANTITY SUPPLIED UPTO MARCH 2017
Sl Item description Total Total
. CR ECoR ECR ER NCR NR SCR SECR SER SR WCR WR Other qty. cost of
B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req B/ Req. ZR supply
1. TM for G-9/P-7 (3Ф) 3 1 2 6 159.35
2. TM for P-5 (3Ф)
3. Stator of TM for G-9 (3Ф) 3 1 2 6 2 1 15 142.54
4. Rotor of TM for G-9 (3Ф) 1 1 5.52
5. Transformer of G-9/P-7 (3Ф) 1
6 696.53
6. Transformer of P-5 (3Ф)(7775 Kva) 2 2 1
7. Auxiliary Converter (3Ф) 2 1 1 1 1 1 3 1 1 2 1 15 589.13
8. Central Electronics (3Ф)
9. Traction Converter (3Ф) 1 2 1 4 770.66
10. O.C.B. Unit (3Ф)
11. E-70 Brake System (3Ф) 1 2 3 110.45
12. Driver’s Display Unit (3Ф) 27 8 4 8 6 14 2 8 4 1 82 347.83
13. TM (Hitachi) 17 48 5 3 17 2 5 12 109 3997.05
14. TM (H)-Armature 12 3 15 264.79
15. Transformer 5400 KVA
16. High Speed Pantograph 20 10 27 15 20 15 10 15 2 134 669.81
17. Oil free Compressor 4 4 8 128.56
18. VCB
19. DBR (Roof Mounted) 1 1 7.57
20. Shunting Contactor 199 20 219 36.58
21. Co-Co Bogie Machined
WAP-4 2 2 57.01
WAP-5
WAP-7
WAG-9
22 Bogie with Brake Rigging
WAP-5
WAP-7 2 2
26.09
WAG-9 2 2
23 Wheel and Axle Assly.
WAG-7 2 2 17.84
WAP-5
WAP-7 6 6 94.39
WAG-9 2 5 7 64.09
24 Fabricated Bolster 2 2 10.00
25 Fire Detection Unit 3 3 3.18
26 Oil Cooler Radiator 8 7 1 16 68.59
27 Oil Cooling Unit 2 2 5.96
28 Pantograph AM-92 2 2 1.88
29 SL-30 4 5 2 11 119.75
30 Diagnostics System 4 1 3 3 1 4 4 3 3 3 4 3 36 450.00
31 CTF 1 & 2 10 10 17.48
Cost of Misc Items in Rs. Lakh 825.41 34.90 154.10 495.62 47.68 99.19 43.41 12.26 75.47 85.08 80.22 311.84 2265.18
Total Cost in Rs. Lakh 1961.87 403.80 1997.82 1165.59 557.36 703.91 660.92 216.06 1086.56 537.57 686.46 1149.89 11127.8
 8

STATUS OF M&P
 8. MACHINARY AND PLANT
Manufacturing, M&P Maintenance, Transport, Machinery & Plant Procurement

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

Manufacturing shops:

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

(ii) Heavy Machine shop: Heavy machine shop undertakes machining of components for loco production of 3
Phase Stators, Transom, Support, Torque Support, Motor support etc. Machining work of Steel Castings from
Steel Foundry like Hitachi Suspension tube, DMW Suspension Tube and CBC Yokes are also done in HMS.
In addition to this, 68 Loco sets, tested Motorized Wheel set assembly were supplied upto March’2017. It has
helped the Bogie Shop and in turn CLW in manufacturing 1002 motorized bogie in house.

(iii) Smithy & Forge shop: SFS undertakes fabrication of Head Stock of WAP7 loco, forging of small
components of loco assembly such as Resting hook, operating handle of CBC.

(iv) Light Machine Shop: Light Machine Shop manufactures 308 small loco components and different kinds
of scheduled work to meet requirement of loco production.

(v) Tool Room: Tool room supplies tooling, gauges, jigs & fixtures for production requirements of various
shops. It also carries out calibration of various gauges, fixtures, instruments etc to meet the ISO requirements.

(vi) Heat Treatment Shop: Heat Treatment Shop undertakes heat treatment of WAP7/WAG9 bogies
manufactured in Loco Shop and other items e.g. Axle Holder, Motor support, Torque support. manufactured in
Mfg Shop.

Performance of Manufacturing Shop is furnished in the Annexure-‘A’

BRIEF REGARDING PLANT MAINTENANCE ORGANISATION(LOCO WORKS)

CLW has more than 860 M&Ps various CNC/Non-CNC Machines including 123 Cranes utilised for
production of Electric Loco Components. Breakdown as well as preventive maintenance of M&Ps including
47 critical machines (Enclosed as Annexure B) is carried out by the Plant Maintenance Organisation consisting
of Millwright Shop(MTS-56), Electrical Repair Shop(Shop-59) and CNC Wing. Plant Maintenance
Organisation deals with repairing, reconditioning, re-engineering, retro-fitment of machinery and plant &
electrical maintenance of lighting inside shops. Installation of new small machineries and plants, condemnation
& uprooting of old M&Ps are also carried out by the Maintenance Shops-56 & 59.

