Electric Loco Assembly and Ancillary unit of CLW at Dankuni has been implemented on a very fast track by RVNL and the aim is to augument production capacity of Electric Locos in Indian Railways. The project was implemented by the team of CPM M RVNL Kolkata- Rajesh Prasad and this coffee table book has been conceived and concluded by him only.

1. ElectricLocoAssembly
andAncillaryUnitofCLW
Dankuni
Project 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.

2. Foranewera
ofprogress
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
DankunihasbeencompletedinarecordtimebytheKolkataPIUofRVNL.
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 workcommenced 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
th
Shri Narendra Modi Hon'ble Prime Minister laid the foundation stone on 25 December 2014 and work
wasalsocommencedonthesameday.
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 sub- station, drainage
system, water supply along with overhead tank, water treatment plant and track connectivity from
Dankuniyard.
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
wishtheKolkataPIUgreatsuccessforalltheirfutureendeavors.
Message

3. Rail Vikas Nigam Limited
ELAAUC,Dankuni–ArarerealityofFaster
TrackProjectImplementationbyRVNL
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
ofstateoftheartIGBTbased3phaselocomotives.
However, as CLW has transformed from steam engine manufacturing to 3 phase locos, there has always been constraint in modernizing
infrastructuretoadoptmodernmanufacturingpracticesandincreasetheproductioncapacity.
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
Rs200croreshasbeencompletedandareinplace.
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
Locomotivewithoutanycrossmovementofsemi-finishedproduct.Thisrequiredconstructionof700mlongshed.
• SecondarystorageareaalongwithassemblylinetoimplementJIT(JustinTime)manufacturingphilosophywithminimuminventory.
• 2Kmlongtesttrackfortestingoflocomotiveinmotion.
• Wideroadnetworkformovementofstoreswithouthindrance.
• Skylightandsolarpowerforenergyconservation.
• Administrativebuildingwithbirdeyeviewofentireassemblyline.
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
datesprovidedinthecontractagreementandthiswasregularlyfollowed.
• Drawingsweremade,concludedandfrozenwellinadvance.
• 3monthsrollingprogrammeandmonthlyprogrammesweremadebytheagencymatchingtherequirementofworkprogramme.
• Weeklyreviewmeetingandtargetswerefixedforachievingintermediategoalstoaddressconstraints,resourcemobilization,etc.
• MicrosoftProjectwasusedformonitoringtheprojects,dashboardchartswerealsopreparedforbetterappreciation.
• 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
siteinrealtimethroughwebsitewhichisprotectedwithpassword.
• 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
thequalitycontrolmeasuresadopted.
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
likelytobedelayed.
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
approvedspecifications,drawings,etc.Itwasbasedonthefollowingqualitysystemprocedure:
• 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)andQualityControlPlans(QCP).
Details about the project:
The turn key contract was awarded incorporating Civil Engineering, Electrical Engineering, Mechanical Engineering and S&T. The
department-wisebriefdescriptionsoftheworkswereasunder:
Civil Engineering
(I) Mainshed(700mlong)withleantostructures:
Thevariousshopstoconstructedaspartofthemainshedareasfollows:
• OPENGANTRY 25MX70M
• SHELLSHOP 25MX140M
• PAINTSHOP 25MX190M
• PIPINGANDCABLINGSHOP 30MX250M
• TRANSFORMERMOUNTINGSHOP 30MX40M
• EQUIPMENTMOUNTINGSHOP 30MX200M
• BOGIE&WHEELINGSHOP 30MX90M
• TESTINGSHOP 30MX120M
Constructionof700Mlonggiganticshedinvolvedfabricationofthefollowingcomponents:-
• 258Columns,
• 74rooftrusses,
• 158GantryGirders
• 555BracingGirders
• 194RoofLegs
Furtheritinvolvedinstallationof–
• 57700 SQM sheeting including 20% roofing with 2 mm U/V protected polycarbonate transluscent
sheets)
• 103TurboVentsforkeepingthetemperaturepleasantandworkable
(ii) Otherstructures:
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
SecurityBlocks(2Nos.),3mX3MPumpHouse.
(iii) OtherCivilworks:
• Drainagearrangementincludingnetworkof450mmdiaand750mmdia,NP4humepipesandsurfacedrains.
• Roadof2.5KMwithconcretepavementinsidethefactory.
• Pathwayswithpaverblocksformovementwithinthefactory.
• Railwaytrackof5.5KMtakingofffromthetrackofEasternRailwayatDankunistation.
• 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
stonedust.
• Water supply arrangement including bore well, pump house, overhead tank (50,000 gallons), water supply pipelines, water
treatmentplantetc.
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Rail Vikas Nigam Limited

