Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
G-33 (Rev. 1)
. TECHNICA:LPAMPHLET
. FOR
REQUIREMENTS OF TIPPLER INSTALLATION
FOR APPROVAL BY RDSO
S.No.
1.
MonthlY ear of
issue
May, 2010
Revision /
Amendment
Revision 1
Page No.
ISSUED BY
May, 2010
Page 1 of 13
-- ~ -Cl-a-llse No;
1.
Scope
2.
Types of wagons
3.
Design parameters
4.
General requirements
5.
Safety requirements
6.
7.
8.
0h
Page No
Description
01-..~r.1
...
_ 1,
-~I~~~--------rl--~_c----------------------------------r-~--~~-------l
-:
ANNEXURES
Annexure 1
Annexure 2
Annexure 3
Annexure 4
Annexure 5
Annexure 6
Annexure 7
Annexure 8
Annexure 9
Annexure 10
')
Annexure 11
Annexure 12
Annexure 13
Annexure 14
Page 2 of 13
--~l-J) __ - --_---~ope
1.1
1.2
2.0
Types of wagons
2.1
2.2
2.3
2.5
2.6
2.7
3.0
Design parameters
3.1
These guidelines shall be applicable for both Side discharge and Rotary type
wagon Tipplers.
3.2
Single wagon tippler shall be designed for handling a gross load of 140t,
taking into consideration a 4-axle bogie wagon with an axle load of 32.5t plus
the overloading caused due to variable density of the bulk material and heap
loading of the wagon. For tippling two or more wagons at a time, the capacity
parameters will increase proportionately.
3.3
The tippler shall be capable of handling either one or more open wagons of
BOXNHL length i.e 10.963 m over couplers. The minimum length of the
tippler table should 10.963 m or in multiples thereof, depending on the nos. of
wagons to be tippled. When two or more wagons are tipped simultaneously,
the wagons should be in coupled position.
Page 3 of 13
3.4
However, wherever, older BOXC wagons have to be tippled (user shall have
.... - 4u.=evn~ult.theconcemed zonal railway f(]Fthrsconfinnation},theminimum
length of the tippler table shall be at least 13. 729m.
3.5
Additional extension piece may be utilized for tippling of iron orlt wagons (i.e.
BOY wagon variants), to compensate for their less height of the wagon, as in
the,:.e,xisting tipplers.
3.6
Where a locomotive is required to pass over or stand on the tippler, the tippler
shall be able to bear the load of the locomotive without sustaining any
permanent deformation. The clearance diagram for the diesel loco is indicated
vide Annexure -_14. For electric loco, a bypass track to be provided parallel to
the wagon tipplers
4.0
General requirements
4.1
4.2
The top clamping pressure shall be such as will hold the wagons firmly in
.,
1 1
"
.
,'" 1
1
1
1
_ _~R~sltlon -on ;~(l11S anti Ke~p Tile. rllnnl~g_ gear IrOTI1 :.,get-ong. UlSlQ.9geq _ _ wltnOllt
--c-a-usi-ng- allY deformation -to the vvagort -structure.
~
4.3
4.4
The side supports for tipplers shall meet the following requirements:
a) The side support shall consist of a longitudinal beam, which shall be as
long as the longest wagon to be tippled. This beam shall be
continuous.
b) The side support shall be articulated so that it can take the tapered as
well as parallel stanchions on the body of the wagons. Alternatively,
the cradle shall be articulated on trunion to achieve this.
c) Full-face contact between the side support beam and the side
stanchions shall be ensured. The side supports shall extend from a
height of 1000 mm up to 2950mm, from rail level, i.e. contact the side
of the wagon over a width of not less than 1950mm. [For wagons of
height less than 2950mm, typically iron ore wagons, (user shall have to
consult the concerned zonal railway for this confirmation) suitable
slots shall be provided in the side support beam, to permit the top
clamping of the wagons] There shall be metal to metal contact
between the side support beam and the side stanchions of the
wagon i.e. no rubber pad or any other alternative, shall be provided on
the contact face of the side support beam
d)
The side support beam shall be moveable type, the movement being
done by hydraulic arrangement. (No external or moveable counter
Page 4 of 13
4..,...
11.
Page 5 of 13
f.
