Design Approach for Wagon Tippler for CHP of a

power plant

GROUP 2
Karri Krishna Teja
Anku Kumar Pandey
Manglam Sharda
Contents
 Introduction
 Components of Wagon Tippler
 Platen Assembly
 End Rings
 Clamp Assembly
 Spill Truss
 Wheel Grippers and Wheel Chocks
 Drive Units
 Working Mechanism
 Drawing Layout
 Civil Aspects
 Side Arm Charger
Working Principle
Introduction
 Wagon tippler is a facility where the coal is unloaded from railway wagons
one by one by holding and tippling the wagon upside down into hopper
below.
 The coal discharge from the wagon is collected in hoppers and then
evacuated by APPRON feeder on to conveyors.
 Wagon tippler is underground structure and is generally in rcc
construction.
 It is less costly in construction than track hoppers and requires less space.
 The length is about 30m in contrast to track hopper which is generally
250m of above.
Components
 Platen Assembly
 End Rings
 Clamp Assembly
 Counterweight
 Spill Truss
 Wheel Grippers
 Wheel Chocks
 Drive Units
Platen Assembly
 It is a fabricated steel
structure frame consisting
of an inner platen and an
outer platen.
 The inner platen is placed on
top of the outer one and the
weigh bridge cells are
mounted between the two.
 The entire platen is designed
so that an Indian locomotive
engine of 150T in weight
can pass over it at a
maximum speed of 8km/hr.
 8 load cells of adequate
capacity are provided in
between the inner and the
outer platen.
End Rings
 They are fabricated
steel frames of semi-
circular shape.
 Two end rings are
connected by the spill
girder, top clamp beam
and counterweight box
girder.
 The end rings support the
platen assembly, along
with the loaded wagon to
be tipped.
Clamp Assembly
 The wagon tippler is equipped
with six hydraulically-
operated steel clamping arms
moving through the hydraulic
cylinder. 
 All the clamps are designed to
move into position as the
wagon tippler begins to rotate,
and they clamp on the top of
the wagon at a pre-determined
angle and hold the wagon
firmly until it returns to its
normal resting position, when
the clamps release the wagon. 
 The clamping system is
designed so that it can clamp
both the maximum and the
minimum height of the wagon
being tipped. 
Spill Truss
 The side supporting beam,
also known as the spill
truss or spill girder, is of
welded steel
construction. 
 It connects the two end
rings and supports the
loaded wagon lengthwise
during operation. 
 The side wall moves
through hydraulic
cylinders and touches the
wagon standing on the
platen without applying
pressure.
Wheel gripper and wheel chocks
 Two sets of hydraulically operated wheel grippers on the
rails are fitted to the platform to grip the wagon wheels and
prevent any derailing during the tippling operation.