4. Electrical works:
PowersupplyarrangementwithTwoNos.ofelectricalsub-stationseachof33KV/440V,3x2.5MVA
Signalling works:
TelecommunicationworksincludinginstallationofelectronicexchangeandLANnetworking
Mechanical works:
Supply, erection, installation, testing and commissioning of various machineries and plants including 6 Nos. of EOT cranes, traverser,
compressor,tools,gauges,instrumentsetc.
Progress report through dash board chart : Dashboard chart is one of
the most effective management tool to ensure proper monitoring and
timely completion.
Rail Vikas Nigam Limited
Railway Board’s Target vis-à-vis progress
Finalization of scope of the work and transfer by Railway Board
by30.04.2012
TheworkwastransferredtoRVNLbyRly.Boardon07.05.2012
Completion of soil, investigation, survey, sanction of detailed
estimate& BOQbyRVNLby31.05.2012
Detailedestimate& BOQworksanctionedon23.05.2012
CallingofTenderbyRVNLby15.06.2012 Tenderwascalled on28.05.2012
Contract to be awarded and the work to commence in October,
2012withdateofcompletion of2years
Letter of acceptance issued on 02.10.2012 and mobilisation period
of 42 days. Work started in Dec. 2012 and Physically completed in
Jan2015.
Additional Works executed by RVNL
RVNL has accommodated several additional works asked at the later dates :-
• Deploymentof2nos.ofadditionalcranesinthe30Mbay
• Provisionofsolarpowerplant
• Provisionofroofcoveringwithtrussesintheadministrativebuildingandcoveringwithgreencolourpolycarbonatesheet
• Provisionoffountainandgardeninsidetheadministrativebuilding
• Provisionofwatertreatmentplant
• Provisionof2nos.ofcrosstracks
• Provisionofoffice/conferenceroomonthesecondflooropenterrace area
• 140numbersofquickcouplingswhichwereearliernotintheoriginal contractspecifications.
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Rail Vikas Nigam Limited

5. DetailsabouttheProject
Civil Engineering
Main Shed (700m long) with lean to Structures
• OpenGantry 25Mx70M
• ShellShop 25Mx140M
• PaintShop 25Mx190M
• PipingandCablingShop 30Mx250M
• TransformerMountingShop 30Mx40M
• EquipmentMountingShop 30Mx200M
• Bogie&WheelingShop 30Mx90M
• TestingShop 30Mx120M
Other Structures
• AdministrativeBuilding(G+2) 35Mx30M
• StoreBuilding(PEB) 30Mx20M
• ElectricSubstation(HWHEnd) 40Mx25M
• ElectricSubstation(DelhiEnd) 40Mx25M
• SecurityBlock(HWHEnd) 10Mx10M
• SecurityBlock(DelhiEnd) 10Mx10M
• PumpHouse 3Mx3M
Electrical Works
Power Supply arrangement with two nos. electrical substations each of 33
KV/440V,3x2.5MVA
Mechanical Works
• EOTCrane(50T)for30MBay 4Nos.
• EOTCrane(50T)for25MBay 2Nos.
• Traverser (50T) 1No.
• Compressor (500cfm) 3Nos.
• MIG/MAG5Nos. 5Nos.
Rail Vikas Nigam Limited
Pile,PileCap&Pedestal
Piling work commenced by CMD/RVNL in Dec. 2012
06 07
Rail Vikas Nigam Limited
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.

6. Rail Vikas Nigam Limited
StructuralWork SheetingSpecification
• ZincalumeSteeltrapezoidalsheet/EaveGutter/Ridge,etc.withnominal28mmdeepribs.
• End ribs designed for anti-capillary action, to avoid any seepage of water through the lateral
overlap.
• 0.55mmBaseMetalThickness(BMT)&0.6MMTotalThickness(TCT)
• Hightensilesteelwithminimum550MPayieldstrength
• 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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Rail Vikas Nigam Limited
First column erected by the then Member Electrical on 01.03.2013

7. Administrative Building ElectricSub-Station-1&2
Rail Vikas Nigam LimitedRail Vikas Nigam Limited
10 11

8. Rail Vikas Nigam Limited
StoreWard(with 20% Skylight and Turbovents)
12 13
Rail Vikas Nigam Limited
RPFBlock(Howrah & Delhi End)
Pre-engineered concept for faster execution

9. Rail Vikas Nigam Limited
Quarters(G+3,Type-II)-40 Nos.
14 15
Rail Vikas Nigam Limited
Machinery&Plants

10. MiscellaneousWorks
Rail Vikas Nigam Limited
PowerSupplyArrangementCommissioningoftwoElectricSub-StationswithSolarPanelonrooftopofHowrahendsubstation.
16 17
Rail Vikas Nigam Limited
WaterSupplyArrangement
Construction of new over head water tank and water pipeline, an old unused water tank was dismantled. Filter plant was also installed
andaconnectionwithDCF,Dankunihasbeenmadetotakecareofeventuality.

