कनिहा / KANIHA

Page - 1
Rev. No.: 1

Location Management Instructions

LMI/OGN/OPS/SYST/037
Issue No.1, Revision No.0, and Date: June’2020
(Ref: COS-ISO-00-OGN/OPS/SYST/037, Rev No: 0)

LMI
Operating Procedures for
Wagon Tipplers

Approved for
Implementation

...............................................................................
Chief General Manager, TSTPS, Kaniha
Date: ....................

NTPC LIMITED
KANIHA SUPER THERMAL POWER STATION

COAL HANDLING PLANT – FUEL MANAGEMENT DEPARTMENT

 कनिहा / KANIHA

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Rev. No.: 1

LMI: Operating Procedures for Wagon Tipplers

LMI NO : LMI/OGN/OPS/SYST/037

Issue No. 1 Revision : 00 Date: 19.06.2020

Name Designation Signature

Amit B shinde DGM (CHP-Opn)

Prepared By
GHOLAM R GHAUSE DGM (CHP-MM)

Checked By S.K.Sahoo AGM (CHP-OPN)

Checked By C. Vijay Kumar AGM (CHP-MM)

Checked &
A.K.Das HOD (FM)
Reviewed By

Reviewed By N.S.Rao GM (O&M)

Approved By Sudip Nag CGM (TSTPS)

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LMI - Operating Procedures for Wagon Tipplers

INDEX

1.0 Introduction 1

2.0 Superseded Documents 1

3.0 Record of Revision 1

4.0 Main Document 1

4.1.0 Hazard Identification & Risk Assessment & Control Measures 2

4.2.0 Standard Operating Procedures (SOP) 7

4.2.(A) Operating Procedures & Resources 7

4.2.(B) Additional Protection & Interlocks 11

5.0 Review 12

Appendix -I SAC Positions of WT 13

Protection & Interlocks of Wagon Tippler and Side Arm

Appendix -II 14
Charger (SAC)

Appendix -III Monthly Wagon Tippler Protection Checking Protocol Format 16

Appendix -IV Risk Assessment 18

Appendix -V Auto Audible warning System at Wagon Tipplers 23

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1.0 INTRODUCTION

Unloading of coal from BOX-N/NS/BOST wagons of IR rakes is carried out by using

Wagon Tipplers and Side arm Chargers in Kaniha. Operation of wagon tipplers
involves multiple functions requiring both Auto/Manual/Local mode interventions. To
ensure safe and reliable operations and to mitigate the risks involved in wagon
tippler operations this document has been prepared.

NTPC Talcher Wagon unloading facility includes two wagon tipplers supplied and
erected by Thyssenkrupp Industries India to unload loaded wagon and two nos. side
arm chargers with transform platform & puller cum pusher for handling empty wagon.
Apron feeder below each wagon tippler hopper is feed to underground conveyor 34A/B,
further stream of conveyor 35A/B and 36A/B (partially over ground) feeds to existing
conveyor 1A/B.
This control philosophy for NTPC, Talcher wagon tipplers and conveyor package
consists of two parts as follows

Part A: Wagon Unloading facility

It comprises of Control philosophy of the material handling equipments such as wagon
tippler, side arm charger, Transfer platform & puller cum pusher.

Part B: Conveyor facility

It comprises of conveyor and auxiliary equipments of the BC-34A/B, BC-35A/B, BC-
36A/B and their respective junction houses TP-29, TP-30 & TP-31.

2.0 SUPERSEDED

DOCUMENTS Nil

3.0 RECORD OF

REVISION Nil

4.0 MAIN DOCUMENT

This LMI consists of two sections:

4.10: Section A:

Hazard Identification, Risk Assessment & Control Measures (HIRAC)

4.20: Section B:

4.20 (A): Operating Procedures for WT Operation and Resources for facilitating safe
unloading operations through wagon tipplers.

4.20 (B): Additional Protection & Interlocks

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4.10 Section A: Hazard Identification, Risk Assessment & Control Measures (HIRAC)

