Minutes of Conference held at JMP on 02.09.11 and 03.09.11
for 140T Crane (Gottwald Design) spares requirement and repair requirement
Present:
Rly. Board Representative:
Sri Manish Jain/ DME (P)-II
Jamalpur Representative:
Sri Animesh Kr. Sinha/CWM/JMP
Sri C. P. Sharma/ Dy.CME/Cr/JMP
Sri G. C. Rao/ AWM/Crane/JMP
RDSO/LKO Representative:
Sri Pankaj Saxena/ADE/RDSO/LKO
ER HQ Representative:
Sri S. K. Biswas/ Dy.CME/HQ/ER
Sri J. K. Pal/ SME/HQ-I/ER
Firm’s Representative
Mr. Anmol Batra/Cummins/Kol.
Mr. J.D.Petkar/Mechanica/Pune
Mr. Binod Kumar/ Hi-tech/Delhi
Crane User Representative:
(1) Sri B. Lakra, CMPE/NFR
(2)
(3) Sri A. K. Gupta, CMPE/SECR
(4)
(5) Sri A. K. Gautam, Sr. DME (O&F)/ALD
(6)
(7) Sri S. N. Roy, Sr.DME (C&W)/SEE
(8)
(9) Sri B. K. Pandey, Sr.DME/Gonda
(10)
(11) Sri P.K. Mukhopadhyayay,DME(P)/ER/ASN (12)
(13) Sri A. Gupta, DME/NFR/NJP
(14)
(15) Sri B. Nath, DME/NFR/NBQ
(16)
(17) Sri A.K. Srivastava, DME/NR
(18)
(19) Sri S. C.Behra, SME (HQ)/SER/GRC
(20)
(21) Sri S.K. Tiwari, AME/ER/SBG
(22)
(23) Sri J.P. Singh, AME/NFR/NGC
(24)
(25) Sri R. Rangarao, ADME/SECR/BIA
(26)
(27) Sri Chintamani, ADME/SECR/BSP
(28)
(29) Sri P.S. Kumar, AME/NED
(30)
(31) Sri B.K.Saha, ADME/Gondia
Sri Satish Kumar, CMPE/NER
Sri A. K. Shivhare, Dy.CME/HQ/NCR
Sri K. N. S. Yadav, Sr. DME (P)/DHN
Sri N. N. Sarkar, Dy.CME (OP)/SDAH
Sri C.S. Yadav,DME(P)/NR/LKO
Sri K.L. Saini, DME/WR/RTM
Sri C.H.V. Ramanna, DME/ECoR/VSKP
Sri Shivaji Kadam, DME/CR/Ajni
Sri G.S.Reddy, AME/ECoR/BBS
Sri B.Sampat Kumar, AM E/SCR/PAU
Sri A.K.Gupta, ADME/ECR/SEE
Sri K.K.Deva, ADME/NFR/TSK
Sri D. Kumar, ADME (P)/ECR/MGS
Sri P. Behra, ADME/ECoR
Sri K. Raja, ADME/SR/TVC
This meeting conducted as follow-up to Crane Review Meeting conducted at RDSO on 29-7-11.
1.
CAMC of Cummins Engine:
(Item-4, decision-4 of RDSO-MOM)
M/s Cummins was represented by Mr. Anmol Batra (Cummins/Eastern Zone/Kol).
Points discussed were as follows:
S.N.
POINT
EXISTING PROPOSAL
1
No of visits
8 visits per annum
2
Payment
terms
Pro rata on annual basis for
AMC& bi-monthly submission of
bills
3
Response
time to
Report for
Brake Down
Repair
<50Km………….within12hrs
<51200Km………….within24hrs
>201Km……… within48 hrs
TO BE REVISED AS
4 Regular visits + 1B check visit +1C
check visit per annum to be equally
inter-spread to the extent possible
Actual basis. Billing per visit or bimonthly as suitable for firm.
Response time for emergency Break
Down at site should be not more than
02 hours for <50 kms. The service
engineer will move along with required
spares according to preliminary
message from site. If crane returns to
depot , it should be attended within 03
days.
For > 201 Kms it should be <24 hrs
except NFR (east of New JalpaiGuri)
and J&K where it will be 48 hrs.
Page 1 of 14
Detailing of
consumables
during6 visits
Lump Sum provision
4
5
Materials List
Lump Sum provision
Detailed break-up of Consumable and
material list to be give for 4 regular
visits + B check + C check. Individual
price of mandatory parts to be
replaced in schedules shall be
mentioned. Firm will exempt cost for
consumables provided by Rlys. Rlys.
will provide manpower , available tools
& space free of cost.
a)Mandatory list as per Para 4 above.
b) Materials which may be required
with individual cost- optimal list.
c) List of material with individual costto be kept per crane.
d) List of material with individual cost-
to be kept per zone.
6
7
Inclusive
clause
Existing proposal does not
mention
AMC to be effective from date of expiry
of std. warranty for new or POH/MLR
engine.
Exclusive
clause
a) Failure due to operational
fault/accident/unusual
operating environment
b) Replacement of exhaust
silencer/piping/battery
c) Replacement of cylinder
block, crank shaft, cam
shaft,, cylinder head, liner,
piston, piston rings, PT
Pump, Gear Pump, Cylinder
casting, Turbo wheel and
shaft, injector body.
d) Radiator and its accessoriesHyd. Motor, Hyd Pump, Fan
&
Hub,
ECPG/Governor
controller, Fuel actuator,
Wiring
Harness
&
compressor.
e) E-check & major overhauling
If std warranty for new or POH/MLR
engine is alive, the coverage of
these parts shall be according to
std warranty.
