Project Doc. No. Rev. No.

Sheet
GANGAVARAM PORT 2119 – 2120 - 01 0 1 of 10
Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

ROTASIDE TIPPLER (Hi-Lift XL),

SIDE ARM CHARGER AND
APRON FEEDER SYSTEM

FOR

FELGUERA GRUAS Y ALMACENAJE

(Contract No. FGA-19-60-024-5004)

SITE: GANGAVARAM PORT, VISAKHAPATNAM,

ANDHRA PRADESH STATE, INDIA

MODIFICATION RECORD

Rev. Sheet
Modification Checked & Approved Date
No. No.
Mech: PS Apte,
17-Aug-06
0 1 to 10 First Issue PL Thanneermalai
Elec: AG Khanwalkar 17-Aug-06

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
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Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

CONTENTS

1. INTRODUCTION 3

2. SPECIFICATIONS AND DRAWINGS 3

3. DESIGN PARAMETERS 3

4. DESIGN RULES 5

5. FOUNDATION DESIGN 5

6. TIPPLER DESIGN 6

7. CHARGER DESIGN 7

8. APRON FEEDER DESIGN 8

9. ELECTRICAL 8

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
GANGAVARAM PORT 2119 – 2120 - 01 0 3 of 10
Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

1. INTRODUCTION

The Technical Particulars are with regard to and limited to the contract being
executed by Metso Minerals (India) Pvt. Ltd. for supply of one Rotaside Wagon
Tippler (Hi-Lift XL), one Side Arm Charger and two Apron Feeders to M/s. Felguera
Gruas Y Almacenaje, S.A for Gangavaram Port Project, Visakhapatnam, Andhra
Pradesh State, India.

2. SPECIFICATIONS AND DRAWINGS

2.1 The technical parameters are based on conditions per contract no. FGA-19-60-024-
5004 between M/s Felguera Gruas Y Almacenaje, S.A and Metso Minerals (India)
Pvt. Ltd.

2.2 Reference Drawings:

a) Metso Drawing: No. 2119-2120-02 – Tippler Complex Layout

b) Metso Drawing: No. 2119 001 – General Arrangement of Wagon Tippler
c) Metso Drawing: No. 2120 001 – General Arrangement of Side Arm Charger
d) Metso Drawing: No. 5006 001 – General Arrangement of Apron Feeder
e) Metso Drawing: No. 2119-2120-05 – Wagon Positioning through Plant
f) Metso Drawing: No. 2119 900 – Electrical Schematic Diagram
g) Metso Drawing: No. 2119 901 – Single Line Diagram for WT, SAC & AF

3. DESIGN PARAMETERS

Wagons to be handled:- Indian Railway’s Broad Gauge (1676 mm) Open Wagons
- BOX, BOXN and BOY per IS: 10095-1982 within following range of dimensions:

Length over buffers/coupling : 10,715 mm to 14,428 mm

Height : 3,735 mm Max./ 2375 mm Min.
Width over all : 2,955 mm to 3,250 mm
Gross Weight : 81.3 t
Tare Weight : 23.6 t

Wagon gross weight for tippler design : 92 t Fatigue, (25 t Tare)

110 t Strength

Wagon gross weight for charger design : 92 t

(5400 t max. train load)

Main track & tippler platform rail size : 52 kg/m (156 ht, 67 hd, 136 flg)

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
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Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

Locomotive clearance as per IS: 10095-1982

No. of wagons to be Unloaded per hour : 24

No. of wagons in the train to be handled: 58 (Maximum train load 5400 t)

Charger arm rating : 37.5 t (Maximum load 43.5 t)

Design cycle time : 147 sec

Time to tip & return : 73 sec (41 tip, 1 pause, 31 return)

Wagon tipping angle : 1600 max.

Track layout : Straight (no curvature) and Level ( no

slope) Track at both In haul and Out haul
for the entire rake length
Materials handled : Iron Ore Fines

In haul track (Clicking) stop : Provided

Out haul track (Runback) stop : Provided

No. of apron feeders and capacity : 2 nos. x 770 tph rated (850 tph design)

Dust suppression system : Chemical mixed water spray system for

tippler hopper and for apron feeder
discharge is provided.
Site Conditions:

Electrical Supply : 415V, 3 phase

50 Hz 3 wire AC

Control Supply : 110V AC

Supply Variation : Voltage +/-10%

Frequency +/-3%
Combined voltage & frequency +/-10%

Ambient Temperature : 500 C max., 120 C min.