S. No Activity Hazards Control Measures

Hitting of a person by A. Functioning of warning Siren system
1. Placement wagon / run over in should be ensured.
of Rake track during rake B. The following interlocks for placement
placement. of rake should be ensured:
Derailment due to i) Table Down at 0 degree & rails
cradle Misalignment. alignment
Collision of Empty ii) SAC Arm Up
standing wagon with iii) All Clamps in released position.
Incoming loaded iv)No empty rake in Outhaul side
wagon. (Railway signal permissive)
Fouling of Loco/ If all above permissive from B (i-iv) are clear
Wagon with Side Arm then signal will be “YELLOW” otherwise it
Charger/ Wagon should be “RED”.
Tippler C. Proper Safety Indication Boards should
be ensured indicating “DO NOT
CROSS TRACKS” to avoid hitting of
personnel by rake.
Roll Over of Wagon i) Gradient of 1:1000 is maintained in
2. Brake Kaniha and hence there is no rollback
Release observed. Further, contoured wedges /
Incomplete brake fix skids are being placed under the
release. wagon wheels from suitable distance
with the help of long operating handle.
Hit by wagon during ii) Adequate illumination should be
manual adjustment of ensured (Preferably in the range of
hose. 300- 500 Lux) at brake release area.
iii) Safe approaches should be ensured on
both sides along the rail line to avoid
slip/entanglement/fall of personnel.
Regular Housekeeping of the
approaches should be done to keep it
clean and free from stone/ coal/
Fall of Person while boulder/ vegetation and wetness etc.
at work iv) Visual observation should be done to
ensure whether brake release is
complete/not.
v) One experienced person should be
engaged for monitoring the brake
release process and ensuring safety of
personal.
vi) Brake release clearance (in written)
should be given by FT to WT Control
Room to avoid miscommunication.
a) Hitting of i) Protection and Interlocks should be
3. Side Arm Unloading provided with EPB and LED glow
Charger personnel by lamp to disable any SAC movement
Operation SAC/Wagon when the personnel is performing any
during of the
following activities:
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following  Decoupling/ Coupling

operations: at inhaul/outhaul side.
 Arm Up  Sampling at wagon top.
 Arm Down ii) Movement of SAC should be linked
 Forward with flash beacon with buzzer for
Motion alerting the personnel at work.
 Reverse iii) SAC Movement area should be
barricaded to avoid uncontrolled
Motion
movement of personnel.
 Coupling
iv) Manual interventions of coupling /
 Decoupling
decoupling activities should be done
 Hose with the help of operating handles / L-
connection. Rods by standing at a suitable
distance from tracks. If person is to
enter the tracks it should be done with
the help of respective EPB’s
interlocking with the SAC movement.
(Refer to SOP)
Sudden opening of The personnel should stay at the marked
loose areas.
Wagon door / Bulged
wagon hitting the
person.
SAC festoon trolley Weekly checking should be done for
fouling & healthiness of Festoon Trolley in Wagon
entanglement Tippler-II /Energy Chain in Wagon Tippler-I.
Decoupling of i) SAC Coupler inspection should be
Wagon from SAC done before placement of each rake
before reaching the and after tippling of each rake.
designated point i.e. ii) To ensure healthiness of SAC
at wagon tippler Coupler, weekly preventive
table (Position maintenance shall be done.
SWCPL in
Appendix-II)
a)Slipping of Wagon Monthly Protection/Interlock checking
4. Tippling should be done for wagon clamping. Clamp
Operation holding pressure should be monitored.
b) Wagon Derailment Cleaning of Check rail should be ensured
at regular intervals.

c) Clearing coal from Pocking EPB with beacon should be

hopper grill applied to disable tippling when
stone/boulder removal is in progress.
Also, the hopper grill cleaning equipment
must
have reverse horn to alert the personnel
working nearby.
d) Over Travel of Position switches functioning to be ensured
Wagon and should be checked in every scheduled
Tippler on both sides protection checking.
e) Fall of wagon Bulged wagon detection system feedback
during tippling in should be considered for deciding
case of Handling of placement of rake on WT-I/WT-II.
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Bulged Wagon where Chain blocks arrangement to be kept

clamps do not hold ready for tippling the bulged wagon.
the wagon properly.
f) Free Fall of i) Healthiness & Cleanliness of Rack and
Wagon Tippler Pinion should be ensured.
during tippling ii) Pressure in hydraulic circuit should be
operation. as per Design/OEM guidelines.
iii) Functioning of Online oil filtration unit
should be ensured to maintain oil
quality (NAS Value 7 or below) in
order to prevent hydraulic drive
abnormalities.
iv) Healthiness of drive pinion, Plummer
block holding/fixing/foundation bolts
and pivot stool foundation should be
ensured by regular inspection.
v) Proper operation & gripping of top
clamp to be ensured.
g) Impact by fall of Door Lock should be checked during
loose/defective door/ decoupling to avoid wagon door opening
coal spillage due to during tippling operation. Also, no personnel
Wagon Door opening should be allowed near tippler
during tippling table/pit/hopper during tippling.
operation
h) Personnel being No personnel should be allowed to stand in
hit by Wagon during tippler table / track / pit. Photocell
placement Over functioning should be ensured.
table.
a) Derailment of Table alignment and Indication of Tippler
5. Empty empty wagon table position should be ensured. The zero
Wagon / degree position to be checked at frequent
Rake intervals.
b) Impact / Hit by Operation of EPB with lock should be
Formation
wagon to operating ensured at Out Haul Side to disable
personnel. movement of SAC when personnel are
engaged in empty Rake formation to avoid
any push by SAC movement.
c) Run over by Operation of EPB with lock should be
wagon of person ensured at Out Haul Side to disable
engaged in hose movement of SAC when personnel are
pipe connection. engaged in empty Rake formation to avoid
any push by SAC movement.
a) Electrocution due Proper isolation of OHE cable & requisite
6. Associated to OHE cable fouling PTW should be taken before start of work.
Activities with boom of
Excavator/ Crane
while movement of
equipment/ working
above hopper grills.
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b) Housekeeping The hopper grill cleaning equipment must

