Professional Documents
Culture Documents
G-33 (Rev. 1)
, TECIINICAL PAMPHLET
FOR
REQUIREMENTS O:FTIPPLER INSTALLATION
:FOR APPROVAL BY RDSO
ISSUED BY
RESEARCH
May, 2010
Page 1 of 13
CONTENTS
--
Description
Clause No.
Page No
3
1.
Scope
2.
Types of wagons
"
.)
-----
------
"
3.
Design parameters
.)
4.
General requirements
5.
Safety requirements
6.
11
--
-------_-----
7.
_-
~----------
~~--~.
9.
~----------~-- --
ANNEXURES
-----
Annexure
[....'
Annexure 2
Annexure 3
'---------
Annexure 4
Annexure 5
Annexure 6
--------_-- ---
1-------
Annexure
Annexure 8
Annexure 9
----------
Annexure
10
Annexure
11
-----
Annexure
12
Annexure
13
1---------------------
Annexure
'----
14
Page 2 of 13
---------
---------.-
---------_.--
1.0
Scope
1.1
1.2
2.0
Types of wagons
2.1
2.2
2.3
2.4
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 1401,
taking into consideration a 4-axle bogie wagon with an axle load of 32.51 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
3.5
However, wherever, older BOXC wagons have to be tippled (user shall have
to consult the concerned zonal railway for this confirmation), the minimum
length of the tippler table shall be at least 13.729m.
Additional extension piece may be utilized for tippling of iron ore wagons (i.e.
BOY wagon variants), to compensate for their less height of the wagon, as in
the existing 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
position on rails and keep the running gear from getting dislodged without
causing any deformation to the wagon 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
11.
Page 5 of 13
f.
The beam shall be so arranged that the discharge of the contents of the
wagon is not impeded to any appreciable extent
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 thick. 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
Safety requirements
--- Notwithstanding
statutory regulations, safety requirements
following three stages, shall be followed:
5.1
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
Installation stage
a. All tippler installations shall be marked permanently and legibly in a
clearly visible place, with the following information:
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) Maximum speed of the wagon passing through the tippler and
iv) An instruction forbidding the tippler 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.
i)
Page 7 of 13
5.3
at the time of
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
e. If so specified by the purchaser, a dust collection system shall be
installed at the tippler.
7.1
7.2
Retractable
wheel chocks
a.
Requirements
1.
J.
k.
1.
m.
n.
o.
p.
Note: '*' -- This range is true for coal wagons. However, the height
requirement for iron ore wagons is lesser, range being
2393mm to 2650m111.
Page 10 of 13
'#' - For tipping of older BOXC wagons, the minimum rail table
S !
Check
Item
Remark
N
End
frame
latform
side
P
beam
,--'----------
(i)
(ii)
--_._---
Drive gear
(i)
(ii)
_J
__
_]_r-{;i__lil_~~~~ln~_
})_ -_-__
Page 11 of 13
clamp
(ii)
(iii)
(iv)
(v)
(vi)
Rail table of
wagon tippler
(i)
Limit switches
In haul & out
haul
stop
linkage
(i)
Side
charger"
(i)
Damages
wagons
(i)
(ii)
or not.
--- -- .._--_-
arm
Page12of13
----
--
[:[-::::_:::::I__.-.I- :__
_=:____ __ ;
-~~~~~~l:e~~~ages_ ..
"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 placement and removal of wagon on tippler table. The practice 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
Siding owner
of the
Page 13 of 13
Annexure-I
Fax:
'rnxcr
91-0522-2452494
'~1lRCf)'
c>1'{SP1\.1J
Telegram: 'RAILMANAK~
Lucknow
-t-cfllm-~/Tele: 2451200 (PBX)
2450567 (DID)
No.
rM 1c12~
\PCf)[~ - ~
~r:t~1tlFf3iRiC{)01
31f"! '1FFfJ
c;r{SG'l\f) -
+r lCFl
J
226011
2
_)
4
5
6
7
8
User/Consignee
Site
Nearest Railhead
Tippler Model no
Drg. reference
9
10
Type of Tippler
Capacity (Wt & height of
wagon)
Max rotation angle
Tipping Cycle time
Area of contact(top clamp & side
support)
RDSO no allotted
Approval
,...,
11
12
13
---
14
15
GM/Mech, Railway.
UseriOwner
Sr. DME Division, Railway.
Ti ppler Sll pplying firm.
(Wagon)
Annexure-I
!:ist of conditions
for tipplers
d. The forces exerted by the top clamps of the tipplers on wagon copings
shall not exceed 1.5t per clamp pad. This shall be ensured by providing
some positive arrangement,
other than provision of rubber pads, for
absorbing
the clamping forces (permitting
release of bogie springs).
Note:
'*'
l.
m.
n.
o.
p.
Annexure-l
Operation of the tippler shall be suspended on request of the Sr.DME of
the concerned Division in case of its causing damage to the wagons and
not meeting any of the above conditions and requiring maintenance
Sr DME of the concerned Railway Division or his representative may
inspect the Tippler and its operation, whenever such a need is felt, or may
depute Railway staff permanently for inspection of wagons after each
tipping. The entire cost of inspection and attention to the wagons shall be
borne by the owner of the tippler.
It shall entirely be the responsibility of the owner for ensuring that no
damage whatsoever is caused to the wagons during handling on the
tippler. The owner shall guarantee to pay to the Railway the rectification
charges in case of any damage to the wagons.
The approval for operation of tippler is subject to withdrawal at any time
in event of owner's fai lure to ensure handling of wagons without damage.
Owner/User or his representative shall submit a certificate to Sr DME of
the concerned Rly/Division in the prescribed format that the tippler is in
good working condition, once in every six months
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