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South Central Railway
Carriage Workshop
Lallaguda
Brochure - 2020
Page 1 of 60
1.0 General
1.1 सकषिपतइकषिहास Brief History:
The Carriage Workshop / Lallaguda was established in 1893 as the Locomotive,
Carriage and Wagon Workshop of the Nizam State Railway (NSR). The Government
of Hyderabad took over direct control of the Railways in 1930 and renamed it as the
Nizam Guaranteed State Railways (NGSR).
It is one of the oldest surviving examples of modern Industrial Architecture in the Twin
Cities. It signaled the beginning of major industry in the state. A few structures in use
today date from the time of the workshop’s initial commissioning.
The precinct provides us with a glimpse of not only the industrial advances made over
more than a century but is also a repository of heritages from a bygone era. Restored
wagons, coaches and a variety of artifacts relating to railway history have been
preserved and quite a few are displayed at the site. Notable among these one finds a
meticulously restored coach of 1886 vintage.
South Central Railway was carved out on 2nd October 1966, and Lallaguda Workshop
went on to become a major workshop of the zone. It continued to be a composite
workshop for MG/BG rolling stock till 1973. As a result of phasing out of steam locos,
the Workshop took up POH of all types of BG coaches and hence rechristened as
“Carriage Workshop” during 1997.
Page 2 of 60
1.2 परमखउपलकषधिया Major milestones:
1893 Established as Loco, Carriage and Wagon workshops under “NIZAM’S GUARANTEED STATE RAILWAY”.
1951 Brought under Central Railway. 1966 Carved out as South Central Railway. 1975 POH of BG steam cranes. 1981 POH of AC coach. 1997 Rechristened as CARRIAGE WORKSHOP. 2000 Awarded ISO-9002: 1994 Certification. 2003 Commenced POH of DHMUs trailer cars. 2006 Commenced POH of EMU TCs and Tower wagons. 2007 Awarded ISO-9001: 2000 Certification. 2007 Commenced 18 months POH. 2008 Commenced IOH of bogies (9 months). 2009 Commenced Refurbishment of coaches. 2009 Commenced modernization of workshop (from Nov’09). 2011 Commenced POH of power cars of DHMU and DEMU. 2012 Awarded ISO 9001:2008 Certification. 2012 Commenced LHB Coach SS1 Schedule. 2013 Commenced LHB Coach SS2 Schedule. 2015 Commenced POH of EMU & MEMU Motor coach. 2015 Commenced SS1 of Double Decker coaches. 2015 Implemented WISE-II. 2016 Commencement of LHB Coach SS3 Schedule. 2016 Implemented IPAS. 2016 Accredited with 5S Workplace Management System (WMS). 2016 Accredited with IMS, Containing QMS (ISO 9001:2015); EMS (ISO 14001:2015); OSHAS (180001:2007) & EnMS (ISO 50001:2011). 2017 Awarded Green-Co Silver Rating by CII/Hyderabad. 2017 Accreditation of NABL certificate to CMT Laboratory. 2017 Received best innovation award for “Automated single car test rig”. 2018 Received Railway Minister Shield (sharing) for “Best Workshop
over IR”. 2019 Received “Best Establishment Award” for imparting training to 550
Trade Apprentices for the year 2018-19. 2019 Received “Gold Prize” for Energy conservation in 2018-19
from “Her Excellency Tamilisai Soundararjan , Honorable Governor of Telangana on 20-12-19.
2020 Received Certificate of “Best Energy Efficient unit” from Confederation of Indian Industry in August 2020.
Page 3 of 60
1.3 मखयकषिशषिाए Salient features:
2. Total area of Workshop 13.97 hectares
3. Covered area 4.25 hectares
Rail track length 8.25 kms
4. M&P 549 nos.
5. Railway quarters 584 nos.
6. WMS budget Grant 2020-21 Credits –322 Crores (Mech- 256.14 ; Elec – 65.86crores) Debits – 301.72crores (Mech – 240.67 ; Elec – 61.05)
7. Avg Monthly Target 2020-21 a) POH –133.64 VUs (RB) b) IOH of bogies – 230 nos c) IOH of Fiat Bogies (SS1)- 58 nos
8. Average power consumption/month 2020-21.
1.60 lakh units.(including Solar)
9. Manpower as on 01.01.2021. (Mech + Elec)
Sanctioned Actual Vacancies
3256 2660 596
1.4 काययशालाकीिियमानगकषिकषिकषिया Present activities of the Workshop:
• POH of AC & Non AC BG ICF/RCF/BEML coaches.
• POH of LHB Coaches i.e. SS-II and SS-III schedules
• POH of Duronto (Hybrid) coaches
• POH of DEMU Power &Trailer cars & SPART coaches
• POH of EMU/MEMU coaches
• POH of Tower cars
• IOH of ICF conventional bogies for divisions.
• IOH of FIAT bogies for SS-I schedule of LHB coaches
• POH of Defence owned coaches.
• Supply of wheel sets to divisions.
• Fitment of Bio-toilet tanks on coaches.
• Over hauling of DVs, BMBCs & other air brake components for division.
• Nodal workshop for implementation of WISE-II
• Chemical and Metallurgical testing/analysis of components.
• Manufacturing of all types of locomotive filters at LOFP/SC.
• Rail Bogie Karkhana/Yadgir : Manufacturing of FIAT bogie frames
• Basic Training Centre offers a) Refresher courses to Artisan Staff
b) Imparting training to Apprentices engaged against Apprentice Act, 1961
c) Skill development programmes.
Page 4 of 60
1.5 सगठनचारयOrganization chart:
S. Rabindranath Sabar
Sr.DEN
S. Dakshna Murthy
AEME/LOFP
Prasun Chakraborty
CWM
[Vacant]
PE/LGDS
Prashant Kumar
Dy.CME/LGDS
N. Ganga Raju
Dy. CEE/LGDS
Ch. Eswaraiah
Dy. CMM
Y. V. S. Prakash Rao
WAO
G. Seshadri
AWM-II
K. Krishna
Chaitanya
AWM-III
Sk. Salauddin
AWM-I
K. Srinivasa Rao
ADEE
K. Thavare Naik
SMM/M&E
K.K. Subramani AWAO
R. Papa Rao ACMT
S. Laxman Rao
WPO
S. V. S. Raju
AWM/RBK/YG
B. S. Sarswati
IPF/RPF
Sandeep Kumar
WM/LGDS
Page 5 of 60
1.6 लालागडाकारखानकालआउर Layout of LGD Workshop.
Page 6 of 60
1.7 परमाणनCertifications Achieved:
• 5S – Workplace Management System (WPS): 5S recertification done on Feb’20. Validity up to Feb’2023.
• Integrated Management System (IMS): (Four International standards).
Awarded to M/s.IR Class/ Secunderabad on 31.05.2020.
Agreement to be signed, delayed due to COVID-19 pandemic.
Firm yet to respond.
• Green-Co rating system “Silver”Certificate awarded on 26.04.2017. Valid upto March’2020. Revaluation under process.