8
On site
Requisition
Not clear
9
Payment
agency
(Divn/JMP)
Not clear
10
Inter-dealer
mapping
In case of B/Down at site, M/s
Cummins will depute rep within
shortest possible time. However last
leg may have to be covered by train.
For which the engineer will report
within 2 hours at the Railway Station.
Cummins
representative
to
be
authorized
to
travel
by
train/Loco/TC/ATR on authorization
given by ART I/C or AME(P)/DME(P)
or higher office. Parts will be replaced
as required however Service Report to
be accepted by Rlys. For post facto
approval and payments to Cummins.
Jmp(W) shall have a centralized
contract but modalities of payment by
Div as in case of DEMU engines.
Reference (1) ICF Rate Contract
No.MD/DMU/HHP/ECHECK/RC/CIL/2009-11/1 DT.07-5-10
specifying in para21.1 that payment
will be made by Zonal Rlys. (2)ICF
Rate Contract No.MD/DMU/HHP/DCHECK/RC/CIL/2010/12-2 DT.16-1210.
CAMC will be through nearest
Cummins dealer with respect to Crane
Page 2 of 14
11
Contract
Value
12
Training
13
Availability /
MTBF /
Maximum
b/down
window for 1
failure
based location but in case of b/down in
other area, inter dealer mapping to be
ensured by Cummins.
to be modified by Cummins as per
para-1 above.
M/s Cummins to give know- how
regarding daily and weekly checking of
engine in proper procedure to users.
To be specified considering low usage
hours and intermittent use.
The service level should improve when direct contract with Cummins is done at the same cost as
being paid at present by users individually.
(a) Rly. Bd’s Comments: In spite of AMC or CAMC, user’s responsibility will be final to avoid any
delay of Break Down of the crane.
(b) CWM Comments: Determination of Contract & other clauses of GCC must be followed.
(c) Final decision of house: All crane users agreed for central CAMC of engine. ZRs will ensure
provision of funds.
(d) Crane list, location & model of engine to be given by JMP on demand.
(e) The contract could later be extended to cover E-check/POH of the main engine which could be
synchronized with POH of the crane at JMPW.
DECISION TAKEN:
Fresh offer to be submitted by CUMMINS at the earliest covering the above points , which will
be processed by JMP for approval and entering into contract.
1.2
AMC of SLI system:
(Item-4, decision-3 of RDSO-MOM)
Points discussed were as follows:
(a) All users are interested for AMC on SLI. JMPW too recommends it. However costs being
charged at present needs to be critically looked at.
(b) All crane users present at seminar were explained the seven points given by JMP to E.
Rly./HQ and RDSO/LKO for up gradation of SLI system. Three more points (viii to x) were
discussed.
(i) Indication & warning of tilted angle of Prop. (Horizontality of crane).
(ii) Automatic indication & control of Prop position.
(iii) Automatic indication of CWT status in new design.
(iv) Automatic selection/indication by SLI clarifying whether main or Aux. hook is under use for
both designs not considered necessary.
(v) Automatic indication of tail radius in new design.
(vi) For more accuracy of actual load, shear pin in lieu of load cell for new design & old design.
(vii) SLI indication for auxiliary hook of old design cranes.
(viii) Hour meter provision – not required as engine hour meter is already avl.
(ix) Audio alarms in addition to visual – not considered necessary.
(x) Event recorder
(c) One or two users proposed SLI cut off in case of abnormal wind force experienced by load
resulting in swaying of load (e.g. in case of high wind speed) Calculations justifying wind
speed sensor will be submitted by SLI manufacturer to RDSO for scrutiny. If considered
necessary, it may be installed on cranes in coastal areas on trial basis only.
(d) Users did not suggest any other point during seminar, other than (b) (vi) & (c) above.
DECISION TAKEN:
(a) Modifications/up gradation suggested above to be developed by SLI manufacturers and
to be submitted to RDSO for approval.
(b) Any change in design of SLI should have approval of RDSO and JMP works. Users
should not undertake any modification (as done by TPJ) on their own.
Page 3 of 14
1.3
Current status of AMC by users
(Item-4, decision-1 of RDSO-MOM)
(a) SLI- Out of 52 users only 33 having AMC. JMPW recommends that SLI cards must be
under AMC as know-how of mother board & cards not available with Elect.sec./JMPW.
(b) Main Engine – Out of 52 users only 17 having AMC. JMP works recommends that engine
must be under AMC.
(c) Full Crane except main engine – About 15 users are having this type of AMC.
(d) Efforts on for Centralized AMC for main engine. Rate recd earlier is Rs 5 lacs + per day
charges for 1 year covering B&C checks AND another 4.68 lacs for D check after 2 yrs.
NOTE – JMPW opined that those users having part/full crane under AMC should not call JMP to
attend that particular part of crane covered under AMC, except in very exceptional
circumstances.
DECISION TAKEN:
Any user who enters into AMC for any part of crane should send intimation/agreement copy to
JMPW as well. Presently this information is received through JMP staff attending the crane.
