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S.No.1

INDIAN RAIL WAYS

G-33 Rev. 1. TECHNICA:LPAMPHLET

. FORREQUIREMENTS OF TIPPLER INSTALLATION

FOR APPROVAL BY RDSO

MonthlYear of Revision / Page No. Reason for Arneissue AmendmentMay, 2010 Revision 1 - First issue

ISSUED BY

RESE RCH DESIGNS AND STANDARDS ORGANISATIONMINISTRY OF RAILWAYSLUCKNOW-226 011

May, 2010

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-- -Cl-a-llse No; Description Page No1. Scope ) 32 Types of wagons 33 Design parameters 34 General requirements 45 Safety requirements 66 Positioning system for wagon 87 Train wagon holding devices 88 Requirements for RDSO s approval for tippler 8installation0 0 1 . . ~ r . 1 1.....-. c' ~ ~ _ J . ':-i - - c:;.r-..L ...I I ' - . .>Hc\.;K Hl;; l ; ; l lUl jU l l l l l n : : ;p , , , t l on _ 1 1 I I~ ~ r l ~ _ c r ~ ~ ~ l

: -

ANNEXURESAnnexure 1 Format of approval certificateAnnexure 2 Schematic diagram for tippler (G-33-2008)Annexure 3 Schematic diagram for BOY wagonAnnexure 4 Schematic diagram for BOXC wagonAnnexure 5 Schematic diagram for BOXN wagonAnnexure 6 Schematic diagram for BOXNLW wagonAnnexure 7 Schematic diagram for BOXNHL wagonAnnexure 8 Schematic diagram for BOY25 wagon ')

nnexure 9 Schematic diagram for BOXN25 wagonAnnexure 10 Conceptual diagram for 25t axle load Iron ore

wagon for DFCAnnexure 11 Conceptual diagram for 25t axle load Coal

wagon for DFCAnnexure 12 Conceptual diagram for 32.5t axle load Iron ore

wagon for DFCAnnexure 13 Conceptual diagram for 32.5t axle load Coal

wagon for D FCAnnexure 14 Proposed Maximum Moving Dimension of

Diesel locomotive for DFC

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- - ~ l - J - _ ~ o p e1.1 This document provides guidelines for selection of tipplers for BG openRailway wagons ofa. _ Current designb. Wagon designs, of 5t axle load, for existing routes

c. Proposed wagon designs, of 32.St 2St axle load, for DFCFeeder routes1.2 This document also gives the basic requirements to be met for obtainingRDSO s approval for installation.2.0 Types of wagons2.1 The existing population of open wagons in the Indian railways consist ofBOY, BOX, BOXN and BOXNHA wagons, of which BOXN wagons formthe bulk.2.2 However, new types of open wagons like BOY25, BOXNLW, and BOXNHLBOXN25 are being introduced in the Indian Railways.2.3 New designs for open wagons for coal and iron ore for DFC Feeder routes

are also under consideration conceptual_diagrams h ~ e b e _ e n J ; l e v ~ J o p e d .

2.5

2.6

2.7

3.03.1

3.2

3.3

~ - C o n - c e p t u a l Oiagrams- arid other details of these ~ / a g o n s (both St - 32.51 axleload) o re covered in the annexure.These wagons are suitable for transporting coal, ore, lime stone etc., hencewhile planning for mechanised unloading, the parameters of these types ofwagons should be taken into consideration.For handling of any other special type of wagons, the purchaser should takeinto consideration the size gross weight of the wagons or intimate the sameto RDSO.Introduction of new type of freight wagons is a continuous process. Hence,limiting boundary dimensions should be taken into consideration whileplanning a tippler. The limiting boundary dimensions are indicated in the item8.2 (g).Design parametersThese guidelines shall be applicable for both Side discharge and Rotary typewagon Tipplers.Single wagon tippler shall be designed for handling a gross load of 140ttaking into consideration a 4-axle bogie wagon with an axle load of 32.5t plusthe overloading caused due to variable density of the bulk material and heaploading of the wagon. For tippling two or more wagons at a time, the capacityparameters will increase proportionately.The tippler shall be capable of handling either one or more open wagons ofBOXNHL length i.e 10.963 m over couplers. The minimum length of thetippler table should 10.963 m or in multiples thereof, depending on the nos. ofwagons to be tippled. When two or more wagons are tipped simultaneously,the wagons should be in coupled position.

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3.4 However, wherever, older BOXC wagons have to be tippled user shall have.... - 4 u = e v n ~ u l t t h e c o n c e m e d zonal railway f ]Fthrsconfinnation},theminimumlength 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 tipplershall be able to bear the load of the locomotive without sustaining anypermanent deformation. The clearance diagram for the diesel loco is indicatedvide Annexure -_14. For electric loco, a bypass track to be provided parallel to

the wagon tipplers4 0 General requirements4.1 The design and construction of components of tipplers and auxiliary handlingequipment coming into contact with any part of wagon shall be such that no

damage whatsoever is caused to the wagon equipment or its paint.4.2 The top clamping pressure shall be such as will hold the wagons firmly in

. 1 1 . , ' 1 1 1 1~ s l t l o n -on ; ~ l 1 1 S anti K e ~ p Tile. r l l n n l ~ g _ gear IrOTI1 :.,get-ong. UlSlQ.9geq wltn lltc a usi ng allY deformation to the vvagort structure.