• ISO 3834 – 2: 2005: (Quality requirements for fusion Welding of metallic materials)
Certificate awarded on 26.04.2017 and valid upto 25-4-2020. Agreement for recertifcation to be issued to Firm. Firm yet to respond.
• NABL Accreditation for CMT Lab: Certificate awarded on 06.10.2017 and recertified for another
two years in Sept’19. Valid upto 5-10-2021
• LEAN SIX SIGMA Certification Certificate awarded on 30.01.2019
A one time certification.
Page 7 of 60
2.0 कषनषपादन Performance:
2.1 POH Outturn - Target/Actuals (VUs):
Note: a)Target for 2020–21 is 1583 coaches as per HQrs and 1605 as per RB.
b) In 20-21, actual outturn less due to lock down in April’20 and May’20.
2.2 Type wise outturn –last 3 years in (VUs)
Type wise 2018-19 2019-20 2020-21 (up to Dec’20)
Tar Actual Target Actual Annual Target (RB)
HQ Annual target as
per arising
Target (upto
Dec’20)
Actual (upto
Dec’20)
AC coaches 300 326 324 312 288 288 200 200
Non AC 1008 1019 1080 1085 996 994 739 739
LHB 44 53 45 44 108 86 45 45
EMU/MEMU ( incl of PC)
65 76 82 74 101 101 54 54
DEMU ( incl of PC)
220
175 216 194 97 97 60 60
SPART ( incl of PC)
04 17 13 09 09 05 05
Tower car 16 12 12 06 08 08 08
Total 1637 1669 1776 1734 1605 1583 1111 1111
16371733
15831669 1734
11111247 1331
1111
2018-19 2019-20 2020-21 (up to Dec'20)
Target Actual Prop actual up to Oct'20
Page 8 of 60
2.3 Outturn of Power cars:
Year EMU/
MEMU DEMU SPART
2017-18 26 47 6
2018-19 21 37 3
2019-20 21 40 7
2020-21
(up to Dec) 54 60 5
2.4 Ineffective Avg. Holding of coaches:
Year Avg.holdings
2017-18 74.42
2018-19 79.98
2019-20 74.97
2020-21
(up to Dec)
57.39
2.5 Average Cycle Time (in working days):
2.6 Average POH Cost/VU ( in Lakhs):
9.91
19.15
10.81 11.7912.14
18.95
13.93 14.52
11.27
23.15
14.3212.18
Non-AC AC EMU DEMU
18-19 19-20 20-21 (Q.E.Dec'20)
8.28
14.5413.64
12.511.67
9.16
11.610.01
15.2913.06
8.05
17.12
10.69
14.5112.35
Non-AC AC LHB EMU DEMU
18-19 19-20 20-21(up to Dec)
Page 9 of 60
2.7 Average NTXR initial advice (in % age):
2.8 Fitment of New Bio-Toilet tanks (No.of tanks):
Note: Bio toilets have been provided on all eligible PCV coaches.
1.811.90
2.04
1.50
17-18 18-19 19-20 20-21(up to Dec)
% In
itia
l ad
vise
17-18 18-19 19-20 20-21(up to Dec)
2339
1525
920
20
17-18 18-19 19-20 20-21 ( up toDec)
No
.of
tan
ks
17-18 18-19 19-20 20-21 ( up to Dec)
Page 10 of 60
2.9 Scrap Disposal (in MT) (Mech. + Elect.):
in MT
2.10 Support to Divisions (in nos)
6124
5003
13151374593 337
18-19 19-20 2020-21(up to Dec)
Ferrous Non-Ferrous & others
2442
110
421
22412460
258 354
19531794
430
147
564
IOHed Bogie Fiat Bogies BMBC Wheels
18-19 19-20 20-21 ( up to Dec)
Page 11 of 60
2.11 Important modifications undertaken on coaches:
S.N Item Cumulative so far
(upto Dec’20)
1. Conversion from ‘P’ trap to ‘S’ trap (no .of coaches)
938
2. Controlled discharge flushing valve for Bio toilet coaches
2490
3. SLR coaches modified to bogie bracket and chain with trunions block in hand brake arrangement.
470
4
Retro fitment of coaches with threaded joints in lieu of ferrule joints near cut off angle cock in the FP & BP pipe arrangement of ICF conventional mainline coaches.
735
5 Coaches modified from single pack to BDG in CBC coaches. ICF coaches.
158
6 LHB toilet side window modification - AC 72
7 Retrofitment of LED lights in TL & AC coaches 544
8 AC Coaches modified with WRA Mono block type compressor type during this month to improve reliability
26
9 Provision of Exhaust fans in Bio Toilet AC coaches (each coach consists of 04 No’s)
194
Page 12 of 60
3.0 उतकषटिा का क दर Centre of excellence:
3.1 Air brake shop (2017-18):
Housekeeping Test benches
BMBC-Overhauling section Air brake shop sub stores
3.2 CBC shop
Page 13 of 60
3.3 Roller Bearing section:
3.4 Welding laboratory (BTC) (2019-20)
Pneumatic Balancer for
handling Axle Box Pneumatic Balancer for
handling roller bearing
Air Gauge to measure Inside
Diameter of Roller Bearing Automatic Grease dispensing
machine
Page 14 of 60
3.5 RMPU Section (19-20)
Digital intelligent microprocessor inverter based synergic pulse MIG/MAG welding systemWith down draft fume extraction system
Welding laboratory equipped with digital intelligent microprocessor
inverter based synergic pulse MIG/MAG, and TIG welding systems.
AC-Stores
Dispatch section Motors Overhauling
Assembling section Cleaning section.
RMPU - Layout
Page 15 of 60
4.0 Innovations
4.1 Innovations done by the Workshop in 2017-18
S.no. Description Photograph
1.
Automatic single car test rig for LHB: Automatic Single Car Test Rig is used to perform Air Brake testing on LHB coaches to ensure proper functioning of Air Brake System. This testing procedure is generally done during the POH of LHB coaches or change of any Air Brake sub-assembly.The Automatic Single car test rig minimizes the time for testing, avoids human errors, and records the tested parameters and stores the data in database. And it gives saving of 2 employees per shift and assures accuracy in the job.
2.
Automatic Grease dispensing machine:
Automatic filling of grease into the roller bearing
directly from the grease drum. Quantity to be filled is
controlled by PLC embedded in the circuitry
3.
Integrated Test Bench for WSP & brake equipment of LHB Coaches )Knorr Make: Integrated test bench with real time simulation of train speed, designed and developed in-house on 02-08-2017, is a replica of Complete Disc Brake System of Knorr make fitted in LHB Coaches .This integrated test bench can check the functional test of complete disc brake equipment and WSP equipment of a LHB coach as a complete coach set .
Page 16 of 60
4.
Air spring test stand: The Air Spring Test bench is developed to check any air leakages /rubber burst/ O-ring damages of the air bellow during POH. The Air bellow is tested with air pressure of 10kg/Cm2. It helps in reducing the laborious work of finding out leakages/damages in air bellow, so that air bellow can be rectified or replaced with new spares
5.
Automated Electro pneumatic Brake test stand. This EP brake system provided in EMU, DEMU, MEMU PCs is for brake application, works in conjunction of Electrical and pneumatic brake control application
6.
