Electric Loco Factory Dankuni, Eastern Railway

State of Art Turnkey project for manufacturing of Electric Locomotives implemented by RVNL on fast track at Dankuni of Eastern Railway.

1. 7 ELECTRIC LOCO ASSEMBLY

AND ANCILLARY UNIT OF CLW
re

sone»
¡ego Josey

Rail Vikas Nigam Limited
( t of India Enterpri

3. her for Jet eo for fees

ee El pls
~ Satish Agninote —— ee en se Fee 0 n
Rail Vikas Nigam Limited

{Chairman & Managing Ouector
{A Core tin tree

lock, Floor August Kran Bhaman,

Bil Gama Pace, Now Deln:110006

1

Message

Itieindedhearteningta ot that th construction o Electric Loco Assembly aná Anilary Unit of CL
Dankunihas been completed iarcorátme by the Kell PIU ERVIN

Thi Pojct was transered by Raiay Bear to RVNL in May 2012 for eaction ona fat rack basis
Subsequento the avardingof the contract physial work commencedin December 2012andthe project
hasbeen completed in January 2015, Ths endeavor has ben widely appreciated by senor fils
including Member Electra and GM/CLW uring heirinepecton. Inthe pat two years, RYN hae also
ben able to complete the constructanf Del Loco Component Factory Dankun and DMU Factory at
Haldia. These factories wer alse complete in record time and have already bean handed oer to
Rays fer use Further RUN hasbeen manébtede execute the expansion of DLW/Varanasior which
Shi Narendra Mo Hon be Prime Minister athe foundation stone on 25° December 2016 an work
wasals commence onthe same dy,

The lt Los Assembly and Ancilary Unito.CLW Dani includes rain speci features auch as
System, water supply along wi ovehead lank, wate raten! plant an track connect rm

tak this opportunity to compliment Kolkata PIU or successful complting this projet inrcorstime
‘andar binging ou Cole Table Book to recor this achievement. Th great achievement and

wisin Kata PIU great success rather utureendeaors.

(Sat kann)
conn PRES Gran

4. MAF vas was rogue tos

ELAAUC, DANKUNI - A RARE REALITY OF FASTER
TRACK PROJECT IMPLEMENTATION BY RUNL

LW stare in 1950 wth prediction of Steam Engines and gradually ranslrmas to Electric Loco production unit rom 197s wth
‘anvrtonl 25KS ap changertypeEactreacometwes uth DE Malos ith avancemenoftecholgyitnassartedmanulacuıng
State of near GET based paca cool.

However a8 CLW as ranstormes rom team engine manufacturing to pha lca, thee has ay ben antrintin moderiing
Inrstustureta adap modern manutacturng practesrandinerearthe proauctoncapae

Implementation details:

ELAAU (Electric Loco Assembly and Anc Uni of CLW at Dankun hasbeen implement on a very fst rack to augment the
production capaci electric cs in nan Rays a Chtaranjan ala Bera Iii of Rawaysl dise RUNL eter.
705 20121r mplamantatonot turn oy project wth 2 yes me of completion, The dead estimate, 800, een scope se
‘were concluded by 2052012 andthe tener was td on 2852012 Subrequnt te ne award! he work and moliation period
[geen tothe agency epica work commencedin December 2012andin roughly 2 years atime eee ion ra co aout
Re Der bean compltedandareinpacs

Salient features of the factory design implemented at site:

+ nea assamly cain wi recen of sels at one anand rling ou of Locomotive ater camplat assembly and testing of

+Sacondry storage ara along with seme timplement Tustin Tine manucturn philosophy ithminimaminvntoy.
+ 2kmiongtestracklortestngotlacometvein mate,

+ Wideroadnetwerklormovementol stores without hindrance.

+ Skylgmandsolar power tr energyconseration

Management tools followed for faster implementation by RVNL:

+ Work Programme deal we programe was made for complain he varus cts matching the requirement ate
Snes proie contrat agreement ae ma regan load

+ Drawings were made concludedand roenwllinadane.