2. Material for maintenance of Crane:
(Item-3, decision-4B of RDSO-MOM)
Points discussed were as follows:
2.1 Emergency Spares
Users had been requested to submit list of emergency spares, as proposed by them. Summary
of their submission is as below:
(1) Crane No. 144010 / KURLA/CR
227 items
(2) Crane No. 143004/SBG/ER
NOT SUBMITTED
(3) Crane No. 144020 /ERS/SR
NOT SUBMITTED.
(4) Crane No. 143006/KBJ/ECoR
NOT SUBMITTED.
(5) Crane No. 144006/TNP/SR
NOT SUBMITTED.
(6) Crane No. 144019/TPJ/SR
NOT SUBMITTED.
(7) Crane No. 143010/DNR/ECR
37 items
(8) Crane No. 144005/SBP/ECoR
NOT SUBMITTED
(9) Crane No. 142033/MGS/ECR
06 items.
(10) Crane No. 142042/TSK/NFR
42 items
(11) Crane No. 143002/GHY/NFR
40 items
(12) Crane No. 142032/BSP/SECR
25 items
(13) Crane No. 142271/DLI/NR
NOT SUBMITTED
(14) Crane No. 142270/CNB/NCR
08 items
(15) Crane No. 142038/LKO/NR
NOT SUBMITTED
(16) Crane No. 142037/HWH/ER
(17) Crane No. 144007/RPH/ER
(18) Crane No. 142039/ASN/ER
(19) Crane No. 143007/BGA/ER
(20) Crane No. 144015/Rajkot/WR
(21) Crane No. 144011/NBQ/NFR
(22) Crane No. 144008/Miraj/CR
(23) Crane No. 144001/VSKP/ECoR
(24) Crane No. 142269/NJP/NFR
(25) Crane No. 142265/RTM/WR
(26) Crane No. 143009/BKSC/SER
(27) Crane No. 142266/GONDA/NER
(28) Crane No. 143003/SEE/ECR
(29) Crane No. 144021/GONDIA/SECR
(30) Crane No. 142041/BIA/SECR
(31) Crane No. 144012/PURNA/SCR
(32) Crane No. 144003/AJNI/CR
NOT SUBMITTED
NOT SUBMITTED
160 items
131 items
NOT SUBMITTED
132 items
NOT SUBMITTED
53 items
36 items
18 items
NOT SUBMITTED
101 items
NOT SUBMITTED
opined it will follow JMP recommendations.
NOT SUBMITTED
NOT SUBMITTED
NOT SUBMITTED
Page 4 of 14
SUMMARY:
a) Some users stated that List of Emergency Spares may be finalized by JMPW.
b) 17 out of 32 users above have not submitted any list of emergency spares. Another 20 users
(Div. level) did not attend this seminar. Bd. stated that list of emergency spares submitted by
JMP shall be approved after getting opinion of users. Seeing the above response Bd. will be
requested separately to approve the reviewed list (dt. 26-09-11) of Emergency Spares (Cat-A91 items & Cat-B-624 items) so that emergency spares could be procured through Rate Contract
under process at E.Rly/H.Q. from 26-09-11(Lists attached). The lists should clearly identify the
exception between old and new design spares.
c) Parel stocks 2 crane sets of emergency spares for 12 Nos. Old Design Crane & 01 Crane Set for
04 nos. New Design Crane. For emergency spares, indents are generated by users in case of
Cowans Crane.
d) In 2012-13 JMP will have 22 Old Design Cranes & 36 New Design Cranes, many of them aged.
e)
If Parel formula is copied, one crane set of emergency spares per five nos. of cranes (whether
old design or new design) shall be required. However in view of large population to avoid nonmoving items, it was decided to keep 2 sets of old design and 3 sets of new design crane spares.
2.2
Rate Contract
(Item-3, decision-1&3 of RDSO-MOM)
Points discussed were as follows:
1. JMPW had submitted to E. Rly. H. Q a list of 1259 Nos. items previously for procurement
through RC. RC for 611 items (sorted out by HQ- in sixteen Cases) were under process by
Eastern Railway HQ. Two cases for 40 types of Hoses finalized and valid up to 30.09.12.
Copies have been uploaded on crane web-sitre for ready reference.
a) RC No.04/140T/Crane/ Hose Assly/RC on M/s Hydraulic Syndicate for 32 types of
Hoses.
b) RC No.04/140T/Crane/ Hose Assly/RC on M/s Hydrocrimp for 08 types of Hoses.
Users may utilize these two contracts as per their requirement.
2. Bd. advised Dy.CME/HQ/ER to finalize the cases early who advised Dy.CME/Cr/Jmp to
review the list of remaining items. Target for finalizing the RC should be intimated by ER HQ
to Board latest by 10-Oct-2011.
Action taken by JMPW after the meeting:
a) JMPW has reviewed (added/deleted) the R.C list items and sent it to E.R.HQ on 23-0911 ( Total 788 items now) , so as to cover up to future MLR requirements of major items
through RC, just like Parel. This will automatically cover future POH requirements &
Emergency Spares ( Cat-A-91 items & Cat-B-624) items too. 73 out of 161 reviewed Ccategory items are included in reviewed RC list of 788 items.
b) For minor items not in extended RC list, requirements shall be covered through estimates or
otherwise.
Spares for regular use to be purchased/Stocked at depot level (“C” Category Items)
(Item-3, decision-4A of RDSO-MOM)
2.3
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Users had been requested to submit list of regular use spares to be purchased/stocked at
depot level, as proposed by them. Summary of their submission is as below:
Crane No. 144010 / KURLA/CR
NOT SUBMITTED
Crane No. 143004/SBG/ER
151 items
Crane No. 144020 /ERS/SR
NOT SUBMITTED.