Hydraulic press fixture for Scragging of Draft Gear of Faively make Hydraulic press fixture for Scragging of Draft Gear developed in-house for scragging of draft gear equipment during POH repairs. The main features of the equipment is to compress the draft gear to 430mm by using hydraulic press fixture and release the draft gear to 512mm,by releasing the hydraulic pressure. Recording serial number of assembly and corresponding period value for future reference.
7.
Automatic Integrated test bench for Air Spring control equipment. Automatic Integrated test bench for Air Spring control equipment developed in house, for testing Air spring Levelling valve & Duplex valves which are used for controlling secondary Air suspension of DEMU/EMU DPC and TC coaches. This test ensures quality of above valves for air suspension, before fitment on coach, thus ensuring coach reliability
Page 17 of 60
8.
Horizontal Tensile Testing Machine for screw
coupling and draw hook
The software programming for horizontal tensile testing machine have the advantages of hydraulic power pack for controlling the pressures, measurement of elongation to the respective load applied measurement of load, sensing of the pressures, auto cut off of hydraulic pressure item tested, recording of elongation, load applied, pressures, date tested and name of the staff tested with print out.
9.
Sunk in type Hydraulic Jack commissioned:
Sunk in type Hydraulic Jack commissioned at
Corrosion shop to aid in precise lifting of coach
bodies during the corrosion repairs.
10.
De-clamping and Re-clamping device
De-clamping and Re-clamping device
Commissioned for lifting and lowering of FIAT
bogie during POH of secondary suspension.
Page 18 of 60
4.2 Innovations done by the Workshop in 2018-19
S.no. Description Photograph
1.
Pre-cleaning machine for Roller Bearing of
Coach wheels:
Pre-cleaning machine for roller bearing of wheels is developed In-house by Millwright staff of LGDS. It works on the centrifugal force, on rotating the roller bearing, an air pressure of 8kg/cm2 is applied on the roller bearing. The grease on the roller bearing is thrown out of bearing. For manual cleaning of Roller bearing, it takes around 2 to 3 minutes/Roller bearing. By this machine, we can clean two roller bearing in 2 minutes; 15-20 sec for loading, 15-20 sec for unloading, 1 minute for cleaning.
2.
Computerized Automatic DV test bench for
testing Distributive valves of Faiveley make in
LHB coach Distributor
Valve Testing is performed whenever during
SS-II and SS-III of coach to ensure proper
functioning Automatic DV test bench is utilised
to test each distributor valve as per test
procedure/parameters of OEM manuals
3.
Software on wheel shop Data recording
system
software on wheel shop Data recording system
has been developed in house with various
parameters like Receipt of wheels, wheel tread
profile, Roller bearing inspection, ultrasonic test
of wheel assembly, Wheel and Axle press-in
and press out particulars
Page 19 of 60
4.
Exhaust Muffler Cleaner – DEMU
Dust chamber for cleaning of exhaust mufflers,
exhaust pipes and panel filters of DEMU
coaches is developed in-house at power car
shed
5.
Press-in and Press-out Fixture for Silent
block of Control arm for FIAT Bogies
Special Team of LGDS Developed Press-in
and Press-out Fixture for Silent block of
Control arm for FIAT Bogies. Earlier, the
fixture available at LHB bogie section served
the purpose of only press-in operation of silent
block of Control arm of FIAT bogie. It was very
challenging to press-out silent block from
control arm. To overcome this problem, Fixture
for press-in and press-out the silent block from
control arm was developed in-house, which is
very useful.
6. Primary Spring clamping & De-clamping
machine- LHB Coaches
7.
CBC functional test fixture
A CBC functional test fixture was commissioned in the CBC shop which is inaugurated by PCME on 04-01-19. According to RDSO quality audit check sheet, overhauled CBCs are to be checked for Functional test. This was demonstrated to PCME.
Page 20 of 60
4.3 Innovations done by the Workshop in 2019-20
S.no. Month Description Photograph
1. April’19 A Helical Spring muck cleaning
machine:
A Helical Spring muck cleaning
machine:
i.Semi-automatic machine.
ii.Fabricated in house.
iii.Human effort has come down and
effective.
iv.4 springs are cleaned in one cycle i.e
degreasing and cleaning in a cycle of
6 to 7 minutes.
2. Jun’19 A Kiosk was developed in house and
installed in wheel shop for Self-
learning:
A Kiosk was developed in house and
installed in wheel shop for Self-learning
and Performance evaluation of Wheel &
RB Sections. This enhances the
technical knowledge of the workforce.
3. Aug’19 Automatic Grease Dispensing Unit :
Automatic Grease Dispensing Unit for
direct mounted roller bearings at both
ends of wheel set simultaneously.
4. Aug’19 Development of Wheel Data Base Management System: A Wheel shop Data base management system was developed in house Details of roller bearings & axles mounted on wheels sets are computerized, thereby facilitating easy traceability
Page 21 of 60
S.no. Month Description Photograph
5. Aug’19 Kiosk for self-learning and
performance evaluation application
for welding training.`
6. Aug’19 Website of BTC under
scr.indianrailways.gov.in
7. Aug’19 Centre of Excellence in RMPU.
Computerized RMPU cooling test
facility.
8. Dec’19 CBC lifting gadget (500kg).
Facilitates lifting and transportation of
CBCs.
9. Jan’20 LHB bogie work station with
Manipulator for LHB coaches
LHB bogie work station with Manipulator
for LHB coaches Disassembly and
assembly of LHB bogie components by
moving up/down and rotating the bogie
frame to 1800 for attention.
10. Jan’20 Dynamic wheel balancing machine
for LHB wheel sets.
It is Used for correction of unbalanced
new LHB wheel sets.
Page 22 of 60
11. Jan’20 Industry 4.0 in roller bearing section.
▪ 9 machines connected against 11 ordered. Report generation under development.
▪ 2 machines under break down .i.e. One VTL and one AJTB.
12. Jan’20
LHB shock absorber testing machine
Testing of yaw damper and other
dampers of LHB coaches
13. Jan’20
Helical spring load deflection testing
machine for LHB coaches
14. Jan’20
Computer Controlled Direct Reading
Optical Emission Spectrometer for
Analysis of Metal & Alloy
Compositions
15. Jan’20
Computerized Universal Testing
Machine (CUTM) a CMT Lab.
Page 23 of 60
4.4 Innovation during 2020-21
S.no. Month Description Photograph
1 July Testing gadget for DEMU ventilation
pump - In order to ensure the proper
functioning of the ventilation pump before
fitment on coach, this test gadget was
developed in house to test the
performance of the pump. If any
malfunction of the hydraulic motor is
detected, it would be attended
immediately. Grouping of new ‘C’ groove
belts is also possible with this gadget
2 July Mobile test gadget for radiators/ heat
exchangers.
A Hydraulic mobile pressure testing gadget was fabricated in-house for testing of radiators and transmission oil heat exchangers. This mobile gadget has facilitated pressure testing of radiators and heat exchangers at site, which hitherto was not available
3 Oct Automatic thermal scanner cum
sanitizer Dispenser machine was
developed in an eye-catching robot
shaped design and other sanitising
machines of 10 nos. also provided for the
use of staff.
