I -

S.No.
1.
INDIAN RAIL WAYS
G-33 (Rev. 1)
. TECHNICA:LPAMPHLET
. FOR
REQUIREMENTS OF TIPPLER INSTALLATION
FOR APPROVAL BY RDSO
MonthlY ear of Revision /
Page No. Reason for Arne
issue Amendment
May, 2010 Revision 1 - First issue
ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
LUCKNOW-226 011
May, 2010
Page 1 of 13
-- -Cl-a-llse No; Description Page No
1. Scope
)
3
2. Types of wagons 3
3. Design parameters 3
4. General requirements 4
5. Safety requirements 6
6. Positioning system for wagon 8
7. Train & wagon holding devices 8
8.
Requirements for RDSO's approval for tippler
8
installation
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-
ANNEXURES
Annexure 1 Format of approval certificate
Annexure 2 Schematic diagram for tippler (G-33-2008)
Annexure 3 Schematic diagram for BOY wagon
Annexure 4
Schematic diagram for BOXC wagon
Annexure 5
Schematic diagram for BOXN wagon
Annexure 6
Schematic diagram for BOXNL W wagon
Annexure 7 Schematic diagram for BOXNHL wagon
Annexure 8 Schematic diagram for BOY25 wagon
')

Annexure 9 Schematic diagram for BOXN25 wagon
Annexure 10 Conceptual diagram for 25t axle load Iron ore
wagon for DFC
Annexure 11 Conceptual diagram for 25t axle load Coal
wagon for DFC
Annexure 12 Conceptual diagram for 32.5t axle load Iron ore
wagon for DFC
Annexure 13 Conceptual diagram for 32.5t axle load Coal
wagon for D FC
Annexure 14 Proposed "Maximum Moving Dimension" of
Diesel locomotive for DFC
Page 2 of 13
__ -
1.1 This document provides guidelines for selection of tipplers for BG open
Railway wagons of
a. _ .Current design
b. Wagon designs, of25t axle load, for existing routes
c. Proposed wagon designs, of 32.St & 2St axle load, for DFC &
Feeder routes
1.2 This document also gives the basic requirements to be met for obtaining
RDSO's approval for installation.
2.0 Types of wagons
2.1 The existing population of open wagons in the Indian railways consist of
BOY, BOX, BOXN and BOXNHA wagons, of which BOXN wagons form
the bulk.
2.2 However, new types of open wagons like BOY25, BOXNL W, and BOXNHL
& BOXN25 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
2.5
2.6
2.7
3.0
3.1
3.2
3.3
Oiagrams- arid other details of these (both 2St &- 32.51 axle
load) .o.re covered in the annexure.
These wagons are suitable for transporting coal, ore, lime stone etc., hence
while planning for mechanised unloading, the parameters of these types of
wagons should be taken into consideration.
For handling of any other special type of wagons, the purchaser should take
into consideration the size & gross weight of the wagons or intimate the same
to RDSO.
Introduction of new type of freight wagons is a continuous process. Hence,
limiting boundary dimensions should be taken into consideration while
planning a tippler. The limiting boundary dimensions are indicated in the item
8.2 (g).
Design parameters
These guidelines shall be applicable for both Side discharge and Rotary type
wagon Tipplers.
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.
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
.... - 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 The design and construction of components of tipplers and auxiliary handling
equipment 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
___ -on anti Tile. gear IrOTI1 :.,get-ong. UlSlQ.9geq ___ wltnOllt
--c-a-usi-ng- allY deformation -to the vvagort -structure.
4.3 Adequate compensating measures shall be taken in top clamps and side
support beam to compensate for manufacturing imperfections, within the
permissible limits, in the top copings and side stanchions of the wagon, so that
clamping pressure on the contacting area on the side and top of the wagon is
uniformly 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 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
weights should be used with the side support beam) Facility of
-Jl1o\tem-ent--sh-ould :e-xist,- that- it
to move & touch the wagon without applying any pressure on the
wagon side-wall. At this position it should get locked and the tilting
operation can begin. At the end of the tippling cycle, the side support
should return to its home position, so. that thenext\vagon can be
,-:.-. ',__ . ___ .:_:-'- ___':-0.:: _ _ _ ' - '-' "'" _ ' , 4..,...
positioned on the tippler
Movement of the side support should be controlled & the speed should
be crawling just before making contact with the wagon sidewall.
e) Pressure gauge/s should be mounted, at easily accessible location, for
reading the hydraulic pressure of the side support hydraulic
arrangement.
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 be
us"ed with the hydraulic clamps
b. Top clamps should engage when the wagon tilts by more than 15
locks shcyuld include a viaguil relief
-for' perm.itting '--release -of boogie -'Springs. Top---
sho.uld.exert the bare minimum pressure on the top coping of the
wagon, so as to just keep it in position. The pressure exerted by the top
clamps at the tilt angle of 160 degrees should be just enough to bear
