1
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
140T Gottwald Design Crane at
Accident Site
New Design
Old Design
3
Crane Motions
 Derricking IN-OUT
 jib motion up or down
JIB
 Travelling Forward-
Backward
 Movement of bogie on
the track
4
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.
LOAD
5
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
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
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
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
Operation Control in Cabin
 Left Hand Joystick
 Right Hand Joystick
Main HoistDOWN
Derrick-OUT
SlewRIGHT
SlewLEFT
Aux
HoistDOWN
Aux
Hoist-UP
Main HoistUP
Derrick-IN
PILOT CHAIR
Winching
Travelling
10
Display Board
Prop
position
CWT
position
Main Hook
position
Aux. Hook
position
11
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
Continued
 Hook Position
 Main Hook
 Auxiliary Hook
 Tail Radius Position
 At 5.5 m
 At 6.5 m
13
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
M1
14
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
U2
15
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 Photo
Propping
OutRigger
In-Rigger
Propping
Cylinder
17
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
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
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
21
Precautions
• Prop as instructed
 Select proper Cwt slabs
from M/T
 Crane body level be
HORIZONTAL
 Wheel just tends to
LIFT the track
22
Precautions
 Slect proper wire rope
slings.
 Staff deployed as
instructed
 DO NOT by pass SLI
System
 SLEW when load in
HANGING condition
23
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
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
(A) RESTORATION OF COACHES IN ELECTRIFIED
SECTION BY 140 Te. CRANE
Preparation Chart:
S.N.
Item/Status
Action
01
OHE
To be slewed towards coach movement and ensure that
OHE of adjacent line has been made dead.
02
Condition of props and availability
of staff
Full propping to be done and 04 staff on each prop
should be deputed.
03
Suitable packing and its size
Wooden/synthetic packing of size 4’x2’x14” and
6’x1’x12”
04
Position of SLI duty selector
To be kept on No. 1
05
Wire rope Sling and SWL
30 Te. 5 Mtrs sling and 70 Te. SWL as per requirement
06
Chain sling as per requirement
25 Te. Capacity chain sling
07
Position of Cant of the track
Should not be more than 140 mm
08
Position of SLI
SLI should be kept in working.
09
Maximum working radius
16 meters by main hook.
10
Place where sling to be inserted
(under frame) Solbar
S.N.
Item/Status
Action
11
Gas cutting equipment
DA and Oxygen gas with equipment
12
Availability of wooden wedges
04 wooden wedges
13
Position of coach trolley
Lashing chain to be used for securing with structure.
14
Lighting arrangement
To be arranged during dark/night.
15
Observation for suitable place
Analyze suitable place for 360º slewing and placing the
coach/damaged trolley.
16
Arrangement of rope for coach
adjustment
02 Nos. in sufficient length at both the ends of coach.
17
Availability of Megaphone/
Communication
One person should be deputed with equipments
18
Photography/Videography
Videography of all critical operations and clues
collection.
19
Average timing for restoration of
each coach
Average – 55 minutes
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
Restoration of Coaches in nonelectrified 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
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.
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 360º within 11 meters
radius.
31
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
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
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
Restoration of Derailed oil tank wagons
involved in fire.
Preparation Chart :
S.N.
Item/Status
Action
01.
OHE
Working line OHE to be slewed. OHE of adjacent line to
be made dead.
02.
Requirement of fire brigade
Heavy duty fire brigade is called
02.
Condition of props
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 selector
To be kept on No. 1
05.
Suitable wire rope sling
30 Te. 5 mtrs sling
06.
Suitable chain sling as per
requirement
25 Te. Capacity chain sling
07.
Position of Cant on the track
Should not be more than 140 mm
08.
Position of SLI
SLI should be kept in working.
09.
Maximum working radius
16 meters by main hook and 19 mtrs. By Aux. hook.
and
S.N.
Item/Status
10.
Place, where sling to be
inserted
Under frame barrel bracket
11.