4 Oct Virtual Welding Simulator is procured to
impart virtual training at BTC to welders
to experience efficient welding techniques
on a simulation environment to feel a real
welding process before attempting on a
real welding machine.
Page 24 of 60
5 Nov Winch With Pulley Arrangement: this arrangement is developed at D1 & D2 lines in new DEMU shed for smooth movement and exact placement of coaches. This arrangement enhances safe working environment and also helps the staff in saving time.
6 Dec Laser Engraving Machine - It is used to engrave the POH date and Station on Roller bearing in standard pattern and all the data is stored in computer.
Page 25 of 60
5.0 Good Works
5.1 Good works done 2019-20
S.no Description Photograph
1
To reduce the gap between backrest in
DEMU coaches.
• Modification is under trial.
• Use of LP sheet to secure and fill-up the
gap between two seats in DEMU coaches.
Before After
2
Jute Felt on Corners of Berths:
Providing Felt on side surfaces of seats and
berth metal frames to give cushioning effect at
sides also. This will prevent tearing of rexine
at sharp edges of seats and berth Frames
3
PVC Soft Sleeve:
Providing PVC soft sleeve for all berth chains
which will give soft feel and aesthetic look
4
Spring pallets for handling LHB Springs:
A new pallet has been made for transporting
LHB Springs between shops and also to
prevent damage to them.
5
Rexine Moulding:
Bed cum backrest, where staples were
provided previously now is being provided with
a rexine
moulding to prevent giving up of rexine and
improve aesthetics
Page 26 of 60
6
Pasting Rexine before Stapling:
Pasting rexine on back side of seats and
berths
compreg sheet before securing with staples
to give extra strength
7 Reducing the length of flap from 14 “ to 8”
Before After
8 TC Backrests provided with metal strip
back side to prevent rexine giving up
9
Fitment of Fire-Extinguisher:
Workshop has started fitment by using bolt &
nut instead of screws. Work started since 4-2-
20. Divisions are advised to watch the
performance.Fitted in 112 coaches as on date.
10
Repair of Body Bolster at location away from
Centre pivot and side bearer of Coach
No.12063
Page 27 of 60
11
Isolation coaches:
One Isolation coach prototype (coach no.SC
GSCN 00205) was made ready on 31-3-20
which was inspected by PCME on 31-3-20.
The second Cabin at each end of the coach
i.e. 2 nos were converted for keeping COVID-
19 patients under isolation/ quarantine (Details
at PPT enclosed).
12
A set of new synchronised lifting Jacks were
collected from Jamalpur workshop These are
utilised in corrosion shop line no.6 for
facilitating lifting of coaches and keeping them
on trestles for undertaking heavy corrosion.
Lowering of the coach on overhauled bogies is
done here itself, thus avoiding multiple
movements of coaches to Lift lower shop
crossing the two traverser lines. This is found
very helpful as it has reduced considerable
time on shunting of coaches also.
13
A Central Railway coach no. CR LWCZ 18632
was received for special repairs. This was
found with all the window frames missing. This
was made good in addition to the Special
repairs attended on the coach. A total of 9 nos
of new full body window frame arrangement
were provided by taking material assistance
from RCF.
15
Provision of 8 additional window bars at 2nd
window from main doors in GSCN coaches is
ensured. Work commenced from May’19. 100
% provision ensured during POH.
Page 28 of 60
17
Improving bio toilet ventilation system to avoid
bad odour
18 Exhaust bellow in 1600 HP DPC fitted in DPC
No. 15083. Designed and supplied by OEM as
per LGDS advise
19
Exhaust Mufflers were getting cracked. Same
were replaced in 6 DPCs duly claiming
warranty and also made a trail of
Manufacturing exhaust muffler with
available SS: 301 which is being used for
trough floor manufacturing which was done
in-house fabrication. Same was fitted in
DPC No. 15083
20
Developed in-house.Eliminate the spreading
of dust during cleaning of Traction motor
using pressurized air.
Environment friendly
21 A safety ladder for coach Roof painting was
developed in house
22
Corrosion Attentionof outer head stock in 2017
built ICF coaches:
Five coaches (2017 built) which were received
for first POH had corrosion of outer head stock
thickness below the permissioble level.these
coaches ICF had sent representative for
inspection.as the firms have not attended.
LGDS has given strenghthing arrangement
along with ribs for the head stock and turned
them out with due intimation to ICF.
Page 29 of 60
23
13th International Railway Equipment
exhibition (IREE) was held from 22.10.19 to
24.10.19 at AERO city/NDLS. This was led by
Shri. Prasanth Kumar Dy.CME/LGDS along
with Supervisors and staff were represented
SCR for the exhibition. .
24 Inauguration of Bio toilet maintenance shed
for POH on 07.06.2019 by PCME/SC.
25 A Contractors performance review meeting
was conducted on 16.05.2019
26
Mock Drills/Civil Defence Demo/Elect Shop
Drill Demo by CR & SCR Civil Defence
Team on-Rescue Management Fire
Fitting/First Aid &Evacuation from High-rise
Buildings during Emergencies
27
World Environment Day was celebrated on
06/06/2019 Theme was ‘Air Pollution’. An
awareness program was conducted on the
Causes & Effects of Air Pollution with an
audio/visual presentation. Banners and
posters were displayed across the workshop
for spreading awareness
28
A water balance study was conducted in
workshop through outside agency for the
following:
1. Improve ground water level by rain harvesting pits at 5 locations.
2. Recycling of sewage water by means of constructing wet land of feasible capacity at low lying area.
Page 30 of 60
29 Cornicorpus plantation
Total plants: 200 nos were planted near Bio-
tank Maintenance Shed.
30 Miyawaki plantation
Total Plants: 475 nos were planted near Sand
Blasting Machine
31 Green toilets for women employees:
• Developed In-house.
32
E-toilet as a part of Green-Co initiative is
under commissioning
• IT Enabled toilet.
• Automatic self-cleaning,
washing/flushing mechanism.
• Procured through GeM.
• Water tank Capacity: 225 Ltrs
33
Model toilet.
Sensor based flushing system for toilets.
Proper Ventilation and Natural light is
developed to reduce energy consumption.
34
Effluent Treatment Plant (ETP).
Power car shop-20KL/day.
For treating the effluents released from
Cleaning of Power car components and
cleaning of IOH bogie frames
Wheel shop-10KL/day. For treating the
effluents released from Roller Bearing
Cleaning Plant.And also, Effluents released
from nearby Shops are diverted to these ETPs
for treatment.
Page 31 of 60
35
“BEST ESTABLISHMENT AWARD” was
given to BTC/Lallaguda by Sri.Ch Malla
Reddy, Hon’ble Minister for labour,
Employment, Women & Child Development
Government of Telangana for imparting
training to 550 Trade Apprentices for the year
2018-19 on 15.10.19.
36
“JOHN MORRIS FIRE ENGINE-1914 built”
has won the “53rd Statesman Vintage and
Classic car rally” held at Delhi on 10th
Feb’2019. The Fire Engine is maintained by
LGDS staff at NRM/NDLS.
