minutes 2nd 3rd sep by WV05FP

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									                     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:                        Jamalpur Representative:
 Sri Manish Jain/ DME (P)-II                       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)        Sri Satish Kumar, CMPE/NER
 (3) Sri A. K. Gupta, CMPE/SECR             (4)        Sri A. K. Shivhare, Dy.CME/HQ/NCR
 (5) Sri A. K. Gautam, Sr. DME (O&F)/ALD    (6)        Sri K. N. S. Yadav, Sr. DME (P)/DHN
 (7) Sri S. N. Roy, Sr.DME (C&W)/SEE        (8)        Sri N. N. Sarkar, Dy.CME (OP)/SDAH
 (9) Sri B. K. Pandey, Sr.DME/Gonda         (10)       Sri C.S. Yadav,DME(P)/NR/LKO
 (11) Sri P.K. Mukhopadhyayay,DME(P)/ER/ASN (12)       Sri K.L. Saini, DME/WR/RTM
 (13) Sri A. Gupta, DME/NFR/NJP             (14)       Sri C.H.V. Ramanna, DME/ECoR/VSKP
 (15) Sri B. Nath, DME/NFR/NBQ              (16)       Sri Shivaji Kadam, DME/CR/Ajni
 (17) Sri A.K. Srivastava, DME/NR           (18)       Sri G.S.Reddy, AME/ECoR/BBS
 (19) Sri S. C.Behra, SME (HQ)/SER/GRC      (20)       Sri B.Sampat Kumar, AM E/SCR/PAU
 (21) Sri S.K. Tiwari, AME/ER/SBG           (22)       Sri A.K.Gupta, ADME/ECR/SEE
 (23) Sri J.P. Singh, AME/NFR/NGC           (24)       Sri K.K.Deva, ADME/NFR/TSK
 (25) Sri R. Rangarao, ADME/SECR/BIA        (26)       Sri D. Kumar, ADME (P)/ECR/MGS
 (27) Sri Chintamani, ADME/SECR/BSP         (28)       Sri P. Behra, ADME/ECoR
 (29) Sri P.S. Kumar, AME/NED               (30)       Sri K. Raja, ADME/SR/TVC
 (31) Sri B.K.Saha, ADME/Gondia


      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               TO BE REVISED AS
                                                             4 Regular visits + 1B check visit +1C
     1        No of visits   8 visits per annum              check visit per annum to be equally
                                                             inter-spread to the extent possible
                             Pro rata on annual basis for    Actual basis. Billing per visit or bi-
              Payment
     2                       AMC& bi-monthly submission of   monthly as suitable for firm.
              terms
                             bills
                                                             Response time for emergency Break
                                                             Down at site should be not more than
                                                             02 hours for <50 kms. The service
              Response                                       engineer will move along with required
                             <50Km………….within12hrs
              time to                                        spares according to preliminary
                             <51-
     3        Report for                                     message from site. If crane returns to
                             200Km………….within24hrs
              Brake Down                                     depot , it should be attended within 03
                             >201Km……… within48 hrs
              Repair                                         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
                                                         Detailed break-up of Consumable and
                                                         material list to be give for 4 regular
                                                         visits + B check + C check. Individual
     Detailing of     Lump Sum provision                 price of mandatory parts to be
4    consumables                                         replaced in schedules shall be
     during6 visits                                      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.
5    Materials List   Lump Sum provision                  c) List of material with individual cost-
                                                          to be kept per crane.
                                                          d) List of material with individual cost-
                                                         to be kept per zone.
                                                         AMC to be effective from date of expiry
      Inclusive       Existing proposal does not
6                                                        of std. warranty for new or POH/MLR
     clause           mention
                                                         engine.
                      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,
                                                         If std warranty for new or POH/MLR
                         piston, piston rings, PT
     Exclusive                                           engine is alive, the coverage of
7                        Pump, Gear Pump, Cylinder
     clause                                              these parts shall be according to
                         casting, Turbo wheel and
                                                         std warranty.
                         shaft, injector body.
                      d) Radiator and its accessories-
                         Hyd. Motor, Hyd Pump, Fan
                         &     Hub,     ECPG/Governor
                         controller, Fuel actuator,
                         Wiring        Harness      &
                         compressor.
                      e) E-check & major overhauling
                                                         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.
     On site                                             Cummins       representative     to   be
8                     Not clear
     Requisition                                         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
     Payment                                             No.MD/DMU/HHP/E-
9    agency           Not clear                          CHECK/RC/CIL/2009-11/1 DT.07-5-10
     (Divn/JMP)                                          specifying in para21.1 that payment
                                                         will be made by Zonal Rlys. (2)ICF
                                                         Rate Contract No.MD/DMU/HHP/D-
                                                         CHECK/RC/CIL/2010/12-2 DT.16-12-
                                                         10.
     Inter-dealer                                        CAMC will be through nearest
10
     mapping                                             Cummins dealer with respect to Crane