The beam shall be so arranged that the discharge of the contents of the
,
;!
1...1
lvva'gefl-13-not-tlnpC\..leu-to-an-yappreCHlvre-exient
g. Each bearing face shall contact the top of the wagon over a width of
not less than 250 mm and shall be provided with rubber pads or
suitable alternative not less than 50 mm thiclc The shore hardness of
the rubber pad should not be less than 70A
h. The total force between the wagon tops and supporting beam shall be
not more than is necessary to ensure retention of the wagon and
engagement of wagon wheels with the rails of the tippler throughout
the tippling cycle
1.
The design of the appliance shall take account of the nature of the
material to be discharged, bearing in mind the maximum lump size,
moisture content, possible climatic conditions and other influencing
factors
4,6
4.7
4.8
4.9
5.0
Construction stage
a. The design of the tippler shall avoid, as far as possible, any spillage of
the material handled by the wagons.
b. Devices shall be built-in to prevent any over run of the wagons in
either direction.
c. The tippler shall be designed so that the wagon is securely held in all
operating positions.
d. Automatic devices shall be provided to hold the tipplers securely in
any position in the event of failure of the drive unit.
e. All tipplers shall have means to limit the angle of tippling.
f. Arrangement shall be made on tipplers to prevent feet being trapped
between the platform and the base of the tippler.
g. Whenever possible mechanical or electrical devices shall be built-in to
ensure that all the conditions allowing wagon tipping are coordinated.
h. Additionally, a device shall be provided to prevent an empty wagon
from being released until the tippler is back in original position.
1.
A device shall be provided to prevent the entry of a non-scheduled
wagon into a tippler.
Page 6 of 13
J.
:
---- :nc;
-'Tb
l.
Installation stage
a. All tippler installations shall be marked permanently and legibly in a
clearly visible place, with the following information:
i) Maximum capacity of the wagons & the type of wagons to be
tippled.
ii) If locomotives are required to run over the tippler, the maximum
permissible mass, maximum permissible axle loading and speed.
iii) l\1aximurn speed of the vvagon passing tl1fOtlgh tIle tippler and
A:fi:--irls-trnction -forbidding the tippfet to- be operated- as long -as the
.wagon,is not held on the platform in its tippling position. This
instruCtion shall also state that the tippler shall be held in
appropriate position before an attempt is made to remove the empty
wagon.
b. The emergency stop controls shall be provided adjacent to the wagon
tipplers in the readily accessible positions.
c. Frequently used lubrication points shall be accessible without being
necessary to remove guards and shall be painted to standard pattern.
d. All starting and stopping devices shall be clearly indicated and easily
accessible and shall be painted or printed as a standard pattern.
e. Gangways, handrails, staircases, ladders, guards, etc. wherever
provided shall be erected before installation is put into service.
f. The outhaul side track should satisfy the following conditions:
The gradient of the outhaul track should not exceed" 1 in 1200"
The length of the outhaul track, with the specified gradient, is
not less than 650 m for full rake tippling.
For partial rake tippling (not less than the half rake),
proportionate track length (equal to the half the rake length or
more) with track gradient not exceeding "1 in 1200" will be
permitted.
In case of limitation of adequate track length on the outhaul
side, as specified above, the user can consider use of transfer
platform for shifting the empty wagons, on a parallel trade
This parallel track shall satisfy the same conditions of gradient
as listed out above.
It should be certified that the length & the gradient of the
outhaul track is within the limits, as per above, by the
competent railway authority, under whose jurisdiction the
tippler location lies. The same certificate should be submitted
Page 7 of 13
5.1
Utilization stage
a. The inspection, adjustment, maintenance and cleaning of moving
components and of cleaning devices shall be carried out regularly
according to the manufacturer's instructions.
b. No person, other than a qualified and competent person so authorized
shall operate the tippler.
c. Normal and emergency stopping devices shall be made known to all
personnel and be easily accessible. All areas giving access to them
shall be kept clear of obstacles.
d. All restarting operations on tipplers which have been in operative
because of an emergency of accidental stoppage shall be preceded by
an inspection aiming at:
i) Determining the cause of the emergency or accidental stoppage
ii) Repairing the fault
b. Drive unit for the side arm charger should be of positive type e.g. rack
& pinion, so that sudden jerks/slippages are avoided. Suitable
technology should be used, so that the wagon can be moved at slow
speeds for placement on tippler table e.g. Low speed hydraulic motors,
Variable frequency AC motors or thyrister controlled DC motors
(through epicyclical reduction gearing), etc.
c. Charger should be able to slow down to creeping speed just before the
final positioning
7
7.1
ensure that force on each gripper is same and should have some lateral
~~..,
OF"lo.
