Slide 1

1

Slide 2

Objective List all crane motions. List safety instructions taken during crane operations at accident site. Describe instructions for safe crane handling List precautions to be taken at accident site. Know about lifting of capsized loco/loaded wagon 2

Slide 3

140T Gottwald Design Crane at Accident Site 3 New DesignOld Design

Slide 4

Crane Motions Derricking IN-OUT jib motion up or down Travelling Forward- Backward Movement of bogie on the track 4 JIB

Slide 5

Crane Motions Hoisting UP - DOWN Load lifted or lowered through main/aux. hook. Slewing LEFT - RIGHT Super structure moves left or right alongwith cabin & counter weight slabs Winching Used when load is out from working radius. 5 LOAD

Slide 6

Staff Needed for Crane Operation & Maintenance Supervisor-1 Crane driver-1+1(Stand By) Gunner-1 Technician-2(Dsl fitter mech.)+1 Elec.+1 Gen. Helper-8 6

Slide 7

Deployment of Staff during Operation Driver operates crane from cabin Gunner with two staff for loading/unloading. One staff at each prop One staff watches the wire ropes in drum Supervisor is the gang leader. 7

Slide 8

Safety Measures in Crane Operation Before starting the engine, check Hydraulic oil level Fuel oil level Water level in radiator Belt tension After starting the engine, check All pressure gauges All temperature gauges SLI System 8

Slide 9

Safety Measures Visual checking of wire ropes DO NOT bypass SLI system Feed 4 datas in display board Visual checking of wire rope slings Check wire rope binding on drum Protect wire ropes during welding 9

Slide 10

Operation Control in Cabin Left Hand Joystick Right Hand Joystick 10 Derrick-OUT Derrick-IN Slew- LEFT Slew- RIGHT Main Hoist- DOWN Main Hoist- UP Aux Hoist-UP Aux Hoist- DOWN Travelling Winching PILOT CHAIR

Slide 11

Display Board 11 Prop position CWT position Main Hook position Aux. Hook position

Slide 12

Control Lever in Display Board Prop Position No prop(Free on Rail) Full Prop at 5.8 m Prop at 5 m Half Prop at 2.9 m CWT Position No Cwt Half Cwt(24T) Full Cwt(47T) 12

Slide 13

Continued Hook Position Main Hook Auxiliary Hook Tail Radius Position At 5.5 m At 6.5 m 13

Slide 14

Multi Spools in Super Structure M1- Assly of 4 DC valves Travelling Main Hoist Aux. Hoist Winching. M2- Assly of 3 DC Valves Travelling Derricking U/C & Rear Frame Assly 14 M1

Slide 15

Multi Spools in Under Carriage U1-Assly of 4 DC Valves. Two valves for Out riggers control Two valves for Propping Cylinder control U2-Assly of 5 DC valves. Four valves like above. One valve for AXLE Blocking operation 15 U2

Slide 16

Axle Blocking In axle blocking operation Travel gear engage. Service Brake ON Suspension spring in Home position. Without A/Blocking,crane can roll at gradient. 4 A/Blocking Cylinders/Bogie 16

Slide 17

Propping Photo 17 Propping Cylinder In-Rigger Out- Rigger Propping

Slide 18

Propping Method Check space for propping Check condition of the soil Use wooden slabs below propping cylinder Prop any two corners of the same bogie Propping pad should be horizontal Prop on any specified prop-position for sensing SLI. 18

Slide 19

Rigging Secquence of operations from starting the crane Axle Blocking ON/OF Crane in train formation-Axle Blocking OFF Self crane motion-Axle Blocking ON Proper propping Taking Cwt position as instructed Jib IN-OUT Hoist UP-DOWN Slew LEFT-RIGHT 19

Slide 20

Precautions taken at Accident Site Crane should be ready in all respect. Fuel oil,Hyd. Oil,Water upto proper level All Pr, Temp.gauges & sensors in working condition Axle Blocking in ON position Observe site for propping Nearest the job Temporary track made if needed Space for prop Condition of soil OHE cut off taken if required 20

Slide 21

21

Slide 22

Precautions Prop as instructed Select proper Cwt slabs from M/T Crane body level be HORIZONTAL Wheel just tends to LIFT the track 22

Slide 23

Precautions Slect proper wire rope slings. Staff deployed as instructed DO NOT by pass SLI System SLEW when load in HANGING condition 23

