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