+ Smonthroling programme andmonthyprogremmesweremadebythe agency mateing the requirement programme,

+ Weostyrevewmasting andtargteworefixedor achieving intermediate grlst ares contraints, resource mailto, te

+ MicrosttPrejectwasusestor manitrng the projects dashbcardcaris werealsopreparedor beter appreciation

+ REMS - RVNL has introduced a remate eye mentoring system ad the PMCIRVNL Supervisor have been provided with mobile
Panes wi cyto uplo pres al ne wars The enables the Nissan management o mentor remy oct
Eteinreatimehroughweoste ven protected ith pasos

+ Quali Management Detail quaiy assurance programmes & qaliy conto plans were made fr al the projects. General
anager durng e inspection card nine sect ot abou the qual ang sud ths oils ar Ana oval or
tro ly control measure acopio

5. IT sas tics gem Limited

Quality assurance:

For ast track implementation he projects, tas necessary that he aspect related o quality should nota ae compromise
‘ualtyessuranceandcontols not one proper the werkcannt be done ons rackand the project mondo no cus ce and
aly tobe ely

"Aus Assurance programme was prepared lang wih quality control plan The objective of qualty assurance programme
was toansuretheconstrucionactiesarecaredoutinasjtematizmanerandqualiyel constuction worisinconfermiy withthe
Sporondspectcaon, drawings tc wasbsedonthefoloning qual system procedure

Document Cool «Mae Coto ‘Nn cnfomance Cott
‘Procurement Control + TrrngofPesonel + Production Control
+ Sena conto,

Contrat processes and special processes were exercised rough seriesfinstruction documents designatedas Method Statements
(MSland OualıyControlPlnstocP)

Details about the project:

‘The tum key contrat wa awarded incorporating Cl Engineering Electrical Engineering, Mechanical Engineering and SAT. The
eparment-isa bret descriptonsef the works were asunder:

Civil Engineering

{U Mainshed 70% angles structures
Thevariousshopsto constructed asportethe ain shedareas follows:

+ OPENGANTRY zum
2 SHELLSHOP ZEMX OM

© PRINTSHOP vom

= PIPINGANDCABUINOSHOP S0MX250M

| TRANSFORNERMOUNTINGSHOP omo

| EQUIPMENTMOUNTINGSHOP 50m X210M

À Tesmeshor Ein

Constructions! 00M long igonicahed motes abiatontthe flowing components
+28 coumes

2 1580anty der

2 s8SBrecngGraers

2 i9eReottegs

Furtberitinones naaationot

O OM sheeting nl 20% ong wih 2mm UN protected para anse

+ 103Turbovenstorkeping he temperature pleasantand workable
la Omer structures
35m m Adminitrative Busing 621 0m 20m Stare BuiingiPED40m25r Eee Subattiona? Nos 10m 10m
Security Blok Nas], mM Pump House,
li oterciviworks
+ Drainage arrengementncluding network SO mm
+ Roadet2 5kMwitnconretepovementnsidethelactory,
+ Pathways paver backs for movementwthintefactan
‘+ Raiwaytrackot5.5KM aking rom he racket Easter RainayatOankun tatin.

‘+ Thelen yng are ofthe factory ste has been ile up with ash lr bung & shed area aná ne sand lo open areal The
career been constructed by ling coarse ando ras he ee The rackhar been contract by ling ert and
Sones

‘+ Water supi arrangement including bore wel pump house, overhead tank (5,00 gallons), water supply pipelines, water

{reamentplantete

14750 media, NPéhume pipes an aurfce drains.

6. ‘all Vikas Nigam Limited

Mechanical works

Progress report through dash board chart : Dashboard chart is one of
the most effective management tool to ensure proper monitoring and
timely completion.

7. ST sos ias Niger Linie

Railway Board’s Target vis-a-vis progress

Fnazaton of scope ofthe work andtranserbyallwayBoard The workwas transfered to VAL y Ry Bardon 705.2012
by 90.04.2012

ol so Investigan, survey, sanction o deal Detaled estimate & 800 work sanctioned on 28.05.2012
estimate 4800 by VW y 31.05 2012

ating ot Tender by AVAL y 15962012 Tener was called on 28.05.2012
Contrat be warded andthe workto comence in clober, Leterf acceptance sued on 2.1.2012 and mobilisation period
2012wi gate olcompltono!2 years 9142 day, Work tre in De, 2012 and Pyselly competesin

Jan2018.