                                                                                     Page 2 of 14
                                                               based location but in case of b/down in
                                                               other area, inter dealer mapping to be
                                                               ensured by Cummins.
                Contract                                       to be modified by Cummins as per
        11
                Value                                          para-1 above.
                                                               M/s Cummins to give know- how
                                                               regarding daily and weekly checking of
        12      Training
                                                               engine in proper procedure to users.

                Availability /
                MTBF /                                         To be specified considering low usage
                Maximum                                        hours and intermittent use.
        13
                b/down
                window for 1
                failure

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              NOT SUBMITTED
      (17) Crane No. 144007/RPH/ER              NOT SUBMITTED
      (18) Crane No. 142039/ASN/ER              160 items
      (19) Crane No. 143007/BGA/ER              131 items
      (20) Crane No. 144015/Rajkot/WR           NOT SUBMITTED
      (21) Crane No. 144011/NBQ/NFR             132 items
      (22) Crane No. 144008/Miraj/CR            NOT SUBMITTED
      (23) Crane No. 144001/VSKP/ECoR           53 items
      (24) Crane No. 142269/NJP/NFR             36 items
      (25) Crane No. 142265/RTM/WR              18 items
      (26) Crane No. 143009/BKSC/SER            NOT SUBMITTED
      (27) Crane No. 142266/GONDA/NER           101 items
      (28) Crane No. 143003/SEE/ECR             NOT SUBMITTED
      (29) Crane No. 144021/GONDIA/SECR         opined it will follow JMP recommendations.
      (30) Crane No. 142041/BIA/SECR            NOT SUBMITTED
      (31) Crane No. 144012/PURNA/SCR           NOT SUBMITTED
      (32) Crane No. 144003/AJNI/CR             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-A-
   91 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 non-
      moving 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 23-09-
               11 ( 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 C-
               category 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.


2.3         Spares for regular use to be purchased/Stocked at depot level (“C” Category Items)
            (Item-3, decision-4A of RDSO-MOM)

            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:
      (1)   Crane No. 144010 / KURLA/CR           NOT SUBMITTED
      (2)   Crane No. 143004/SBG/ER               151 items
      (3)   Crane No. 144020 /ERS/SR              NOT SUBMITTED.
      (4)   Crane No. 143006/KBJ/ECoR             NOT SUBMITTED.
      (5)   Crane No. 144006/TNP/SR               12 items
      (6)   Crane No. 144019/TPJ/SR               NOT SUBMITTED.
      (7)   Crane No. 143010/DNR/ECR              06 items
      (8)   Crane No. 144005/SBP/ECoR             NOT SUBMITTED
                                                                                             Page 5 of 14
      (9)    Crane No. 142033/MGS/ECR                24 items.
      (10)   Crane No. 142042/TSK/NFR                51 items
      (11)   Crane No. 143002/GHY/NFR                NOT SUBMITTED
      (12)   Crane No. 142032/BSP/SECR               81 items
      (13)   Crane No. 142271/DLI/NR                 33 items
      (14)   Crane No. 142270/CNB/NCR                03 items
      (15)   Crane No. 142038/LKO/NR                 27 items
      (16)   Crane No. 142037/HWH/ER                 opined it will follow JMP recommendations.
      (17)   Crane No. 144007/RPH/ER                 opined it will follow JMP recommendations.
      (18)   Crane No. 142039/ASN/ER                 37 items
      (19)   Crane No. 143007/BGA/ER                 56 items
      (20)   Crane No. 144015/Rajkot/WR              NOT SUBMITTED
      (21)   Crane No. 144011/NBQ/NFR                08 items
      (22)   Crane No. 144008/Miraj/CR               NOT SUBMITTED
      (23)   Crane No. 144001/VSKP/ECoR              29 items
      (24)   Crane No. 142269/NJP/NFR                34 items
      (25)   Crane No. 142265/RTM/WR                 19 items
      (26)   Crane No. 143009/BKSC/SER               NOT SUBMITTED
      (27)   Crane No. 142266/GONDA/NER              173 items
      (28)   Crane No. 143003/SEE/ECR                NOT SUBMITTED
      (29)   Crane No. 144021/GONDIA/SECR            124 items
      (30)   Crane No. 142041/BIA/SECR               179 items
      (31)   Crane No. 144012/PURNA/SCR              NOT SUBMITTED
      (32)   Crane No. 144003/AJNI/CR                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.