personnel being hit have reverse horn to alert the personnel
by stone / boulder working nearby.
removal vehicle/
hopper cleaning
equipment.
c) Impact by falling Pit cleaning is not allowed during tippling
coal due to Wagon operation. It should be done with proper
Tippling during permit.
hopper cleaning / pit
area cleaning.
d) Fall of Hopper grills should be intact and in healthy
housekeeping condition. Gratings shall be used while
personnel in pit area/ working near the pit areas and pit area
hopper grill during should be suitably barricaded.
cleaning.
e) Unloading Warning sign boards should be displayed
personnel/ Vehicle and audio warning systems should be
being hit by loco / healthy all times.
wagon during rail
crossing.
f) Fall / Slip / Illumination should be adequate in the
Entanglement / Run entire wagon tippler complex & tracks.
Over of personal due Additionally, personnel should be provided
to poor visibility/ with Fluorescent/Reflective Jackets,
illumination. Helmets, torch/flash lights.

Notes:
Note-1: Monthly protection and interlocks checking should be done. Protection & Interlock
checklist is placed at Appendix-III.

Note-2: Risk Assessment Comprising of Probability and Severity of Hazard is placed at

Appendix-IV.

Note-3: Based on the Risk Assessment, regular monitoring of necessary

compliance/precautionary measures should be revised time to time.

Note-4: Adequate Training should be imparted to personnel associated with Wagon Tippler
Unloading Activities and it should be ensured that they are deployed to work independently
only after working with experienced personnel for a certain period of time.
Note-5: Regular safety pep talks/ Tool Box Talk should be conducted to make the
unloading personnel aware about the hazards associated and the risk mitigation measures
for safe operation of wagon tipplers.
Note-6: Complete walk down inspection should be done after completion of each rake
unloading, to check the healthiness of all system components and if any abnormality is
observed/detected it should be informed to the concerned for rectification.
Note-7: Ensure the availability of First Aid Kit at Wagon Tippler Complex/Control Room.
Note-8: Personnel deployed in wagon tippler unloading operation should not enter the
tracks. However, under work exigencies/exceptional circumstances, if any person is
required to enter the track it must be ensured that all necessary precautions enlisted in
HIRAC & SOP is taken care of.
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Section B 4.20 (A): Operating Procedures for WT Operation

1. Infrastructures, Equipments & Manpower required
S.No Description Responsibility
1.1 Jr. Engineers/Jr. Operator, 2 nos. for operation of each wagon CHP-Oprn.
tippler
TPM’s - 2 Members (Retired Railway) per shift for coupler FT/FC
1.2
operations, Hose connections, Break lever operations etc.
Unloading Manpower – 6 Members (1 supervisor + 5 Unskilled). FC/FT
Proper sit outs/rest room should be provided for personnel
1.3
involved in unloading operations.

1.4 Location Manpower – 4 member per shift (2 Skilled + 2 Unskilled) CHP-Oprn

JCBs for Boulders clearing from grills. They should be fitted with
CHP-Oprn
1.5 reverse horn and should be of low boom/height to avoid fouling
with OHE cables

EMD
Illumination should be adequate at Wagon Tippler area.
1.6 Accordingly provision of high lighting masts/poles/focus lamps etc.
as applicable should be ensured.
TPM’s, Poking gang and Unloading supervisor should be equipped FC/FT
1.7 with Adequate nos of Walkie – Talkies / Handsets for seamless
communication.
Operating Handles, L-Rods, Shovels, Hammers, Rope etc. for FC/FT & CHP-
1.8
clearing the grills, Chutes and deck sheets. Oprn.
Mechanical wedges, properly contoured fix skids/wooden Not applicable
wedges/other suitable durable material should be provided if there (Wheel gripper
1.9
are any issues of gradient. These wedges should be placed with & stopper
the help of operating handles from adequate distance of rail provided.)
tracks.
CHP-Oprn./C&I
CCTV cameras should be installed in wagon tippler areas to
1.10 provide real time view of men & material movement and unloading
activities. The CCTV views should be displayed and monitored in
wagon tippler control room.
PPE’s: All relevant PPE’s like Safety Helmet, Safety Shoe, Nose FC/FT/CHP-
1.11 mask and Reflective Jackets should be ensured for Personal Oprn.
working in wagon tippler areas.
FC/FT
Signal Torches/LED Batons (Hand Held): For improved visibility
1.12 during night/foggy/rainy conditions signal torches/LED Batons
may be used.
CHP-MMD
Online Oil Filtration Unit should be provided for hydraulic system to
1.13 ensure smooth and proper functioning of associated systems for
safe operations.
Annexure:
 SAC positions: Appendix-I
 WT permissive and protection Interlocks: Appendix-II
1.14
 Protection Checking Protocol: Appendix-III
 HIRAC WT: Appendix-IV
 Auto Audible warning System: Appendix-V
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2. Placement of Rake on Tippler