=

Additional Works executed by RVNI

RVNL has accommodated several additional works asked at the later dates

+ Deployments. ofadonaleranesinthe SOM boy
+ Proisionstslarpowerplant

Provisianol rel covering wthrusesin the administrative buldingndcoveringwih green osa paycartonte sheet
Provisional funtinandgardeninsidethe ministrative busing
2 Proisionatwatr treatment pont

2 Proisonot2nos oerostracks
+ Prosionofoticelconterencereomonthesecendceropenterrace area
+ Mmumbers oui eoupings ire arr notinthe origin! conrctspeictns

8. IT sus ins Ngan Lites

DETAILS ABOUT THE PROJECT

Civil Engineering

+ Ministre Building +2) asco
“+ Store Busing FEB] ‘MxM

+ BectieSutstanen(HWHEnd! om
+ EecicSotstaian (Dehn oz
+ Security Bac End) ou ou
+ Security Back (Del End tom 10m
+ Pumphouse aman,

Electrical Works

Lorna :

Mechanical Works

+ EOTCranelBDT fer S0M Bay anos.
+ e0TCranls0T}or25M Boy 2108.
2 Toners som) ine
+ Compresor (00m) Noe
+ MGMAGS NES Nos

Erecting Contractor M/s Simplex tures Lt,

Project Management Const
Design Consultant -M/s Consul

«cross Engineers] Pate Ld
ng Sans Indi] PA. Lis

9. MA sas tas gem iis

Piling work commenced by CMD/RVNL in Dec. 2012

10. ST sas as ça ited

11. MA sas as gem iis

SHEETING SPECIFICATION

+ 055mm Base Metal Thickness (OMT 8O.SMM Tota
+ Hightersiesteathminimum 50MPa lé strength

+ Metalic hat sip coatedath Aluminium Zinc Aly ape AS 1397-2150 minimum 1S0am/n
toalon bth ist Super drole popeste qual paint coat conforming ASINZS 2728

ss

12. ST sa tas gu Lived

ADMINISTRATIVE BUILDING

13. IT sas ias gem iis

15. MA sas tas gem iis

RPF BLOCK (Howrah & Delhi End)

"y 0 um + m’

17. FT vas ice Nig ited

MACHINERY & PLANTS

19. pe

WATER SUPPLY ARRANGEMENT

20. TRACK & OHE WORK

21. N

22. SITE VISIT

23. A vas ne Nig ited

SITE VISIT

25. MA sas tas gem iis

Removal of HT wires in Di end - HT wire was
removed any on 2204201. I flected 36 ples. Ths
flecos the work tn machinery was demobilized
Guetonen ayaabiiyofsteferavrylongime

Removal ofthe existing traction substation = The
structure could be dsmanis in December, 2013.
cad 101 ples and éranage system. Ths was
‘mojurbotlenec.

Removal of ether L ine & HT line a Howrah end =
‘These were remevedeapectielyinthemonhsot May
ne. 2013 Ping work an movement of machinery
‘wasbadtyatectedauetotheslines

‘St Nos. of ees which could be cut and dispos ls
loteas n July. 2013. Ping make cations was
‘Mectesdvetotres,

Encrschment = There were some encroachment
ich could be relocate shies only in November os à
ZU. These acte the ealway track constructan

apart trombeinga nuisance

‘Abandoned Raiay bridge -RemovedinFeb 216,

Underground HT cata Honra nd entrance gate coló e ot shied ani June 2014 Because ofthis cable, he grange
theappreachreascouldnotbe dane tere morse,

The st for construcion of quarters which sa very A
Une aan cat made eat 1
+ Stocks &.0-07.022019{ARerémonthsofLOA)
+ BlockE-120720131aterneary neyoar ofLOA]
+ Blocks AL 8-25:12013 (Aer nary 14 months a

SALON

26. ST sas as ça ited

NOTE OF MEMBER ELECTRICAL, RAILWAY BOARD

‘The manner in which the entire project site has been developed and ithin a period of 18

ves commendation, | would like to place on record my a rRVNLand
ordination in construction ofthis unique facility.

INSPECTION NOTE OF GM/CLW
REGARDING QUALITY CONTROL

11.0 | we equipped site atoratory has been set up where the required testing | CPM/RVNL
Rave been calibrated. One cube was tested fer M3S pile alter 28 days | CE/CLW
{sting andthe results was 46 Noma. The same kind of aualiy contrat tab | CE/Metro
‘ould adpteoy Mandat ana state terse. Rly

INSPECTION NOTE OF HOD, EASTERN RAILWAY

+ Agoedquatiyworkwithgoedplanninghasbeen executed.