  c)   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.

  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.   Crane No. 144002/Agra/NCR
        2.   Crane No. 142270/CNBE/NCR
        3.   Crane No. 143005/Roja/NR
        4.   Crane No. 144011/NBQ/NFR
        5.   Crane No. 143010/DNR/ECR
        6.   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 :
        st                        th
       1 POH of a crane………….8 year
         nd                           th
        2 POH of a crane………….14 year
                                     th
        Rehab of a crane………….20 year
         rd                          th
        3 POH of a crane………….28 year
                                         th
        Condemn of a crane………….36 year

     DME (P)-II reiterated that condemnation of the crane is not to be planned on age basis.

                                                                th
    (b) For cranes which have already undergone MLR in 14 year, second Rehab level attention
                               th
        shall be required in 28 year after structural audit by RDSO (Item-5,decision-1 of RDSO-
                   th
        MOM) in 26 year.
                                                          nd         th
    (c) For cranes which have not undergone MLR, the 2 POH (14 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
                     st     th
        required in 1 POH (8 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 RDSO-
        MOM. 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 in-
         charges as per jointly signed SEG reports.SSE to be made i/c.
     f) Crew details submitted by participants is tabulated below:


A   Crane No. &     144010         143004        144020        143006        144006          144019
    Consignee       KURLA/CR       SBG/ER        ERS/SR        KBJ/ECoR      TNP/SR          TPJ/SR
    Crew Details    09 Trained     12            29            16 Trained.   06 Trained      07 Trained
                    03             Trained       Trained                     04 Untrained    19 Trained
                    Untrained



    Crane No. &     143010        144005         142033        142042        143002          142032
    Consignee       DNR/ECR       SBP/ECoR       MGS/ECR       TSK/NFR       GHY/NFR         BSP/SECR
    Crew Details    09 Trained    09 Trained     07            04 Trained    05 trained      08 Trained
B
                    05            06             Trained       17            01 Untrained    01
                    Untrained     Untrained      09            Untrained                     Untrained
                                                 Untrained

    Crane No. &       142271        142270        142038         142037         144007         142039
     Consignee        DLI/NR       CNB/NCR        LKO/NR        HWH/ER         RPH/ER         ASN/ER
    Crew Details    Not            08            17            13 Trained    10 Trained      14 Trained
C
                    submitted.     Trained       Trained       01            07 Untrained    05
                                   05                          Untrained                     Untrained
                                   Untrained

    Crane No. &     143007        144015        144011      144008           144001          142269
    Consignee       BGA/ER        Rajkot/WR NBQ/NFR Miraj/CR                 VSKP/ECoR       NJP/NFR
D   Crew Details    13 Trained    07 Trained 06 Trained     08 Trained       08 Trained      08 Trained
                    06            12 Untrained 10 Untrained                  05 Untrained
                    Untrained

    Crane No. &     142265       143009         142266          143003       144021          142041
    Consignee       RTM/WR       BKSC/SER       GONDA/NER       SEE/ECR      GONDIA/SE       BIA/SECR
                                                                             CR
E
    Crew Details    04 Trained 13 Trained       09 Trained      09           09 Trained      10 Trained
                    06                          06 Untrained    Trained
                    untrained

    Crane No. &        144012      144003
     Consignee      PURNA/SCR     AJNI/CR
F
    Crew Details    21 Trained 05 Trained
                               06 Untrained
                                                                                         Page 9 of 14
    Summary:
                                            rd
    Users (among above 32) having < 1/3 trained staff= 12.5%
    Users (among above 32) having < 50% trained staff= 28.1%
    Users (among above 32) having 50% trained staff= 15.6%
                                       rd
    Users (among above 32) having > 2/3 trained staff= 18.7%

    CONCLUSION:
    Staff who receive training should be kept attached to the crane. No. of staff trained by JMP for Kurla-
    27, 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           instructions for better maintenance
           and to keep the crane properly.