I. SPECIAL WORK DONE

1. HEC Wheel Lathe of Shop-09 was under breakdown due to problem with PCB. The same has been
rectified in-house successfully and the machine has been put in service within a very short period.
2. 85 Nos. Energy efficient LED Bridge light have been commissioned in different EOT Cranes.
3. Premier CNC Vertical Turret Lathe No. 09/1789/02 was under breakdown due to critical hydraulic
leakage problem at ram head. The leakage problem was set right by the maintenance staff.
4. Danovat CNC Axle Turning Lathe No. 09/1115/01 was under breakdown due to defect in telescopic
cover. The staff of MTS opened the cover & repaired the cover thoroughly.. .
5. Shigiya Grinding M/c No. 09/4625/01 was under breakdown due to table movement defect. Hydraulic
locking gear and spring of the machine have been changed and the problem was set right.
6. Premier TC Milling Machine of Shop-08 was under breakdown as the universal tool head of the
machine was defective. The same has been dismantled and repaired by the maintenance wing staff and
set right the machine.
7. EOT Crane 4C was under breakdown due to damage of LT bearing and wheel. The wheel with
coupling and shaft assembly has been replaced with new one.
8. Crane No. 23/E/15 was under breakdown due to defect in wheel bearing. The bearing has been
replaced by dismantling of wheel.
9. Premier make Plano Milling M/c No. 08/2463/02 was under breakdown due to spindle head movement
defect. Spindle head gear box of the machine has been dismantled. Power shifting gears along with
shaft keys have been rectified in-house and the machine has been put in service.
10. Unique-2(19/E/09) 50/5T Crane of Shop-19 was under breakdown due to problem in damaged bearing
of LT Idle Wheel.. The Wheel was dismantled and new bearings was fitted.
11. Crane No. 23/E/13, 5T of Shop-23 was under breakdown due to LT Wheel, Axle and bearing
damaged. The total assembly was replaced by new set with new bearings. The crane is now running
with full load.
12. 1 No. old Oil Filtration Plant brought from TATA Loco Shed with fault in control unit, PCBs and set
of filters. These are repaired in-house successfully by the Maintenance Wing and the Plant was put in
service.
13. Crane No. 396 of Jessop make at AIF Store was under long breakdown due to problem in resistance,
limit switches, power line, brash collector shoe and drum controller. The crane has been successfully
put in service by repairing the above mentioned items and complete rewiring by ERS staff.
14. SBCNC 30(Rotor Shaft Turning Lathe) was under breakdown due to problem in steady rest. The
problem has been rectified successfully by modifying the steady rest with provision of non-wearing
rollers by In-house maintenance staff and put into service.

15. HEC Surface Wheel Lathe of Shop-09 which was under breakdown due to underground conveyor
system not working. Safety device of the conveyor crasher got damaged. The gear arrangement was
completely dismantled and rectified.
16. Crane No. 20/E/01(5A) was under breakdown due to LT gear box damaged. New gear box has been
fitted in the crane and the crane set right.
17. Fortuna Cylindrical Grinding M/c No. 20/4671/01 was under breakdown due to failure of hydraulic
system. The same has been repaired and put in service in-house by the maintenance wing of CLW. .
18. Zayer CNC Universal M/c (Mini Zayer) No. 08/2595/03 was under breakdown due to universal tool
head movement defects. Universal head locking device was damaged and the same has been replaced
with new one by in-house staff of maintenance wing.

19. BBM Wheel Press 09/7537/01 of Wheel Shop was under breakdown due to defect in head trolley
movement.. The same has been repaired in-house by the maintenance wing of CLW and put in service.
.
20. HMT Universal Grinding Machine No. 20/4680/01 was under breakdown. Rewinding of motor of the
machine was done and wiring cable thoroughly changed.
21. Tantus Turret Punch, M/c No. 15/6951/01 which was under long breakdown due to defect in encorder.
The encorder has been procured & fitted & and the machine made functional..
22. 6 Nos. Feeder Pillar and 21 Nos. Distribution Box have been replaced/newly installed at Main
Assembly Shop.
23. HEC Surface Wheel Lathe No. 09/1042/01 was under breakdown due to damage of ball screw. The
same has been repaired and fitted in the machine. The machine is now running satisfactorily.
24. Wheel Parking area of Wheel Shop was without any light. Illumination of the Wheel Park was done
with provision of energy efficient .
25. Maintenance free earthing was provided in 5 CNC M/c
26. Rewiring of Sutripti Canteen was carried out near TM Gate.
27. Repairing of Induction Puller at TM shop was done.
28. 3 Phase Motor testing Plant at TM Shop which was under long breakdown has been rectified with
inhouse effort. .
29. Thorough renovation of Coach and Bogie of 1/4th Steam Loco(Fairy Princes) at Loco Park was done
30. Repairing of Pro-Arc M/c. No. 17/6093/03 at ELS-17 Corta Section was done
31. Rectification of Kellen Berger M/c. at Tool Room/Shop-52 was carried out
32. HMT HCG grinding Machine NO. 09/4626/01 was under breakdown due to breakage of shaft. The
same was made inhouse and the machine was rectified.