Relative Humidity : 76% max,however maximum temperature

and relative humidity are not likely to
occur simultaneously.

Atmosphere : Dusty

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

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Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

4. DESIGN RULES

4.1 For Tippler and Charger structural design BS 2573 Part 1:1983 is referred with

Wagon Mass for Cyclic Loading Gross: 92t (to allow for surcharge)
Tare : 25t
Wagon Mass for Non-Cyclic Loading Gross: 110t
Tare : 25t

Tippler structure is designed with classification A8 and fatigue life of 1 x 106 cycles.

4.2 For Tippler and Charger Mechanical design BS 2573 Part 2:1980 with classification
M8 is referred to.

4.3 Wagon Top Clamp mechanism shall be designed for load case combining 110t
wagon (strength case) and three (3) clamps only operating out of four.

5. FOUNDATION DESIGN

5.1 Reference Drawings for Foundation Loads and Profile:

a) Metso Drawing: No. 2119 002 - Foundation Profile and Load Data for Wagon
Tippler
b) Metso Drawing: No. 2120 002 - Foundation Profile and Load Data for Side
Arm Charger
c) Metso Drawing: No. 5006 002 - Foundation Profile and Load Data for Apron
Feeder

5.2 Consideration of Foundation Loading for civil engineering design:

a) Live loads based on a 1.1 impact factor applied to all wheels.

b) Concrete loading based on live loads x 1.4 to give an equivalent dead load.

c) Buffer loads to be based on charger along with single wagon at 2/3 of rated
travel speed with an impact factor 2.

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
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Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

6. TIPPLER DESIGN

The design of the tippler is Hi-Lift XL Rotaside type with hydraulic drives (3 pinions,
one end only), hydraulic clamp gear (4 clamps) and integral weigh bridge. Hydraulic
power unit is housed in a room adjacent to tippler and supply of hydraulic power to
clamp gear is through festoon arrangement.

3 nos. of locomotives, each with 130t maximum gross weight can pass over tippler
platform at 8 km/hr maximum speed, when tippler is in lowered (grounded) position.

Wagon Top Clamp Force: 5.66t Normal per clamp

: 7.55t Maximum per clamp with only 3 out of 4 clamps
sharing considered for design

Clamping Angle : Fully engaged at 700 tipping angle

Cylinders locked at 800 tipping angle for the remainder of
the tip & return cycle until at 800 tip angle on return the
cylinders are unlocked and start retracting for 15 sec to
fully stroke in.

Cycle Time Breakup for Tippler:

Activity Time, sec Travel Distance, deg

(wagon tipping angle)

Tip Cycle:

Acceleration period 3 6.5

Constant velocity 35 147
Deceleration period 3 6.5

Total tipping (41) (160)

Return Cycle:

Acceleration period 3 8.5

Constant velocity 25 143
Deceleration period 3 8.5

Total return (31) (160)

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
GANGAVARAM PORT 2119 – 2120 - 01 0 7 of 10
Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

7. CHARGER DESIGN
The design is Side Arm Charger type with 3 pinions meshing with a ground mounted
rack. Each pinion is driven by a hydraulic motor. Disc brakes are provided as integral
units with hydraulic motors. Charger consists of a fabricated frame supported by 4
support rollers and guided by 2 pairs of rollers acting on the sides of a ground
mounted spine bar. Arm luffing is achieved by means of a hydraulic cylinder.
Hydraulic power unit is mounted on the charger frame and electric power supply to
the charger is through a festoon arrangement.

At the in haul side a powered clicking stop is provided to prevent undue rolling of
wagon/ rake towards tippler and a runback stop is provided to prevent rolling back of
rake so that it remains within the reach of the charger. Runback stop is also provided
at the out haul to prevent rolling back of ejected wagon towards tippler. Stops can be
manually retracted, if wanted.