S.No Description Responsibility
Rake arrival information to CHP-Control room. Rly. Exp. Person/
2.1
SCE – TH CR
SCE-CHP CR to communicate the rake arrival information to
2.2 wagon tippler control room. SCE to ensure deputation of SCE-CHP CR
Wagon tippler operators to Wagon tippler control room.
Allotment of tippler and clearance for placement of rake in the
2.3 SCE - CHP CR
allotted tippler i.e WT-I or WT-II to SCE-TH CR
Placement of Rake on the allotted tippler up to SWL**
Rly. Exp. Person/
2.4 Loco Driver and TPMs to be in continuous communication for
SCE – TH CR
placement of rake. SCE-TH to monitor the activities.
Clearance for removal of empty rake if available. Rly. Exp. Person/
2.5
(Already unloaded rake on the out haul side). SCE – TH CR
On Arrival of the BOXN load rake at Wagon Tippler, break
release activity to be carried out by experienced person / Rly. Exp. Person/
2.6
TPMs. Upon completion of the break release, written SCE – TH CR
clearance /
communication to be given to WT CR.
** refer to the Appendix-II for various SAC positions.
3. Responsibilities of wagon tippler operator before start of tippling/shift:

S.No Work Description Responsibility

Ensure usage of relevant PPEs by all personal present in Wagon tippler
3.1
wagon tippler area. operator
Ensure availability of Tippler supervisor and location
manpower with all relevant PPE’s.
Take feedback of Apron feeder, 14A/B tail end (Tippler tunnel)
and Head end (Pent house-I & II). Wagon tippler
3.2
(If any abnormities are observed with any of the operator/FC /FT
equipment/areas the information to be communicated to Shift
In charge – CHP CR for onward communication to
respective
maintenance groups.)
Perform the following Physical checks
 Ensure working condition of all Walkie-Talkies and
handsets.
 Walk down checks of the WT and SAC areas and
Rly. Exp. Person/
ensure all areas are clear off physical obstructions.
SCE – TH CR /
3.3  Check oil levels of Tippler and SAC power pack oil
Wagon tippler
tanks. Oil level should not fall below the range of sight
operator
glass of oil reservoir.
 Check for any loose/hanging items, Oil leaks etc.
(Any abnormalities to be immediately communicated to SCE-
CHP CR and SCE – TH CR)
Ensure working condition of OWS (Operator Work Station) Wagon tippler
3.4
operator
Ensure availability of cameras views in wagon tippler control Wagon tippler
3.5
room operator
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4. Operational Procedure:

S.No Work Description Responsibility

Confirm brake release of wagons from TH-Control room FC/FT/Wagon
4.1
tippler
operator
Check healthiness of the equipment electrically and Wagon tippler
4.2 hydraulically. operator
All feedbacks/permissive are to be checked from OWS in the
wagon tippler control room along with the following for start of
tippling
 Clamp – Release feedback
 Bench (Tippler Table) Zero position Wagon tippler
4.3  Photo cells feedback Operator
 Pocking EPB release feedback
 Railway Clearance - EPB on the outhaul side
 Railway EPB release on the inhaul side
 Coal Sampling EPB feedback
Ensure release of all Local stops (Desk EPB, SAC & Power Wagon tippler
4.4 Pack) Operator
Communication to CHP-CR informing healthiness of the entire Wagon tippler
4.5 system operator
After receiving the information from wagon tippler CR, CHP CR
4.6 to line-up the streams for direct bunkering/stacking and start the SCE-CHP CR
Conv. 14A/B & Apron feeder.
After receiving run permissive for Apron feeder the following
sequence to be followed for further operation:
 Put the Auto/Manual/Local mode selector switch in
manual mode. (Interlocks will work in Manual mode
only.)
 Start the Dribble conveyor Wagon tippler
4.7
 Start Apron feeder at set the speed operator
 Give announcement in Walkie-Talkies for Side arm
charger movement and placement of the first wagon on
the table.
 Start Side arm charger Motor; bring the SAC to SBL
position and down the arm.
Proper adjustment of the Side Arm charger coupling is to be
done with a rod to match the coupling of the front load wagon
by standing outside the track. The operator doing the
coupling/decoupling should apply the SAC Rev. Permissive
Rly. Exp. Person/
EPB before doing the adjustment of coupling. After
SCE – TH CR /
4.8 completion of the activity the SAC Rev. Permissive EPB
Wagon tippler
should be released. (Decoupling person should not go inside
operator
the track after release of SAC Rev. Permissive EPB).
Wagon coupling/decoupling adjustment activities are to be
monitored by the WT operator through camera view provided
in
the control room.
After getting clearance from decoupling person through Walkie
– Talkie, local supervisor and SAC Rev. Permissive provided Wagon tippler
4.9
in OWS, the operator gives command for SAC REV-2 Operator
movement
from SBL to SWL for coupling with the loaded wagon.
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Wagon coupling activity to be monitored by the WT operator
through camera view provided in the control room.
Obtain SAC forward permissive from TPM through Key type Rly. Exp. Person/
EPB located at outhaul TPM room and also sampling EPB SCE – TH CR /
4.10
feedback from coal sampling arrangement. Wagon tippler
Operator
After coupling the Side arm charger with the load wagon
Wagon tippler
4.11 and obtaining the permissive, Forward command to be
Operator
given from OWS to move SAC from SWL to SWUL.
The loaded wagon is to be decoupled from the rake (at
Rly. Exp. Person/
inhaul side) and EPB is to be pressed for granting
SCE – TH CR /
4.12 permissive to advance the side arm charger from OWS.
Wagon tippler
Wagon decoupling activity to be monitored by the WT
Operator
operator through camera
view provided in the control room.
Move the SAC from SWUL to SWCPL for positioning the loaded Wagon tippler
4.13 wagon on Tippler table. Operator
From SWCPL after 5sec time delay, SAC decouples from the
Wagon tippler
4.14 loaded wagon and moves up to SNRL position. (Auto
Operator
Operation)
Ensure Proper release of SAC coupler from loaded wagon
as mentioned at Sl. no 4.14. In case SAC doesn’t decouple
in Auto mode and pulls the loaded wagon beyond SWCPL,
stop the SAC movement from OWS.
Wagon tippler
4.15 Operate SAC in local mode and place the loaded wagon at
operator
SWCPL position. Decouple the loaded wagon and move the
SAC to SNRL position locally.
After reaching to SNRL position put the SAC in Remote mode
again for continuing the operation from OWS.
Wagon tippler
4.16 Raise the SAC arm from OWS. Operator
Start the Tippler motor and Clamping Motor. Give
announcement in Walkie-Talkies and start the tippling from Wagon tippler
4.17
OWS. During movement of tippler table ensure auto siren for 5 operator
sec.
Observe clamps movement and proper holding of wagon
Wagon tippler
4.18 securely via feedback in OWS as well as physically. Ensure
operator
clamping motor gets off at 80 Deg.
At table position of 80deg, SAC travel command shall be Wagon tippler
4.19
given from SNRL to SBL for coupling with next loaded operator
wagon.
Tippling continues up to 140 deg and stops there. Take
Wagon tippler
4.20 feedback from local operator/camera view reg. complete
operator
unloading of the wagon.
Return the table back to 0 deg, while returning ensure Wagon tippler
4.21
starting of clamping motors at 80 deg and release of clamps operator
STARTS at 40 DEG deg and clams are released completely
at 10 deg.
Continue the unloading process by repeating the sequence of Wagon tippler
4.22 activities from 4.9 onwards. operator
For clearing of any foreign material from the grills,
communication to be given to wagon tippler operator through Rly. Exp. Person/
walkie-Talkie. Unloading personnel should press the Poking SCE – TH CR /
4.23
EPB and ensure working of Beacon provided at the top of Wagon tippler
tippler so that the tippling will not take place while working Operator
on the grills.
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Rly. Exp. Person/
JCB to be engaged for removal of boulders. Poking EPB to SCE – TH CR /
4.24
be operated while clearing the boulders form hopper grill Wagon tippler
area. Operator
Rly. Exp. Person/
Poking EPB shall be released only after all the persons SCE – TH CR /
4.25
come out of the grill. Wagon tippler
Operator
The wagon couplings are to be adjusted for proper alignment
at the empty wagon out haul side by TPM’s. TPM’s should Rly. Exp. Person/
4.26
inhibit the permissive for Side arm charger by keeping the SCE – TH CR
push button
in locked condition that was provided in the TPM room.
Only after making proper alignment for both the wagon
Rly. Exp. Person/
4.27 couplings, unlock and press the pushbutton for granting
SCE – TH CR
permissive to side arm charger advancing.
After full rake unloading completion, the engines are to be
attached to the empty rake and pulled to 10 wagons distance Rly. Exp. Person/
4.28
by coordinating with the TPM and Loco pilot to facilitate the SCE – TH CR
next
rake unloading to start.
Additional provisions.
 Camera views are provided in the WT control room/Track Hopper CR
4.29
for monitoring Coupling and decoupling activates.
 Entire WT area is under surveillance of IP cameras.
4.20 (B): Additional Protection & Interlocks