8.3.1 UPTIME AVAILABILITY OF CRITICAL MACHINES

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

8.3.2 CONDEMNATION OF M&Ps

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

Annexure ‘A’
8.4 Production Performance of manufacturing shop

Sl. Name of Item 2015-16 2016-17 Comparison of Prod.

No. 2016-17 with
2015-16
1 Wheel Set Assembly 265 L/S 300-3/6 L/S +13.2%

2 Stator 3 Phase 502 Nos. 583 Nos. (+) 13.9%.

(G9/P7/P5)
3 WAP-7 Head Stock 34-5 L/S 40 L/S (+) 15.5%

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

Procurement status of various M&Ps during last year(2016-17) is as follows:

1. INDENTS PENDING WITH COFMOW (as on 31.03.17 ) :-

S Sanction Alloca Description of Sanc. Consignee Status

N under tion machine/Qty. .
Cost
1 M&P 16- CAP 16 Wheellabrator 865 Dy.CME/ Spec. sent to COFMOW on
17 Grit Blast Plant, lakh ELA 17.03.2017.
01 no.
2 M&P 16- CAP EOT Crane, 30T, 156 Dy.CME/ Tender due on 11.04.2017.
17 Qty.02 nos lakh ELA
3 PH-42 CAP CNC Machining 1382 Dy.CME/ Tender due on 26.04.2017.
Centre, 01 no. lakh Mfg .
2. Progress of work by M&P Deptt. during the year 2016
2016-17

( Position
tion from April’16 to Mar’17)

Particulars M&Ps M&Ps M&Ps P.O Placed

Received Commissioned. Under
commissioning

M&P Programme items sanctioned 04 05 02 03

by Rly. Board
GM’s Out of turn items sanctioned 17 13 04 -
by GM/CLW

Project items ( 200 Loco Project & - 02 - -

50 Loco Project & 275 Loco
Project )
Total 21 20 06 03

(a) Machines Commissioned –20

20 Nos.

(i) M&P Programme Items :- 5 Nos.

S/ Item No. Description, Qty. & MT No Supplier & AT/PO No Consignee/

No & Yr. of allocation Location
san.
1 M&P Portable Radial Drilling MT/ M/s. Energy Machine Tools, Dy.CME/
11-12 Machine, DRF Qty.01 no., 2131 Jamnagar, COFMOW/IR/S- ELF, shop-
cost 35,99,958. 4757/P-I/OP-2219 26 new shed
dt 04.01.14.
2 M&P CNC Vertical Turret MT/ M/s. HYT Engg. Co. Pvt. Ltd., Dy.CME/
13-14 Lathe.
the. (Swing dia. 1400 2163 New Delhi, OP – 2309 dated – Mfg., WS-
mm), PO Cost – 1.57 Cr. 10.09.14. 09
DRF
3 M&P Induction Brazing MT/ M/s. EFD Induction Pvt. Ltd., Dy.CEE/
13-14 Equipment. 2165 Karnataka, P.O no. 05/2014/ TMM,
(Qty. – 2 nos.), CAP 7114 /05862 shop-21
84 Lakh dated – 20.08.15.

4 M&P/ Utility Vehicle MT/ M/s. Mahindra & Mahindra SC/RPF

16-17 587598.59 , DRF 2201 Ltd, Mumbai, P.O no. 05/2016/
7115/08050 dated- 04.11.16
5 M&P CNC Axlee Turning Lathe. MT/ M/s. Askar Microns, Mysore. Dy.CME
13-14 (Length 3000 mm)., 2164 G – 600 841, /Mfg.
7.93Cr. Key No. 214101.

(ii) GM’s Out of Turn Item : 13 Nos.

S/ Item No. Description, Qty. & MT No Supplier & AT/PO No Consignee/

No & Yr. of allocation Location
san.
1 GM OT Magnetic Particle MT/ M/s. K. Electronics, Gujrat, Dy. CC&
12-13 Inspection Equipment 2160 P.O.No.05/2014/7107/ M, shop-09
 (Qty. – 01 No.) CAP, 05093 dated – 17.04.15
27.25 Lakhs

2 GM OT Horizontal High Pressure

Press MT/ M/s. Shri Hari International, CMO/
13-14 Sterilizer, 01 no., Cost 2173 Kolkata, P.O no. 05/2015/ KGH
8.20 lakhs 7106/06510 dated- 25.05.16.
3 GM OT Hydraulic Motorised Pipe MT/ M/s. VANKOS & Co., Dy.CME
14 – 15 Bender with Power Pack. 2181 Patna. P.O no.02/2015/7108 /ELA, shop-
(Qty. – 02 Nos.) DRF. /06408 dtd-14.12.15. 16
5.41 lakh
4 OT Mobile X-RayRay Machine, MT/ M/s. Sigma Medical CMO/
15-16 DRF 4.76 lakh 2186 Systems, Kolkata, P.O KGH
no.05/2016/ 7107/07635
dated-22.07.16
5 GM OT Mig Welding sets. MT/ M/s. Metal Care, Burdwan Dy.CME/
13-14 (Qty. – 2 nos.) 2178 P.O no.05/2015/7104/ Mfg., HMS-
16.05 lakhs, DRF 07293 dated – 13.06.2016. 08

