File - SOUTH CENTRAL RAILWAY ACCIDENT RELIEF

SOUTH CENTRAL RAILWAY
No. TP.8/ART/Policy/Vol- XX
Head Quarters Office
Trans Power Branch
Secunderabad- 500071
Dt: 22-12-14
Sr.DME/C&W/SC & GTL
Sr.DME/HYB, BZA, GNT & NED
Sr.DME/DSL/KZJ & BZA
Sub: Restoration operations with HREs (MFD, LUKAS & BEMCO).
Ref: This office letter of even no. dated
***
All the ARTs on S C Railway are provided with Hydraulic Re-railing Equipments manufactured
by MFD, LUKAS of Germany and BEMCO of Indian make. General design and working principles are
more or less same for all the designs.
Each set is provided with different capacity Jacks and other tools/equipment along with
different attachments for specific use/purposes during restoration work. Information on how to use
these equipment and tools has been supplied along with original supply. However, it is noticed that,
some of the depots, BD staffs does not aware of all the accessories/attachments received along with
HRE and also the purpose of few of the special tools and equipment.
Basic awareness of the equipment available and knowledge on how to and where to use
them is quite essential for better performance of the ARTs during accident restorations. Similarly
various methods of application of the equipment in different conditions is also to be known by all
the staffs nominated for BD. This is applicable for all other equipment available in ARTs.
All the ART in-charges may please be advised to go through the operating/maintenance
manuals supplied along with the equipment and ensure all the staffs nominated for BD are aware of
the information.
Manuals of Lukas HRE are placed at ART website (www.scrart.weebly.com). The following
link http://scrart.weebly.com/lukas-manuals.html may be used for the manuals. NCR report on
methods of restoration of various stocks with HRE is available at link
http://scrart.weebly.com/restoration-by-hre.html. Manuals of other equipment will be uploaded
time to time. A brief write up on HREs is attached here with for information and all concerned are
sensitised accordingly.
Encl- As above.
(T S N Murthy)
Dy.CME/R&L/HQs
Brief Write up on HREs
1. Following types (designs) of HRE available on S C Railway system:A) MFD
B) LUKAS
C) BEMCO
– Germany make
– Germany make
– Indian make
All these three makes are more or less same, baring few design features, since procured by
COFMOW against same specification.
Power Pack and Control stand operations differ slightly from model to model.
Methods of using these equipments for restoration and other operations are mostly same
for all the models. Hence, if some knows how to use (apart from initial setting) one type of
HRE, they can easily do the same with other models.
On general enquiry, it is found that most of the staff working in ARTs are not fully aware of
the complete equipment/tools received as part of HRE, capacities of each and specific
purpose etc.
So, the following information is furnished for better usage of the available equipment for
quick and efficient restoration.
2. List of important Items/Tools/Equipment in each set of HRE S.
No
MFD
Description
1
LUKAS
BEMCO
Capacity
in Ton
Stroke
mm
Part No.
Qty
Capacity
in Ton
Stroke
mm
Part No.
Qty
Capacity
in Ton
Stroke
mm
Qty
Part No.
Power Pack
Con Stand
Tel. Jack
120/60
488
04
165/70
400
HP65/T400R
04
120/60
420
04
RTJ-12455-420
Tel. Jack
120/60
180
02
100/50
185
HP50/T 185R
02
120/60
180
02
RTJ-12455-175
Tel. Jack
60/30
566
04
65/30
450
HP25/T 450R
04
60/30
430
04
RTJ-6527-430
Tel. Jack
(Step)
Jack
Tilting Jack
Pusher Jack
60/30
215 +
320
660
400
350
TH 1200/600
-420
TH 1200/600
-250
TH600/300450
TH600/300250
EH 250/1030
EH 200/597
EH 120/60575
02
65/30
185 +260
HP25/T 185R
02
60/30
02
RTJ-6527-175
03
01
03
25
25
10
800
400
160
HP50/T 850R
HP25/K 400R
LZM 10/160R
03
01
01
35
20
10/9
175 +
352
800
400
315
03
01
03
Hauling
device
Traverser
Plain
Traverser
with Jack
Re-Railing
Bridges
25
01
22
460
HOP22/460R
01
20
450
01
RSJ-38-810
BCD- 4905
RAPJ-10180-1
RPJ708325
RH-20-456
35
20
12/06
02
1.1 mtr,
2.2 mtr,
3.3 mtr,
4.4 mtr
02
00
02
00
01
01
01
01
01
01
01
01
01
01
01
01
3. Other Tools/Special purpose attachments.
a) Equipment for tilting rolling stock consisting of (1) high construction jack (Rope lift
cylinder) (Bomber jacks), (2) Radius Plate, (3) Tilting Jack, (4) Lifting Belt (Rope Ladder),
(5) Pressure Piece, (6) Holding Rope top (nylon), (7) Holding Rope Bottom (Wire)
4
6
5
3
1
7
2
b) Tilting/up righting with MFD.