37
Buffing of all stainless steel items like wash
basins, toilet pans & wall protectors are
carried out to improve aesthetics
38
To improve general appearance of berth
upholstery fitment:Stiff and tight fitment
ensured. Jute felt along the corners provided
Double stitching of rexine to avoid wrinkles.
39
Window curtains are stitched with six frills and
twelve rings to maintain uniform height when
hung so as to avoid sunlight ingress, and
when curtain is closed it enormously improved
the internal aesthetics in POH of AC coaches.
229 coaches provided in current year
Page 32 of 60
40
Provision of Emergency lights:
All AC coaches are provided with LED
emergency lights and in all non-AC coaches
with more than 10 years residual life have
been provided with emergency lights.
41
Provision of mobile charging sockets:
All AC and CN coaches are provided with
mobile charging facility. As per the directives
of Railway Board, CN, GS, CZ & SLR
coaches are provided with 18 mobile charging
sockets.
42
Berth Indication Light & Night Lamp:
All AC coaches are provided with berth
indication light & night lamp for easy
identification of bay and berth. All coaches are
provided with 100% LED night lights
Page 33 of 60
5.2 Good work done during 2020-21
S.No. Month Description Photograph
1 Isolation coaches: 76 coaches were converted to COVID-19 Isolation wards as per Railway Board instructions during April & May’20. The second Cabin at each end of the coach i.e. 2 nos were converted for keeping COVID-19 patients under isolation. One toilet was converted to bath room at one end. Middle berths were removed.
2 2000 nos of Coverall were
manufactured and supplied to Central Hospital / LGDS on 20-5-20 as part of PPE manufacture for COVID-19 pandemic.
3 17295 face masks were
manufactured and distributed to
HQrs, Divisions and LGDS staff.
4 Project Utkristh phase II 202-21:
• Target 23 rakes.
• 14 Rakes turned out.(upto Dec’20)
• Bal – 9 rakes
5. May’20 Coach No. SC VPH 99843 of Train
No. 07258 special express of HYB
Division was taken for special
repairs “Near Body sole bar crack at
SC End Trolley” at LGDS in view of
demand for parcel vans for
transportation of essentials during
lockdown period
6. May’20 LGDS has taken a step forward for
welfare of contract staff by providing
groceries during COVID-19
pandemic crisis. Staff of LGDS
contributed voluntarily an amount of
Page 34 of 60
Rs 1,17,000/- . Groceries i.e. Wheat
powder, Tur Dal, Sugar, Upma rava,
Tea powder, Tooth paste, Toilet
soap, Vim liquid, Rin washing
powder were packed in suitable
bags and then distributed to 252
contract staff at the canteen on 30-
5-20.
37. Aug’20 LGDS secured “Energy efficient
Unit award” at 21st CII National
award for Excellence in Energy
Management 2020: Virtual event
held on 25th-28th Aug 2020.
8. Aug’20 First e-pass issued through HRMS
by the Workshop on 27-8-20.
9. Sept’20 Mass covid-19 RT-PCR testing was
organized for employees of LGDS,
EWS/LGD, Scrap depot & FBWP/Mly
at New Car parking area of the
workshop from 22.09.2020 to
26.09.2020. All staff, supervisors and
officers had undergone the testing at
the centre. A total of 3300 staff have
undergone the COVID test. 151 staff
of LGDS have been tested positive.
These staff have been advised to
consult the Four nominated Doctors
of Railway Hospital / LGD for further
treatment.
Page 35 of 60
10. Sept’20 Thavare Naik Karmathota,
SMM/M&E/LGD has been GOLD
CERTIFIED for completing the
online assessment that covered
ADVANCED functionality of the
Government e-Marketplace (GeM)
portal.
11. Nov’20 As per Railway Board instructions vide lr.no.2002/M©/137/7 dt.07.10.2020, LGDS planned to convert four VPRs into NMGs. In this regard one VPR is converted into VPU and shop out done on 30.11.2020.
12. Dec’20 As per modification the material
required and operation involved was
managed in –house to complete the
modification job.
By implementing lock pin
arrangement on Dellner Coupler,
lock lift safety can be ensured.
Page 36 of 60
5.3 कषडधबोमसरिासकषनकषििकरनकीपरणाली Systems to ensure safety in
coaches:
Grit blasting of bogies are undertaken to clean the bogies to the bare metal to detect damages/cracks, if any.
Cleaned bogies after grit blasting are subjected to chalk testing to detect damage/cracks in bogies. About 8.0 % is the rejection.
Tests on springs: Springs are subjected to shot blasting for thorough cleaning and detection of crack followed by Magna-flux test to detect sub-crack, if any and finally tested for tensile strength on computerized load testing machine.
Digital bore gauge for measuring bore of Wheel disc: Digital bore gauge is used to accurately measure the bore diameters of Wheel discs
Zyglow& DPT tests of critical components: Axle box, LHB brake discs, bogie frames & roller bearings are subjected to Zyglow & DPT tests to detect cracks.
Overhauling and testing of Alarm-chain: Alarm chain setting is certified by NTXR for all the coaches under POH.
MAGNAFLUX testing to detect sub cracks
Shot blasting for thorough cleaning
Computerized load testing
Page 37 of 60
6.0 सिचालनपरकरियािीन Automation under process.
S.No Innovations Details
1. Industry 4.0 • Being installed by M/s Parivartan Automation – RaiBareli UP.
• Total 11 machines are covered.
2. LHB Manipulator. Machine commissioned on 29.07.2020
3. Automation of Spring shop
• Ultra-Model Facilities at Spring Shop (Centre of Excellence of Spring Shop): o Load deflection testing machine with lateral
measurement for flexi coil springs o Renovation of existing conveyor system of springs
shop proposed under umbrella works o Automation of Spring Testing Machine o Magnetic Crack detector for coil spring for LHB
coaches
4 Integrated Station for LHB FIAT Bogie Assembly and Disassembly
o Umbrella Works 2019-20 sanction: Cost Rs. 15,15,25,000/- o Automation in working, inspection, record keeping & record
transmission in workshops” for both Lallaguda &Tirupati workshops. Allocation for SC Rly under Umbrella Work PB No. 660 of 2020-21.
o Detailed Estimate vetted by unit finance for Rs.
15,39,83,895 and the same along with Technical specification/Scope of work is sent to HQRS on 09.10.2020 for onward submission to COFMOW for procurement
Page 38 of 60
7.0 एम&पी, काययऔरआिकषनकीकरण M&P, works & modernization:
7.1 Works Programme (2020-21):
(Rs. in crores)
Name of work &
Sanctioned Cost
Expenditure (upto 19-20)
Revised Grant 2020-21
Expenditure 2020-21 (Upto
27.01.2021)
LHB Shed (19.1crores) sanctioned : 12-13
7.16 3.03 1.7206
Special Coaching Stock Shed (11.91crores) sanctioned : 12-13
2.03 2.32 1.4737
7.2. Modernization:
Objectives :
a) Augmentation of POH capacity viz., from 100 to 120 coaches/month
b) Improve the layout leading to decongestion of Workshop and
c) Provide infrastructure for expansion activities.