4.3 Adequate compensating measures shall be taken in top clamps and sidesupport beam to compensate for manufacturing imperfections, within thepermissible limits, in the top copings and side stanchions of the wagon, so thatclamping pressure on the contacting area on the side and top of the wagon isuniformly distributed.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 aslong as the longest wagon to be tippled. This beam shall becontinuous.b) The side support shall be articulated so that it can take the tapered aswell 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 sidestanchions shall be ensured. The side supports shall extend from aheight 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 ofheight less than 2950mm, typically iron ore wagons, user shall have toconsult the concerned zonal railway for this confirmation) suitableslots shall be provided in the side support beam, to permit the topclamping of the wagons] There shall be metal to metal contactbetween the side support beam and the side stanchions o thewagon i.e. no rubber pad or any other alternative, shall be provided onthe contact face of the side support beam

d The side support beam shall be moveable type, the movement beingdone by hydraulic arrangement. No external or moveable counterPage 4 of 13

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weights should be used with the side support beam) Facility of~ ~ o _ ~ f { j l . : \ v f t f d l - - b a - c k w a - r d ~ -Jl1o\tem-ent--sh-ould :e-xist,- - s u c - h ~ - that- it s h - a u l d - ~ - - b e : - - a b l - @ - - - -

to move touch the wagon without applying any pressure on thewagon side-wall. At this position it should get locked and the tiltingoperation can begin. At the end of the tippling cycle, the side supportshould return to its home position, so. that thenext\vagon can be-:.-. ', . .:_:-- :-0.:: __ ' - '-' _ , 4.positioned on the tipplerMovement of the side support should be controlled the speed shouldbe crawling just before making contact with the wagon sidewall.

e) Pressure gauge/s should be mounted, at easily accessible location, forreading the hydraulic pressure of the side support hydraulicarrangement.

4.5 The top clamping arrangement shall conform to the following requirements.a. The top clamping of the wagon shall be done through hydraulically

locked top clamps. No external or moveable counter weights should beus ed with the hydraulic clampsb. Top clamps should engage when the wagon tilts by more than 15

c ~ _ g r e e - ~ : T ~ - p _ _ c l a m p locks shcyuld include a viaguil ~ 9 g ~ e s p r . ~ ~ _ g - reliefi - i ~ : : e - h ~ l ' n i s n 1 . -for' perm.itting '--release -of boogie -'Springs. Top--- - c l a ~ u l p ssho.uld.exert the bare minimum pressure on the top coping of thewagon, so as to just keep it in position. The pressure exerted by the topclamps at the tilt angle of 160 degrees should be just enough to bearthe weight of the empty wagon, which should be achieved through thebogie spring relief mechanism incorporated n the tipplers design.

c. Pressure gauge/s should be mounted, at easily accessible location, forreading the hydraulic pressure of the top clamping hydraulicarrangement

d. The top clamping arrangement shall be of longitudinal/ transverse typeand provided with self-aligning feature, whereby the load is borne onthe top at each of the wagons.

1. The transverse type top clamping shall have 6 nos transversetop clamping beams i.e. the bearing face of the beam shallcontact the top of the wagon at 12 locations (six on each side).Each of the six top hydraulic clamps shall be individuallyarticulated, to ensure firm clamping of wagon at every grippingpoint. The location of the clamping pads shall be as under:

11. The longitudinal type top clamping shall be such that theclamping pads cover the full length of wagon top coping.Each top hydraulic clamp shall be individually articulated, toensure firm clamping of wagon at every gripping point.

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f. The beam shall be so arranged that the discharge of the contents of the; 1...1lvva gefl-13-not-tlnpC\..leu-to-an-yappreCHlvre-exient

g. Each bearing face shall contact the top of the wagon over a width ofnot less than 250 mm and shall be provided with rubber pads orsuitable alternative not less than 50 mm thiclc The shore hardness ofthe rubber pad should not be less than 7 A

h. The total force between the wagon tops and supporting beam shall benot more than is necessary to ensure retention of the wagon andengagement of wagon wheels with the rails of the tippler throughoutthe tippling cycle

1. The design of the appliance shall take account of the nature of thematerial to be discharged bearing in mind the maximum lump sizemoisture content possible climatic conditions and other influencingfactors

4 6 Devices shall be built-in for spotting of wagons on the tippler table so as todischarge the material in hoppers.

4.7 Size and gauge of rails on the wagon tippler platform shall be as per railwayspecifications taking into considerations the maximum duty condition that thewagon tippler has to undergo in field operation.

4.8 If so specified by the purchaser integrated vveigh bridges _load cell type or-mechanical type,-- conforming to rele\la11t Indian Standard shall be p r o v ~ i e Oflthe tippler to weigh the gross and tare \veight of wagons which are beingharidled. There may also be a provision to record gross load tare load dateand number of wagons.

4.9 Marking - All tipplers shall be marked permanently and legibly at a clearlyvisible place with the name of the manufacturer serial number the year ofmanufacture type and capacity of tippler and RDSO allotted Serial No.