the weight of the empty wagon, which should be achieved through the
bogie spring relief mechanism, incorporated in the tipplers design.
c. Pressure gauge/s should be mounted, at easily accessible location, for
reading the hydraulic pressure of the top clamping hydraulic
arrangement
d. The top clamping arrangement shall be of longitudinal/ transverse type
and provided with self-aligning feature, whereby the load is borne on
the top at each of the wagons.
1. The transverse type top clamping shall have 6 nos transverse
top clamping beams i.e. the bearing face of the beam shall
contact the top of the wagon at 12 locations (six on each side).
Each of the six top hydraulic clamps shall be individually
articulated, to ensure firm clamping of wagon at every gripping
point. The location of the clamping pads shall be as under:
11. The longitudinal type top clamping shall be such that the
clamping pads cover the full length of wagon top coping.
Each top hydraulic clamp shall be individually articulated, to
ensure firm clamping of wagon at every gripping point.
Page 5 of 13
f. The beam shall be so arranged that the discharge of the contents of the
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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 Devices shall be built-in for spotting of wagons on the tippler table, so as to
discharge the material in hoppers.
4.7 Size and gauge of rails on the wagon tippler platform shall be as per railway
specifications taking into considerations the maximum duty condition that the
wagon 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 Ofl
the tippler to weigh the gross and tare \veight of wagons which are being
haridled. There may also be a provision to record gross load, tare load, date
and number of wagons.
4.9 Marking - All tipplers shall be marked permanently and legibly at a clearly
visible place with the name of the manufacturer, serial number, the year of
manufacture, type and capacity of tippler and RDSO allotted Serial No.
5.0 Safety requirements - Notwithstanding anything contained in various
statutory regulations, safety requirements for tipplers, divided into the
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
J. Sharp edges and corners in all working spaces shall be avoided.
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IP
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l. All the frequently used lubrication points shall be accessible without it
being necessary to remove the guards.
m. It is recommended that equipment shall be so designed that
andcleaning is facilitated.
n. FulTyintegrated controls should be provided for wagon positioning
system, wagon holding devices and wagon tippler. The controls should
be interlocked so that there is no chance of accident due to error in
sequence of operation.
5.2 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
to this office, along with other documents, at the time of
approval b-y-the- .firml-user.-
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
i:nstaJled -at the tippler.
6 . Positioriing system for wagon
Wagon tipplers shall be provided with side arm charger for positioning of
wagons on the tipplers, such that
a. Side arm charger should be of sufficient capacity, depending on
whether complete train or some wagons are to be moved / positioned.
There should be some positive system for centering of wagon on
the tippler table.
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 Wagon & Train holding devices
7.1 Wheel grippers
a. These are mandatory & should be located on the tippler table, to
prevent inadvertent motion of the wagons during tippling operation.
b. These should be so designed that balanced pressure is applied on both
sides of the wheel rim. It should have a floating arrangement so as to
Page 8 of 13
ensure that force on each gripper is same and should have some lateral
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:';:)U H-len 11. vall --tal\..y- a '-It;-W PV;)l-tlVll In-- \,.-ct(St; 01 -V-ctll'-lUUI1--111-
gauge. Wheel grippers should be free from serrations or any such
provision on its holding face. Wheel grippers should be made of soft
material.
7.2 Retractable wheel chocks
a. 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 into
account the wheel incline, so that a line contact is made with the
wheel.
8 Requirements for RDSO's approval for tippler installation
8.1 List of documents to be supplied to RDSO
a. Name of the manufacturer.
b. l'Ja:n1e-- of t11e user & site' of installation.
-c. Number 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 certificate
should be submitted to this office, along with the other documents.
1. The maximum dimensions of the wagons that can be handled on the
tippler should also be indicated.
J. The clamping forces per pad achieved and the clamping angle for
different types of wagons. Calculations of the clamping force shall be
furnished separately for the all the type of open wagons, which will be
tippled. (User shall have to consult the concerned zonal railway for this
