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
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