-'-Cl~l:v'a-t~ :';:)U
~ ____'"""--""'-"'-""
8.2
-,~-
',I ,,-~
"/,';
i,
If
Note: '*' -- This range is true for coal wagons. However, the height
requirement for iron ore wagons is lesser, range being
2393mm to 2650mm.
Page 10 of 13
'#' - For tipping of older BOXC wagons, the minimum rail table
S
N
1
Item
Check
End
frame (i)
platform side
(ii)
beam
Drive gear
(i)
(ii)
Top hydraulic
(i)
Remark
clamp
I.
II--"'-.\, .,
11
5
6
Side
charger*
arm
(i)
(ii)
(iii)
(iv)
(v)
Damages
wagons
to
~1lC:;"
~a;l
- '---1- _ f1.
(i)
UiC ICV
Tk",
1",'1"')
-.111"",, Iv ~ L-.1
ail
11 111 1
L..
*Note: (1) There should not be any loose shunting of the wagons. In-haul and
out-haul arrangements consisting of side arm charger should be used
.. - for.,k~Qemenkandrem\).valo:fwagonon4ippl.elAahle,ThepraGtice of
shunting empty wagon after tippling by rake of loaded wagons, is not
acceptable as it results into large scale damages to CBC and bogies
Representative of the
Siding owner
Page 13 of 13
91-0522-2452494
\lR
'~c>ilil"lCf)' ~
Telegram: 'RAILMANAK'
Lucknow
ec1li{ll"l/Tele: 2451200 (PBX)
2450567 (DID)
No.
!I
~
~4
5
6
7
-tcf
226011
i: I Manufacturer
i"~
'l-TR\'f ~
~'i::lR ~ ~R ~ ~
IContractor
. . . ..
..
UsedConsignee
Site
Nearest Railhead
Tippler Model no
Drg. reference
..
9 , Type of Tippler
10 Capacity (Wt & height of
wagon)
11 Max rotation angle
12 Tipping Cycle time
13 Area of contact(top clamp & side
support)
14 RDSO no allotted
15 Approval
Remarks: The above approval is provisional and subject to following conditions:
I. RDSO allotted No. may be indicated on the control panel of the wagon
tippler.
2. The tippler shall have the capacity to tip at least 25 wagons per hour i.e. 25
tips per hour.
(DSW/WD)
For Director General (Wagon)
Copy to.
1.
2.
3.
4.
GM/Mech, Railway.
User/Owner
Sr. DME, Division, Railway.
Tippler supplying firm.
Note: '*' - This range is true for coal wagons. However, the height
requirement for iron ore wagons is lesser, range being 2393mm
to 2650mm.
'#' - For tipping of older BOXe wagons, the minimum rail table
length will be 13.729m
h. The tippler shall be capable of handling a single wagon of upto 140t
(gross). For tippling two or more wagons at a time, the capacity will
increase proportionately.
I.
No tippler/handling equipment component should protrude more than 100
mm from the rail level within the rails.
J. The tippler shall have such parking/arrangement as would facilitate
placement of wagon centrally on the tippler table.
k. After installation and commissioning of the tippler, Sr.DME of the
concerned Division, Railway shall certify it safe for the operation.
-Annexure;;::l
I.
----------------------------------~--------~r'
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2000 WH EL BASE
6524 BOGIE CENTRES
1630
1630
::===1
464.5
S.NO.
DESCRIPTION
1.
ESTIMATED TARE
PAY LOAD
3.
4.
GROSS
AXLE LOAD
5.
6.
7.
8.
MEASURES
21.0t.
79.0t.
lOOt.
25t.
3.75
9.33t./m.
58
4582t.
580ot.
28.44m2
37.94m3
O.853m
1.663m
NOTE:
MATERIAL USED IS:IRSM44- UNDERFRAME & BODY.