+ Theshed roof and vais made 010.6 MM zincalume sheet and rre els provision ol 20% slight inthe form of 2 MM
{ck UV protected poycarbanate sheets for enblng unit ener the shed. There ar turbovets reeling bet ar
through he rot without consuming electric energy Thus shed has been esgnedwallkeepingnviewTorenegyeficency
moco

+ Theresa pie arrangement of two stirases for ging 1 ey cranes and walk ways along te gantry girders for
Comiartable movement.

+ Theroiso el designs éainge system an water supply tem A oodarrargementhas ben made by connecting the

dec 160 any with hat o o dee oc component fort ake cae of unforeseen
eestmentplanthasbaenmstaletarensunngbes quai oar

+ Foraeznaticoppeal brutale designed ceramic moralshave een installedinthefactryataroulcatans.Thereie
rowel mural showing ony onan alway rom ary queente modern horsepower cometes

+ The administrative fc a state of the ar bung wih beautiful elevator wih anspaent wall The two faces of the
bung have lazed lading made for aesthetic appeal and proper clear vew ofthe fairy rom ne oe: Theres

+ Thotratra attack hasbeen done ad cri ub-staicncommisioned and water supply system commissioned The
factor autre thus rod echando y RYNL and use By EUW.

27. IST nas as Nigam Lied

SAFETY MEASURES

A

Aca
Bs Boa A!

RVNL Railway
ShriRajeshPrasa.chietProjetManagevM | SHO CEEI
Shri. Seat OME Shi S KAgioal CEE Doan
Shi Sabu Mina) St Say Soa, recto ead
Shi Singh. AGMP/RNLAOL ShiRapbRoy.CEELoco
SB Ray JM Mec. Shi Karwar EC
Shrike. JOM/SET SR Mata 0 CC
SK KMS Magee) Shih KO DEN

Sri Pat SEE co

Si Choa SEE

‘The work was executed under continuous guidance and support of Shri Kulbhushan, then ML, Rly. Board, Shri
Radhey Shyam, then GM/CLW, Shri C.P.Tayal, GM/CLW, Shri Satish Agnihotri, CMD/RVNL, Shri Vijay Anand,
Director Project/RVNL, Shri D. Ghosh Roy, ED/Mechanical RVNL, Shri Ved Prakash, ED/RS Rly. Board, Shri
‘Sudhir Kumar, ED/Dev. Rly. Board and Shri HS. Yadav, CGM/RVNL.

30. RUNL'S MISSION

+ Creating statetrtaileansportcapectytomeet groing demand

‘+ Executing projects on fast rack bass by adopting international projec execution,

‘+ Adhering to sound business principles and prudent commercial practices o emerge
India topratinfrastture? SU,

ocres elicentrointerms otcotanstime,

+ To implement Ral Infrastructure ra
Paleprmaiefarneranpmedels,

+ Toachiewe International Quali Standards trough innovations.

+ Toachieweprojectcompltonsintagetimeandwithbest quay

+ eying priate sector in nancing th constructional ejects and development
‘ican models of Pub Pre Partnerships win jt verre SP win guy
Baricpaton by Strategic & Financ investors Including funding options From
‘nor mutates agencies tix te tan Doelogment nk

on commercial format trough various

31. ey

in the world.

- Mahatma Gandhi

4 Purty, patience, and perseverance are the three ) J
‘essentials to success, and above all, ove.

-Swami Vivekananda

AAA JJ
re
ns vod

46 To thinks ony To cts aint. act ax one Y) Y)
thinks is the most difficult.
-Joham Wolfgang Von Goeth
Success is never certain, but self-doubt,
negativity, and low expectations guarantee
failure.

à - John F. Murray

a eee

66 ‘The new source of power is not money in the
many.

„John Naisbitt

EA A ones

32. Go not to the temple to put flowers upon the feet of God,
First fill your own house with the fragrance of love.

Go not to the temple to light candles before the altar of God,
First remove the darkness of sin from your heart.

Go not to the temple to bow down your head in prayer,
First learn to bow in humility before your fellowmen.

Go not to the temple to pray on bended knees,
First bend down to lift someone who is down-trodden.

Go not to the temple to ask for forgiveness for your sins, ¡Y
First forgive from your heart those who have sinned against you.

Rabindranath Tagore