Crane No. 143006/KBJ/ECoR
NOT SUBMITTED.
Crane No. 144006/TNP/SR
12 items
Crane No. 144019/TPJ/SR
NOT SUBMITTED.
Crane No. 143010/DNR/ECR
06 items
Crane No. 144005/SBP/ECoR
NOT SUBMITTED
Page 5 of 14
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Crane No. 142033/MGS/ECR
Crane No. 142042/TSK/NFR
Crane No. 143002/GHY/NFR
Crane No. 142032/BSP/SECR
Crane No. 142271/DLI/NR
Crane No. 142270/CNB/NCR
Crane No. 142038/LKO/NR
Crane No. 142037/HWH/ER
Crane No. 144007/RPH/ER
Crane No. 142039/ASN/ER
Crane No. 143007/BGA/ER
Crane No. 144015/Rajkot/WR
Crane No. 144011/NBQ/NFR
Crane No. 144008/Miraj/CR
Crane No. 144001/VSKP/ECoR
Crane No. 142269/NJP/NFR
Crane No. 142265/RTM/WR
Crane No. 143009/BKSC/SER
Crane No. 142266/GONDA/NER
Crane No. 143003/SEE/ECR
Crane No. 144021/GONDIA/SECR
Crane No. 142041/BIA/SECR
Crane No. 144012/PURNA/SCR
Crane No. 144003/AJNI/CR
24 items.
51 items
NOT SUBMITTED
81 items
33 items
03 items
27 items
opined it will follow JMP recommendations.
opined it will follow JMP recommendations.
37 items
56 items
NOT SUBMITTED
08 items
NOT SUBMITTED
29 items
34 items
19 items
NOT SUBMITTED
173 items
NOT SUBMITTED
124 items
179 items
NOT SUBMITTED
NOT SUBMITTED
DISCUSSION
a) List of spares for regular use to be purchased/ stocked at depot level (Cat-C- 76 items)
circulated earlier were re-circulated. Few users have made noticeable procurement/stocking
of some minor spares.
b)
JMP proposed to add 09 more items (Belts etc.) in this category for consignees.
Some users suggested adding more materials in ‘C’ category list to be kept at
Consignee end. This should include: Small bearings, Seal kits, Nylon items, Hoses at zonal
basis, Electrical items, Gauges and sensors.
CWM/JMP’s comments: This extended list of ‘C’ category items to be prepared by JMP within
very short period.
c)
Action taken by JMPW after the meeting:
Previous list of 76 items reviewed. List of 161 C-category items (attached) prepared on 26-09-11.
73 out of 161 reviewed C-category items are included in reviewed RC list of 788 items.
2.4
Users Requirement of Spares
(Item-3, decision-2 of RDSO-MOM)
In LKO meeting, some users pointed out that they do not get ALL spares from JMP. JMPW
supplies spares against extra purchase made through Estimates. During last 3 yrs, 16 zones
approached us for spares & all received part/ full compliance depending upon availability.
Feedback received from users almost confirm this, though some records/data vary.
Railway Board’s comments on spares: There is no compromise with spares non-availability at
accident spot and crane item could not be procured in open market basis. Users should submit
vetted indents to JMP so that procurement action can be taken in advance.
DECISION TAKEN:
(a)Future requirements should be met through RC as done by Parel. This has been discussed in
para 2.1, 2.2 & 2.3 above.
(b)Material Released from MLR: Presently JMP has 61 types of released parts which even after
completion of 8, 15 or 19 years of service are still workable. Interested crane users may see
the list in Crane Cell/JMP and submit demands for these which may be given free of cost. In
case of no demand, these may be scrapped after six months.
Page 6 of 14
2.5 Schedule Maintenance
(Item-7 & item 9-(5&6) of RDSO-MOM)
DISCUSSION
a) Even decades old users have not yet arranged hydraulic torque wrench required in 04 yearly
schedules in spite of collection of procurement details from JMP by many. Hydraulic torque wrench
to be procured by all crane users (old & new design) for the 04 yearly schedules to test the
specified torque of slewing ring fasteners (studs & nuts). Soft copy and hard copy of detail
specification and cost details has been distributed among participants.
b) CMPE/NER advised that this procurement may be done by JMPW against their zone wise vetted
indents. This was agreed to.
c) Data collected by SEG teams for 28 cranes show that many users do not follow maintenance
schedules even partly. Some examples are:
1.
2.
3.
4.
5.
6.
Crane No. 144002/Agra/NCR
Crane No. 142270/CNBE/NCR
Crane No. 143005/Roja/NR
Crane No. 144011/NBQ/NFR
Crane No. 143010/DNR/ECR
Crane No. 142267/BRWD/ECR
For remaining cranes too, the statistics (22% users not maintaining even partly) expected to be
same. Many users conduct Schedules partly.
Conclusion:
All agreed that schedules are required to be done. Some users complained about shortage of staff
whereas some complained about lack of infrastructure.
DECISION TAKEN:
DME (P)-II/R.B. distributed the authority letter regarding staff requirements and instructed users to
keep the desired strength of crane staff. Regarding infrastructure, DME (P)-II/R.B. repeated the
instructions given earlier during meeting at RDSO and stated that failure in achieving the targets will
be viewed seriously by Board. It was agreed that procurement of hydraulic torque wrench may be
done by JMPW against zone wise vetted indents.