Apart from the protection and interlocks originally provided by the OEM/OES in Wagon
Tippler unloading operating system, the following additional protections and interlocks are
provided.

i) Coal Sampling EPB with LED Glow Lamp for Indication

Before entering in wagon top for collecting sample, the sample collecting
personnel should press EPB and this shall disable any command to operate
SAC. After ascertaining Becon lamp indication only, coal sampling activity to be
started.
Once the sample collection process is completed and sample collecting
personnel have come back to sampling platform, then EPB should be released.
After checking feedback In OWS, operator can issue command to SAC for
movement.
ii) In Haul EPB (SAC reverse EPB) with Glow Lamp for Indication
When the personnel is adjusting the SAC-Wagon/Wagon-Wagon coupling, he
has to push the EPB and the beacon will glow depicting that personnel is at work
and all commands for SAC movement shall be disabled.
Once the personnel have completed the adjustment/decoupling/coupling
operation, EPB shall be released and after checking feedback in OWS, the
command can be given.
iii) Out Haul EPB (Railway forward permissive
At out haul side also, there are instances where manual intervention is required
for adjusting the wagon to wagon couplings. In such cases the personnel at
Outhaul side has to manually adjust the couplings through operating handles/ L
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Rods at a suitable distance from tacks. During this activity it has to be ensured that SAC does not
move the wagon
When the personnel is adjusting the Wagon-Wagon coupling, he has to push the EPB (Railway
forward permissive) with lock provided in the railway operator room depicting that personnel is at work
and all commands for SAC movement shall be disabled.
Once the personnel have completed the adjustment/coupling operation, EPB shall be released and
suitable indication shall glow to indicate that command can be given.
iv) SAC forward warning Siren with Glow Lamp for Indication
After released of Railway permissive EPB, SAC forward command is issued. While SAC takes all
forward commands, warning Beacon shall glow with buzzer, alerting the TPM and other staff.

v) Wagon Tippler Hopper Grill Cleaning EPB (Poking EPB) with Lamp Glow.
Whenever the Excavators/ Steer Loaders/ Pay Loaders/ hopper cleaning equipment/ Housekeeping
Personnel is entering the hopper grill, EPB shall be pressed and suitable indication should glow
indicating that work by equipment is in progress and tippling operation should be disabled.
Once the EPB is released, after checking feedback in OWS, the command for tippling operation can
be issued.

vi) Auto warning Siren system for wagon placement:

While rake is about to be pushed towards wagon tippler, a Siren is started in auto alerting the
maintenance staff and also the road users.
Detailed scheme is attached herewith at Appendix-v.

vii) Direct placement railway signal lamp:

Railway signal posts are placed in haul side of both wagon tipplers to give permission to railway loco
driver for engine movement for rake placement. Signal post turn to Yellow colour upon meeting all the
following permissive conditions:
1. Table at 0 deg position
2. All 4 clamps in released condition
3. SAC arm in UP (vertical) condition
4. No empty rake in outhaul side.
If any one condition does not meet, signal post turns to RED colour.

Safety Interlocks

Following safety interlocks must be ensured in Local / Auto / Manual modes of operation:-

