ELAAU, Dankuni executed on very fast track by RVNL

Electric Loco Assembly and Ancillary Unit of CLW

DankuniProject Implementation on Fast Track Basis

Rail Vikas Nigam Limited(A Government of India Enterprise)

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,First forgive from your heart those who have sinned against you.

Rabindranath Tagore

The project has been implemented by Kolkata PIU-CPM(M) Unit and this booklet has been conceived & compiled by Rajesh Prasad, Chief Project Manager (M), RVNL, Kolkata with the help of Satyajeet Paul, Computer Assistant, RVNL, Kolkata.

For a new era of progress

Sanctioned Estimate : ` 179.95 Cr.

Transfer of Project to RVNL : May 2012

Calling of Tender : May 2012

Letter of Acceptance : October 2012

Physical work Commencement : Dec’ 12

Actual Completion : Jan 2015

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Rail Vikas Nigam Limited

It is indeed heartening to note that the construction of Electric Loco Assembly and Ancillary Unit of CLW Dankuni has been completed in a record time by the Kolkata PIU of RVNL.

This Project was transferred by Railway Board to RVNL in May 2012 for execution on a fast track basis. Subsequent to the awarding of the contract, physical work commenced in December 2012 and the project has been completed in January 2015. This endeavor has been widely appreciated by senior officials including Member Electrical and GM/CLW during their inspections. In the past two years, RVNL has also been able to complete the construction of Diesel Loco Component Factory, Dankuni and DMU Factory at Haldia. These factories were also completed in record time and have already been handed over to Railways for use. Further, RVNL has been mandated to execute the expansion of DLW/ Varanasi for which

thShri Narendra Modi Hon'ble Prime Minister laid the foundation stone on 25 December 2014 and work was also commenced on the same day.

The Electric Loco Assembly and Ancillary Unit of CLW Dankuni includes certain special features such as 700 meter long shed, 6 Nos. of EOT cranes,1 traverser, 2 electric sub-stations, staff quarters, store ward with pre-engineered building, administrative building, solar panel on top of substation, drainage system, water supply along with overhead tank, water treatment plant and track connectivity from Dankuni yard.

I take this opportunity to compliment Kolkata PIU for successfully completing this project in record time and for bringing out a Coffee Table Book to record this achievement. This is a great achievement and I wish the Kolkata PIU great success for all their future endeavors.

Message


ELAAUC, Dankuni – A rare reality of FasterTrack Project Implementation by RVNL

Background: CLW started in 1950s with production of Steam Engines and gradually transformed to Electric Loco production unit from 1970s with conventional 25 KG tap changer type Electric Locomotives with DC Motors. With advancement of technology it has started manufacturing of state of the art IGBT based 3 phase locomotives.However, as CLW has transformed from steam engine manufacturing to 3 phase locos, there has always been constraint in modernizing infrastructure to adopt modern manufacturing practices and increase the production capacity.

Implementation details: ELAAUC (Electric Loco Assembly and Ancillary Unit of CLW) at Dankuni has been implemented on a very fast track to augment the production capacity of electric locos in Indian Railways at Chittaranjan. Railway Board (Ministry of Railways) advised RVNL vide letter dt. 07.05.2012 for implementation of a turn key project with 2 years of time of completion. The detailed estimate, BOQ, freezing of scope etc. were concluded by 23.05.2012 and the tender was invited on 28.05.2012. Subsequent to the award of the work and mobilization period given to the agency, the physical work commenced in December, 2012 and in roughly 2 years of time the entire factory now costing about Rs 200 crores has been completed and are in place.

Salient features of the factory design implemented at site:• Linear assembly chain with receiving of shells at one end and rolling out of Locomotive after complete assembly and testing of

Locomotive without any cross movement of semi-finished product. This required construction of 700 m long shed.

• Secondary storage area along with assembly line to implement JIT (Just in Time) manufacturing philosophy with minimum inventory.

• 2 Km long test track for testing of locomotive in motion.

• Wide road network for movement of stores without hindrance.

• Skylight and solar power for energy conservation.

• Administrative building with bird eye view of entire assembly line.

Management tools followed for faster implementation by RVNL:

• Work Programme:- A detailed work programme was made for completion of the various activities matching the requirement of key dates provided in the contract agreement and this was regularly followed.

• Drawings were made, concluded and frozen well in advance.

• 3 months rolling programme and monthly programmes were made by the agency matching the requirement of work programme.

• Weekly review meeting and targets were fixed for achieving intermediate goals to address constraints, resource mobilization, etc.

• Microsoft Project was used for monitoring the projects, dash board charts were also prepared for better appreciation.

• REMS – RVNL has introduced a remote eye monitoring system and the PMC/RVNL Supervisors have been provided with mobile phones with facility to upload pictures of the work site. This enables the officials and management to monitor the remotely located site in real time through website which is protected with password.