2.5 Life extension beyond 26 yrs.( Item-5 of RDSO-MOM)
(a) Schedule suggested by Parel mentioned below :
1st POH of a crane………….8th year
2nd POH of a crane………….14th year
Rehab of a crane………….20th year
3rd POH of a crane………….28th year
Condemn of a crane………….36th year
DME (P)-II reiterated that condemnation of the crane is not to be planned on age basis.
(b) For cranes which have already undergone MLR in 14 th year, second Rehab level attention
shall be required in 28th year after structural audit by RDSO (Item-5,decision-1 of RDSOMOM) in 26th year.
(c) For cranes which have not undergone MLR, the 2 nd POH (14th year )will have to be conducted
with complete overhauling of Hyd Pumps, Hyd Motors & G/boxes for which B/Q
no.AGRO/JMP/Repair dt 31-8-11 has been collected from M/s Agromach. This was not
required in 1st POH (8th year) as per earlier classroom instruction by Gottwald.
(d) The consequent excess POH/MLR arising (19 nos in 2012-13 and 12 nos in 2013-14) for
JMPW is very high. During RDSO meeting, CWE/ER had suggested sharing of this load with
Parel (which has much lesser load of cranes) to liquidate overdues—Item 5&6 of RDSOMOM. DME(P)-II clarified that Gottwald design crane related work will be handled completely
by JMP only.
Page 7 of 14
2.6
Defect/failure reporting to JMP
Points discussed were as follows:
•
JMP receives AVERAGE 60 to 74 reports for 52 cranes in 12 months. This amounts to 1.25
visits per crane per year though 35 cranes are indigenous. For Parel this figure is higher in
spite of ALL cranes being imported.
•
Users had been asked to deposit details of on-site & off-site failures. Summary of report
received is given below:
1.
Crane No. 144010 / KURLA/CR
On site – 0
Off site -0
2.
Crane No. 143004/SBG/ER
On site – 0
Off site -1
3.
Crane No. 144020 /ERS/SR
On site – 0
Off site -1
4.
Crane No. 143006/KBJ/ECoR
On site – 1
Off site -3.
5.
Crane No. 144006/TNP/SR
On site – 0
Off site -11
6.
Crane No. 144019/TPJ/SR
On site – 0
Off site -0.
7.
Crane No. 143010/DNR/ECR
On site – 3
Off site -14
8.
Crane No. 144005/SBP/ECoR
On site – 0
Off site -5
9.
Crane No. 142033/MGS/ECR
On site – 1
Off site -2.
10. Crane No. 142042/TSK/NFR
On site – 1
Off site -4
11. Crane No. 143002/GHY/NFR
On site – 0
Off site -2
12. Crane No. 142032/BSP/SECR
On site – 0
Off site -0
13. Crane No. 142271/DLI/NR
On site – 0
Off site -0
14. Crane No. 142270/CNB/NCR
On site – 1
Off site -7
15. Crane No. 142038/LKO/NR
On site – 1
Off site -1
16. Crane No. 142037/HWH/ER
On site – 0
Off site -29.
17. Crane No. 144007/RPH/ER
On site – 0
Off site -3.
18. Crane No. 142039/ASN/ER
On site – 1
Off site -6
19. Crane No. 143007/BGA/ER
On site – 2
Off site -5
20. Crane No. 144015/Rajkot/WR
On site – 0
Off site -14
21. Crane No. 144011/NBQ/NFR
On site – 1
Off site -1
22. Crane No. 144008/Miraj/CR
On site – 0
Off site -0
23. Crane No. 144001/VSKP/ECoR
On site – 1
Off site -10
24. Crane No. 142269/NJP/NFR
On site – 1
Off site -1
25. Crane No. 142265/RTM/WR
On site – 0
Off site -0
26. Crane No. 143009/BKSC/SER
On site – 0
Off site -4
27. Crane No. 142266/GONDA/NER
On site – 2
Off site -21
28. Crane No. 143003/SEE/ECR
On site – 0
Off site -1
29. Crane No. 144021/GONDIA/SECR
On site – 1
Off site -1
30. Crane No. 142041/BIA/SECR
On site – 3
Off site -1
31. Crane No. 144012/PURNA/SCR
On site – 0
Off site -8
32. Crane No. 144003/AJNI/CR
On site – 6
Off site -24
Conclusion:
Checking the reports of 2008-09 (13 users), 2009-10 (18 users) , 2010-11 (31 users) & current year
(10 users till now), it is found that some users are more efficient in “Do’s & Dont’s “and “Trouble
shooting” where as some users are extremely slack. DME (P)-II stated that few cranes have very high
Page 8 of 14
rate of failures, which is not acceptable and suitable action should be taken by ZRs to improve. He
also emphasized that preventive maintenance schedules must not be compromised with.
Action taken by JMPW (Item-1, decision-6 of RDSO-MOM):
CD containing pictorial Do’s & Dont’s distributed to participants. Users advised to log complaints on
web/portal with defect code. The Do’s and Don’t’s should be fixed to the crane structure at
appropriate places by all users.