5.0 Safety requirements - Notwithstanding anything contained in variousstatutory regulations safety requirements for tipplers divided into thefollowing three stages shall be followed:5.1 Construction stage

a. The design of the tippler shall avoid as far as possible any spillage ofthe material handled by the wagons.

b. Devices shall be built-in to prevent any over run of the wagons ineither direction.

c. The tippler shall be designed so that the wagon is securely held in alloperating positions.

d. Automatic devices shall be provided to hold the tipplers securely inany 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 wagonfrom 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.

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J. Sharp edges and corners in all working spaces shall be avoided.: - T b ~ ~ ~ C t Y . : r r l L ~ . a L : J + ~ Y 1 _ ~ _ . I . . r . . _ l x ~ ____ n ~ ~ ~ _ l . . . - ; . . : l ~ L _ 1 . . . . ~ --P-_ -_ ' - - _ a l l - - ~ ~ _ -.-..ue- '--ILVl P ------- :nc; --C:'VJ ' - 'UI1C\ ,l1lV-VVVl1'\.lHC\ PUvc ,eJ HUH VC;ab-:- l I I I l 1 - 1 1 : - l p vu i S v . -l. All the frequently used lubrication points shall be accessible without it

being necessary to remove the guards.m. t is recommended that equipment shall be so designed thatl l l ~ t e l l . : ; j . n g e andcleaning is facilitated.n. FulTyintegrated controls should be provided for wagon positioningsystem, wagon holding devices and wagon tippler. The controls shouldbe interlocked so that there is no chance of accident due to error insequence of operation.

5.2 Installation stagea. All tippler installations shall be marked permanently and legibly in aclearly visible place, with the following information:

i) Maximum capacity of the wagons & the type of wagons to betippled.ii) If locomotives are required to run over the tippler, the maximumpermissible mass, maximum permissible axle loading and speed.iii) l\1aximurn speed of the vvagon passing tl1fOtlgh tIle tippler andA:fi:--irls-trnction -forbidding the tippfet to- be operated- as long -as the

.wagon,is not held on the platform in its tippling position. ThisinstruCtion shall also state that the tippler shall be held inappropriate position before an attempt is made to remove the emptywagon.

b. The emergency stop controls shall be provided adjacent to the wagontipplers in the readily accessible positions.c. Frequently used lubrication points shall be accessible without beingnecessary to remove guards and shall be painted to standard pattern.

d. All starting and stopping devices shall be clearly indicated and easilyaccessible and shall be painted or printed as a standard pattern.

e. Gangways, handrails, staircases, ladders, guards, etc. whereverprovided 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, isnot 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 ormore) with track gradient not exceeding 1 in 1200 will bepermitted. In case of limitation of adequate track length on the outhaulside, as specified above, the user can consider use of transferplatform for shifting the empty wagons, on a parallel tradeThis parallel track shall satisfy the same conditions of gradientas listed out above. t should be certified that the length & the gradient of the

outhaul track is within the limits, as per above, by thecompetent railway authority, under whose jurisdiction thetippler location lies. The same certificate should be submitted

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to this office, along with other documents, at the time ofapproval b y the .firml user.

5 1 Utilization stagea. The inspection, adjustment, maintenance and cleaning of movingcomponents 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 themshall be kept clear of obstacles.

d. All restarting operations on tipplers which have been in operativebecause of an emergency of accidental stoppage shall be preceded byan inspection aiming at:i) Determining the cause of the emergency or accidental stoppageii) Repairing the faulti:nstaJled at the tippler.

6 . Positioriing system for wagonWagon tipplers shall be provided with side arm charger for positioning ofwagons on the tipplers, such that

a. Side arm charger should be of sufficient capacity, depending onwhether complete train or some wagons are to be moved / positioned.There should be some positive system for centering of wagon onthe tippler table.

b. Drive unit for the side arm charger should be of positive type e.g. rackpinion, so that sudden jerks/slippages are avoided. Suitable

technology should be used, so that the wagon can be moved at slowspeeds 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 thefinal positioning

7 Wagon Train holding devices7.1 Wheel grippers

a. These are mandatory should be located on the tippler table, toprevent inadvertent motion of the wagons during tippling operation.

b. These should be so designed that balanced pressure is applied on bothsides of the wheel rim. t should have a floating arrangement so as to

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ensure that force on each gripper is same and should have some lateral~ ~ . . OF lo. io_k.n._ ,, r.. '. ' ' .1 r>. -- '- '- '- '.:t : .. .: .L>L- '-- '- ' '- __ . . , . . . 4 , _ ~ _ ... . p _ ~ ; . r . . _ , ~ __ :.:,:..-____ - . , . , ~ l - . - . . . . . ~ 1- - C l ~ l : v a - t ~ :';:)U H-len 11. vall --tal\..y- -It;-W PV; l - t lVl l In-- \,.-ct(St; 0 1 -V-ctll -lUUI1--111- W l l t ; : ~ . a :gauge. Wheel grippers should be free from serrations or any suchprovision on its holding face. Wheel grippers should be made of softmaterial.