(Rs. in Crores)
Departments Sanctioned cost
Grant Expenditure (Upto 27.01.2021)
Civil 42.23 48.54 43.15
Mechanical 40.39 20.41 18.76
Electrical 8.23 7.89 9.40
S&T 0.69 0.70 0.21
Total 91.54 77.53 71.52
Page 39 of 60
7.3 Modernization works under Progress:
Description of the work
Cost (lakhs)
Status
Pre-inspection shop
163.35
a) Location - Infront of existing Lift & Lower shop b) 31m X16.16 m covered shed completed. Laying of
Surface track completed and pitline work completed
c) For 34mx8m Shed completed and pit line work completed
d) Final stage of completion e) PDC – Feb, 2021
7.4 Umbrella Works:
S.no. Name of Work and Sanction Year Sanc. Cost Status of Work
Sanction of 2018-19 : Up gradation of Critical Work Centres of Rolling Stock Works Shops, PB No. 655 of 2020-21
1.
Renovation of existing
conveyor system of spring
shop at LGDS
2.26Cr Indent forwarded by HQRS to COFMOW on 15.06.2020. Specification under finalization at COFMOW
Sanction of 2019-20: Up gradation/Improvement in Infrastructure and Augmentation of Maintenance and Manufacturing Capacity (PB No. 661 of 2020-21)
1
Augmentation CCTV
surveillance system in LGD
shop 0.39Cr
a) Specification and drawing
finalized at LGDS.
b) Proposal for processing
the work through works
tender is with unit finance.
c) Reply awaited.
2
Bogie Frame Painting shed
1.6Cr
Detailed Estimate under vetting at
unit finance
3 Construction of new shed for stacking stores items
2.0Cr Work dropped
Sanction of 2019-20: Automation in working, Inspection, record keeping and record transmission in
Page 40 of 60
workshops (PB No. 660 of 2020-21)
1.
Integrated bogie assembly line and disassembly line
15.39 Cr
i. Item under procurement at COFMOW. Draft COFMOW specification for item has been received for comments/confirmation on 07.12.2020, the same is scrutinized and sent to COFMOW on 11.01.2021.
2.
Real time feeding and backup of shop level data with hand held devices through mobile app/web/cloud
i. Item is returned by
COFMOW for
procurement at LGDS.
CRIS consent regarding
this item has been
received on 05.12.2020
and is under scrutiny at
SSE/IT.
Page 41 of 60
8.0 गह वयिसथा Housekeeping:
03 (three) contracts exist for housekeeping:
1. Daily Housekeeping, Canteen Cleaning, Roads Cleaning, Toilets Cleaning and Scrap Disposal at nominated place at Carriage Workshop, Lallaguda, Secunderabad.
2. Collection, Segregation and disposal of Hazardous waste accumulation.
3. Disposal through sale of non-metallic scrap mixed with embedded metallic contents.
9.0 सामगरी परबिन Material management:
i. Every year AACs are reviewed by three member committee of JAG grade
officers comprising of Dy.CME, DY.CMM && DY.FA&CAO/WAO.
S.No. Year Saving Achieved
1 2015-16 Rs. 99,69,064/-
2 2016-17 Rs. 7,18,71,106/
3 2017-18 Rs. 1,55,75,642/-
4 2018-19 Rs 3,20,759/- increase in AAC value
5 2019-20 Rs 3,42,72,619/-
6 2020-21 Rs 2,10,60,097/-
Page 42 of 60
10.0 कषिदयि Electrical:
Dy. CEE/S/LGDS Electrical Department is assisted by ADEE to look after POH
works of AC, TL, DEMU, EMU/MMTS Power cars, ART, SPART, SPIC, TRCs,
Inspection carriages , etc.. and the Electrical Maintenance of Four workshops
viz., CWS/LGD, EWS /LGD, FBWP/MLY and S&T Workshop /G&S/MFT and
STC/SC.
10.1 Electrical energy consumption of CWS/LGD V/S Vehicle
units (VUs):
S.No Description 2018-19 2019-20 2020-21 (up to Dec)
1. Electrical Energy consumption(KWh)
2257699 2367557 1441232
2. Connected load(KW) 11996 11996 11996
3. VUs (Nos) 1804.4 1853 1222
4. Consumption/VUs (SEC)
1251 1278 1179
10.2 Electrical Assets of LGDS:
S/No Workshop Capacity Qty
1 CMD 1000 KVA -
2 Major Sub-Stations(11KV) 3
3 Transformers 1000 KVA 6
4 DG sets 250 KVA 2
320 KVA 1
5 Solar Power Capacity 566.7 KWp 9 locations
Page 43 of 60
A. Solar Power plants installed at different locations:
Capacity Installed location
Units generated till date
Remarks
60 kWP CMT 152554
530 KW solar power plants installed on 16.03.18
150 kWP Ward-7 365035
200 KWP Ward-11 424309
60 KWp ESTC 131844
60 Kwp ASB ward -9 157803
4 KWp A sub - station 25668 Commissioned on Nov -14
4.5 KWp RPF out post 17274 Commissioned on Sep-16
10 KWp CMT/LGD roof top
33719 Commissioned on18.04.17
18.2 KWp Main sub-station
34840 Commissioned on 28.02.18
TOTAL 1343046
A. Solar power generated 2019-20: 782190 KWH.
(Average /month =65182.2units)
Page 44 of 60
10.3 Good works done (Electrical):
S No Description Photograph
01 Carriage Workshop Lallaguda received GoldPrize from Telangana State for Energy Conservation for the year 2019 from Honorable Governor of Telangana on 20.12.19:
02 Provision of energy meters for air compressors
to monitor energy consumption pattern resulted energy Savings: 2180 units/month
03 Commissioning of ring main system resulted in savings of energy Savings: 4365 units/month
04 Installation of Solar day light pipe system in M&E Stores and CMT lab Savings: 1060 units/month
05 Installation of Solar Street lights with timers Savings: 650 units/month
06 Provision of Star rated BLDC fans resulted in 50% power saving.
07 Provision of Energy savers to all welding plants Savings: 8500 units/month
Page 45 of 60
S No Description Photograph
08 1000LPD solar water heater at Canteen Savings: 1500 units/month
09 Installation and commissioning of new
Charge/Discharge Panel: for saving of power during testing of POHed/IOHed Alternators and RRUs/ERRUs. Earlier resistive loading arrangement was being used. New Smart Energy savers were installed on 22.06.2019. The units saved are 6199 (June 19-Dec,19)
10 Automated test bench for testing of RBCR, EBCR & SBCR: A new automated test bench for testing of RBCR, EBCR and SBCR of LBH AC coaches was procured and commissioned on 03.10.18 for testing the equipment as per the required parameters and the test results are compiled minute to minute and is saved in the in built computer. Till date 24 nos. of RBCRs, 135 nos. of EBCRs and 18 nos. of SBCRs have been tested on the panel since the date of commissioning
11 Fabrication and installation of new test bench for testing of ventilator fan motors: A new testing stand was developed for testing of various ventilation fan motors of EOG type Power Cars During POH
12 Provision of meta aramid fabric with silica
rubber coating duct canvas in LHB coaches
13 Modified Anti-rotating clamps: To avoid the rotation of Suspension Hanger Pins of 25KW Alternators. It was developed by ER Shop/LGD and later approved by recently held MSG meeting as per drawing no. RDSO/PE/SK/AC/0164-2016 (Rev.1)
Page 46 of 60
S No Description Photograph
14 Belt transmission alignment tool: Axle Pulley to Alternator Pulley alignment is being tested using Belt transmission alignment tool during POH to avoid the dropping of V Belt.