Tilting of Rolling stock with HRE is warranted at times during accidents particularly under wire or
when cranes are not available nearby and the rolling stock involved in accident cannot be re-railed.
Depending on the site and rolling stock condition, rolling stock can be tilted by the following
methods.
I)
When ground clearance is less, there is no space/support to apply the jacks, Lifting Belt
(Rope ladder) which is supplied along with HRE to be tied and by using high construction jack (Rope
lift cylinder) (Bomber jacks) as illustrated above, stock can be toppled. Care shall be taken to secure
the bottom end of rope properly and while lifting wooden packing is given at opposite end of
toppling.
II)
When ground clearance is less, but there is a scope for applying the jack as shown above, toppling
can be done with high construction jack (Rope lift cylinder) (Bomber jacks). While lifting wooden
packing shall be given at opposite end of toppling.
III)
When ground clearance is available to apply the jack as in above case, directly jacks can be
used at one side for toppling to other side. Support of wooden packing shall be given time to time to
for releasing jacks and for safety.
IV
If sufficiently strong support is available to fix the hydraulic hauler (pulling device), rolling
stock can be toppled with it as shown above.
c) (1) Base plate, (2) Multistage Set.
Base plates are provided for the jacks of Lukas and Bemco makes. These shall be used
with Jacks to increase the stability.
Multistage Set to be used to increase the stroke (jack lift) without re-setting thus
reducing the operation time.
1
2
Usage of Base plate and Multi stage Set.
d) Axle pusher. This is small arrangement with which mounted wheel flange can be set on
rail in very short time duly avoiding lifting traversing. This can be applied to rail also in
case of spread gauge is the cause of flange mount on rail.
4. Know the limits of the equipment.
All the Supervisors and staff must know the working limits including capacities to lift/pull
etc. Table in para 2 above, the capacities and stroke (in the bracket) are indicated. Staff shall
understand the difference in capacities in telescopic jacks (multiple cylinders) and nontelescopic jacks (single cylinder). The lifting capacity of telescopic jack is reduced as soon as
second/third cylinder starts lifting. Example a 120/60 T Telescopic jack’s capacity is 120 T for
first stage cylinder and reduces to 60 T when second stage cylinder takes load.
Second Stage Cylinder – 60 T Capacity
First Stage Cylinder – 120 T Capacity.
Re-Railing Bridge carrying capacities depending on the bottom support.
Bridge height
[mm]
[in.]
184
7.24
Support width
[m]
[ft.]
Max. load
[kN]
[lb]
0*
0*
1
3.28
1,43
4.69
1200
269,784
900
202,338
650
146,133
As far as possible, supports under the bridge shall be given exactly below the lifting Jack and
when traversing to be done, at close locations (less than 1 Mtrs).
5. Know how to and where to use the equipment.
a. Each equipment/tool has a specific purpose of use in accident restoration. Supervisors
and staff must know them and use appropriate equipment/tool properly/correctly
depending on the need.
b. Set the RPM of the power pack engine correctly as per the end use (high when load
lifting/quick operations and low when idling).
c. Use maximum number of connections with hoses connected in advance for multiple
operations. This avoids change of hoses frequently from one to another during
operation. If required, use distributor valve for simultaneous lifting of two jacks.
d. Standard practice of traversing is to place traversor on the re-railing bridge and Jack is
kept over it. However, in most of the cases, particularly while re-railing four wheeler
trucks, it is easy to apply jack at CBC or at sides depending on the place availability, lift
the stock and use both traversors under the trolley over the bridge and lowered on
wooden packing kept on traversor as shown above.
Below is the extract from Lukas manual for similar operation.
Traversing system with two roller carriages and separate load lifting system
(recommended method)
Required components:
-
Controlled hydraulic supply (e.g. hydraulic unit with control valve)
Separate load lifting system (e.g. hydraulic jack with accessories)
Rerailing bridge
2 roller carriages
1 traverse jack
2 distance bars
Support material (e.g. hardwood blocks)
e. Schematic diagram of Hauler setting.
This is one of the equipment less used during accident restorations. With the above
setting, gap between two vehicles can be created in most cases without waiting for a
locomotive.
As already explained, when a securing/fixing arrangement is available, this can be used
for toppling the rolling stock.
Lukas distributor Valve
MFD Distributor valve.
f.
Jacks must be set vertical with its base plate wherever provided on level base of wooden
packing. The capacity of the jack shall be matching with the load being lifted. If required
use multiple jacks. When using single jack for lifting load, jack shall be set at the centre
of the load and when using multiple jacks, the load shall be evenly distributed on all
jacks. Lifting operation in second case shall be simultaneous.
6. Know the safety precautions while using the equipment.
Please read the operating instructions/manuals supplied along with each equipment
whether it is HRE or other. Supervisors must sensitise the BD staff about safety precautions
to be taken for operations of each equipment during every technical mock drills.
Note: For detailed operation methods, operating manuals may please be studied)