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Design Approach for Wagon Tippler for

CHP of a power plant

Karri Krishna Teja
Anku Kumar Pandey
Manglam Sharda


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


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.



End Rings



Spill Truss


Wheel Chocks

Drive Units

Platen Assembly

It is a fabricated steel
structure frame
consisting of an inner
platen and an outer
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
8 load cells of adequate
capacity are provided in
between the inner and the
outer platen.

End Rings

They are
fabricated steel
frames of semicircular shape.

Two end rings are

connected by the
spill girder, top
clamp beam and
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
hydraulicallyoperated steel
clamping arms moving
through the hydraulic

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

Spill Truss

The side supporting

beam, also known as
the spill truss or
spill girder, is of
welded steel

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

Wheel gripper and wheel


Two sets of hydraulically operated wheel

grippers on the rails arefitted 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

Drive Unit

The drive unit is either

electromechanical or

A electromechanical drive
consists of an electric
motor coupled with a
speed reductiongear
boxand 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

The brake is built into the

hydraulic motor, and an
external hydraulic
thrusters brake is

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).


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.


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 topclamping 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


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

Feedersshall be provided from 11 kV Station

Switchboards for CoalHandling 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 415VSwitchgears

Power and control cables including cables from 11 KV

station switchboardsand 415V unit PMCC.

Cable layingalong withcabling accessories, cable trays

and termination/jointing kitsof 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.


The full rake of 58 wagons is brought in by locomotive and

stopped with the first wagon within range of the Side Arm

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

The charger then propels the first wagon on to the tippler table
centrally and then automatically decouples and clears off the

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

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.

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


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

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.


Thank You