• Quality Management- Detailed quality assurance programmes & quality control plans were made for all the projects. General Manager, during his inspection recorded in the inspection note about the quality and asked the officials of other Railways to visit for the quality control measures adopted.

Quality assurance: For fast track implementation of the projects, it was necessary that the aspects related to quality should not at all be compromised. If Quality assurance and control is not done properly, the work cannot be done on fast track and the project would go into a vicious cycle and likely to be delayed. A Quality Assurance programme was prepared along with a quality control plan. The objective of quality assurance programme was to ensure the construction activities are carried out in a systematic manner and quality of construction work is in conformity with the approved specifications, drawings, etc. It was based on the following quality system procedure:

• Document Control • Material Control • Non-conformance Control

• Procurement Control • Training of Personnel • Production Control

• Setout control

Control of processes and special processes were exercised through a series of instruction documents designated as Method Statements (MS) and Quality Control Plans (QCP).

Details about the project: The turn key contract was awarded incorporating Civil Engineering, Electrical Engineering, Mechanical Engineering and S&T. The department-wise brief descriptions of the works were as under:

Civil Engineering(I) Main shed (700m long) with lean to structures:The various shops to constructed as part of the main shed are as follows:

• OPEN GANTRY 25M X 70M• SHELL SHOP 25M X 140M• PAINT SHOP 25M X 190M • PIPING AND CABLING SHOP 30M X 250M• TRANSFORMER MOUNTING SHOP 30M X 40M• EQUIPMENT MOUNTING SHOP 30M X 200M• BOGIE & WHEELING SHOP 30M X 90M• TESTING SHOP 30M X 120M

Construction of 700M long gigantic shed involved fabrication of the following components:- • 258 Columns,• 74 roof trusses,• 158 Gantry Girders• 555Bracing Girders • 194 Roof Legs Further it involved installation of –

• 57700 SQM sheeting including 20% roofing with 2 mm U/V protected polycarbonate transluscent sheets)

• 103 Turbo Vents for keeping the temperature pleasant and workable

(ii) Other structures: 35 m x 30 m Administrative Building (G+2), 30m x 20 m Store Building(PEB), 40 m x 25 m Electric Substations(2 Nos.), 10 m x 10 m

Security Blocks(2 Nos.), 3mX3M Pump House.

(iii) Other Civil works:

• Drainage arrangement including network of 450 mm dia and 750 mm dia, NP4 hume pipes and surface drains.

• Road of 2.5 KM with concrete pavement inside the factory.

• Pathways with paver blocks for movement within the factory.

• Railway track of 5.5 KM taking off from the track of Eastern Railway at Dankuni station.

• The low lying area of the factory site has been filled up with flyash (for building & shed area) and fine sand (for open area). The concrete road has been constructed by filling coarse sand to raise the level. The track has been constructed by filling earth and stone dust.

• Water supply arrangement including bore well, pump house, overhead tank (50,000 gallons), water supply pipelines, water treatment plant etc.

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Electrical works:Power supply arrangement with Two Nos. of electrical sub-stations each of 33 KV / 440 V, 3 x 2.5 MVA

Signalling works:Telecommunication works including installation of electronic exchange and LAN networking

Mechanical works:Supply, erection, installation, testing and commissioning of various machineries and plants including 6 Nos. of EOT cranes, traverser, compressor, tools, gauges, instruments etc.

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


Railway Board’s Target vis-à-vis progressFinalization of scope of the work and transfer by Railway Board by 30.04.2012

The work was transferred to RVNL by Rly. Board on 07.05.2012

Completion of soil, investigation, survey, sanction of detailed estimate & BOQ by RVNL by 31.05.2012

Detailed estimate & BOQ work sanctioned on 23.05.2012

Calling of Tender by RVNL by 15.06.2012 Tender was called on 28.05.2012

Contract to be awarded and the work to commence in October, 2012 with date of completion of 2 years

Letter of acceptance issued on 02.10.2012 and mobilisation period of 42 days. Work started in Dec. 2012 and Physically completed in Jan 2015.

Additional Works executed by RVNL

RVNL has accommodated several additional works asked at the later dates :-

• Deployment of 2 nos. of additional cranes in the 30 M bay

• Provision of solar power plant

• Provision of roof covering with trusses in the administrative building and covering with green colour polycarbonate sheet

• Provision of fountain and garden inside the administrative building

• Provision of water treatment plant

• Provision of 2 nos. of cross tracks

• Provision of office/conference room on the second floor open terrace area

• 140 numbers of quick couplings which were earlier not in the original contract specifications.