ANNEXURE"'I~'
,W~r;rERN
CORRIDOR OFC
'j
I!
-:"i-'
9784 LENGTH
INSIDE
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464.5
1630
S.No.
1
WAGON DATA
ESTIMATED PAY LOAD (WITH HEAP=5.2m3)
71 t.
1630
~j
1--:-
0
g >
~2
o
RL
rN
1676 GAUGE
464.5
BOXN25
77t.
GROSS
100 t.
91.6 t.
100 t.
AXLE LOAD
25 t.
22.9 t.
25 t.
9.33 tim
8.35 tim
9.33 tim
58
58
58
4756 t.
4118 t.
4466 t.
4.55
3.45
3.35
--
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"t~Z1.1jQ'iillJry032Ei1}H~;(}.jg;f<.2fjfiJf:J&
....~m
....
MEASURE
S.NO.
1.
2
2.5ot
1.
0.951
3.
3.
S,NO,
DESCRIPTION
4.
wr.
5.
6.
7.
8.
9.
10.
a:
mm
11105
240.5
S.NO.
NIL
1.
3.
HEIGHT OF SPRINGS
1.32t.
(f)
JOURNAL CENTRE
J()lJRN!L SIZE
10.84l
(f)
~
,
12
ESTIMATED TARE
20.41t
13
CARRYNG CAPACITY
60.871
81.281
rv
14
GROSS LOAD
15
AXlE LOAD
20.321
16
2.98
17
7.59t/M
18
NO. OF WAGONS
19
35331
20
4714\
(f)
(f)@
(f)
21
flOOR AREA
29.57lt
22
58.84CuM
23
1021mm
i[)
24
1913mm
58
NOTE:I
(f)
mm
-',- I----165
.,- t-m-
932
254
twoo
..' - I-----
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i[
i[)
11
IN 820M
".~"'_~
0.7ot
. ._ _ _ _ _ . _. . . . .
1lI IMIX* IS EXICIl.Y SIIUR'R)1KV1H Dflllltf;wO. 'IIH8OM-5/2lI ALT.l, THE INfBtIiOIOtT FOR M:H
KG Bmt aHXlNED Br lHE RAU~ 8CWI01ET1fR 1((I!IO/Cf1XJr.JV11Wm 17.1.1"
906
.,- ~
2260
44X27S
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OOED
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COI~RIDOR
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1071.3
WAGON DATA
S,No.
70.89
80Y25
79 t.
;;
I GROSS
13D t.
91.6 L
100 L
:)
I ;\XLE LOAD
325 L
22,9 L
25 t.
5
6
7
No.OF
620m. LOOP
PAY
TARE RAnG
7,678
112.13
52
58
6264
4.9
3686.3
3.39
I 4582
t.
3.'15
1
2.
0.
SPEC!F!CAT~ON
OFC \
n
Mil)" MOVING DIMENSION
r~::':T:'::-::""---'
l DIAGRAM NO. 10-2004 ______ .. - I / - . l . . .
w'
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464.5
464.5
OESCRIPTION
NEASURES
1. UNOERfRAlIE
2.701.
2
3.
0.981.
4.101.
FLOOR PlATE
BODY STRUCTURE COMPLETE
10.81.
NOTE:-
12 ESTIMATED TARE
20.61.
!3 PAY LOAD
71.01.
91.61.
22.91.
3.45
14 GROSS
15 AXl LOAD
16 RAno (PAY LOAD TO TARE)
17 TRACK LOADING DENSITY (GROSS)
18 NO. OF WAGONS IN 636 m.
19 PAY LOAD PER TRAIN (58 WAGONS)
20 GROSS LOAD PER TRAIN
THE WAGON IS E!TTED WlTH:1. SINGLE GRADUATED RElEASE AIR 8RAKE SYSTEM
2. HIGH TENSILE (NON TRANSITION TYPE CENTRE 8UFFER COUPlER.)
(]) 3. CAST STEEL CASNU8 22NL8 BOGIES
TO STR No.WD-21-CASNUB 22NL8-BOGIE-93
8.lSl/m.
58
41181.
53131.
1062mm
2842mm
30.32m'
24 VOWNETRIC CAPACITY
61.05""
(])
~~~
ANNE~URE-J'
,._._._._._._._._._. __ ._.,
(HEAP LOADING)
Vi
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464.5
1630
S.No.