       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.

       Crane No. &         144010        143004           144020             143006           144006       144019
       Consignee         KURLA/CR        SBG/ER           ERS/SR           KBJ/ECoR          TNP/SR        TPJ/SR
      Details      of   Not as per     Not as per     Estimate under       NIL             Not as per     Under
A
      Infrastructure    RDSO           RDSO           preparation                          RDSO           develop
      available at      instruction.   instruction    sanction Amount                      instruction.   ment.
      Crane base                       .              Rs.1.5 crore

      Crane No. &         143010        144005              142033           142042          143002        142032
      Consignee          DNR/ECR       SBP/ECoR            MGS/ECR          TSK/NFR         GHY/NFR        BSP/SE
                                                                                                              CR
      Details      of   Not as per     Not as per         Under            Not as per      50% as per     Not as
B     Infrastructure    RDSO           RDSO               proposal         RDSO            RDSO           per
      available at      instruction.   instruction.       stage.           instruction.    instruction.   RDSO
      Crane base        Estimate is                                                                       instructio
                        under                                                                             n.
                        process.

       Crane No. &        142271         142270       142038 LKO/NR           142037          144007       142039
       Consignee          DLI/NR       CNB/NCR                               HWH/ER          RPH/ER        ASN/ER
      Details      of   NIL            At present     Not available,       Not as per      Not as per     50% as
C     Infrastructure                   NIL, under     crane is             RDSO            RDSO           per
      available at                     proposal       attached with        instruction.    instruction.   RDSO
      Crane base                       stage.         Diesel                                              instructio
                                                      Shed/AMV/LKO.                                       n.

      Crane No. &       143007              144015          144011         144008           144001          142269
      Consignee         BGA/ER              Rajkot/WR       NBQ/NFR        Miraj/CR         VSKP/ECoR       NJP/N
                                                                                                            FR
      Details      of   Not   available,    Not as per      Not as per    Not as per        Not             Not as
D
      Infrastructure    but sanctioned      RDSO            RDSO          RDSO guide        Submitted       per
      available at      inGM's Lumsum       instruction     instruction   line but under                    RDSO
      Crane base        2011-12.                                          process                           instruct
                                                                                                            ion


                                                                                                   Page 10 of 14
          Crane No. &                      142265                       143009        142266             143003        144021         142041
          Consignee                        RTM/WR                       BKSC/SE       GONDA/NER          SEE/ECR       GONDIA/SE      BIA/SEC
                                                                        R                                              CR             R
          Details      of                  50% as per                   Infrastruct   Under process.     NIL           Not as per     50% as
    E
          Infrastructure                   RDSO                         ure work                                       RDSO           per
          available at                     instruction.                 under                                          instruction    RDSO
          Crane base                                                    progress.                                                     instructio
                                                                                                                                      n.
                                              144012                     144003
          Crane No. &
                                              PURNA/                     AJNI/CR
          Consignee
                                                SCR
                                           Under                        Under
    F       Details of                     progress,                    progress.
          Infrastructure                   likely to be
           available at                    completed
           Crane base                      by 30th Nov
                                           2011.

            DECISION TAKEN:
            DME (P)-II/R.B. repeated the instructions given earlier during meeting at RDSO.
2.9      Toppling Cases of 140T Gottwald( Vendor Issues,Item5 of RDSO-MOM)
                                Consignee




S        Crane                                                   Reason of Toppling                       Action taken by Jamalpur
                                                   Accident
                   Year of



                                                    Date of




N         No.
                    MFG




                                                                 The accident occurred as       i. Training of consignees being done from time
                                Sr.DME/BIA




                                                                 the soil below the propping    to time.
                                                     11.01.95
                    1994-95




        142041                                                   subsided due to heavy rain     ii. Training Manual for 140T Crane has been
1                                                                during operation.              prepared and distributed to all consignees.
        (Bhilai)
                                                                                                iii. Trouble shooting guide and Do's & Don'ts
                                                                                                have been prepared for 140T Crane users.
        143002                                                   Props subsided due to          i. Training of consignees being done from time
                                Sr.DME/ GHY