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Details about the Project

Civil Engineering Main Shed (700m long) with lean to Structures

• Open Gantry 25M x 70M

• Shell Shop 25M x 140M

• Paint Shop 25M x 190M

• Piping and Cabling Shop 30M x 250M

• Transformer Mounting Shop 30M x 40M

• Equipment Mounting Shop 30M x 200M

• Bogie & Wheeling Shop 30M x 90M

• Testing Shop 30M x 120M

Other Structures

• Administrative Building (G+2) 35M x 30M

• Store Building (PEB) 30M x 20M

• Electric Substation (HWH End) 40M x 25M

• Electric Substation (Delhi End) 40M x 25M

• Security Block (HWH End) 10M x 10M

• Security Block (Delhi End) 10M x 10M

• Pump House 3M x 3M

Electrical WorksPower Supply arrangement with two nos. electrical substations each of 33 KV/440V, 3x2.5MVA

Mechanical Works• EOT Crane (50T) for 30M Bay 4 Nos.

• EOT Crane (50T) for 25M Bay 2 Nos.

• Traverser (50T) 1 No .

• Compressor (500 cfm) 3 Nos.

• MIG/MAG5 Nos. 5Nos.


Pile, Pile Cap & Pedestal

Piling work commenced by CMD/RVNL in Dec. 2012

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Executing Contractor -M/s Simplex Infrastructures Ltd.Project Management Consultant -M/s Data Technosys (Engineers) Private Ltd.

Design Consultant -M/s Consulting Engineering Services (India) Pvt. Ltd.


Structural Work Sheeting Specification• Zincalume Steel trapezoidal sheet/ Eave Gutter/ Ridge, etc. with nominal 28 mm deep ribs.

• End ribs designed for anti-capillary action, to avoid any seepage of water through the lateral overlap.

• 0.55 mm Base Metal Thickness (BMT) & 0.6MM Total Thickness(TCT)

• High tensile steel with minimum 550 MPa yield strength

• Metallic hot dip coated with Aluminium Zinc Alloy as per AS 1397-AZ 150 (minimum 150 gm/m2 total on both sides) with super durable polyester quality paint coat conforming to AS/NZS 2728 Type-4.

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First column erected by the then Member Electrical on 01.03.2013

Administrative Building Electric Sub-Station-1 & 2Rail Vikas Nigam LimitedRail Vikas Nigam Limited

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Store Ward (with 20% Skylight and Turbovents)

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RPF Block (Howrah & Delhi End)

Pre-engineered concept for faster execution


Quarters (G+3,Type-II)-40 Nos.

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Machinery & Plants

Miscellaneous Works


Power Supply ArrangementCommissioning of two Electric Sub-Stations with Solar Panel on roof top of Howrah end substation.

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Water Supply ArrangementConstruction of new over head water tank and water pipeline, an old unused water tank was dismantled. Filter plant was also installed and a connection with DCF, Dankuni has been made to take care of eventuality.


Track & OHE Work Trial Run on 07.01.2015

Site Visit

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Site VisitRail Vikas Nigam Limited

Site Visit

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Tree Plantation HindrancesRemoval of HT wires in Delhi end – HT wire was removed only on 22.06.2014. It affected 36 piles. This affected the work as the machinery was demobilized due to non-availability of site for a very long time.

Removal of the existing traction sub-station – The structure could be dismantled in December, 2013. It affected 101 piles and drainage system. This was a majour bottleneck.

Removal of other LT line & HT line at Howrah end – These were removed respectively in the months of May & June, 2013. Piling work and movement of machinery was badly affected due to these lines.

54 Nos. of trees which could be cut and disposed of as late as in July, 2013. Piling work at some locations was affected due to trees.

Encroachments – There were some encroachments which could be relocated/ shifted only in November, 2013. These affected the railway track construction apart from being a nuisance.

Abandoned Railway bridge – Removed in Feb. 2015.

Underground HT cable at Howrah end entrance gate could be got shifted only in June,2014. Because of this cable, the regrading of the approach road could not be done before monsoon.

The site for construction of quarters which is a very time consuming activity could not be made available in time.• Blocks C & D- 07.02.2013 (After 4 months of LOA)

• Block E- 12.09.2013 (After nearly one year of LOA)

• Blocks A & B- 25.11.2013 (After nearly 14 months of LOA)

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Note of Member electrical, Railway Board“The manner in which the entire project site has been developed and executed within a period of 18 months, deserves commendation. I would like to place on record my appreciation for RVNL and CLW officers for ensuring close co-ordination in construction of this unique facility.

An award of ̀ 50,000/- was announced by ML for RVNL after his inspection on 19.07.2014.

Inspection Note of GM/CLW regarding Quality Control

11.0 Well equipped si te laboratory has been set up where the required test inge q u i p m e n t s h a v e b e e n ke p t a lo n g w i t h re le v a n t c o d e . T h e e q u i p m e n t sh a v e b e e n c a l i b r a t e d . O n e c u b e w a s t e s t e d fo r M 3 5 p i le a f t e r 2 8 d a y scasting and the results was 44 N/mm2. The same kind of quality control labshould be adopted by CLW and Metro Railway at other work-sites also.