confirmation and submit a copy of the same to RDSO.)
k. Suitability of tippler for accepting locomotives weighing up to
140t, 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 periodical
inspection for different components of the tippler for its proper
functioning.
p. Force, pressure and moment calculations at 90 degree and 150 degree
of rotation for the wagons to be tipped, as mentioned above.
Page 9 of 13
q. Pressure calculations on top coping and side stiffener at various angles
-l\/ioment--o-n- sid:e---stiffrrer and
with respect to centreline of bogie pivots.
r. Checklist of items as shown in a indicative sketch No. G-33-2000 and
their details & type, namely
Side arm Charger
11. Top clamps, hydraulically operated
111. Movable side support beam, hydraulically operated
iv. 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 be
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
discharge tippler.
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
V'lagon is not damaged in the __ If tht:. _
-of- tips,---concui"rence--uf the-- c-orrcerned- -railway shail
be,obtaiued,
d. Theforces 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). The rubber pads on the clamps are to be provided
to take care of constructional undulations of wagon copings.
e. The length & the gradient of the outhaul track are within the limits [as
per clause 5.2(f).
f. The location of the top clamp pads on the tippler should be as indicated
below:
j , r
',I I "/,'; t i,
If
g. The tipplers shall be capable of handling wagons with the following
overall measurements without heavily impacting the wagons during the
course of tippling.
1. Width
11. Height*
111. Length over #
coupler faces
: 3130 mm to 3660 mm
: 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 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
iellg-th :"vilI--: be
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.
L should pr.otrude 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.
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 wagons
and not meeting any of the above conditions and requiring
maintenance
m. 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.
11. It shall entirely be the responsibility of tb.e Ovvnei for ensuring_ that po
damage \)\lh:atsoe\;er-- is caused- to the v/agons during handling ori the
. tippler. The owner shall guarantee to pay to the Railway the
rectification charges in case of any damage to the wagons.
o. The approval for operation of tippler is subject to withdrawal at any
time in 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
of the concerned Rly/Division in the prescribed format that the tippler
is in good working condition, once in every six months.
9.0 Check sheet for joint inspection
S
N
1
2
3
Check sheet for the six monthly JOInt inspection of the tipplers to
conducted by DME/Sr.DME (C&W) of the concerned division or his
authorised representative and representative of the siding owner, as per
Railway Board letter no.98/M(N)/951112 dated 27.11.02, is as follows:
Item Check Remark
End frame
(i)
Steel work to be examined for
platform side damage or defects
beam
(ii)
Check & record the gap between
the side beam and the wagon side
stanchion, during tipping operation.
Drive gear
(i)
Check proper matching of rack and
(ii)
pinion tooth & tooth wear
Check whether coupling gives jerk
during rotation. The tippling
operation should be smooth &
without any jerks
Top hydraulic
(i)
Check the level of clamp pad.
Page 11 of 13
I
5
6
7
8
clamp
I.
Whether sitting properly or not.
the conditIon & thickness of
(iii)
(v)
(vi)
I -. .,
I--"'\, 11 tau,,,,' \';
-., -v!agon tippler-
Limit switches
(i)
In haul & out
(i)
haul stop
linkage
(ii)
Side arm
(i)
charger*
(ii)
(iii)
(iv)
(v)
Damages to
(i)
wagons
clamp pad (thickness should not be
less than 50 mm)
Check the smoothness of clamp
movement
Check for provision of indicators
on the tippler table for all types of
wagon stock, which are likely to be
tippled on the tippler. This is to
ensure that wagons are placed on
the tippler table in such a manner
that the top clamping pads position
is near the side stanchions.
Force exerted by the top clamps
should not exceed 1.5t per clamp
pad. Check & record the value.
Check for provision of a wagon
bogie spring relief mechanism in
the top clamp locks for permitting
_ I release of bogie springs.
I UiC ICV I ail 11 111 1
Tk", 1",'1"')
- '---1- _ f1. -.111"",, Iv L-.1 Vi U 'vi Vii (.lpj!iYl.
tableand that of approach rails
should be the same so that the
wagons do not experience any jerk
during in-haul and out-haul
Check for proper function
Check satisfactory working of stop
movement
Check the gradient on the outhaul
side
Check damage / defects of steel
work
Check proper matching of drive
pinion & rack & tooth wear
Check the smooth movement and
final position of arm hoist
Check the proper tightening of
fastener & condition of track
Check for proper functioning of
limit switches & proximity
switches
Damages during tippling & post
tippling damages:

Dents/nick on the side
stanchions, top copings,
wagon body, etc

Displacement of bogie
pivot or suspension springs

Damages to air brake pipes

Axle box adopter shifting
Page 12 of 13
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
.. - 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
Sr DME (C&W) IDME
or
Authorised representative
Format of approval certificate
91-0522-2452494
\lR
Telegram: 'RAILMANAK'
Lucknow
ec1li{ll"l/Tele: 2451200 (PBX)
2450567 (DID)
No.
I
'l-TR\'f -tcf

- 226011
Government of India - Ministry of Railways
Research Designs & Standards Organisation
Lucknow - 226011
Dated:
APPROVAL FOR TIPPLER INSTALLATION
! I CertIficate No. and Date
i: I Manufacturer
I Contractor ...... .. . ..

UsedConsignee
..
5 Site
6 Nearest Railhead
7 Tippler Model no
8 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. GM/Mech, Railway.
2. User/Owner
3. Sr. DME, Division, Railway.
4. Tippler supplying firm.
List of conditions for tipplers
a, )'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 discharge
tippler.
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 not
damaged 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 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).
The rubber pads on the clamps are to be provided to take care of
constructional undulations of wagon copings.
e. The length & the gradient of the outhaul track are within the limits [as per
clause 5.2(t).
f.Ihe location of the top ciamp pads on the tipp!ershou!dbe asindicated
below:
g. The tipplers shall be capable of handling wagons with the following
overall measurements without heavily impacting the wagons during the
course of tippling.
I. Width : 3130 mm to 3660 mm
II. 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 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. 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
.. R&ihw8cY Diyj.si.QcI1.or!lisrepres.entative 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.
n. 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.
o. The approval for operation of tippler is subject to withdrawal at any time
in 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 of
the concerned Rly/Division in the prescribed format that the tippler is in
good working condition, once in every six months

M,AX. MOVING DIMENSION r'-';:-":T<-::"'--' ,.
DIAGRAM NO. 1D-2004 ______ . ..J/ '-'l..
. r'-'-- i _.-.,
I i I
I I I
I
FOR IRON ORE
;:1'1;;1"1'
I h
1]'
i
t;:
'"
'"
"

"-1000 WHEEL DIA. ON TREAD
2000 WH EL BASE
1630 6524 BOGIE CENTRES 1630
9784 LENGTH OVER HEADSTOCK
10713 LENGTH OVERCOUPUNG FACES
::===1 464.5
1
S.NO. DESCRIPTION MEASURES
1. ESTIMATED TARE 21.0t.
2 PAY LOAD 79.0t.
3. GROSS lOOt.
4.
AXLE LOAD 25t.
5. RATIO (PAY LOAD TO TARE) 3.75
6. TRACK LOADING DENSITY (GROSS)
9.33t./m.
7. NO. OF WAGONS IN 636 m. 58
NOTE:
MATERIAL USED IS:-
IRSM44- UNDERFRAME & BODY.
8. PAY LOAD PER TRAIN (58 WAGONS) 4582t.
9.
GROSS LOAD PER TRAIN 580ot.
10.
FLOOR AREA
28.44m2
11.
VOLUMETRIC CAPACITY 37.94m3
12. C.G. (TARE CONDITION) O.853m
13. C.G. (LOADED CONDITION) 1.663m

CONCEPTUAL SKETCH OF 25 t. AXLE LOAD OF COAL WAGON{EOR DFC)
(WIDE BODY WITH HEAP LOADING)
---l II!.