7.2 Retractable wheel chocksa. These are mandatory & should be fitted at the in-haul & out -haul

tracks, to prevent accidental rolling of the wagons on the tippler table.b. They should be so designed that flange of the wheel is not contacted

while blocking tread of the wheel. Shape of the chock should take intoaccount the wheel incline, so that a line contact is made with thewheel.

8 Requirements for RDSO s approval for tippler installation

8.1 List of documents to be supplied to RDSOa. Name of the manufacturer.b. l'Ja:n1e-- of t11e user & site' of installation.

-c. Number f ~ - t - i p p l e r s - - t o be supplied / installed &-their m-odel no., if-any.d. . Nearest railhead.e. . Commodity to be handled.f. Site layout drawings (duly approved by the railways)g. General arrangement drawings of tippler, clearly showing side support

beam and top clamp with dimensions.h. Certificate, that the length & the gradient of the outhaul track is within

the limits [as per clause 5.2(f)], by the competent railway authority,under whose jurisdiction the tippler location lies. The same certificateshould be submitted to this office, along with the other documents.

1. The maximum dimensions of the wagons that can be handled on thetippler should also be indicated.

J. The clamping forces per pad achieved and the clamping angle fordifferent types of wagons. Calculations of the clamping force shall befurnished separately for the all the type of open wagons, which will betippled. (User shall have to consult the concerned zonal railway for thisconfirmation and submit a copy of the same to RDSO.)

k. Suitability of tippler for accepting locomotives weighing up to140t, at a speed of 8 kmph

1 Capacity of the tipplers.i. Maximum height of the wagon that can be handled.

ii. Number of tips per hour.m. Sketch showing location of clamps with respect to centre-line of the

tippler.n. Details of side arm charger to be used for placement of wagons on the

tippler.o. Complete maintenance instructions manual should be supplied along

with trouble shooting, preventive maintenance and periodicalinspection for different components of the tippler for its properfunctioning.

p. Force, pressure and moment calculations at 90 degree and 150 degreeof rotation for the wagons to be tipped, as mentioned above.

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q. Pressure calculations on top coping and side stiffener at various angles: : : - : { ) - f : ~ - , - r - j * a t - i { ) j j - a 3 ~ - , g i - v ; ; 1 1 : ~ ( f b o v e - . l\/ioment o n sid:e stiffrrer and w h e - e t - - : f l a n g - e : ~

with respect to centreline of bogie pivots.r. Checklist of items as shown in a indicative sketch No. G-33-2000 andtheir details type, namely

Side arm Charger11. Top clamps, hydraulically operated

111. Movable side support beam, hydraulically operatediv. Wagon holding device.s. A demand draft for consultancy charges, as prevalent, drawn in favour

of Executive Director (Finance), RDSO, Lucknow.8.2 List of conditions for tipplers

a. Minimum 50 mm thick rubber lining on top clamp pads shall beprovided. The shore hardness of the rubber pads shall be at least 70A.

b. Max. Angle of rotation should not exceed 160 degree for sidedischarge tippler.c. The tippler shall have the capacity to tip at least 25 wagons perhour i.e. 25 tips per hour, with suitable provisions so that theV'lagon is not damaged in the t i p p ~ i i g p r ~ _ ~ e s s & If tht:. _ l i e n t _ ~ e s i ~ ~ _ s _

l e s s e f - ~ ~ - i i - u n i b e r s o tips,---concui rence--uf the c orrcerned -railway shailbe,obtaiued,

d. Theforces exerted by the top clamps of the tipplers on wagon copingsshall not exceed 1.5t per clamp pad. This shall be ensured byproviding some positive arrangement, other than provision ofrubber pads, for absorbing the clamping forces (permitting releaseof bogie springs). The rubber pads on the clamps are to be providedto take care of constructional undulations of wagon copings.e. The length the gradient of the outhaul track are within the limits [asper clause 5.2(f).

f The location of the top clamp pads on the tippler should be as indicatedbelow:j , r - , ~ -,I I / , ' ; i,

f

g. The tipplers shall be capable of handling wagons with the followingoverall measurements without heavily impacting the wagons during thecourse of tippling.

1. Width11. Height*

111. Length over #coupler faces

: 3130 mm to 3660 mm: 3160mm to 4000 mm: min. 10963 mm ( or in multiples thereof forsimultaneous tipping of two or more wagons)

Note: * This range is true for coal wagons. However, the heightrequirement for iron ore wagons is lesser, range being2393mm to 2650mm.

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' ' For tipping of older BOXC wagons, the minimum rail tableiellg-th : vilI--: be i 3 : ~ 7 _ 2 9 r nh. 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 willincrease proportionately.

L N o t i p p L ~ r f h a n c i l i n g e q u i p m e n t c o m p o n e n t should pr.otrude more than100 mm from the rail level within the rails.J. The tippler shall have such parking/arrangement as would facilitateplacement 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.1. 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 wagonsand not meeting any of the above conditions and requiringmaintenancem. Sr DME of the concerned Railway Division or his representative mayinspect the Tippler and its operation, whenever such a need is felt, ormay depute Railway staff permanently for inspection of wagons aftereach tipping. The entire cost of inspection and attention to the wagonsshall be borne by the owner of the tippler.