Slide 24

Precautions Only authorised officials deliver the instructions to the crane driver. Operate the joystick gradually Keep sharp observation over the crane wheels. Lifting of any wheels to be communicated to driver immediately. 24

Slide 25

Precautions Avoid dragging of cylinders with OHE wires. Do not lift the load to the excessive height from the ground level. Do not override the SLI during restoration. During slewing,observe the train movement on the adjacent electrically charged line. 25

Slide 26

(A)RESTORATION OF COACHES IN ELECTRIFIED SECTION BY 140 Te. CRANE Preparation Chart: S.N.Item/StatusAction 01OHETo be slewed towards coach movement and ensure that OHE of adjacent line has been made dead. 02Condition of props and availability of staff Full propping to be done and 04 staff on each prop should be deputed. 03Suitable packing and its size Wooden/synthetic packing of size 4 x2 x14 and 6 x1 x12 04Position of SLI duty selectorTo be kept on No. 1 05Wire rope Sling and SWL30 Te. 5 Mtrs sling and 70 Te. SWL as per requirement 06Chain sling as per requirement25 Te. Capacity chain sling 07Position of Cant of the trackShould not be more than 140 mm 08Position of SLISLI should be kept in working. 09Maximum working radius16 meters by main hook. 10Place where sling to be inserted(under frame) Solbar

Slide 27

S.N.Item/StatusAction 11Gas cutting equipmentDA and Oxygen gas with equipment 12Availability of wooden wedges04 wooden wedges 13Position of coach trolleyLashing chain to be used for securing with structure. 14Lighting arrangementTo be arranged during dark/night. 15Observation for suitable place Analyze suitable place for 360 slewing and placing the coach/damaged trolley. 16Arrangement of rope for coach adjustment 02 Nos. in sufficient length at both the ends of coach. 17Availability of Megaphone/ Communication One person should be deputed with equipments 18Photography/VideographyVideography of all critical operations and clues collection. 19Average timing for restoration of each coach Average 55 minutes

Slide 28

Removing Entangled Coach Ensure full prop & attach CWT slabs. Insert Aux. Hook in the solbar of coach at facing end and lift slowly with slewing actions. Remove entanglement of coach at another end also in the same manner If coach trolleys are in good condition, re-rail the coach by MFD Jacks. 28

Slide 29

Restoration of Coaches in non- electrified sections Restoration can be executed with 140 T Crane by placing coaches on the adjacent track:- Insert Hook in the solbar of rear end of coach and lift. Again release the hook, and pick up the coach in the center by 30 T 5 mtrs wire rope and lift. 29

Slide 30

Restoration of tilted coach: 1.If the trolleys of coach are intact, secure the trolleys with lashing chains so that trolleys remain with the coach structure. 2.But, if the trolleys are damaged or have got uncoupled, remove damaged trolleys first by Aux. hook. 3.Bring 140 T crane near the coach, ensure complete propping and insert hook at this end. 04. Lift the rear end. of tilted coach, it will get turned straight by this operation and further do next exercise for removing the coach.

Slide 31

Restoration of Loaded 4 Wheeler Wagon Establish the crane and ensure full propping. For loaded vehicles: use 30 T 5 mtrs wire rope sling and insert hook in the barrel bracket/body bracket. Initiate lifting operation and place wagon any where at 360 within 11 meters radius. 31

Slide 32

Restoration of Loaded BCN/BOX-N by 140 T Crane Ensure that centre of the wagon is not more than 8 meters of radius. Insert 70 T 6 meters two leg 02 wire rope sling in the solbar near cross bar support in the centre of the wagon and lift slowly just above the ground. 32

Slide 33

Restoration of damaged BCN/BOXN by 140 T Crane Advise commercial staff/officers for unloading. Insert Aux hook and remove the vehicle.. If it is not possible to unload the vehicle, permission of competent authority must be obtained for toppling of the wagon. 33

Slide 34

Damaged BCN/BOXN After getting permission, inert 30T, 5 Mtrs wire rope slings in the one side solbar and lift the same for toppling activities. Again insert slings on one side solbar of the wagon taking support of cross member and continue slewing and derricking as per requirement till unloading of the wagon.. Further insert 25 T capacity hook in the supporting channel of center seal near center pivot and lift accordingly. The wagon in this operation will get toppled completely. 34