6 OT ICU Ventilator Qty. 01, MT/ M/s. Sigma Medical CMO/KGH

15-16 Cost- 22,84,800 2184 Systems, Kolkata, P.O
no.05/2015/7110/07864
dated-19.09.2016
7 OT Defibrillator with facility MT/2193 M/s. Shir Hari International, CMO/
15-16 of external pacing, Kolkata, P.O no. 05/2016/ KGH
9,98,901/- DRF 7108/07745 dated-
05.09.2016
8 OT TMT machine, Qty.01, MT/2194 M/s. The Medi Power, CMO/KGH
15-16 DRF Cost Cost- Kolkata,
2,99,985.00 P.O no.
05/2016/7110/07962
Dated - 14.10.2016.
9 OT Micro convex Probe for MT/2196 M/s. Sigma Medical CMO/ KGH
15-16 Diagnosis of Dieses Systems, Kol, PO
related to Cardiovascular no.05/2016/7112/ 08068
System, cost- 4.23, dated-10.11.2016
WMS
10 GM OT Dimmer Stat Variable MT/2177 M/s. Deswetch Engineers, Dy.CME/
13 – 14 Auto Transformer 200 Thane, P.O no.05/2015/ Mfg
KVA. (Qty.–1no.)CAP
1no.)CAP 7107/ 06505 dtd 22.01.16.
13.13lak
11 OT Ultrasonic Flaw Detector MT/2189 M/s. Electronic Engineering Dy. CC&M
15-16 with a scan Storage.(Qty. Company India Pvt. Ltd.,
– 03 nos.) 07.33 lakhs Mumbai, P.O no.05/2016/
CAP 7102/07283 dated –
30.05.16
12 OT Air Plasma cutting MT/ M/s. Nextgen Plasma Pvt. Dy.CME/
15-16 Machine with air 2185 Ltd., Kolkata,P.O ELF
compressor- 03 nos, no.05/2016/7104 /07756
Cost Rs.7,87,000/- dated-23.08.16.
CAP
13 OT Digital Rockwell MT/ M/s. Shiv Trading Dy. CC&M
15-16 Hardness Testing M/c. 2190 Corporation, Kolkata. P.O.
Qty. – 01 No. 275000/--
275000/ No. 05/2016/ 7101/08006
DRF dated 26.10.2016
 (iii) Under PH-42 : 2 Nos.

S/ Item No. Description, Qty. & MT /No Supplier & AT/PO No Consignee/L
No & Yr. of allocation ocation
san.
1 PH 42, EOT crane 5T MT/AP – M/s. Saico Cranes Pvt. Ltd, Dy.CME/
275 (Qty. – 01 No.) 275/18 Nasik, OP-2235/13 ELA, new
Loco PO Cost - 2469472/-- paint shop-
16
2 275 CNC Axle Turning M/C MT/AP – M/s. Askar Microns, Dy.CEE
Loco (for Shaft), 1.69 Cr, 275/08 Mysore. /TMM
Project OP – 2130 Dt. 23.04.12

(b) Machines under Installation & Commissioning – 06 Nos.

(i) M&P Programme items - 2 Nos..

SN M&P Description of machine Received Suppliers name with PO no. Consignee

Ref. on
1 MT/ Double Ended Facing, 07.06.16 M/s. Geeta Machine Tools Pvt. Dy.CME
2166, Centering and Drilling M/c. Ltd. /Mfg.
1.04 Cr., Jamnagar. OP– 2134
Amendment no. 2 Dated –
09.07.15.

2 MT/ EOT Crane 30T (Qty. 01). 18.02.17 M/s. Alpha Services, New Dy.CME
2182 Key No. 215347. 60.96 Delhi. /ELF
Lakh DRF OP – 20 061,

(ii) GM’s Out of Turn Items :- 04nos.

SN M&P Description of machine Received Suppliers name with PO no. Consignee

Ref. on
1 MT/ X-Ray Machine – 01 No. 25.01.17 M/s. Rainbow Enterprises, CMO/ KGH
2188 DRF . 690000/- Lucknow.
P.O. 05/2016/7103/07768
dated 206.10.2016.
2 MT/ Induction Heater (Micro 06.03.17. M/s. Unitech Instruments, Dy.CME /
2191 processor controlled) – 02 P.O no.05/2016/ 7111/08024 Mfg.
nos, CAP 9.46 lakhs dated-17.11.2016

3 MT/ Audio Conference 11.03.17 M/s. Sandeep Tradex Pvt. Ltd., ASTE
2183 System,Qty.01 no., DRF Kolkata, P.O no.
11.14lakhs 05/2015/7109/08246 dated-
12.01.2017.
SN M&P Description of machine Received Suppliers name with PO no. Consignee
Ref. on
4 MT/ 20 ton Tensile Machine, Qty. 27.03.17 M/s. Ashian Engineers Dy. CC&M
2204 01. CAP 4 lakhs Company India, Delhi. P.O.no.
05/2016/7116/08365 dated
16.01.2017.
(C ) P.O Placed, but machine not received- 03 nos.