11. It shall entirely be the responsibility of tb.e Ovvnei for ensuring_ that podamage \ \lh:atsoe\;er-- is caused- to the v/agons during handling ori the. tippler. The owner shall guarantee to pay to the Railway therectification charges in case of any damage to the wagons.

o. The approval for operation of tippler is subject to withdrawal at anytime in event of owner's failure to ensure handling of wagons withoutdamage.p. Owner/User or his representative shall submit a certificate to Sr DMEof the concerned Rly/Division in the prescribed format that the tippleris in good working condition, once in every six months.

9.0 heck sheet for joint inspection

SN1

2

3

Check sheet for the six monthly JOInt inspection of the tipplers toconducted by DME/Sr.DME (C W) of the concerned division or hisauthorised representative and representative of the siding owner, as perRailway Board letter no.98/M(N)/951112 dated 27.11.02, is as follows:

Item heck RemarkEnd frame (i) Steel work to be examined forplatform side damage or defectsbeam (ii) Check record the gap between

the side beam and the wagon sidestanchion, during tipping operation.Drive gear (i) Check proper matching of rack and

(ii) pinion tooth tooth wearCheck whether coupling gives jerkduring rotation. The tipplingoperation should be smoothwithout any jerks

Top hydraulic (i) Check the level of clamp pad.Page 11 of 13

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I

56

7

8

clampI

Whether sitting properly or not.. c c 1 i j ) ~ J B h e c k the conditIon & thickness of

(iii)

(v)

(vi)

I . .,I-- '\, 11 t au , , , , \ ;-. -v agon tippl r

Limit switches (i)In haul & out (i)haul stoplinkage (ii)

Side arm (i)charger*(ii)(iii)(iv)(v)

Damages to (i)wagons

clamp pad (thickness should not beless than 50 mm)Check the smoothness of clampmovementCheck for provision of indicatorson the tippler table for all types ofwagon stock, which are likely to betippled on the tippler. This is toensure that wagons are placed onthe tippler table in such a mannerthat the top clamping pads positionis near the side stanchions.Force exerted by the top clampsshould not exceed 1.5t per clamppad. Check & record the value.Check for provision of a wagonbogie spring relief mechanism inthe top clamp locks for permitting_ release of bogie springs.I 1 l C : ; UiC ICV I ail 11 111 1

~ a ; l Tk , 1 ,'1 ') ~ + + ~ a ~ l ( ~ . ~ t ; ~ ~ n ~- ---1- _ f1 -.111"",, I v L-.1 Vi U vi V i i ( . lpj iYl .tableand that of approach railsshould be the same so that thewagons do not experience any jerkduring in-haul and out-haulCheck for proper functionCheck satisfactory working of stopmovementCheck the gradient on the outhaulsideCheck damage / defects of steelworkCheck proper matching of drivepinion & rack & tooth wearCheck the smooth movement andfinal position of arm hoistCheck the proper tightening offastener & condition of trackCheck for proper functioning oflimit switches & proximityswitchesDamages during tippling & posttippling damages: Dents/nick on the sidestanchions, top copings,wagon body, etc Displacement of bogiepivot or suspension springs Damages to air brake pipes Axle box adopter shiftingPage 12 of 13

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*Note: 1) There should not be any loose shunting o the wagons. In-haul andout-haul arrangements consisting o side arm charger should be used.. - f o r . , k ~ Q e m e n k a n d r e m \ . v a l o : f w a g o n o n 4 i p p l . e l A a h l e , T h e p r a G t i c e oshunting empty wagon after tippling by rake o loaded wagons, is notacceptable as it results into large scale damages to CBC and bogies

Representative o theSiding owner

Page 3 o 3

Sr DME (C W) I MEorAuthorised representative

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Format o approval certificate~ F a x : 91-0522-2452494\ lR ' ~ c > i l i l l C f ) 'Telegram: RAILMANAKLucknowec1li{ll l/Tele: 2451200 (PBX)

2450567 (DID)No.

l-TR\ f tcf~ ' i : : l R ~

- 226011Government of India - Ministry of RailwaysResearch Designs & Standards Organisation

Lucknow - 226 11Dated:

PPROV L FOR TIPPLER INST LL TIONertIficate No. and Date

i: ManufacturerContractor .~ 4 UsedConsignee ..

5 Site6 Nearest Railhead7 Tippler Model no8 Drg. reference9 , Type of Tippler10 Capacity (Wt & height ofwagon)

Max rotation angle12 Tipping Cycle time13 Area of contact(top clamp & sidesupport)14 RDSO no allotted15 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. 25tips per hour.

(DSW/WD)For Director General (Wagon)Copy to.

1 GM/Mech, Railway.2. User/Owner3. Sr. DME, Division, Railway.4. Tippler supplying firm.

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List of conditions for tipplersa )'yfiJl,imum.50 mrn thickrubher iningon.top.c amp pads::;ha Lbe provided.