464.5 1630
S.No.
1
2
3
4
5
6
7
9784 LENGTH INSIDE --- -
6524 BOGIE CENTRES
9784 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 tlm3
GROSS 100 t. 91.6 t.
AXLE LOAD 25 t. 22.9 t.
TRACK LOADING DENSITY(GROSS) 9.33 tim 8.35 tim
No.OF WAGONSjTRAIN(IN 620m. LOOP LENGTH)
58 58
PAY LOAD PER TRAIN
4756 t. 4118 t.
PAY TO TARE RATIO 4.55 3.45
BOXN25
77t.
100 t.
25 t.
9.33 tim
58
4466 t.
3.35
--
t.I.t.I.O;fOR CORRIDOR OFC
(VIlE iiiy.Bo:-iimER iiil"iTDls/CE-ll/1S/2Ilo\lm 17.10.07)
'-;-.

1630
NOJE:-
RL
464.5

w
a
Vi
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I
.....
t<1
N

::c
g 1--:- 0>

o
r-
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1676 GAUGE
1. BOGIE WILL BE AS PER R.DS.O. SPECIFICATION NO. WD-45-MISC.-2006,
l
'j
I!
-:"i-'


ro



Q



2. COUPLER/DRAFT GEAR WILL BE AS PER R.D.S.O. SPECIFICATION, NO. WD-65-BDL .. 06
3. ,BODY DESIGN WILL BE BASED ON TTCI PROJECT FOR 25t. AXl.E LOAD.

,.,'-'1..,
.-.- -"'-
-"

u
:v- ,.

I", - "
._3f3Y...if!Ef:0f:'!3flL"
...- ...... ..---.....- ....
.... .... ... ...... ..... ,,_ .. ___ __ ... _ .. _____ ._ .....
S,NO, DESCRIPTION MEASURE
1. UNDERFRAME (iNCLUDING WELDING de RI'iETING ALLOWANCES) 2.5ot
2 flOOR PlATE (INCLUDING WELDING de RI\IET1NG ALLOWANCES) 0.951
3. BODY STRUCTURE COMPi.TE (INCLUDING WE1.DING de RI\IET1NG ALLOWANC ) 4.1ot
4. wr. OF AIR BRAKE FITTINGS.PIPING de BRAKE GEAR ON U'FRAME 0.7ot
5. 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 WHEElS & AXLES
8. EIGHT CARTRIDGE TAPER ROLLER BEARINGS
10.84l
9. SOLSTER AND SNUSBER SPRINGS
10. BOGIE BRAKE GEAR COMPi.TE
11 TWO TOP CENTRE PIVOTS
12 ESTIMATED TARE 20.41t
13 CARRYNG CAPACITY 60.871
14 GROSS LOAD 81.281
15 AXlE LOAD 20.321
16 RATIO PAY TO TARE 2.98
17 TRACK LODING DENSITY (GROSS) 7.59t/M
18 NO. OF WAGONS IN 820M 58
19 PAY LOAD PER TRAIN 35331
20 GROSS LOAD PER TRAIN 4714\
21 flOOR AREA 29.57lt
22 VOLUMETRIC CAPECITY (FOR I.EVEI. LOADING) 58.84CuM
23 C.G. FROM R.L (EMPl'I) 1021mm
24 C.G. FROM R.L (LOADED) 1913mm
D
(f)

i[


i[)
(f)

rv


I (f)
(f)
(f)@
(f)

i[)

S.NO.
1.
2
3.
WAGON DATA UGHl mm S.NO. BOGIE DATA CASNUB 22HS (TARE)
HEIGHT OF CENTRE BUFFER C9UPlfR FRI
DISTANCE SETWEEN WHEEl fLANGES de A
1. H.T. OF SOTTOM BOGIE FRAME FROM R.L AT CENTRE
2 OISTANCE FROM R.L TO TOP OF TOP PIVOT
FROII RL. 11105 I
.COR 240.5
SIDE BEARER CUEARANCE (NOMINAI)- NIL 3. DISTANCE FROM R.L TO TOP OF SIDE BEARER
4 HEIGHT OF SPRINGS
5 WHEEL DIA. ON TREAD
6 WHEEL DIA. ON TREAD CONDEMNING SIZE
7 DI.... OF WHEEL SHEAT
8 JOURNAL CENTRE
, 9 J()lJRN!L SIZE
NOTE:-
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 8CWI01ET1fR 1((I!IO/Cf1XJr.JV11Wm 17.1.1"
mm
-',-I-----
165
.,-
932
t-m-