SL Item No. & Description Supplier name & AT/PO No. DP

No. year of
sanction
1 M&P CNC Press Brake M/s. Maanshan Hudong Heavy Industry 31.08.17
13-14 Hydraulic 650T Machinery Manufacturing Co. Ltd., China,

2 M&P Hydraulic System for M/s. Crimpwell Services, COFMOW AT 30.09.17

16-17 Pinion Mounting & no. COFMOW /IR/S-4970/P-I/OP-402450
Extraction dated- 28.02.2017
3. M&P EOT Crane 5T, 02 M/s. Meeka Machinery Pvt. Ltd,, 31.07.17
14-15 nos. Ahmedabad, OP – 501 010

8.6 Transport Shop :-

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

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

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

8.7 Yard Organization

For movement of traffic wagons, inward & outward departmental wagon and locomotives shell on
dummy bogies, two shunting engines have been deployed. These locomotives are maintained and
operated by Yard staff. Shunting requirement is met in three shifts. Yard organization also keeps
liasion with the Asansol Division of Eastern Railway for movement of Traffic Wagons.
 8A

STEEL FOUNDRY
8A.1 OVERVIEW
Location of the Factory: P.O. & P.S. : Chittaranjan
Dist : Burdwan, Pin – 713331

The Factory is located at Chittaranjan, Dist: Burdwan, West Bengal, approx. 305 km. from Kolkata.
The location is well connected by road and rail from Howrah Station.

Chittaranjan Locomotive Works, Steel Foundry, a unit of Ministry of Railway is set up for supplying
Steel casting products of locomotives. It has two Arc furnace of 15T and 7T capacity. The 7T Furnace
is being replaced by a 10T Direct Arc Furnace, CLW follows stringent quality processes, duly
certified with

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

Total Area of the Plant : 45 acres (182108.70 sq. m.)
Covered Area : 12.4 Acres (50181.064 sq. m.)
Product : Steel casting for rolling stocks

8A.2 IMPORTANT MILESTONES

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

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

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

 CLASS-A CERTIFICATE- Steel Foundry/CLW has been certified as CLASS-‘A’ FOUNDRY by

RDSO on 9th August 2012 vide RDSO Vendor No. 419.

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

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

8A.3 PRODUCT RANGE

8A.3.1 STEEL CASTINGS:
Loco-items—
 Flexi coil Bogie for WAP-4 loco.
 Flexi coil Bolster for WAP-4 loco.
 Co-Co Bogie BG for WAG-5 & WDM-2 Loco.
 Suspension Tube for Hitachi TM.
 Suspension Tube for 3phase TM.
 Rotor Clamp for Hitachi TM.
 Commutator Spider for Hitachi TM.
  Centre Pivot for WAP-4 loco.
 Ballast Blocks for WAG-9 loco.
 Ballast Block for IGBT loco.
 Ballast Weights for WAG-7 loco.
 Loco Couplers for Electric loco (Assly. with Yoke, Knuckle also)
 Striker Castings for Electric loco.
 ‘E’ type Couplers for Diesel loco

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

C.B.Coupler Items (Wagon) —

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

Spares for Zonal Railways—

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

8A.3.2 DEVELOPMENT OF NEW STEEL CASTING ITEMS:

(a) DEVELOPED & SUPPLIED REQUIRED TO RAILWAYS-
 Clevis for coupler items
 N.G. Wheel for N.F. Rly
 N.G. Wheel for Kalka
 N.G. Wheel for Gwalior

8A.3.3 FABRICATED ITEMS for LOCO:

 Side Sill
 Centre Sill
 Head Stock Assembly
 Casnub Dummy Bogie(TG/TPP)
 Conversion of HH Dummy Bogie into TP Dummy Bogie
 Under frame Assembly for WAG-9H
 Loco Piping at LW.
8A.3.4 New Development
BLC wagon bogie: it is under project. An order of 63 Nos of BLC Wagon Bogie has been received from Rly.
Board. The same casting has been cast and two bogie are ready for inspection by competent authority.
A. Under frame for WAG-9H: under Frame of WAG-9H Loco was started at Steel foundry in Bay No. 11
w.e.f. 22.07.2016. Fixture for under frame was manufactured. Two Complete Under Frame for WAG-9H
Loco are ready for dispatch for Loco are ready for dispatch for Loco Workshop for Loco No. TG-
859,TG-860. Letter has been given to CME/Loco for lifting two Loco sheds of under frame assly, Vide
letter No. SFM-16/53/LW dt. 07.12.2016.
B. Loco Piping: Loco piping work has been started at loco works /CLW (shop No. 16) w.e.f. March-2016
by the staff of Steel Foundry. Upto Dec-2016 loco Nos. (TG-707, TG-714, TG-753, TG-766, TG-763,
TG-764, TG-773, TG-771, TG-772, TG-790, 792, TG-800, TG-817, & TG-819, TG-826, TG-827,
TG814, TG-850 & TG-861 has been completed upto March-2017.
8A.4 QUALITY:
Steel Foundry/CLW, despite following Green Sand moulding system, is endeavoring to contain the
rejection level within 3%. Rejection percentage for the last 5 years is produced below which show that
they are contained within the targeted limit.