The shore hardness of the rubber pads shall be at least 70A.b. Max. Angle of rotation should not exceed 160 degree for side dischargetippler.c. The tippler shall have the capacity to tip at least 25 wagons per hour

i.e. 25 tips per hour, with suitable provisions so that the wagon is notdamaged in the tippling process. ~ = ~ = ~ = ; ; : ; ; . ; : : ; : : : : : . . . : : . = ~ = = = . : : : . . . : : : : . : :til, s, concurrence ofthe concerned railway shaH be obtained.

d. The forces exerted by the top clamps of the tipplers on wagon copingsshall not exceed 1.5t per clamp pad. This shall be ensured by providingsome positive arrangement, other than provision of rubber pads, forabsorbing the clamping forces (permitting release of bogie springs).The rubber pads on the clamps are to be provided to take care ofconstructional undulations of wagon copings.e. The length the gradient of the outhaul track are within the limits [as perclause 5.2(t).

f I h e location of he top ciamp pads on the tipp ershou dbe asindicatedbelow:

g. The tipplers shall be capable of handling wagons with the followingoverall measurements without heavily impacting the wagons during thecourse of tippling.

I. Width : 313 t 366II. Height*

III. Length over #coupler faces

: 3160mm to 4000 mm: min. 10963 mm (or in multiples thereof for

simultaneous tipping of two or more wagons)

Note: '*' - This range is true for coal wagons. However, the heightrequirement for iron ore wagons is lesser, range being 2393mmto 2650mm.' ' - For tipping of older BOXe wagons, the minimum rail tablelength 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 willincrease proportionately.

I. No tippler/handling equipment component should protrude more than 100mm from the rail level within the rails.J. The tippler shall have such parking/arrangement as would facilitateplacement 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.

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Annexure;;::lI 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 andnot meeting any of the above conditions and requiring maintenance

m . r D M E o L t h ~ . , , ; , ) n c e I f 1 ~ R ihw8cY Diyj.si.QcI1.or lisrepres.entative mayinspect the Tippler and its operation, whenever such a need is felt, or maydepute Railway staff permanently for inspection of wagons after eachtipping. The entire cost of inspection and attention to the wagons shall beborne by the owner of the tippler.

n. t shall entirely be the responsibility of the owner for ensuring that nodamage whatsoever is caused to the wagons during handling on thetippler. The owner shall guarantee to pay to the Railway the rectificationcharges in case of any damage to the wagons.

o. The approval for operation of tippler is subject to withdrawal at any timein event of owner s failure to ensure handling of wagons without damage.

p. Owner/User or his representative shall submit a certificate to Sr DME ofthe concerned Rly/Division in the prescribed format that the tippler is ingood working condition, once in every six months

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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - ~ r

M,AX. MOVING DIMENSION r'-';:- :T

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A N N E X U R E ' I ~ 'CONCEPTUAL SKETCH OF 25 t XLE LO D OF CO L WAGON{EOR DFC

WIDE BODY WITH HEAP LOADING)

l II .

464.5 1630

S.No.1

234567

9784 LENGTH INSIDE-

6524 BOGIE CENTRES9784 OVER HEADSTOCKS

10713 LENGTH OVER COUPLER FACES N.T.)WAGON DATA DFC WAGON BOXNHL

ESTIMATED PAY LOAD WITH HEAP=5.2m3) 82 t. 71 t.DENSITY OF COAL = 1.06 tlmGROSS 100 t. 91.6 t.AXLE LOAD 25 t. 22.9 t.TRACK LOADING DENSITY GROSS) 9 33 tim 8 35 timNo.OF WAGONSjTRAIN IN 620m. LOOP LENGTH) 58 58PAY LOAD PER TRAIN 4756 t. 4118 t.PAY TO TARE RATIO 4.55 3.45

BOXN2577t.

100 t.25 t.

9 33 tim58

4466 t.3.35

t I t I O;fOR W ~ r ; r E R N CORRIDOR OFCVIlE iiiy.Bo:-iimER iiil iTDls/CE-ll/1S/2Ilo\lm 17.10.07

' - ; - .

~1630

NOJE:-

RL

464.5

waVi;:;

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r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - -

l ' i l 1 , , ~ r P f l . E O ~ ,., - 1..,.-.- - '--M : : ~ ~ ~ : = ~ : . ~ : _ : : : = : : ; ;

u

v .I", ~ ~ S J . / . . A - - . , - - ~ / ' - W ~ w L - t

._3f3Y f Ef:0f: 3flL"

\ - - ~ . - t ~ Z 1 . 1 j Q ' i i l l J r y 0 3 2 E i 1 } H ~ ; ( } . j g ; f < . 2 f j f i J f : J & . ... _ . __ .. _ . ~ ' _ ~