2.7 Divisional Core Team for 140T crane
(Item-9-(5&6) of RDSO-MOM)
Points discussed were as follows:
a) 16 nos staff are called for trg prior to handing over a crane.
b) 16 Nos. of divisional staff for crane operation & maintenance needs to be ear marked by all
users. This instruction is violated by many users.
c) For each crane JMPW has trained sufficient no. of staff , but not all of them remain attached
to the crane.
d) It has been reported that Moradabad crane No.143005 in-charge is an MCM. Crane in
charges should be SSE/Grade supervisors.
e) Two other cranes (No.143010-DNR) & (No.143001-DHN) are having JE as crane incharges as per jointly signed SEG reports.SSE to be made i/c.
f) Crew details submitted by participants is tabulated below:
A
B
C
D
E
F
Crane No. &
Consignee
Crew Details
144010
KURLA/CR
09 Trained
03
Untrained
143004
SBG/ER
12
Trained
144020
ERS/SR
29
Trained
143006
KBJ/ECoR
16 Trained.
144006
TNP/SR
06 Trained
04 Untrained
144019
TPJ/SR
07 Trained
19 Trained
Crane No. &
Consignee
Crew Details
143010
DNR/ECR
09 Trained
05
Untrained
144005
SBP/ECoR
09 Trained
06
Untrained
142033
MGS/ECR
07
Trained
09
Untrained
142042
TSK/NFR
04 Trained
17
Untrained
143002
GHY/NFR
05 trained
01 Untrained
142032
BSP/SECR
08 Trained
01
Untrained
Crane No. &
Consignee
Crew Details
142271
DLI/NR
Not
submitted.
142270
CNB/NCR
08
Trained
05
Untrained
142038
LKO/NR
17
Trained
142037
HWH/ER
13 Trained
01
Untrained
144007
RPH/ER
10 Trained
07 Untrained
142039
ASN/ER
14 Trained
05
Untrained
Crane No. &
Consignee
Crew Details
143007
BGA/ER
13 Trained
06
Untrained
144015
144011
144008
Rajkot/WR NBQ/NFR Miraj/CR
07 Trained 06 Trained
08 Trained
12 Untrained 10 Untrained
144001
VSKP/ECoR
08 Trained
05 Untrained
142269
NJP/NFR
08 Trained
Crane No. &
Consignee
142265
RTM/WR
Crew Details
04 Trained 13 Trained
06
untrained
Crane No. &
Consignee
Crew Details
144012
144003
PURNA/SCR
AJNI/CR
21 Trained
05 Trained
06 Untrained
143009
BKSC/SER
142266
GONDA/NER
143003
SEE/ECR
09 Trained
06 Untrained
09
Trained
144021
GONDIA/SE
CR
09 Trained
142041
BIA/SECR
10 Trained
Page 9 of 14
Summary:
Users (among above 32) having < 1/3rd trained staff= 12.5%
Users (among above 32) having < 50% trained staff= 28.1%
Users (among above 32) having 50% trained staff= 15.6%
Users (among above 32) having > 2/3rd trained staff= 18.7%
CONCLUSION:
Staff who receive training should be kept attached to the crane. No. of staff trained by JMP for Kurla27, TNP-21, TPJ-18, DNR-15, KBJ&SBP-39, RAJKOT-15, AJNI-20, GHY-16, MGS-33 nos. But the
actual attachment is less. DME(P)-II asked ZRs to give confirmation on deployment of staff as already
recorded in RDSO minutes.
DECISION TAKEN:
Participating officers agreed to have competent core team.
2.8 Infrastructure development ( for proper maintenance ) by users:
(Item-7 of RDSO-MOM)
Points discussed were as follows:
a) Users have to develop their infrastructure as per RDSO
and to keep the crane properly.
instructions for better maintenance
b) Existing 52 crane users have not developed required infrastructure as per RDSO
recommendations. A.M.(P.U.) has advised in LKO meeting that users to create facilities /
infrastructure by 31.03.12. As per reports submitted by 32 out of 52 users, only some have
developed these partially.
A
B
C
D
Crane No. &
Consignee
Details
of
Infrastructure
available at
Crane base
144010
KURLA/CR
Not as per
RDSO
instruction.
143004
SBG/ER
Not as per
RDSO
instruction
.
144020
ERS/SR
Estimate under
preparation
sanction Amount
Rs.1.5 crore
Crane No. &
Consignee
143010
DNR/ECR
Details
of
Infrastructure
available at
Crane base
Not as per
RDSO
instruction.
Estimate is
under
process.
Not as per
RDSO
instruction.
Crane No. &
Consignee
Details
of
Infrastructure
available at
Crane base
142271
DLI/NR
NIL
142270
CNB/NCR
At present
NIL, under
proposal
stage.
Crane No. &
Consignee
143007
BGA/ER
144015
Rajkot/WR
144011
NBQ/NFR
Details
of
Infrastructure
available at
Crane base
Not
available,
but sanctioned
inGM's Lumsum
2011-12.
Not as per
RDSO
instruction
Not as per
RDSO
instruction
144005
SBP/ECoR
142033
MGS/ECR
Under
proposal
stage.
142038 LKO/NR
Not available,
crane is
attached with
Diesel
Shed/AMV/LKO.
143006
KBJ/ECoR
NIL
144006
TNP/SR
Not as per
RDSO
instruction.
144019
TPJ/SR
Under
develop
ment.
142042
TSK/NFR
143002
GHY/NFR
Not as per
RDSO
instruction.
50% as per
RDSO
instruction.
142032
BSP/SE
CR
Not as
per
RDSO
instructio
n.
142037
HWH/ER
Not as per
RDSO
instruction.