Total Cast Rejection Target Rejection

Years
(in MT) (in MT) Percentage
2012-13 2976 64 3% 2.15 %

2013-14 2770 52 3% 1.88 %

2014-15 2500 55 3% 2.20%

2015-16 2285 64 3% 2.80 %

2016-17 2379 54.3 2.35% 2.28%

8A.4.1 QUALITY ASSURANCE MEASURES:

(a) Switching over to Metal Patterns/Core-boxes-

With an objective to eliminate the casting defects owing to over-aged wooden patterns/core-
boxes, induction of metallic patterns/core-boxes has been introduced.
In this regard, Hitachi Suspension Tube, Knuckle, Coupler Body etc. for locos & wagons,
metallic patterns and core boxes have been procured from out agencies. The quality of the
relevant castings pertaining to dimension and surface finish has been improved.
(b) Mechanization of Foundry Process—
Steel Foundry/CLW is in the process to adopt the Synthetic Sand Moulding System to
overcome the casting defects like- sand inclusion, poor surface finish, blow holes etc. being
induced by the existing Green Sand Moulding Practice.
(c) Other Steps—
In addition, following actions are being taken to improve upon quality/reduction in rejections—
 Periodical checking of patterns & core boxes on quarterly basis.
 Use of exothermic sleeves to eliminate chances of shrinkage and cavities & to increase
yield%.
 Use of branded Zircon based mould washes to improve surface finish.
 Use of pouring ponds and tiles of high refractoriness in metal flow areas.
 Strict control over carbon boiling during melting to avoid pouring of gassy metals.
  Use of quick lime has been introduced to bring down phosphorous content of melt.
 Strict control on heat cycle during heat treatment of castings to achieve prescribed physical
properties.
 100% load testing of Bogies & Bolsters to improve reliability in service.
8A.5 PRODUCTIVITY:
Load Lifted per Direct Worker— The Allowed Time Discharged per Direct Worker per Month for
the last 5 years has been as follows:

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

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

8A.5 PLANT & SAFETY:

8A.5.1Action taken to ensure Safety 2016-17

a) Plant Safety inspection carried out at Sand Plant (61) on 07-04-16 and Pattern repair Shop (65) on
23.04.16.
b) 48 Nos safety posters has been displayed to increase safety awareness among the staff of SF/CLW/CRJ.
c) Stack emission test carried out on 12-05-2016 by Asst. Environment Engineer, WBPCB/ASN to
maintain the pollution level within permissible limit.
d) Plant safety inspection carried out at Moulding Shop (32) on 09-05-2016 by external agency and as per
their report no NC raised in SF.
e) Surveillacne Audit on ISO & OHSAS wre conducted in Steel Foundry on 12-05-2016 and test report
received on 21-06-2016 and found within level.
f) Stack emission test report of GAD furnace conducted by WBPCB/Asansol on 12.05.2016 and test
report received on 21-06-2016 and found within level.
g) Plant safety inspection carrid out at patter shop (65) on 01-06-2016 and melting Shop (34) on 24-06-16.
h) Internal-9001:2008 (Audit No. IQA-01/16), ISO-14001:2004 (Audit No. IEA-01/16) & OHSAS-
18001:2007 (Audit No. OHSAS-01/16) were conducted in Steel Foundry on 20-07-2016 to 22-07-2016
and no NCR raised in the Audit.
i) Stack emission test report of GAD furnace conducted by WBPCB/Asansol on 12-05-2016 and test
report received on 21-06-2016 and found within permissible limit.
j) Plant Safety inspection carried out at Core Shop (31) on 19-072016 and Moulding Shop-32 (Bay3&4)
/SF on 20-07-16.
k) Departmental Safety Committee meeting was held on 13-07-2016 in th4 meeting room of SF and
discussed about different safety aspects of SF/CLW.
l) Plant safety Inspection carried out at Fettling Shop on 22.08.2016 and Sand Plant Shop/SF on 27-08-
2016.
m) Inspector of Factories /Asansol visited Steel Foundry on 06-08-2016 and discussed about safe practices
to be followed.
n) Submitted Quarterly REtu4rn form No. 23A to inspector of Factories/ASansol on 26.08.2016 as it is
statutory requirement.
o) Proposal of Safety Audit of Steel Foundry initiated on 19-08-2016 for safety of staff to comply the legal
obligation.
p) Proposal for Work Environment Monitoring in Steel Foundry initiated on 25-08-2016 as it is statutory
requirement.
q) Plant Safety Inspection carried out at Pattern Repair Shop on 14-09-2016 and moulding Shop/SF/Bay-
10&11) on 27/09/2016.
 r) Inspector of Factories /Asansol visited Steel Foundry on 06-08-2016 and discussed safe practices to be
followed.
s) Submitted Quarterly Return Form No. 23A to inspector of factories/Asansol on 26-08-2016 as it is
statutory Requirement.
t) Stack emission test carried out on 25-10-2016 by Asstt. Environment Engineer WBPCB/ASN and
collected the sample to maintain the pollution level within permissible limit.
u) Modified Plant lay out drawing of Steel Foundry approval by Chief inspector of Factories; Govt of
West Bengal has been received. Thus it complies the issue raised by Inspector of Factories/Asansol.
v) Modified Plant lay out drawing of Steel Foundry approved by Chief inspector of Factories; Govt of
West Bengal has been receivewd. Thus it complies the issue raised by Inspector of Factories/Asansol.
Plant safety Inspection carried out at MTS Shop on 10/11/2016 & Pattern Shop-65/SF on 24-11-2016.
w) Stack emission test carried out on 15-12-2016 by Asstt. Environment Engineer, WBPCB/ASN and
collected the samples to maintain the pollution level within permissible limit.
x) Copy of Change of factory Manager in Form No. 3A submitted to I.O.F./ASansol on 23-12-2016.
y) Renewal of NOC for consent to operate Form submitted on 23-02-16 to S.O./CLW/CRJ for further
action by them
z) Special cleaning drive taken on 22-03-2017 in view of GM’s visit.
8A.6 Machinery & Plant—