'''-
254
twoo
!
..'-I-----
906
.,-

2260
44X27S
;"" ..
CONCEPTUAL SKETCH OF 32.5 t. AXLE LOAD
OF IRON ORE WAGON(FOR OFC)
'<
W.W.O. FOR EASTERN OFC \
"""""" ......" ........"""" .." ...............,,""""",, .
.. .. "";;;;;;;;;;;;;;;;;;;;;;;;;;;;:;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
1071.3
S,No. WAGON DATA DFC WAGON I 80'Y 80Y25
ESTiMATED PAY LOAD 108 L 70.89 79 t.
;; I GROSS 13D t. 91.6 L 100 L
:) I ;\XLE LOAD 325 L 22,9 L 25 t.
TRACK LOADlNG DfJ\SnY(GPCsS'j 112.13 7,678
5 No.OF 620m. LOOP 58 52
6 f PAY LOAD PER TRAJN 6264 t 3686.3 I 4582 t.
7
PAY TARE RAnG 4.9 3.39 3.'15
/ (\'IE RLY. Ill. lDlEII ........NO. ......... 2IXl8. .. '. OOED 23.06.CB) i. t> (\ .
...........................
CORRIDOR OFC
('/IDE RLY. In'lflTERi'r,1OO6/CE-11/lS/2OOED
1
2.
,
0.
""" ::t::.
0::
8
G::
g
0J
WiLL BE AS PER R.D.S.O. Ne}. W} .... 45 .... MiSC.
GEAR WiLL BE AS FER FtD.S.O.
BASED ON 1'T(;1 PROJECT FOR 525t. {\XLf LOAD ..
Mil)" MOVING DIMENSION
l DIAGRAM NO. 10-2004 ______ . .-I/-.l...
w' J" .- J, ,., ..I" ,J. .- ,L d J
I
1
iFF
II II
L......J

IJ'
11",')''1 , -'- IH 'V./ =,
"
( --,
"
j',
ii-! 0 0
:g
'-1000 WHEEL DIA. ON TREADi!
r-j-, 'fL'.=
_L
2000 WHoEL BASE 2000 WIilEEI:. BASE
1672 6690 80GIE CENTRES ..HIT . .?:..---I
464.5 I 0034 lENGTH OVER HEAD STOCK
10963 LENGTH OVER COUPlER FACES
S.NO. OESCRIPTION NEASURES
1. 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 AXLES
7. FOUR PAIRS OF WHEELS .!< AXLES
8. EIGHT CARTRIDGE TAPER ROLLER BEARINGS 10.81.
9. BOLSTER AND SNUBBER SPRINGS
I D. TWO TOP CENTRE PIVOTS
11 BOGIE BRAKE GEAR COMPLETE
12 ESTIMATED TARE 20.61.
!3 PAY LOAD 71.01.
14 GROSS 91.61.
15 AXl LOAD 22.91.
16 RAno (PAY LOAD TO TARE) 3.45
17 TRACK LOADING DENSITY (GROSS) 8.lSl/m.
18 NO. OF WAGONS IN 636 m. 58
19 PAY LOAD PER TRAIN (58 WAGONS) 41181.
20 GROSS LOAD PER TRAIN 53131.
21 e.G. FRON R.LlENPTYl
1062mm
22 C.G.FROM R.L(LOADED) 2842mm
23 FLOOR AREA 30.32m'
24 VOWNETRIC CAPACITY 61.05"" (])
464.5
NOTE:-
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
n
I
i

(])


,._._._._._._._._._. __ ._.,
/ \
I \
CONCEPTUAL SKETCH OF 32.5 t. AXLE LOAD OF COAL WA,.GpN(FOR DFC)



::::: !I,
464.5
S.No.
1
2
3
4
5
6
7
(HEAP LOADING)
9784 LENGTH INSIDE
1630 6524 BOGIE CENTRES
9784 OVER HEADSTOCKS
10713 LENGTH OVER COUPLER FACES N.T.
WAGON DATA DFC WAGON BOXNHL BOXN25
. ESTIMATED PAY LOAD (WITH HEAP=5.2m3)
108 t. 71 t. 77t.
DENSITY OF COAL = 1.06 t/m3
GROSS 130 t. 91.6 t. 100 t.
AXLE LOAD 32.5 t. 22.9 t. 25 t.
TRACK LOADING DENSITY(GROSS) 12.13 tim 8.35 tim 9.33 tim
No.OF WAGONSjTRAIN(IN 620m. LOOP LENGTH) 58 58 58
PAY LOAD PER TRAIN
6264 t. 4118 t. 4466 t.
PAY TO TARE RATIO
4.9 3.45 3.35

w
0
Vi

IIWl II i II II
0
r-
N

:r:
oc
0
0
....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 TTCI PROJECT FOR 32.5t. AXLE LOAD.
'-----------------------------------------------...._ ..._ ..._------------------_._-----'.
'"
='--