Slide 35

Restoration of Derailed oil tank wagons involved in fire. Preparation Chart : S.N.Item/StatusAction 01.OHEWorking line OHE to be slewed. OHE of adjacent line to be made dead. 02.Requirement of fire brigadeHeavy duty fire brigade is called 02.Condition of props and availability of staff All props to be prepared and 04 staff on each prop should be deputed. 03.Suitable packing and its size Wooden/synthetic packing of size 4 x10 x6 and other suitable sizes. 04.Position of SLI duty selectorTo be kept on No. 1 05.Suitable wire rope sling30 Te. 5 mtrs sling 06.Suitable chain sling as per requirement 25 Te. Capacity chain sling 07.Position of Cant on the trackShould not be more than 140 mm 08.Position of SLISLI should be kept in working. 09.Maximum working radius16 meters by main hook and 19 mtrs. By Aux. hook.

Slide 36

S.N.Item/StatusAction 10.Place, where sling to be inserted Under frame barrel bracket 11.Position of wagon trolley Lashing chains to be used for securing with structure. 12.Lighting arrangementTo be arranged during night/dark. 13.Observation for suitable place Analyze suitable place for 360 slewing and placing of wagons. 14.Arrangement of rope for tank adjustment 02 Nos. in sufficient length at both the ends of tank. 15.Availability of Megaphone/ Communication One person should be deputed with equipments 16.Photography/Videograp hy Videography of all critical operations and clues collections. 17.Average per oil tank timing for restoration Average 30 minutes

Slide 37

Generally, it is observed that after derailment of oil tanks, they catch fire, which in turn results internal explosions. In this situation, it is not possible to rerail the tanks by MFD equipments because machine and breakdown staff may have sustain injuries due to explosions. 1. First of all, thorough inspection of accident site should be carried out and fire brigade is called immediately. 2. High pressure foam power is sprinkled on the tanks involved in the fire. 3. Until and unless putting off the fire completely, 140 Te crane should not be brought near accident site. 4. If the track is available and fire is put off, crane is moved and propped fully and aux. Hook/main hook is applied as per requirement on all four barrel brackets of the tank. 5. Now, Lift the wagon and keep anywhere at 360 within the radius of 18 meters. 6. In general, wagons involved in fire are removed/toppled and kept aside because such wagons are always dangerous for running on the track.

Slide 38

Restoration of derailed Locomotive in the dead end siding by 140 T Crane. Preparation Chart : S.Item/StatusAction 01OHEWorking line OHE to be slewed. OHE of adjacent line to be made dead. 02Condition of props and availability of staff All props to be prepared and 04 staff on each prop should be deputed. 03Suitable packing and its size Wooden/synthetic packing of size 4 x12 x12 / 4 x10 x6 04No. of cranes required and Position of SLI duty selector Two cranes.duty selector to be kept on No. 1 05Suitable wire rope sling50/70 Te. 6 mtrs sling (both side eye) 06Position of Cant on the trackShould not be more than 140 mm 07Position of SLISLI should be kept in working. 08Maximum working radius09 meters by main hook 09Place, where sling to be insertedAll four buffer plates 10Lighting arrangementTo be arranged during night/dark. 11Observation for suitable placeAnalyze suitable place for placing of loco. 12Arrangement of rope for loco adjustment02 Nos. in sufficient length at both the ends of loco 13Availability of Megaphone/ Communication One person should be deputed with equipments 14Photography/VideographyVideography of all critical operations and clues collections. 15Gas cutting equipmentDA and Oxygen gas with equipment 16Availability of wooden wedges04 wooden wedges 17Average per loco timing for restoration Average 2.0 hrs. minimum

Slide 39

When diesel or AC locomotive enters in to the dead end siding and derails, it is rerailed with the help of two cranes. Each crane at either end of adjacent track from where working radius is not more than 8 meters. 1.One 140 T crane is kept at one end on the adjacent track and other 140 T at another end. 2.Full propping is done for both the cranes and 50 T, 6 meters wire rope sling with D shackles are used. 3.D shackles are inserted in the lifting holes of buffer plates of loco on four places and both cranes are allowed to lift the loco simultaneously. 4.Lifted loco should be slewed towards adjacent track by both the cranes. 5.One bogie of the loco is placed on track in first occasion and then another crane is permitted to do so. 6.Lifted loco is always kept in dead condition during restoration operation.