Wheel Gripper Interlocks:-

 Movement of wagons by SAC at inhaul waiting position in all modes of operation will be allowed
only when the “Wheel Gripper (WG) at Inhaul Side” must be completely opened.
 Movement of wagons by SAC or Puller cum Pusher at wheel gripper on outhaul side of wagon
tippler on main track in all modes of operation will be allowed only when the “Wheel Gripper at
Side of wagon tippler” must be completely opened.
 Movement of wagons by Puller cum Pusher at wheel gripper on outhaul side of transfer platform
in all modes of operation will be allowed only when the “Wheel Gripper at Outhaul Side of transfer
platform” must be completely opened.
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There are proximity switches provided on each WG cylinder to monitor opening of wheel gripper. 13
WG closed position is monitored through signal from pressure switch mounted on common valve
stand to four / two Nos. WG cylinders.
Moving the rail wheels in the wheel gripper closed position will cause damages to the mechanical
components of the wheel gripper.
 The Wheel gripper on inhaul side must remain in closed position to avoid rolling of rake / wagon
onto the tipper table until SAC couples respective rake / wagon at inhaul waiting position. SAC
coupled to the wagon signal is received from the proximity switch mounted on the SAC de-coupler
mechanism.
 The wheel gripper on outhaul side of WT must remain in closed position to avoid rolling of empty
wagon into transfer platform pit or roll back of empty wagons onto the tippler table until Gripper
Open command is received from the system. In Auto mode of operation gripper open command
will automatically be issued when Transfer platform is aligned to the WT rail track & puller cum
pusher is approaching the empty wagon on outhaul side.
 The wheel gripper on outhaul side of Puller cum Pusher must remain in closed position to avoid
roll back of empty wagons / rake into transfer platform pit until Gripper Open command is
received from the system. In Auto mode of operation gripper open command will automatically
be issued when Transfer platform is aligned to the parallel outhaul rail track to the WT track &
puller cum pusher is pushing the empty wagon on outhaul side.

Rail wheel stopper Interlocks:-

 Rail wheel stopper at outhaul of WT should be always in applied condition when transform
platform is not aligned to the main rail track.
 Rail wheel stopper at outhaul of Transform Platform should be in applied condition when
transform is not aligned to the outhaul track after Transform platform.
 Rail wheel stopper at outhaul of WT should be retracted as soon as puller cum pusher couples to
empty wagon standing at the Wheel gripper at the outhaul of the WG -2.
 Rail wheel stopper at the outhaul of the Transform Platform should be retracted as soon as
transfer platform gets aligned to the outhaul rail track so that puller cum pusher will further push
empty wagon along the rake on outhaul track.

SAC Interlocks:-
 Preset speed interlock must be kept for travel on either forward &/or reverse direction after end
of travel position to ensure smooth stopping. The starting/acceleration/constant
speed/retardation shall be in accordance to the starting & stopping positions based on the Travel
encoder feedbacks through PLC.
 SAC arm must not be allowed to be lowered when traveling in arm raise position in the WT Table
zone, similarly when in arm lowered position it must not be allowed to raise in the WT table zone.
 SAC arm should be lowered at 400 mm before wagon coupled position at inhaul side. This is initial
waiting position.
 SAC arm should be lifted at a distance 400 mm before SAC operational travel end position at
outhaul side. This is outhaul waiting position of SAC.
 SAC must not be allowed to travel in arm lowered position when tippler is in forward / reverse
rotation.
 SAC must not be allowed to travel with Wagon / rake in forward travel until wagon clamps are
fully retracted. Clamps retract position feedback is received from proximity switches mounted at
 कनिहा / KANIHA

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all the three clamping cylinders. 14
 If Wagon Tippler trips during tippling cycle, SAC reverse travel will continue and SAC shall reach
the initial waiting positions and stops with arm raise condition. Any further operation of SAC will
be prohibited until Wagon Tippler operation resumes.

WT Drive Interlocks:-
 Tippler must work in close loop interlock with the SAC travel positions & Wagon positions. The
starting/acceleration/constant speed/retardation shall be in accordance to the starting &
stopping positions based on the Tippling encoder feedbacks through PLC.
 Tippler must not be allowed to tipple when diesel locomotives are being passed from inhaul side
to outhaul side. (Operator to check)
 WT table rotation will be allowed only when platform locking pin is in fully retracted position.
Platform lock pin fully retracted position feedback is received from proximity switch mounted at
platform lock mechanism through external bracket.
 Preset speed interlock must be kept for tippling to avoid over speeding of tippler on either
forward &/or reverse direction before end of tippling position to ensure smooth stopping.
 Tippler forward tippling must not be allowed when SAC is traveling in the WT Table zone with arm
lowered condition.
 Table must not be raised unless it has all the Radar sensors (Inhaul & Outhaul) range is clear for
tippling.
 Apron Feeder running feedback will be used only as start permissive for WT operation. If any of
Apron Feeder or all Apron Feeder trip during tippling cycle, tippling will continue and the material
will be discharged into the hopper. However next tippling cycle will have to wait till Apron Feeder
start again.
 If apron feeder electric motor is drawing 80% of the rated current than the desired then this will
is indication that hopper will full .This the current feedback of AF drive is interlocked with WT
drive. If feedback of current is above certain limit received by PLC during tippling cycle, tippling
will continue for the cycle in operation but further tippling will be stopped until current reading
of apron feeder comes within limit. Settings of current feedback to be done based on actual site
observation.
Following equipment will not come under interlock of the WT drive :
Dust suppression system and ventilation system