1
WAGON DATA
. ESTIMATED PAY LOAD (WITH HEAP=5.2m3)
71 t.
..
BOXN25
77t.
GROSS
130 t.
91.6 t.
100 t.
AXLE LOAD
32.5 t.
22.9 t.
25 t.
6
7
12.13 tim
8.35 tim
9.33 tim
58
58
58
6264 t.
4118 t.
4466 t.
4.9
3.45
3.35
NOTE:.
' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -....
BODY DESIGN WILL BE BASED ON TTCI PROJECT FOR 32.5t. AXLE LOAD.
...
__------------------_._-----'.
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"""""u."-~"""'w"'"'n'-"=-'===.
R.L.
I_.__....J.!~)
_ _ _ _ _ _ _ _ _ _ _ .._
..._ ...
NOTE:
1. BODY STRUCTURE AND UNDERFRAME OF MATERIAL IRSM44
EXCLUDING CENTRE SILl.
2. CENTRE SILL OF MATERIAL IS:8500 Fe 540Cu
3. 4 DOORS PROVIDED
'1
_ . _., " _. 'PROTOTYPE
PRELIMINARY SKETCH
SUPfRSEDED BY
,UI"'tJ(::;t.OES
_1-_'-,
I' ' - " " " " 1 '
1
L::19::.=c.G=.=(L=OA=DE=D)=================i=2=10=2m=m=~____krl~.~~ -,
~~. :m.
GUI~"t."'!."oii;'~)
lOA'
DIAGRAM
N
WD-07005 8-02
JII
_________________~J
..
__. _ - - - - - - - - - - - - - - - - - - -
-------'~f~"~~
.(,'
110. 2006/CE-lI/!S12Do\1ED
17.10.07)~
oom 23.oe.(8)
3660
' - ' - ' - ' - ' - ' - ' - ' - ' - ' - ' - ' . ' - ' - ' - ' -
S,No. I
VJJ\GON DATA
L)i~-C
'flAGON I BOY
84 t.
2 I GROSS
.,
IOD t
25 L
.)
AXLE LOAD
4-
No.OF
620m, LOOP
I 9,33
58
14(372
5.25
8()Y25
I }08i.) L
19 t.
91.6 t
100 t
22..9 t.
'yr'1R
f,D! .;
52
I 25 t
1<.131
'., ....
58
j63ELl t I 4532 t
3..:)9
375
L 80GiE WiLL BE
2.
3. BODY DES1GN
WD-45~MlSC,-2006
1~C-
r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -..- . . . - ... - - - - - - - - - - - - - - - - @
I
~
~.w
!!AX.
9~
OIlEl"'''''
>< - -
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--< ____
rr .....- ....? ,
L.ENCni NSDE
---"l.
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~_
. ~~
____J ,
. '---"""
JlOO fIIDllI C\t:RAU._..
I'
............_ ,
i@ 11]
@~
@
'\...,000
lII<m
200'JIWHffi BloSE
~.rl.
..---j. -..,--_..
ISJO
S.NO
,
I.
,I
i
>.21 L
5.21 l
0.150 L
0.&0 l
U2l
loll l
RATE
EX;HT CATR(X;E
Ba.S1ER
SP~HGS
a:
~u:s
Il
PAY !,.CloD
22
t.
1.296t.
5.2{ l
LCI(]
TO rARE)
C.C.FRCN R.l.(lcw:ED)
2J
FlOC'lIID
"I
VOl.lNETRC CNfOrt
~U
I.
,
2.
HEICHT
OISTAHCE
1.32 l
1,32
~l-~!,~
'Mel UA.ON
'""if.ilti"-DN
J.6J6 l
J.6J6 L
"5l
Q.Jnt.
5.75 t.
OIA..Cf
o.J72l
..K)IJOOt. 00'(1
23.1 t.
O.SO l
23.1t. .
."" l
0.224 l
II.!IO l
0.., L
23.1 t.
2.3.1 l
t.
64.18 l
68.18l
66..18 l
81.28 t
87..28 l
91.28 l
BUB L
~.18
va
2~2
7.59
tim.
3374 l
() 47t4 l
1.015 m
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