S,NO, DESCRIPTION MEASURE1. UNDERFRAME (iNCLUDING WELDING de RI ETING ALLOWANCES) 2.5ot2 flOOR PlATE (INCLUDING WELDING de RI ET1NG ALLOWANCES) 0.9513. BODY STRUCTURE COMPi.TE (INCLUDING WE1.DING de RI ET1NG ALLOWANC ) 4.1ot4. wr OF AIR BRAKE FITTINGS.PIPING de BRAKE GEAR ON UFRAME 0.7ot5. C.S.C. COMPi.TE INCLUDING UNCOUPUNG GEAR 1.32t.6. BOGIE COWlfTE EXCEPT SPRINGS, WHms a AXLES NtJ CTRB(CASHU -22HS OOQE)7. FOUR PAIRS OF WHEES AXLES8. EIGHT CARTRIDGE TAPER ROLLER BEARINGS 10.84l9. SOLSTER AND SNUSBER SPRINGS10. BOGIE BRAKE GEAR COMPi.TE11 TWO TOP CENTRE PIVOTS12 ESTIMATED TARE 20.41t13 CARRYNG CAPACITY 60.87114 GROSS LOAD 81.28115 AXlE LOAD 20.32116 RATIO PAY TO TARE 2.9817 TRACK LODING DENSITY (GROSS) 7.59t/M18 NO. OF WAGONS IN 820M 5819 PAY LOAD PER TRAIN 3533120 GROSS LOAD PER TRAIN 4714\21 flOOR AREA 29 57lt22 VOLUMETRIC CAPECITY (FOR I.EVEI. LOADING) 58.84CuM23 C.G. FROM R.L (EMPlI) 1021mm24 C.G. FROM R.L (LOADED) 1913mm

D(f)i[i[)(f)

rv I f)(f)(f)@(f)i[)

S.NO.1.23.

WAGON DATA UGHl mm S.NO. BOGIE DATA CASNUB 22HS (TARE)HEIGHT OF CENTRE BUFFER C9UPlfR FRIDISTANCE SETWEEN WHEE fLANGES de A

1. H.T. OF SOTTOM BOGIE FRAME FROM R.L AT CENTRE2 OISTANCE FROM R.L TO TOP OF TOP PIVOTFROII RL. 11105 I.COR 240.5

SIDE BEARER CUEARANCE (NOMINAI)- NIL 3. DISTANCE FROM R.L TO TOP OF SIDE BEARER4 HEIGHT OF SPRINGS5 WHEEL DIA. ON TREAD6 WHEEL DIA. ON TREAD CONDEMNING SIZE7 DI.... OF WHEEL SHEAT8 JOURNAL CENTRE

, 9 J()lJRN L SIZE

NOTE:-1lIIMIX* IS EX C Y SIIUR'R)1KV1H Dflllltf;wO. 'IIH8OM-5/2lI ALT. THE INfBtIOIOtT FOR M HKG Bmt aHXlNED Br lHE R A U ~ 8CWI01ET1fR 1(( O/Cf1XJr.JV11Wm 17.1.1

mm-',-I 165.,- 932t-m- 254twoo I 906.,- ~ 226044X27S

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; ~ ' - - - ' - ' ~ - ' - ' .. . ; : - . ~ .

CONCEPTUAL SKETCH OF 32.5 t. XLE LO DOF IRON ORE WAGON FOR OFC)

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Mil) MOVING DIMENSION r ~ : : ' : T : ' : : - : : - - - 'l DIAGRAM NO. 10-2004 ______ . I/ .l...

~ w J" .- J, ,., ..I" - ~ T = ,J. .- ,L ~ 3 , , d r ~ ~ - : ~ ~ , , ~ , : I ~I

i II IIL......J IJ'1 1" 1 , '- I V . / =, ~ ( --, " j ' ,ii- ~ l i ~ ~:g j i ~ ( ] ) --1000 WHEEL DIA. ON TREAD i 2 ' ? 2 " ' . 9 . I W . t t > : l . " " L E ~ L t l l 0 J 2 A D ~ ) /r-j- fL .= _L

2000 WHoEL BASE 2000 WIiEEI:. BASE1672 6690 80GIE CENTRES ..HIT?: I

464.5 I0034 lENGTH OVER HEAD STOCK10963 LENGTH OVER COUPlER FACES

S.NO. OESCRIPTION NEASURES1. UNOERfRAlIE 2.701.2 FLOOR PlATE 0.981.3. BODY STRUCTURE COMPLETE 4.101.4. BRAKE GEAR ON UNDERFRAME . < AIR BRAKE FITTINGS 0.701.5. C.B.C. COMPLETE INCLUDING UNCOUPUNG GEAR 1.321.6. imi'\ a AXLES7. FOUR PAIRS OF WHEELS . < AXLES8. EIGHT CARTRIDGE TAPER ROLLER BEARINGS 10.81.9. BOLSTER AND SNUBBER SPRINGSID. TWO TOP CENTRE PIVOTS11 BOGIE BRAKE GEAR COMPLETE12 ESTIMATED TARE 20.61.3 PAY LOAD 71.01.

14 GROSS 91.61.15 AXl LOAD 22.91.16 RAno (PAY LOAD TO TARE) 3.4517 TRACK LOADING DENSITY (GROSS) 8.lSl/m.18 NO. OF WAGONS IN 636 m. 5819 PAY LOAD PER TRAIN 58 WAGONS) 41181.20 GROSS LOAD PER TRAIN 53131.21 e.G. FRON R.LlENPTYl 1062mm22 C.G.FROM R.L LOADED) 2842mm23 FLOOR AREA 30.32m'24 VOWNETRIC CAPACITY 61.05"" (])

464.5

NOTE:-THE WAGON IS E TTED WlTH:-1. SINGLE GRADUATED RElEASE AIR 8RAKE SYSTEM2. HIGH TENSILE NON TRANSITION TYPE CENTRE 8UFFER COUPlER.)(]) 3. CAST STEEL CASNU8 22NL8 BOGIESTO STR No.WD-21-CASNUB 22NL8-BOGIE-93

n

Ii(])

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A N N E ~ U R E - J,._._._._._._._._._. ._./ \

\ONCEPTUAL SKETCH OF 32.5 t. AXLE LOAD OF COAL WA,.GpN FOR DFC

I,

464.5

S.No.1

234567

(HEAP LOADING)

9784 LENGTH INSIDE

1630 6524 BOGIE CENTRES9784 OVER HEADSTOCKS10713 LENGTH OVER COUPLER FACES N.T.