Position
trolley
Lashing chains to be used for securing with
structure.
12.
Lighting arrangement
To be arranged during night/dark.
13.
Observation for suitable
place
Analyze suitable place for 360º 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
Megaphone/
Communication
One person
equipments
16.
Photography/Videograp
hy
Videography of all critical operations and
clues collections.
17.
Average per oil tank
timing for restoration
Average – 30 minutes
of
Action
wagon
of
should
be
deputed
with
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.
Restoration of derailed Locomotive in the dead end
siding by 140 T Crane.
Preparation Chart :
S.
Item/Status
Action
01
OHE
Working line OHE to be slewed. OHE of adjacent line to be made dead.
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’x12”x12”/ 4’x10’x6”
04
No. of cranes required and Position of SLI
duty selector
Two cranes.duty selector to be kept on No. 1
05
Suitable wire rope sling
50/70 Te. 6 mtrs sling (both side eye)
06
Position of Cant on the track
Should not be more than 140 mm
07
Position of SLI
SLI should be kept in working.
08
Maximum working radius
09 meters by main hook
09
Place, where sling to be inserted
All four buffer plates
10
Lighting arrangement
To be arranged during night/dark.
11
Observation for suitable place
Analyze suitable place for placing of loco.
12
Arrangement of rope for loco adjustment
02 Nos. in sufficient length at both the ends of loco
13
Availability of Megaphone/
Communication
One person should be deputed with equipments
14
Photography/Videography
Videography of all critical operations and clues collections.
15
Gas cutting equipment
DA and Oxygen gas with equipment
16
Availability of wooden wedges
04 wooden wedges
17
Average per loco timing for restoration
Average – 2.0 hrs. minimum
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.
2.
3.
4.
5.
6.
One 140 T crane is kept at one end on the adjacent track and other 140 T at another
end.
Full propping is done for both the cranes and 50 T, 6 meters wire rope sling with ‘D’
shackles are used.
‘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.
Lifted loco should be slewed towards adjacent track by both the cranes.
One bogie of the loco is placed on track in first occasion and then another crane is
permitted to do so.
Lifted loco is always kept in dead condition during restoration operation.
(7) Restoration of Hot Axle/Cold Axle broken
Wagons
Preparation Chart :
S.N.
Item/Status
Action
01
MFD power pack and 120/60 Te. Cap. Jacks with
control table and hoses
Two jacks of 120/60 Te. Cap. and displacing jacks.
02
Suitable packing and its size
Wooden/synthetic packing of size 3’x1’x6”/ 3’x2’x6” and 04 iron plates.
03
Availability of Lashing chains and bolts
03 Lashing chains to be used for securing with structure.
04
Availability of wooden wedges
04 wooden wedges
05
Rail skates trolley
02 trolleys with 36/40 mm pana
06
Availability of MFD tool box
Should be available at site
07
Gas cutting equipment
DA and Oxygen gas with equipment
08
Lighting arrangement
To be arranged during night/dark.
09
Observation for suitable place
Analyze suitable place for jack operation.
10
Availability of Megaphone/
Communication
One person should be deputed with equipments
11
Photography/Videography
Videography of all critical operations and clues collections.
12
Average per wagon timing for restoration
Average – 30 minutes
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.
1.
4. Each skate has two wheels,
which should be observed for
proper sitting on the rail before
moving the wagon.
5.
6.
7.
Move the wagon slowly without jerk, attaching with the
breakdown train or assisting loco, not more than 5 Kmph
speed.
Wagon in this position can travel 10 to 12 KMs at a stretch
for next block station without changing the wheels.
This modification facilitates reduction in restoration timings
and avoids toppling of such axle broken wagons at accident
sites.
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 Aframe 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.
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.
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
Loaded Wagon
45
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
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
Toppling of Ernakulam Crane
48
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
Danapur CraneToppled at Karauta
50
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
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
THANK YOU
53