15 Provision of 36mobile chargers in GS/CN/CZ coaches:
16 Retrofitment of LED Lights: LED lights are providing in place of CFL lights for better illumination and power saving.
17 Robotic Duct Cleaning of AC coaches: 134 Coaches are completed Upto Dec 2019
18 Testing and fixing of Axle pulleys of TL and AC Coaches with suitable gadgets.
Page 47 of 60
11.0 परकषशिणिबीरीसीकीगकषिकषिकषिया Training & BTC activities
11.1 Courses Conducted at BTC/LGDS:
▪ Refresher Course for Technicians ▪ Welder Gradation ▪ Welding Basic Course for Beginners ▪ TIG Welding for Artisans ▪ Selection of Welding Consumables ▪ Welding Power Sources and its Selection ▪ Stainless Steel Welding for Welders ▪ Induction to skilled (RRB & CG) ▪ Special Courses on LHB ▪ APP JE &SSE (RRB) ▪ Pre promotional courses for Group D to Group C staff and JE Ranker ▪ Safety awareness for contract employees. ▪ Project Saksham training. ▪ Act apprentice ▪ Apprentice Graduates & Diploma ▪ Skill Development Program (Internship Mini and Major projects for B.tech
students) ▪ Seminars
11.2. Project Saksham: Concentrated Capsule of Training for All employees Vide letter
no.M.673/Pers/TrgMtg/42 dated 26/04/2019.
Category Total STC BTC Completed Due
Technicians 1817 0 1817 1817 0
Supervisors 202 0 202 202 0
11.3. Capacity Utilization:
Year Total Trainee
capacity
Total Trainee days
given
% Utilization*
2017-18 36604 79863 218.18
2018-19 36704 136847 372.80
2019-20
32398 123169 380.17
2020-21
(up to Dec’20)
14472 57375 396.45
*Note Total trainee days given/ Total trainee days capacity x 100 is % utilization.
Page 48 of 60
11.4. Staff Training:
S.No Courses 2018-19 2019-20
20-21 (upto Dec)
1 Act Apprentices 871 550 267
2 Apprentice Graduates 1 0 402
3 Apprentice Diploma 6 0 0
4 Skilled Artisans (W/S + Divn.)
63 170 0
5 Apprentice SSE’s & JE’s 32 48 11
6 Refresher Course for
Technicians 293 509
25
7 Promotional Courses - 40 0
8 Pre-Selection for JE rankers
25% quota 14 0
0
9 Skill Development for Group-
D staff 1009 742
493
10 Special Courses for shop
floor technicians 0 170
117
12 Initial industrial training for
contract employees 151 48
16
13 Seminars (DEMU, Vacuum
Toilet, Roller Bearing) 0 138
0
TOTAL 2440 2415 1331
11.5. Gradation of welders
S.No Courses 2018-19
2019-2020
1 Welder Gradation 70 84
Page 49 of 60
11.6. Model Room
11.6.1. Existing Models
• Working Model of Twin Pipe Air Brake System with PEASD.
• AC Emergency window of WGACCZ.
• Demonstration model of LHB Bogie.
• Working Model of BMBC For Demonstration.
• BMBC Exploded View Model For Demonstration.
• Bio Toilet Model For Demonstration.
• ICF Wheel & Axel Model for Demonstration.
• ‘H’ Type CBC Cut Model For Demonstration.
• Shaku coupler
• CTRB exploded view for demonstration.
• Spherical Roller Bearing Exploded View For Demonstration.
• EP Brake System Demonstration Model.
• Vacuum bio toilet.
• Different types of welding joints.
• LHB coach miniature model.
• Welding position demonstration model.
• LHB bogie for demonstration.
11.6.2. Proposed Models
A. Digital Models 3D Animation.
• Working of Disc Brake and Wheel Slide Protection System of LHB Coach.
• Working of Conventional Twin Pipe Air Brake System of ICF coach.
• Working system of DEMU Diesel engine.
• Working of Air spring suspension with FIBA device.
• Working of electro pneumatic system.
• Use of safety equipment in welding shop.
B. Physical Models
• Exploded view of AXLE MOUNTED DISC BRAKE CYLINDER with acrylic
enclosure and LED lighting.
• Exploded view of BOGIE MOUNTED DISC BRAKE CYLINDER with acrylic
enclosure and LED lighting.
• Exploded view of C3W of ICF AND KEO OF LHB DISTRIBUTOR VALVES of
coaches with acrylic enclosure and LED lighting.
• WATER FILLING AND PLUMBING ARRANGEMENT OF AC AND NON-AC
(ICF&LHB) coaches with Acrylic enclosure and LED lighting.
Page 50 of 60
12.0 औदयोकषगकसरिा Industrial safety:
12.1. No. of Accidents/IOD cases:
12.2. Man days lost:
12.3. Steps taken to enhance safety of workmen: ● Ladders for EOT cranes - flat steps & ring cage provided.
● Rotating machinery parts -wire mesh guard / Fencing provided.
● Battery operated forklifts and trucks to control air pollution introduced.
● Periodic supply of soaps and cleaning agents (REINOL).
● Periodic supply of personal protective equipment.
● Safety jacket for shunting staff.
● Fire buckets with stands in all the shops.
● Safety nose mask during painting.
● Safety belt for working at heights.
● Safety mat at electrical mains.
3
5
1
IOD Cases
IOD Cases
2018 20192 2020 (upto Dec)
134.5168
23
2018 2019 2020(up to Dec)
2018 2019 2020(up to Dec)
Page 51 of 60
13.00 कारमयक Personnel branch Organization:
13.1 Staff Strength (All Departments)
Department Sanction Actual Vacancy
Mechanical (Sup, Artisans) 2419 2018 401
Electrical (Sup, Artisans, Group- D) 606 493 113
Total 3025 2511 514
CMT Staff 36 22 14
Personnel 63 54 9
Mechanical – Others (non-Personnel, Group-D, Drawing, canteen, computer centre)
110 90 20
Electrical- Others (non-Personnel, Group-D, Drawing)
26 13 13
Stores 121 92 29
Accounts 100 63 37
Engineering 28 7 21
Total others 484 341 143
Grand Total 3509 2852 657
13.2 Grievance redressal: Year Received Disposed Balance
17-18 39 39 0
18-19 81 81 0
19-20 26 26 0
20-21 No camp was conducted due to COVID-19
13.3 Health camps:
Sl Year Month No.of staff screened
1.