144007
RPH/ER
Not as per
RDSO
instruction.
144008
Miraj/CR
Not as per
RDSO guide
line but under
process
144001
VSKP/ECoR
Not
Submitted
142039
ASN/ER
50% as
per
RDSO
instructio
n.
142269
NJP/N
FR
Not as
per
RDSO
instruct
ion
Page 10 of 14
E
Crane No. &
Consignee
142265
RTM/WR
Details
of
Infrastructure
available at
Crane base
50% as per
RDSO
instruction.
Crane No. &
Consignee
F
Details of
Infrastructure
available at
Crane base
144012
PURNA/
SCR
Under
progress,
likely to be
completed
by 30th Nov
2011.
143009
BKSC/SE
R
Infrastruct
ure work
under
progress.
142266
GONDA/NER
143003
SEE/ECR
Under process.
NIL
144021
GONDIA/SE
CR
Not as per
RDSO
instruction
144003
AJNI/CR
Under
progress.
11.01.95
30.7.2000
Props subsided due to
inadequate packing on poor
soil condition.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
27.7.04
Sr.DME/BIA
Sr. DME/
Abu Road
Sr. DME/ Jodhpur
Sr.DME/ GHY
1994-95
1995-96
The accident occurred as
the soil below the propping
subsided due to heavy rain
during operation.
Action taken by Jamalpur
Welding Joint failure of
mechanical lock plate
between Rear section &
super Structure during
taking CWT at 5.5m radius.
i) A design improvement of switching over to
single piece mechanical lock plate done which
was accepted by M/s Gottwald. It is being
followed in all cranes.
16.11.05
143003
(Sonpur)
Reason of Toppling
Crane toppled during
practice session at ART
yard/JU by Jodhpur staff.
Operation failure- angle of
slew & Jib radius was over
looked by the operator.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
01.7.06
5
144009
Jodhpur
Sr. DME/
Sonpur
4
144002
(Abu
Road)
2004-05
3
2005-06
2
143002
1st
based at
NJP &
at
present
(NGC)
2000-01
142041
(Bhilai)
Date of
Accident
Crane
No.
Consignee
S
N
Year of
MFG
2.9
DECISION TAKEN:
DME (P)-II/R.B. repeated the instructions given earlier during meeting at RDSO.
Toppling Cases of 140T Gottwald( Vendor Issues,Item5 of RDSO-MOM)
1
142041
BIA/SEC
R
50% as
per
RDSO
instructio
n.
Soil condition poor, 02 Nos.
props of same side
subsided completely due to
poor soil condition and
crane toppled.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
Page 11 of 14
20.5.06
1985-86
Sr.DME/Bilaspur
Sr. DME /SBP
20.9.06
08.09.10
144020
(TVC)
Sr.DME/TVC/SR
8
143006
(Kantab
aji)
2002-03
7
142032
(Bilaspu
r)
2010-11
6
The lifting load was under
estimated than the actual
load. As per estimation of
under load the working
parameters like CWT
combination, propping,
slewing angle and jib radius
were wrongly used, thus
the crane toppled.
Proper propping was not
done as per soil condition.
During practice session at
consignee end i.e TVC/SR,
the crane was slewed free
on rail with full CWT and
SLI manual selection of full
prop condition, therefore
SLI allowed the most
unstable situation meants
full CWT in back, No load
on hook & rotated more
than 300 and toppled the
crane.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
i. Training of consignees being done from time
to time.
ii. Training Manual for 140T Crane has been
prepared and distributed to all consignees.
iii. Trouble shooting guide and Do's & Don'ts
have been prepared for 140T Crane users.
Cases of toppling have to be treated as a major accident and corrective as well as preventive
action taken immediately.
3.0
Portal & Net connectivity
(Item-1 decision-1&3 of RDSO-MOM)
DISCUSSIONS:
(a) Soft copy & hard copy of ALL manuals prepared by JMP are already available with ALL users.
Less use is made of it. Hence ER has launched Portal containing all manuals, Part list,
Specifications etc along with format for submission of complaints which can be accessed by all
users / RDSO/RB. Complaints shall be received through this mode only. JMP will update
relevant sections of manual where change / up gradation of design has taken place.
(b) CWM/JMP held detailed discussion on Portal & Net connectivity and demonstrated how to
operate the same. Consignee should use the website to fill the complaints & suggestions on
regular basis to optimize the benefit of website.
Website address: (i) http://www.140t.weebly.com
(ii) http://www.sites.google.com/site/140tjamalpurcrane may be followed.
(c ) CMPR/NER suggested that part- list on site be provided with additional columns specifying
whether that part is RC item , Non-RC item, Emergency Spare or Depot level spare. This needs
to be done in due course.
(d) Users have not submitted data on crane usage to workshops / Board as required by RDSO
minutes. A format for the same has been made on JMP portal now and data should be fed in
without fail.
3.1
TRAINING:
A) On an average, JMPW has been conducting five courses per year at JMPW , for each and
every user, since last 21 years. JMPW has trained about 800+ staff during this period, many of
whom have superannuated. After training, all the trained staff have not been essentially
attached to their crane, resulting in wastage of some part of training effort. Few participating
SSE’s pointed out that they have only 3 to 5 staff as regular attachment for their crane. For
every crane user of 05 nos lot, training is being conducted at present.