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

ii. Megatherm 10T Direct Arc Furnace — Complete material received. Civil work is under progress.
PDC- April 2017.
A. Supplier : M/s Megatherm Electronics Pvt. Ltd.
B. P.O. No. : 05/2009/7003/91381 dated 10-08-2011.
C. P. O Cost : ` 6,16,45,113.00
D. Present Status as on 31.12.2017 :
i. Transformer Room :Completed. (All components are placed)
ii. Cooling Tower :Civil work in water complex of 10T EAF is completed
Placement of component has been done. Cooling Water
Circulation testing to be done within 03-04-2017..
iii. Fume Extraction System Civil Work is completed. Placement of components has been
done. Duck line and Cable Termination in anel are under
process.
iv. Furnace Area Civil Foundation work including placement of Components
has been completed.
v. Pipe Line Work Water, pneumatic & hydraulic pipe line are under process.
vi. Control Panel Room Civil work has been completed. placement of components
have been done. Electrical work is under process.
 9

STAFF POSITION
9. STAFF BREAK UP
STAFF BREAK UP DEPARTMENT WISE Gr. C & D (AS ON 31.03.17)
DEPARTMENT SANCTIONED STAFF ON ROLL VACANCY
STRENGTH
ACCOUNTS
GROUP –C 535 348 187
GROUP –D 01 01 00
Total 536 349 187
ADMINISTRATION
GROUP –C 834 691 143
GROUP –D 05 05 00
Total 839 696 143
CIVIL
GROUP –C 827 701 126
GROUP –D 39 39 00
Total 866 740 126
ELECTRICAL
GROUP –C 3123 2377 746
GROUP –D 02 02 00
Total 3125 2379 746
MECHANICAL
GROUP –C 6688 5512 1176
GROUP –D 10 10 00
Total 6698 5522 1176
MEDICAL
GROUP –C 612 361 251
GROUP –D 05 05 00
Total 617 366 251
PERSONNEL
GROUP –C 299 278 21
GROUP –D Nil Nil Nil
Total 299 278 21
RPF
GROUP –C 509 430 79
GROUP –D Nil Nil Nil
Total 509 430 79
S&T
GROUP –C 58 48 10
GROUP –D Nil Nil Nil
Total 58 48 10
STORES
GROUP –C 970 600 370
GROUP –D 01 01 00
Total 971 601 370
TOTAL
GROUP - C 14455 11346 3109
GROUP - D 63 63 00
GRAND TOTAL 14518 11409 3109
 10
UNIT COST OF THE
PRODUCT
10. UNIT COST OF THE PRODUCTS
(Figures in thousands of Rs.)

a. Financial Year 2013 – 14

ED Total
Type of Direct Direct Over Total(ex. Pro. Total(in pro.
(includi
Loco Labour Materials heads Pro. Chgs.) Charges charges)
ng ED)
WAP-4 3914 52800 11886 68600 1029 69629 1400 71029

WAG-7 4413 51856 12331 68600 1029 69629 1400 71029

WAG-9 5642 101094 18064 124800 1810 126610 2800 129410

WAP-7 5225 104136 16039 125400 1881 127281 2800 130081

WAP-5 5310 112428 16462 134200 2013 136213 2800 139013

b. Financial Year 2014-15

ED Total
Type of Direct Direct Over Total(ex. Pro. Total(in
(in.ED)
Loco Labour Materials heads Pro. Chgs.) Charges pro.charges)

WAP - 4 4347 52800 14853 72000 1800 73800 1400 75200

WAG-7 4901 51856 15543 72300 1843 74143 1400 75543
WAG-9 6265 101094 23241 130600 1959 132559 2800 135359
WAP-7 5802 104136 21062 131000 1965 132965 2800 135765
WAP-5 5896 112428 21476 139800 2097 141897 2800 144697

c. Financial Year 2015-16

ED Total
Type of Direct Direct Over Total(ex. Pro. Total(in
(in.ED)
Loco Labour Materials heads Pro. Chgs.) Charges pro.charges)