Slide 40

(7) Restoration of Hot Axle/Cold Axle broken Wagons Preparation Chart : S.N.Item/StatusAction 01MFD power pack and 120/60 Te. Cap. Jacks with control table and hoses Two jacks of 120/60 Te. Cap. and displacing jacks. 02Suitable packing and its size Wooden/synthetic packing of size 3 x1 x6 / 3 x2 x6 and 04 iron plates. 03Availability of Lashing chains and bolts03 Lashing chains to be used for securing with structure. 04Availability of wooden wedges04 wooden wedges 05Rail skates trolley02 trolleys with 36/40 mm pana 06Availability of MFD tool boxShould be available at site 07Gas cutting equipmentDA and Oxygen gas with equipment 08Lighting arrangementTo be arranged during night/dark. 09Observation for suitable placeAnalyze suitable place for jack operation. 10Availability of Megaphone/ Communication One person should be deputed with equipments 11Photography/VideographyVideography of all critical operations and clues collections. 12Average per wagon timing for restoration Average 30 minutes

Slide 41

1. These wagons are rerailed by MFD equipment, and brought in the alignment on the track. 2. Rail Skates are inserted under the wheels of broken axle. 3. 32 mm bolt of the skate is tightened to establish the wheel completely in the container. 4. Each skate has two wheels, which should be observed for proper sitting on the rail before moving the wagon. 5. Move the wagon slowly without jerk, attaching with the breakdown train or assisting loco, not more than 5 Kmph speed. 6. Wagon in this position can travel 10 to 12 KMs at a stretch for next block station without changing the wheels. 7. This modification facilitates reduction in restoration timings and avoids toppling of such axle broken wagons at accident sites.

Slide 42

Responsibility for correct carrying out of rules A.Crane man are responsible not only for the mechanical manipulation of cranes but also for their safe operation and for seeing that all rules pertaining to their working are correctly carried out. B.In general, cranes working on break down operation or where a A- frame or jib is likely to foul adjacent line, must work under the supervision of an officer or competent subordinate. C.In electrified section, before commencing the operation, the crane supervisor / Driver will clearly indicate by a written memo to OHE department present at site to obtained power block and will operate the crane only after receiving the permit to work by authorized TRD staff after OHE has been made dead and earthed. D.During crane operation, the operator must be thoroughly conversant with load chart to assess the duty selection. E.Whenever 140 Te. Crane of ART is ordered to site of accident / derailment is to be accompanied by an officer.

Slide 43

Precautions when lifting with Cranes : 1.The crane must not be used to lift more than the maximum safe working load authorized at the radius. 2.Precautions should be taken to avoid load catching on obstructions as this may seriously overload the crane. 3.Sudden shocks and jerks also tends to overload the cranes and tackles.

Slide 44

Continued Shocks and jerks usually result from: (a). Mistake in signalling to the crane driver. (b).Want of observation by the crane driver. (c).Sudden application of brakes on crane. (d).Kinks in the chains. (e).Slipping of chain due to incorrect slinging or sling hooks not properly secured Lifting Tackles & Wire rope slings should be of suitable capacity 44

Slide 45

Loaded Wagon 45

Slide 46

Single Side Propping If propping space is not available Opposite the load side, just prop near the rail Must do propper prop in load side In this position,SLI do not work Do the work slowly with trial & error method 46

Slide 47

Load Stabilisation Proper propping as instructed Taking counter weight as per load chart Fix the Cwt tail radius as per load chart Fix the wire rope slings symmetrically in the job. Do NOT bypass SLI system 47

Slide 48

Toppling of Ernakulam Crane 48

Slide 49

Observation Crane is on no prop position ie free on rail. Full cwt slabs(47T) already taken. One sided wheels lifted from track Jib damaged & thrown away No fatal ocurred. Operational fault found 49

Slide 50

Danapur CraneToppled at Karauta 50

Slide 51

Analysis Propping is not done properly Old & damaged wooden slabs used in propping No CWT slabs taken Two props on the same side damaged simultenously. Operational fault found. 51

Slide 52

Lubrication of Cranes 1.Crane drivers are personally responsible for adequate and efficient lubrication of all bearing surfaces. 2. Ensure that bearing surfaces are clean and free from dust, dirt. This applies particularly in matching surfaces of clutch gear, center pivots, rollers and motion gears. 3. Ensure that visible parts are adequately lubricated. 4.Greasing of slew ring by grease gun 5. The manufacturers recommendations for lubrication should be strictly followed

Slide 53

THANK YOU 53