2018-19
July 2018 268
2. Aug 2018 1138
3. Oct’2018 36
4.
2019-20
June’ 2019 17.06.19 to 28.06.2019
1279
5. 01.07.19 to 10.07.19 529
6 2020-21 No camp was conducted due to COVID-19
Page 52 of 60
14.0 कमयचारी कलयाणstaff welfare amenities
•
RO plant 3000 Ltrs Scooter parking
Water coolers provided in each shop Subsidized canteen
Reservation terminal Ladies rest /change room in
each shop
Gents rest /change room in each shop
Page 53 of 60
15.0 लयबिलकरिलररपलार Lube oil filter plant:
Brief History:
Lube Oil Filter Plant (LOFP) commissioned
during 1978 and the 1st filter was manufactured
on 17.05.1978. Till recently, LOPF was only one
of its kind on Indian Railways for manufacture of
“Pleated Paper Type Long Life Lube Oil”, Fuel Oil
and EMD Filter Elements required for
DLW/ALCO/GM type diesel locomotives of Indian
Railways.
15.1 Staff position of Lube oil filter plant/ Secunderabad
(As on 30.09.20)
Sanc. Actual Vacancies.
1 Supervisors 02 02 -
2 Laboratory 02 02 --
3 Ministerial
(Mech) 03 02 01
4 Liaison Inspector 01 01 --
5 Technicians 18 17 01
6 Semi Skilled/
Unskilled 22 08 14
Total 48 32 16
Activities of the Plant:
● Manufacture and supply of Long Life Lube Oil, Fuel Oil and EMD Filters to Diesel sheds of Indian Railways as per RDSO Specifications.
● LOFP is equipped with laboratory with all the testing facilities required for testing filter paper, finished filters and other metallurgical properties of other components.
● Supply of filters to other than Indian Railways units like NTPC, IRCON, RITES etc. for diesel Locos operated for their sidings.
Page 54 of 60
● 100% requirement of Long Life Lube oil filters & Low mean-pore size fuel oil filters like Large Primary, Large Secondary, Conventional Primary and Conventional Secondary for Indian Railways are being met by LOFP/SC.
● Manufacturing of 10” X 30” Long Life Lube Oil/Fuel Oil for EMD Locomotives commenced in January, 2011. As per Railway Board directives, 2/3rd requirement of EMD filters to be met by LOFP/SC.
15.2 Performance (Targets and Achievements):
Type/Year
2018-19 2019-20 20-21
Target (Rly Bd.)
Actual Target
(Rly Bd.) Actual
Target 2020-
21
Actual (upto
Sept-20)
122 Days Lube Oil filter
49417 47338 50000 43671 22482 13700
EMD Filters 10000 11582 16000 11908 11961 9950
Large Primary (Fuel Oil)
3200 2953 4000 3396 2178 538
Large Secondary (Fuel Oil)
3200 2921 3700 2764 747 0
Conventional Primary (Fuel Oil)
11789 12455 8000 5116 0 0
Conventional Secondary (Fuel Oil)
9000 10024 6000 3948 0 50
86606 87273 87700 70803 37368 24238
Page 55 of 60
16.0 रल बोगी कारखानाRAIL BOGIE KARKHANA, YADGIR:
(Under Administrative control of CWM/LGD)
16.1 Introduction:
Railway Board has taken a decision to completely switch over to LHB
coaches to ensure safe travel and higher passenger capacity with operating
speed up to 160 km/hr. With the change in Scenario Railway Board
sanctioned two projects for manufacture of Fiat Bogie frames at Budge Budge
& Yadgir.
The Plant is headed by an AWM.
S.No Category Staff on Roll
1 Supervisors 05
2 Artisans 20
Total 25
16.2 Salient Features of Rail Bogie Karkhana, Yadgir:
➢ Year of Sanction : 2013-14 ➢ Executing Agency : RVNL ➢ Sanctioned Cost : Rs. 75 Cr. ➢ Detailed Estimate cost : Rs. 80.92 Cr. ➢ Capacity : 600 FIAT Bogie Frames per annum ➢ Land : Located near Yadgir in Karnataka ➢ Inauguration of unit : On 18th August 2017.
16.3 Status of Production:
Sl Item Status
1 No. of Bogies made ready till Dec ’20 1171
2 No. of bogies dispatched 1104
3 Bogies ready at RBK for dispatch as on 29.01.2021
70
4 From August-2019 RBK has switched over to manufacture of ASR Bogie frames suitable for Air Spring in Secondary Suspension.
510 (ASR Bogies have been
completed. till Dec’20)
Page 56 of 60
16.4 Year wise fabrication & Machining:
(Target 20-21 : Fabrication 500 Nos. Machining 500 Nos.) In nos.
Year Fabrication Machining Despatched
17-18 138 91 83
18-19 385 379 322
19-20 343 405 411
20-21 (upto Jan-2021)
285 276 294
Page 57 of 60
17.0 सरिण Heritage preservation:
17.1 This Workshop was bestowed with the prestigious
Heritage Award of Indian National Trust for Art and Cultural Heritage (INTACH), Hyderabad Chapter on the occasion of the World Heritage Day celebrations held at SalarjungMusuem, Hyderabad on 18th April, 2015. The award was presented to the Carriage Workshop under the Modern Industrial Heritage category.
17.2 NIZAM’S SALOON-1886 built -NGSRly
Restored 1886 builtNizam’s Guaranteed
State Railway’s wooden bodied 4-wheeler
inspection carriage (Saloon) during
December 2006.
17.3 1920 BUILT WAGON: Restored 1920 built wagon, by Birmingham Railway Carriage & Wagon Company (BRC&W), Smethwick, England, during May 2007.
17.4 HERITAGE MG AC SALOON
(SC CTAC-150):
Restored dilapidated 1970 ICF built meter
gauge coach (saloon) stabled at“Purna”and
hitherto utilized by General Manager, South
Central Railway.
Page 58 of 60
17.5 HERITAGE MG STEAM
CRANE 35 TONNES:
Restored 1976 North Eastern Railway
Workshop, Izzatnagar manufactured 35 ton
MG Steam Crane (SCR – S-3508), with a
tare weight of 70 ton and equivalent to
match truck of 15 ton, during August 2010.
17.6 FIRE EXTINGUISHER – NIZAM STATE RAILWAY:
Restored Nizamera’s Vintage fire
extinguisher.
17.7 JOHN MORRIS FIRE ENGINE (1914 MAKE): John Morris Fire engine, housed at
National Rail Museum/ New Delhi, is
maintained by Carriage Workshop,
Lallaguda.
17.8 MAHATMA GANDHI STATUE (BRONZE):
Restored Bronze Mahatma Gandhi Statue manufactured by foundry staff of Lallaguda during 1955 and placed adjacent to the main gate (inside).
17.9 FIRE ALARM BELL – 1925: Bronze bell 1925 manufactured and weighing 83 Kg used as mass alert during exigencies.
Page 59 of 60
17.10 RESTORATION OF LIBRARY COACH – (WPCTLAC- NWR -91565 – 1991 built used in Palace on wheels). Restored 1991 ICF built library coach used on Palace on wheels.