11. Rail Vikas Nigam Limited
Track&OHEWork TrialRunon07.01.2015
SiteVisit
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Rail Vikas Nigam Limited

12. SiteVisit
Rail Vikas Nigam Limited
SiteVisit
20 21

13. Rail Vikas Nigam Limited
TreePlantation Hindrances
Removal 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
duetonon-availabilityofsiteforaverylongtime.
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
majourbottleneck.
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
wasbadlyaffectedduetotheselines.
54 Nos. of trees which could be cut and disposed of as
late as in July, 2013. Piling work at some locations was
affectedduetotrees.
Encroachments – There were some encroachments
which could be relocated/ shifted only in November,
2013. These affected the railway track construction
apartfrombeinganuisance.
AbandonedRailwaybridge–RemovedinFeb.2015.
Underground HT cable at Howrah end entrance gate could be got shifted only in June,2014. Because of this cable, the regrading of
theapproachroadcouldnotbedonebeforemonsoon.
The site for construction of quarters which is a very
time consuming activity could not be made available in
time.
• BlocksC&D-07.02.2013(After4monthsofLOA)
• BlockE-12.09.2013(AfternearlyoneyearofLOA)
• Blocks A & B- 25.11.2013 (After nearly 14 months
ofLOA)
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14. Rail Vikas Nigam Limited
NoteofMemberelectrical,RailwayBoard
“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
officersforensuringcloseco-ordinationinconstructionofthisuniquefacility.
Anawardof `50,000/-wasannouncedbyMLforRVNLafterhisinspectionon19.07.2014.
InspectionNoteofGM/CLW
regardingQualityControl
11.0 Well equipped site laboratory has been set up where the required testing
equipments have been kept along with relevant code. The equipments
have been calibrated. One cube was tested for M35 pile after 28 days
casting and the results was 44 N/mm2. The same kind of quality control lab
shouldbeadoptedbyCLWandMetroRailwayatotherwork-sitesalso.
CPM/RVNL
CE/CLW
CE/Metro
Rly
InspectionNoteofCPDE,EasternRailwayInspectionNoteofHOD,EasternRailway
SafetyMeasures
RVNL Railway
ShriRajeshPrasad,ChiefProjectManager/M
ShriS.K.Srivastav,GM(Electrical–II)
ShriH.K.Sahu,GM(Finance)
ShriH.Singh,AGM/P/RVNL/KOL
ShriB.K.Roy,JGM/Mech.
ShriS.K.Das,JGM/S&T
ShriK.K.Mishra,Sr.Manager(Civil)
ShriH.Rao,CEE/CLW
Shri S.K.Agarwal, CEE Dankuni
Shri Sanjay Saha, Director/Rly. Board
ShriRajibRay,CEELoco
ShriB.R.Kanwar,CE/CLW
ShriR.K.Mishra,Dy.CE/C
ShriA.K.Dey,DEN
ShriS.P.Patra,SEE/Loco
ShriS.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
SudhirKumar,ED/Dev.Rly.Board andShriH.S.Yadav,CGM/RVNL.
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Rail Vikas Nigam Limited
• Agoodqualityworkwithgoodplanninghasbeenexecuted.
• 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
andcomfort.
• There is a nice arrangement of two staircases for going to entry cranes and walk ways along the gantry girders for
comfortablemovement.
• 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
situationsandmaintenance.Awatertreatmentplanthasbeeninstalledforensuringbestqualityofwater.
• Foraestheticappeal,beautifulwelldesignedceramicmuralshavebeeninstalledinthefactoryatvariouslocations.Thereis
arowofmuralsshowingthejourneyofIndianRailwayfromfairyqueentomodernhighhorsepowerlocomotives.
• 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
provisionoffirefightingsystem.
• The trial run of track has been done and electric sub-station commissioned and water supply system commissioned. The
factoryassetsarethusreadyforhandingoverbyRVNLandusebyCLW.
OfficialsAssociated

15. ElectricLocoAssembly
andAncillaryUnitof
CLWDankuni
THEOTHERWORKSHOPs
IMPLEMENTED/UNDER
IMPLEMENTATIONBYRVNL

16. “ ”
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’sMISSION
• CreatingstateofArtrailtransportcapacitytomeetgrowingdemand.
• Executing projects on fast track basis by adopting international project execution,
construction,managementpracticesandstandards.
• TomaketheProjectimplementationprocess,efficientbothintermsofcostandtime.
• Adhering to sound business principles and prudent commercial practices to emerge
India’stoprailinfrastructurePSU.
• To implement Rail Infrastructure Project on commercial format through various
PublicPrivatePartnershipmodels.
• ToachieveInternationalQualityStandardsthroughinnovations.
• Toachieveprojectcompletionsintargettimeandwithbestquality.
• 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
externalmultilateralagenciesliketheAsianDevelopmentBank.
Mantrasfor 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
anyliabilitytoanypartyforanyloss,damages,ordisruptioncausedbyerrorsoromissions,whethersucherrorsoromissionsresultfromnegligence,accidentoranyothercause.