MAX. MOVING DIMENSION
NO. 1D-2004 ----J/----i...
832 __
" "
-
2957 wmH INSIOC
n-'
mlL=!lil35 VrlOTH
'\...1000 WHEEL 01A. ON TREAO CASNUB 25HS BOGI
R.L.
46U I 1630 6524 BOGIE CENTRES I_. __ ....
II :
l'll I
!
I

",.. 00 HEAlJS[()CK ________________ ___________ .._ ..._ ...
10713 LENGTH 00 COUPUNG FACES
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
_ ._., " _ . 'PROTOTYPE
PRELIMINARY SKETCH
SUPfRSEDED BY BOGIE OPEN WAGON" TYPE' BOXN25
,UI"'tJ(::;t.OES lOA'
I
I
'1
1
_1-_'-, I' '-""""1' DIAGRAM J
L::19::. ____ -, N WD-07005 8-02 I
_ ..:m. I
_________________
CONCEPTUAL SKETCH OF 25 t. AXLE LOAD
OF IRON ORE WAGON(FOR DFC)
S,No. I VJJ\GON DATA 'flAGON I BOY 8()Y25
E.SnMATED PAY LOAD
84 t. I }08i.) L 19 t.
2 I GROSS IOD t
.,
.)
4-
s
G
7
AXLE LOAD 25 L
THACK LOADiNG DENSiTY(GROSS) I 9,33
No.OF 620m, LOOP 58
PAY LOAD PEP TRAiN 14(372
PAY TO TARE RAilO 5.25
91.6 t 100 t
22..9 t. I 25 t
'yr'1R 1<.131
f,D! .; '., ....
52 58
j63ELl t I 4532 t
3 ..:)9 375
..__ ._-------------------
lIt.hI.D. CORRIDOR DFC
(\'IlE RlXo lID. Li.r1ER 110. 2006/CE-lI/!S12Do\1ED
WoWoDo FOR EASTERN CORRIDOR OF'C
(\'IlE Rl.Y. lID. LEI1ER NO.
oom 23.oe.(8) 3660
.(,'
l
'-'-'-'-'-'-'-'-'-'-'-' . '-'-'-'-
L 80GiE WiLL BE PER H.D,S,Q, SPECIHCATiON N(\,
2. GEAR WILL 8E AS PER R.f).SD. SPECIF!CA!lON NO.
3. BODY DES1GN 8E BASED ON TTCI PP(';.J[CT FOR AXLE
r------------------------------------..- ..... - ... -----------------
S.NO
I.
,
J.
" 1

I
, .

i ,.
I'
g.
10.
"
IZ
Il
"
"
"
17
"
"
'"
" 22
2J
"I
L.ENCni NSDE

.. I
---"l. -1 ______
!!' lil!! ____J, .. '---""" __--...,."
_ OIlEl"''''' >< ---- . I'
!!AX. 0 _- -- ____ JlOO fIIDllI C\t:RAU._.. ............_ ,
,... <
rr .....- ....?, 2950 MOTH INSU
I