WAP - 4 4315 60539 12746 77600 1400 79000 1940 80940

WAG-7 3898 56476 11526 71900 1400 73300 1790 75090
WAG-9 3920 100207 11873 116600 2800 119400 1749 121149
WAP-7 4778 101405 14817 121000 2800 123800 1815 125615
WAP-5 6490 104059 19451 130000 2800 132800 1950 134750

c. Financial Year 2016-17

Pro. Total(in
Type of Direct Direct Over Total(ex. & Total
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
 11

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:

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

ii. Regular check is conducted at shop floor regarding use of Personal Protective Equipments like Safety
Shoes, Goggles, Helmet, Nose mask etc. Staffs are continuously motivated to wear PPEs and also apprised
of the adverse consequences associated with non use of such equipments.

iii. A proper vigil is regularly maintained to determine whether all critical equipments like Crane, chain,
Pressure Vessel etc. are tested as per Statutory Rules by the agencies approved by the State Inspectorate of
factories. Do’s and Don’ts for safe operation of crane has been circulated to concerned shops.

iv. Crane Drivers, Riggers, staffs engaged for Spray Painting, Electroplating, Battery Charging, Foundry work,
operation and signaling to the cranes etc. are given regular medical check up to assess their vision, chest,
lung function etc. in compliance with the statutory obligation.

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

vi. Work Area Monitoring and HIRA (Hazar Identification and Rist Assesment) have been conducted by the
expert agency approved by the Chief Inspector of Factories in different areas inside the Factory Premises.
The deficiencies hound in course of the above work have been pointed out and the same have been
brought to the notice of concerned authorities to make necessary rectification. Conducting of Plant Safety
Audit is under process.
Accident Statistics of CLW during the following periods 2013, 2014, 2015, 2016 and upto 31.03.2017

Sl no. Year No. of Accident Type of Injury

Fatal Serious Minor
1 2013 10 01 07 02
2 2014 10 01 06 03
3 2015 03 -- 03 --
4 2016 01 -- 01 --
5 2017 03 -- 02 01
upto 31-03-17
 12
FUTURE PLANS
 Future Plan
CMO
o Proposal for tie up with HLG Hospital for emergency cases is in its final stages. Tie up with steriling
hospital/Asansol for dialysis is under process. Printing of Employees and their families health card
including those of Retired (RELHS) employees is under process.

CQAM
o 100% implementation of modified IGBT Ballast Block Assembly is to be ensured.
o 100% radiography test for DMW suspension tube (Spares) to be implemented.

Dy. CC&M
o Procurement of high power & high sensitive ultrasonic flaw detection machine under process.
o Procurement of 5 Ton UTM for rubber / polymer testing.
o Procurement of 2 Nos USFD on replacement A/c.
o Procurement of surface roughness tester.
o Procurement of XRF alloy analyser.
o Procurement of coating thickness gauge.

Dy. CEE/M
o Setting up of Solar PV Power Plant of 100 KW initially and subsequently augmentation of capacity for
10% captive consumption by renewable sources.
 13

OTHER ISSUES
 13. Other issues
CMO
 Medical Check up was conducted for 3220 workers of Locoworks, Steel Foundry and works
office.
 Cleanliness fortnight – 1st May to 15th May, in all the work places, 16th May to 31st May, in all
officers, 1st Just to 15th July in all colony areas.
 Swachh Bharat Mission – Cleanliness drives at Gate No. 1 and Kangoi Bhawan, with the
active participation of the CLW unit of Bharat Scouts and Guides on 17th Septemper 2016.
30th September to 2nd October – special cleanliness drive and Swachchta Sapath.
 Indian Railway Ophthalmic society conference was organized by the Scientific Association of
Railway Medical Officers, CLW/Chittaranjan, from the 21st to 23rd of October 2016.
The following M&P items were commissioned on 15th August 2016.
 Mobile X-ray
 Difibrillator with facility of external pacing, 2 Nos.
 Horizontal high pressure sterilizer.
 The following M&P items have been received and have been kindly inaugurated by GM/CLW
on 26.01.2017.
o Computerised Tread Mill Test Machine
o Biophasic Defibrillator with transthoracic pacine
o Advanced ICU Ventilator.
 School Health: 1075 students were examined in the year 2016.
 World cancer day was observed on 4th February 2017 by organizing awreness programme in
the Seminar hall of KG Hospital.
 Mental health awareness seminar at Locoworks (Shop No. 19) on 21st February 2017.
 No smoking day was organized at Steel Foundry workshop on 10th March 2017. CMO/CLW,
Sr. DMO/P and ADMO/ENT were present at the Function. An audio visual presentation was
organized in the hazards of smoking was discussed in details.

Dy. CC&M
 C&M post is lying vacant since last 1 year.
 Two post of AC&M lying vacant since last 2 and ½ years.