 Hydraulically operated wheel chocks on the inhaul and

outhaul side of the platen prevent  the wagon wheels from
rolling back on the platen.
Drive Unit
 The drive unit is either
electromechanical or
hydraulic. 
 A electromechanical drive
consists of an electric motor
coupled with a speed
reduction gear box and brake
mounted on the input shaft of
the gear box. 
 A hydraulic drive consists of a
power pack with electric motor
and a hydraulic motor coupled
with a helical gear box. 
 The brake is built into the
hydraulic motor, and an
external hydraulic thrusters
brake is mounted on the input
shaft of the gear box.
Working Mechanism
 The loaded wagon to be
discharged is placed to the
central position on the tippler
cradle and is weighed with
Weigh Bridge (If installed).
…Contd
 At rest position of the Wagon
Tippler the Movable side
support moves forwards and
touches the side wall of the
wagon gently and gets locked.
…Contd
 At the start of rotation of the end rings
the rail platform with loaded wagon
lifts from its supports and the wagon
adjusted slightly and rests against the
longitudinal movable side beam.
 The rotation continues and the wagon
is swung towards the top of wagon.
 The tippler is driven by a Hydraulic
motor and the top-clamping device is
actuated by four hydraulic cylinders
mounted on the End Ring.
 Cylinders are operated by a hydraulic
power pack, which gives necessary
fluid flow, and pressure to operate the
cylinders.
…Contd
 During the tippling operation, Top
clamping device starts moving to
clamp the wagon from top.
 At 40 (approx) of the wagon rotation,
top clamp comes in contact with the
wagon's top.
 At this condition cylinders get locked,
in turn wagon is securely held between
cradle platform and top clamp pads.
 Rotation continues up to 160and
material starts to discharge at 40
(approx) and continues up to 160.
 After a pause of 3 sec., return cycle
starts. The cradle platform with empty
wagon comes to rest position.
 The empty wagon is pushed out and
the platform becomes ready to receive
next loaded wagon.
Electrical Equipment
 Feeders shall be provided from 11 kV Station Switchboards for
Coal Handling Plant.
 11/ 3.3kV and 11/0.433kV or 3.3/0.433kV auxiliary transformers to drive
320 kW, 1500 RPM Hydraulic (or) Electro Magnetic Motors
 11kV, 3.3kV and 415V Switchgears
 Power and control cables including cables from 11 KV station
switchboards and 415 V unit PMCC.
 Cable laying along with cabling accessories, cable trays and
termination/ jointing kits of cables, and fire sealing
 Side Arm Charger
Side Arm Charger is a marshalling device to position the loaded wagon centrally on
tippler platform one by one for unloading operation by wagon tippler. Side Arm Charger is
a rail mounted machine used to pull the loaded wagons along with the rake & push out
the empty wagon from the tippler platform after tippling.
Operation
 The full rake of 58 wagons is brought in by locomotive and stopped with the first
wagon within range of the Side Arm Charger.
 The locomotive is then taken away.
 The charger is driven towards the first wagon, its arm is lowered and it is coupled
to the first wagon of the rake.
 The charger then hauls the rake forward by one wagon length and stopped. Here
the first wagon is decoupled from the rake manually.
 The charger then propels the first wagon on to the tippler table centrally and then
automatically decouples and clears off the tippler.
 Now the wagon tippler is ready for operation. In the meanwhile, the side arm
charger is moves back to initial position for next cycle. In next cycle, the rake is
drawn up by the one wagon length, and the previously tippled wagon is ejected
simultaneously.
TRF Wagon Tippler with sidearm charger
TRF Side Arm Charger
Civil Aspects
Side supports for tippler

 The side support shall consist of a longitudinal beam which shall be as long as the
longest wagon to be tipped.

 This beam maybe continuous or non-continuous.

 The side support shall be articulated, so that it can take the tapered as well as parallel
stanchions on the body of the wagons.

 Full face contact between the side support beam and side stanchions shall be ensured.

 The width of the side supports shall be sufficient to take care of the type of wagons
being handled.
…Contd
Clamping arrangement
 Consist of a longitudinal beam or longitudinal and transverse beams,
engaging at the upper edges of the end side walls of the wagon
 Self-aligning feature to bear the load on the top at each end of the wagon
 Ensure that the discharge of the contents of the wagon is not impeded to
any appreciable extent
 Each bearing face of the beam contact the top of the wagon over a width of
not less than 225 mm and are provided with rubber pads or suitable
alternatives not less than 50 mm thick
…Contd
 Force between the wagon tops and supporting beam is just sufficient
to ensure retention of wagon and engagement of wagon wheels with the
rails of the tippler throughout the tipping cycle
 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
 As the frictional force between the wagon body and side supporting
beams can vary widely, it shall not be taken into account in the design of
the top supporting beam
 The load shall be nearly equally distributed over the bearing surfaces of
the beam.
Underground Aspects
 Being underground structure, crack width on outer face should be
restricted to 0.01 - 0.2mm and external water proofing should be provided
under the foundation and sidewall.
 Entire structure should be checked for safety orientation at various stages
of construction.
 Grade of concrete in RCC Hoppers is minimum M25 or as specified in the
contract.
 There shall be provision for adequate number of drain sumps at locations
along with side drains with cellars for catching incidental presence of
sulphurised water etc.
Sources
 http://info.heylpatterson.com/blog/bid/104157/Rota
-Side-Wagon-Tipplers-Handle-Bulk-Materials-for-t
he-Indian-Market
 http://www.trf.co.in/pdf/Products/Wagon%20Tippl
er%20with%20Side%20Arm%20Charger.pdf
 http://www.slideshare.net/lmmgroup/wagon-tippler
-lmm-group
 https://en.wikipedia.org/
Thank You