i@
11]
@
'\...,000 lII<m CIA. "" 1ROO
200'JIWHffi BloSE

ISJO 6524- BCQE CNmei ..---j. -..,--_.. ISJO I .... ,
1784 CMR HEADSlOQ(S . ___ __ . _______ _
".. JO"""'- COORES
@ @
SUMMARY OF WEIGHTS (ESTIMATED) ............. .ASURES .............
U1'()(lI:fiW.I( 0 J.n L 3.79 l
nom RATE 1.296 t. 1.296 l 1.'l9fj L
8COY SlRUC'tUl! CCfIIUTE 0 >.21 L 5.21 l 5.21 L
8fW<t GENI: a; LtiOOlFRN.IE 0.150 L 0.&0 l
.. "
C.B.C. CQ.IP'__'Tt:: NO..LCf'IG I,.t!COJPUttG GOt1 U2l loll l 1.32 l
'6J6 L l.6J6 l J.6J6 l
FOlE PAIRS Of W!El.S a: S.n, L 5.75 t "5l
EX;HT CATR(X;E ums -NfJ AtW'lERS. o.Jn t. 0037.2 t Q.Jnt.
Ba.S1ER NfJ SNUtet SPRfiGS 0.J611 t.
."" L
0.368 t-
CN1"R PIVCJT ASSeIIlJES Q.224l 0.224 t. 0.224 l
BCGIE EJVrKt COR <::oIlP...ETE II.!IO l O.SO l II.!IO l
@eo 23.1 t. 23.1t. . 23.1 t.
PAY !,.CloD @o t. 64.18 l 68.18l
=
81.28 t 87..28 l 91.28 l
AXl."""
20.32 t. 21.82 t. 22.82 t.
RAm (PAY LCI(] TO rARE) va 2.\15
111.00< "'''''''' WISlY (GROSS)
7.59 tim. 8.13 l/m. a.52 Vm..
NO. Cf' WIQ(ffi PER tIW4 {D ,. ,. ,.
PAY l.CW) PER lRAIC WAGONS) @'O 3374 l l72" JOSH
GROSS LON.l PER lRAII () 47t4 l SOOH 5294 t.
c.e, FRQU R.L OPTY) 1.015 m 1.016 m 1.016 m
C.C.FRCN R.l.(lcw:ED) 1.974 m 2.000 m 1.668 m
FlOC'lIID 28.87 m2 .... , m2 28.81 rn2
VOl.lNETRC CNfOrt .56.29 m3 !t6..29 rnl m3
10713 I.DICIH <MR COJJ!\.m f1(:fS (NON _. __ ..__________ _

NEASI.!!ES
"" 1.296t.
5.2{ l
0.60 l
1,32 t.
J.6J6 L
5.75 t.
o.J72l
."" l
0.224 l
0.., L
2.3.1 l
66..18 l
BUB L
22.32 t.
2.88
8.JJ tim.
,.
.l8Ja L
5178 L
1.016 m
'''''' m
26.87 m2
"''' mJ
i':'J
WAGON DATA (LIGHT)
I. HEICHT CDaRE aFfER CCU\.ER FRai Rl..
2. OISTAHCE Me. FlJIa5 0 FlOOft
,
sa: ,..,...,. (:l[MNjC[ ("'""")
NOTE:-
::1 CRW.JATEO EfWrl
1.2 itCH l!HSIt..E (HCt4 T'fP( ro.1R BUrnR CCUPWI.)
tJ CAST srm. fRICrX)j SHlII:IW 8JGES TYPE
TO I.Alm 5FEOFO.lIOH.
mm
"OS
240.5
-
JIO iCIE DATA (TARE)
Tt, .

-iJ:x: FIWtE FROW iU.AT CE.HmE
R.l.lO lUI Of Tefl PMlT


'Mel UA.ON
fU. TO TO? or sa: 9E.WR
OGS
.-
COiO),NjG S1Zt
!AT
"is
mm
"5
'"
I A
I

1000
IlO6
210
2200
'""if.ilti"-DN
OIA..Cf
..K)IJOOt. 00'(1
JOllftt!,l !izr
@ I A'" 917 Fen C'JSli,;(l m. A-921 fOO CA9iU3 -22 W(W). A-921 FOR
-2l :ll/M..f] We 921 CASJB HS BOllE.
8 ,.2M RlF: -22 W,CASf\lI8 -22 W()Il. CASMJ8 .. 22 Nl a: NL8
ii .. : 1 Fa'< tASNI.!B HS acHE.
* TiiE, \w,.IJE (X' I:'G. FOR IRON ORE OK..Y.
::/
M-
11l\1i=---r--,

E

11 ,I II "'-IP:=- ! i
.. :Ii JllS - 8
s


ENLARGED DETAIL AT @
L.._. ___...._ ..______ ..__._.. _______ ._.. ___ . _______________________ ..___ . ___ . ____ . _____ .._______ . ____ .._. _____ --_ ..---.. - .._- -----------------..--_. __ . ________________ ...
/
1. SIDE ARM CHARGER
2. TOP TIPPLER CLAMPS
HYDRAULICALLY OPERATED
4. WAGON
HOLDIN(
DEVICE