Page 12 of 14
B) Training for developing NEW Crane Drivers:
(Item-9, decision- 3 & 4 of RDSO-MOM)
JMPW proposes that new staff sufficiently(Std IX or X) literate , should first be given two weeks
theoretical training at JMPW & then attached for some time to crane nearest to his division
after which the divisional officer would issue competency certificate. JMPW has notified on
www.140t.weebly.com website the date of commencement of training, which is planned for
Oct”11. DME(P)-II stated that a comprehensive long terms training plan has to be developed
joitly by JMP and Parel. Guideline may be taken from Loco Pilot training.
C) Request to NFR & Rly. Bd.
Firstly a Theoretical Training & then some more Hands-On Training during Load-Test is
essential prior to taking over a crane by any new consignee.
In spite of being called for Theoretical Training in May’11 for 1 st crane allotted to Lumding,
trainees were not deputed.
Hence Lumding is presently not in a position to collect this crane likely to be ready soon& next
training is scheduled in Oct’11. Lumding should attend this training.
If agreed to by Railway Board, Samastipur (already trained for 2 nd crane) may take the 1st
crane. DME (P-II) stated that if zones sends formal requests, it could be done. CWM/JMP
stated this requires Railway Board approval.
D) Specific training in Hydraulics is provided by M/s Rexroth at their premises at Ahmedabad, for
which they publish a Jan-Dec Calendar. The Crane Hydraulics Course No.SP11 scheduled for
14 Sep’11 this year, at a cost of Rs.4500/- plus taxes & cess per candidate. Users interested in
such course can avail it in next Jan-Dec Calendar year ie; 2012.
E) (Item-4, decision-2 of RDSO-MOM)
M/s Mechanica Systems was asked to give a date for training of Motherboard & Cards of SLI at
Pune. M/s Mechanica Systems replied that it would propose a date after November end. On
receipt of programme, users shall be intimated to depute in phases their electrical maintenance
man.
3.2 Must change items under POH/MLR ( Item-4, decision-2 of RDSO-MOM)
Majority participants left the decision on JMPW. The list of must change items in existing
manuals for MLR & POH is optimal which is 100% re-wiring in MLR and condition basis rewiring in POH.
3.3 POH manuals ( Item 8 of RDSO-MOM)
Copies of manuals (12 nos) sent to Bd. on 06-8-11. Further up gradation in terms of para 2.5 (c)
above shall be done on time. CD containing pictorial Do’s & Dont’s also distributed to
participants.
3.4
Users (Sr. DME/DME/ADME/SSE) comments during Conference:
a) Sr.DME/DHN raised the issue of nylon packing. It was appraised by Trichy that these are
slipping at site. It was informed that two orders have been placed by COFMOW. Users to send
feedback to RDSO & JMP. However, if required wooden packing can be procured. Most of the
users pointed out that wooden packing are better.
b) Sr.DME/ALD has raised question about purchase of Wire Ropes. Presently the only approved
source is Non-Indigenous, as both indigenous sources have been demoted to Developmental
Status sometime back. SSE/NGP, SSE/ASN, SSE/TPJ & SSE/GKP suggested that M/s Usha
Martin Make was OK whereas Sr.DME/HWH & Sr.DME/DHN stated that M/s Bharat Wire Rope
Make was OK.
c) Sr.DME/CNB pointed out side bearer problem/cracking in his Crane and asked for assistance
in repair. On his request team was sent to run out the bogie so that welding could be done.
d) Sr.DME/DHN & DME/ASN suggested for the provision of SLI System sensibility of U/C system
for propping (horizontality of the crane).Discussed at para 1.2 above.
e) AME/MLDT advised adaptation of CBC coupling in place of hook coupling. RDSO to advise
regarding this.
f) AME/BIA showed photographs regarding infrastructure development of crane. Other users to
take inputs from the same.
Page 13 of 14
g) The testing period of Wire Rope and Chain Slings specified in RDSO report No.727/90 for old
design crane is different from regular “Yearly” practice followed for slings of EOT cranes in
Workshops. Sr.DME/P/HWH desired clarification on this account. RDSO to compare and revise
the RDSO reports if required.
h) Problem after POH:
(i) SDAH, MB, KBJ and majority others - No complaints. (ii) Bhilai
reported complaints regarding off POH engine, which was discussed with Cummins
representative from Kolkata Region.
i) Problem after Mfg: TPJ reported excessive positive variation in load reading in case of new SLI
(Make- Mechanica Systems) fitted in new crane. This point has been discussed in para 1.2 (f)
above. Manufacturer and JMP to check and revert back.
j) Dy.CME/Crane/JMP requested that crane users, who are more than 04 years old, should call
for assistance from JMP only for major b/downs and not for minor trouble shooting or
maintenance.
Other items:
(i)
(ii)
(iii)
(iv)
Gear box overhaul – as discussed in RDSO: system followed by JMP was reviewed and
all users agreed that present system is OK.
Users pointed out that brake system does not work on single pipe. JMP to check and
take corrective action.
M/s Agromech have not provided list of spares with cost to JMP, which was to be
provided by 15-Aug-2011.
M/s P S Engg have not provided list of defects noticed in off-POH cranes to JMP, which
was to be provided by 15-Aug-2011
Dy CME (Crane)
No. F/CR/140T/39
Jamalpur dt. 26/9/2011
Distribution:
1) The three websites
2) CWE/ER/KKK
3) DME (P-II)/Rly. Board
4) Director/ MP/RDSO
Page 14 of 14