Charger speeds: Forward

– Rake 0.45 m/sec
- Single Wagon 0.60 m/sec

Return 0.60 m/sec

Cycle Time Breakup for Charger: (Typical for BOX N wagon)

Activity Time, sec Travel Distance, m

Start auto cycle, pause, position wagon on 15.26 6.86 Forward

platform & eject previous wagon

Dwell 2.5 -

Uncouple charger 3 -

Travel to clear tippler 10.39 3.94 Forward

Raise arm 10 -

Travel back 37.55 20.24 Return

Lower arm 10 -

Back to couple 13.21 1.28 Return

Wait for tippler, release track stop, 40 10.73 Forward

haul rake forward to spot next wagon

Engage track stop, manual de-coupling 5 -

between wagons at de coupling position

Total traction time (147) (21.5 Forward/Return)

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

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Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

8. APRON FEEDER DESIGN

The design of Apron Feeder is shaft less tail wheel design and the tail wheels are
sealed for life. The feeder also consists of sealed crawler tractor type chain of drop
forged induction hardened steel links, hardened bushings and pins, heavy duty cast
manganese steel pans and life lubricated rollers. The apron feeder is fixed speed
type and is driven by electro-mechanical drive.

No. of apron feeders: 2 nos.

Rated capacity: 770 tph (each feeder)

Design capacity: 850 tph (each feeder)

Chain speed: 0.132 m/sec (fixed speed)

Sprocket centres: 4300 mm

Pan width: 1067 mm (42 inch)

Dribble conveyor belt width: 1200 mm

Belt speed: 25 m/min (intermittent operation)

9. ELECTRICAL

9.1 Major electrical loads:

(Motor powers to be reconfirmed during detail engineering depending on hydraulic

suppliers’ recommendations)

Wagon Tippler:

Tippler rotation drive 1 x 160 kW 4P AC for hyd. power unit

Clamp gear & hydraulic clicking stop: 1 x 37 kW 4P AC for hyd. power unit

Side Arm Charger:

Charger travel drive, 2 x 132 kW 4P AC for hyd. power unit

arm luffing cylinder &
uncoupling cylinder

Apron Feeder:

Feeder chain drive: 2 x 15 kW 4P AC (For two feeders)

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
GANGAVARAM PORT 2119 – 2120 - 01 0 9 of 10
Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

Dribble Conveyor drive: 2 x 3.7 kW 4P AC (For two dribble conveyors)

Dust Suppression System:

Water Pump: 1 x 22 kW 2P AC

9.2 Major Electrical equipment:-

1) MCC :-

i. The MCC for wagon tippler, side arm charger and apron feeder drives and auxiliaries
shall be as per single line diagram drg no.2119 901.

ii. The MCC will be housed in the electrical panel room adjacent to the side arm charger
track and the operator’s control room shall be located above this room.

iii. Power supply to the MCC for total load drawn by the equipment will be provided to
Metso’s MCC panel with adequate healthy and stable supply.

iv. All other voltages as required for the system shall be generated by Metso.

2) Tippler and side arm charger is provided with hydraulic drives, as per the hydraulic schemes.

3) A small self-standing PLC panel catering for above drives is provided inside the Operator’s
control room.

4) Main Control Desk shall be in Operator’s control room and also separate control for charger in
Operator’s cab on side arm charger carriage.

5) Various limit switches for safety and interlocks of the wagon tippler, side arm charger and apron
feeder operation.

6) All related power and control cabling for above drives and auxiliaries, along with festooning
cables for side arm charger.

7) Local Push Button Stations are provided for above drives for maintenance purpose.

8) Dust Suppression System control panel , shall be supplied by DS system vendor (or part of
MCC). The incoming supply for the panel will be tapped from wagon tippler MCC.

9) MCC room and operator’s control room are considered to be provided with air conditioning units
of window type.

10) Power socket for welding etc. will be provided at convenient point for maintenance purpose.

11) Adequate lighting will be provided in the MCC room and the operator’s control room.

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)

 Project Doc. No. Rev. No. Sheet
GANGAVARAM PORT 2119 – 2120 - 01 0 10 of 10
Title DETAIL TECHNICAL PARTICULARS
(TIPPLER, CHARGER & APRON FEEDER SYSTEM)

9.3 System Operation:

Control of the tippler will be from the track side control station for normal (automatic)
operations.

A control station will be provided on board the charger to enable positioning of the
rake of wagons ready for automatic operations. This station will also be used for
maintenance and setting up purposes.

A push button station will be provided adjacent to the tippler to provide for
maintenance and setting up purposes.

Emergency stop push buttons will be provided on the control/pushbutton station and
these together with over travel switches on the charger and tippler will operate
independent of the PLC.

-0-

Technical Particulars (GANGAVARAM – WT, SAC & APRON FEEDER)