WAGON DATA DFC WAGON BOXNHL BOXN25.ESTIMATED PAY LOAD WITH HEAP=5.2m3) 108 t. 71 t. 77tDENSITY OF COAL = 1.06 t/m3GROSS 130 t. 91.6 t. 100 t.AXLE LOAD 32.5 t. 22.9 t. 25 tTRACK LOADING DENSITY(GROSS) 12.13 tim 8.35 tim 9.33 timNo.OF WAGONSjTRAIN(IN 620m. LOOP LENGTH) 58 58 58PAY LOAD PER TRAIN 6264 t. 4118 t. 4466 t.PAY TO TARE RATIO 4.9 3.45 3.35

. ~

w0Vi

IIWl II i II II I I I ~ I J I0N

:r:oc00....J- -0

R.U

-

NOTE:=I BOGIE WILL BE AS PER R.D.S.O. SPECIFICATION NO. WD-45-MISC. 2006 (REV. 1)2. COUPL.ER/DRAFT GEAR WILL BE AS PER R.D.S.O. SPECIFICATION Npi. WD-65-BD-06

BODY DESIGN WILL BE BASED ON TT I PROJECT FOR 32.5t. AXLE LOAD.

_ ...__--- - - - - - - - - - - - - - - -_ ._-- - - - .

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'= --

- - - - - - - - - - - - - - - - - - - - ~ r _MAX. MOVING DIMENSION r ' - ' - ' ~ : ' : - ' - ' ' ' ' 'D ~ I A G R A M NO. 1D 2004 J/ i...

832__ ~" "

- 2957 wmH INSIOn -

mlL= lil35 VrOTH ~

'\...1000 WHEEL 01A. ON TREAO CASNUB 25HS BOGI R.L.

6U I 163 6524 BOGIE CENTRES I_. ... . ~ )

II :l ll I I

, . . HEAlJS[()CKI ~ ~ u . - ~ ' w ' ' n ' - = - ' = = = . ___________ _ ..._ ...1 713 LENGTH COUPUNG FACES

NOTE:1. BODY STRUCTURE AND UNDERFRAME OF MATERIAL IRSM44

EXCLUDING CENTRE SILl.2. CENTRE SILL OF MATERIAL IS:8500 Fe 540Cu3 4 DOORS PROVIDED

_ _., _ 'PROTOTYPEPRELIMINARY SKETCH G U I ~ " t . " ' . " o i i ; ' ~ )SUPfRSEDED BY BOGIE OPEN WAGON TYPE' BOXN25,UI 'tJ(::;t.OES lOA'

I

I11_1-_ -, I' ' - 1 ' DIAGRAM JL::19::. c . G = . = L = O A = D E = D ) = = = = = = = = = = = = = = = = = i = 2 = 1 0 = 2 m = m = ~ r l ~ ~ ~ -, N WD 07005 8 02 I~ ~ :m. I_________________

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CONCEPTUAL SKETCH OF 25 t. XLE LO DOF IRON ORE WAGON(FOR DFC)

S,No. I VJJ\GON DATA L i ~ - C flAGON I BOY 8 )Y25E SnMATED PAY LOAD 84 t. I }08i. L 19 t.

2 IGROSS IOD t.,.)

4-sG7

AXLE LOAD 25 LTHACK LOADiNG DENSiTY(GROSS) I 9,33No.OF 620m, LOOP 58PAY LOAD PEP TRAiN 14(372

PAY TO TARE RAilO 5 25

91 6 t 100 t22..9 t. I 25 t

' y r '1R 1< 131f ,D '., ....52 58

j63ELl t I 4532 t3 )9 75

__ _ - - - - - - - ' ~ f ~ ~ ~lIt.hI.D. I I o i ~ W E S T E R N CORRIDOR DFC

(\ IlE RlXo lID. Li.r1ER 110 2006/CE-lI/ S12Do\1ED 1 7 . 1 0 . 0 7 ) ~

WoWoDo FOR EASTERN CORRIDOR OF C(\ IlE RlY. lID. LEI1ER NO. 2 0 0 6 ~ - 6 / 3oom 23.oe.(8) 3660

. ( ,

l- - - - - - - - - - - - - - - 1 ~ C

L 80GiE WiLL BE PER H.D,S,Q, SPECIHCATiON N(\, W D - 4 5 ~ M l S C - 2 0 0 62. GEAR WILL 8E AS PER R.f).SD. SPECIF CA lON NO.3. BODY DES1GN 8E BASED ON TTCI PP(';.J[CT FOR AXLE

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r .- . -

SNOI.,J." 1,. i .

I'g10."ZIl"""7""'""22JI

L.ENCni NSDE

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