CPM/RVNLCE/CLWCE/MetroRly

Inspection Note of CPDE, Eastern RailwayInspection Note of HOD, Eastern Railway

Safety Measures

RVNL Railway

Shri Rajesh Prasad, Chief Project Manager/M

Shri S. K.Srivastav, GM(Electrical –II)

Shri H. K.S ahu, GM(Finance)

Shri H.Singh, AGM/P /RVNL/KOL

Shri B.K.Roy, JGM/Mech.

Shri S.K.Das, JGM/S&T

Shri K.K.Mishra, Sr. Manager (Civil)

Shri H.Rao, CEE/CLW

Shri S.K.Agarwal, CEE Dankuni

Shri Sanjay Saha, Director/Rly. Board

Shri Rajib Ray, CEE Loco

Shri B.R. Kanwar, CE/CLW

Shri R.K. Mishra, Dy. CE/C

Shri A. K. Dey, DEN

Shri S.P. Patra, SEE/Loco

Shri S. K. Choudhari, SEE/W

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 H.S. Yadav, CGM/RVNL.

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• A good quality work with good planning has been executed.

• The shed roof and wall is made of 0.6 MM zincalume sheet and there is also provision of 20% skylight in the form of 2 MM thick UV protected polycarbonate sheets for enabling sunlight to enter the shed. There are turbovents for expelling hot air through the roof without consuming electric energy. Thus shed has been designed well keeping in view for energy efficiency and comfort.

• There is a nice arrangement of two staircases for going to entry cranes and walk ways along the gantry girders for comfortable movement.

• There is a well designed drainage system and water supply system. A good arrangement has been made by connecting the water supply system of the electric loco factory with that of the diesel loco component factory to take care of unforeseen situations and maintenance. A water treatment plant has been installed for ensuring best quality of water.

• For aesthetic appeal, beautiful well designed ceramic murals have been installed in the factory at various locations. There is a row of murals showing the journey of Indian Railway from fairy queen to modern high horsepower locomotives.

• The administrative office is a state of the art building with beautiful elevator with transparent wall. The two faces of the building have glazed cladding made for aesthetic appeal and proper clear view of the factory from the office. There is provision of fire fighting system.

• The trial run of track has been done and electric sub-station commissioned and water supply system commissioned. The factory assets are thus ready for handing over by RVNL and use by CLW.

Officials Associated

Electric Loco Assembly

and Ancillary Unit of

CLW Dankuni

THE OTHER WORKSHOPs

IMPLEMENTED/UNDER

IMPLEMENTATION BY RVNL

“ ”Motivation is the art of getting people

to do what you want them to do because they want to do it. - Dwight D.

“ ”In the middle of difficulty lies opportunity.

- Albert Einstein

“ ”To think is easy. To act is difficult. To act as one

thinks is the most difficult.

- Joham Wolfgang Von Goeth

“ ”Success is never certain, but self-doubt,

negativity, and low expectations guarantee failure. - John F. Murray

“ ”The new source of power is not money in the

hands of a few, but information in the hands of many.

-John Naisbitt

“ ”You must either modify your dreams or magnify

your skills.- Jim Rohn

RVNL’s MISSION• Creating state of Art rail transport capacity to meet growing demand.

• Executing projects on fast track basis by adopting international project execution, construction, management practices and standards.

• To make the Project implementation process, efficient both in terms of cost and time.

• Adhering to sound business principles and prudent commercial practices to emerge India’s top rail infrastructure PSU.

• To implement Rail Infrastructure Project on commercial format through various Public Private Partnership models.

• To achieve International Quality Standards through innovations.

• To achieve project completions in target time and with best quality.

• Involving private sector in financing the construction of projects and development of efficient models of Public Private Partnerships with joint venture SPVs with equity participation by Strategic & Financial Investors including funding options from external multilateral agencies like the Asian Development Bank.

Mantras for Success

“ ”Purity, patience, and perseverance are the three

essentials to success, and above all, love.

- Swami Vivekananda

“ ”Be the change you want to see

in the world.

- Mahatma Gandhi

Disclaimer :- Although the editor and publisher have made every effort to ensure that the information in this Book is correct and accurate, the editor and publisher do not assume and hereby disclaim any liability to any party for any loss, damages, or disruption caused by errors or omissions, whether such errors or omissions result from negligence, accident or any other cause.

ELAAU, Dankuni executed on very fast track by RVNL

Education

electric loco production

transfer of project

record time

dankuni yard

electric substations

cpmm unit

chief project manager

rail vikas nigam limitedit