        1st                                                      inadequate packing on poor     to time.
                                                     30.7.2000
                    1995-96




        based at                                                 soil condition.                ii. Training Manual for 140T Crane has been
2       NJP &                                                                                   prepared and distributed to all consignees.
        at                                                                                      iii. Trouble shooting guide and Do's & Don'ts
        present                                                                                 have been prepared for 140T Crane users.
        (NGC)
                                                                 Welding Joint failure of       i) A design improvement of switching over to
                              Abu Road
                              Sr. DME/




                                                                 mechanical lock plate          single piece mechanical lock plate done which
                    2004-05



                                                     27.7.04




        144002
3       (Abu                                                     between Rear section &         was accepted by M/s Gottwald. It is being
        Road)                                                    super Structure during         followed in all cranes.
                                                                 taking CWT at 5.5m radius.
                                Sr. DME/ Jodhpur




                                                                 Crane toppled during           i. Training of consignees being done from time
                                                                 practice session at ART        to time.
                                                     16.11.05
                    2005-06




                                                                 yard/JU by Jodhpur staff.      ii. Training Manual for 140T Crane has been
        144009
4                                                                Operation failure- angle of    prepared and distributed to all consignees.
        Jodhpur
                                                                 slew & Jib radius was over     iii. Trouble shooting guide and Do's & Don'ts
                                                                 looked by the operator.        have been prepared for 140T Crane users.

                                                                 Soil condition poor, 02 Nos.   i. Training of consignees being done from time
                                                                 props of same side             to time.
                              Sr. DME/
                    2000-01



                                                     01.7.06
                               Sonpur




        143003                                                   subsided completely due to     ii. Training Manual for 140T Crane has been
5
        (Sonpur)                                                 poor soil condition and        prepared and distributed to all consignees.
                                                                 crane toppled.                 iii. Trouble shooting guide and Do's & Don'ts
                                                                                                have been prepared for 140T Crane users.




                                                                                                                              Page 11 of 14
                                                         The lifting load was under
                                                         estimated than the actual




                            Sr.DME/Bilaspur
                                                         load. As per estimation of     i. Training of consignees being done from time
                                                                                        to time.




                  1985-86



                                              20.5.06
    142032                                               under load the working
                                                         parameters like CWT            ii. Training Manual for 140T Crane has been
6   (Bilaspu
                                                         combination, propping,         prepared and distributed to all consignees.
    r)
                                                         slewing angle and jib radius   iii. Trouble shooting guide and Do's & Don'ts
                                                         were wrongly used, thus        have been prepared for 140T Crane users.
                                                         the crane toppled.
                                                         Proper propping was not        i. Training of consignees being done from time




                            Sr. DME /SBP
                                                         done as per soil condition.    to time.
                  2002-03



                                              20.9.06
    143006
                                                                                        ii. Training Manual for 140T Crane has been
7   (Kantab
                                                                                        prepared and distributed to all consignees.
    aji)
                                                                                        iii. Trouble shooting guide and Do's & Don'ts
                                                                                        have been prepared for 140T Crane users.
                                                         During practice session at
                                                         consignee end i.e TVC/SR,
                                                         the crane was slewed free
                            Sr.DME/TVC/SR




                                                         on rail with full CWT and      i. Training of consignees being done from time
                                                         SLI manual selection of full   to time.
                                              08.09.10
                  2010-11




    144020                                               prop condition, therefore      ii. Training Manual for 140T Crane has been
8
    (TVC)                                                SLI allowed the most           prepared and distributed to all consignees.
                                                         unstable situation meants      iii. Trouble shooting guide and Do's & Don'ts
                                                         full CWT in back, No load      have been prepared for 140T Crane users.
                                                         on hook & rotated more
                                                                 0
                                                         than 30 and toppled the
                                                         crane.

              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.
                                                                             st
         In spite of being called for Theoretical Training in May’11 for 1 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.
                                                                                nd                      st
         If agreed to by Railway Board, Samastipur (already trained for 2 crane) may take the 1
         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 re-
       wiring 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)     Gear box overhaul – as discussed in RDSO: system followed by JMP was reviewed and
           all users agreed that present system is OK.
   (ii)    Users pointed out that brake system does not work on single pipe. JMP to check and
           take corrective action.
   (iii)   M/s Agromech have not provided list of spares with cost to JMP, which was to be
           provided by 15-Aug-2011.
   (iv)    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

								
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