WT Clamping Interlocks:-
 Wagon clamping arrangement must be operated in close loop with operation of tippler rotation
in forward & reverse direction. Operation of clamping arrangement should be interlocked with
wagon tippler encoder.
 Prior to placing the wagon on tippler table top clamping arrangement & movable side wall should
be at their extremely retracted position. Wheel gripper on tippler table should be open.
Movement of wagons with SAC or movement of locomotive from tippler table should only be
allowed when top & side clamping arrangement are completely retracted. Wheel gripper on
tippler table should be open during wagon / loco movement.
 When the paws touch the wagon, the cylinder head end pressure increases and pressure switch
operates or desired pressure transmitter feedback is received. This signal shall be monitored and
has to be available at least for 5 seconds to confirm the wagon clamped condition. This signal
must be available before table reaches 45 deg rotation from encoder. The forward tippling cycle
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shall be terminated if clamping OK signal is not received before 45 deg table rotation. 15
 Dosing operation shall start at 45 Deg & shall stop at 85 Deg of the Wagon tippler position in
forward tippling cycle.
 De-clamping shall be permitted only after 60 deg. position of tippler table in reverse rotation.
Table at 60 deg. feedback is received from proximity switch mounted near main bearing pedestal.
 Prior to forward tippling action operator / PLC has to ensure that the wagon is gripped by the
gripper on tippler table. Also it is to be ensured that waiting wagon at inhaul & outhaul is also
gripped to ensure against rolling.

Transfer Platform interlocks:-

 Preset speed interlock must be kept for travel on either forward &/or reverse direction after end
of travel position to ensure smooth stopping. The starting/acceleration/constant
speed/retardation shall be in accordance to the starting & stopping positions based on the Travel
encoder feedbacks through PLC.
 Transfer platform must work in close lop interlock with SAC travel positions, puller cum pusher
positions, wheel gripper sand rail wheel stopper feedbacks.
 It is to be ensued that transfer platform is perfectly aligned to the either of parallel rail tracks &
locked in place by platform locking pin during movement of wagons by puller cum pusher either
on or out of the transfer platform.
 Transfer platform lock pin should be completely retracted prior to start of transfer platform travel.
Locking pin retracted feedback is taken from proximity switches mounted at platform lock
mechanism.
 Transfer platform brakes should be applied when platform is at its positions aligned to main /
parallel rail track.
 Puller cum pusher should be either at its parking position or at its extreme backward position with
wagon on transfer platform prior to start of transfer platform travel. The travel position feedback
can be obtained from puller cum pusher encoder.
 If Wagon Tippler trips during tippling cycle, transfer platform operation will continue and transfer
platform shall reach its position aligned to main rail track and stops with puller cum pusher at its
parking position. Any further operation of transfer platform will be prohibited until Wagon Tippler
& SAC operation resumes.

Puller cum pusher interlocks:-

 Preset speed interlock must be kept for travel on either forward &/or reverse direction after end
of travel position to ensure smooth stopping. The starting/acceleration/constant
speed/retardation shall be in accordance to the starting & stopping positions based on the Travel
encoder feedbacks through PLC.
 Puller cum pusher must work in close lop interlock with SAC travel positions, transfer platform
operation, wheel gripper and rail wheel stopper feedbacks.
 Movement of puller cum pusher in forward/reverse direction should not be allowed until transfer
platform is aligned to either of the rail tracks & locked with particular rail track by platform locking
pin. Transfer platform position feedback is obtained from encoder mounted on transfer platform
travel wheel. Also transfer platform locking pin cylinder extended feedback is obtained from
proximity switch mounted at platform lock mechanism.
 Hydraulic brakes of puller cum pusher should be in applied condition when puller cum pusher is
at its parking position or extreme backward position with empty wagon coupled during
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movement of transfer platform. 16

Apron feeder interlocks:-

 Apron Feeder will work in interlock with the succeeding conveyor BC-34A/B. During starting
sequence Conveyor should be started first & then Apron Feeder. Similarly in stopping sequence
Apron feeder to be stopped first & then with predetermined time delay preceding conveyor is
stopped.
 Apron feeder running /trip feedback to be interlocked with wagon tippler drive as explained under
WT drive interlock ; Cl.2.4.3
 Apron feeder drawings 80% of rated current feedback will indicate hopper full condition. This is
to be interlocked with WT drive is explained under WT drive interlock Cl.2.4.3

5.0 REVIEW
The HOP Kaniha shall be responsible for reviewing this LMI on a three yearly basis or as necessary.
 कनिहा / KANIHA
LMI/OGN/OPS/SYST/037
Rev.0.0, Page | 16

Appendix-III

MONTHLY WAGON TIPPLER PROTECTION CHECKING PROTOCOL FORMAT

WT: Date:
Interlock/Protection
S.no Area Status Remarks
description
1 SAC-Limits/ encoder In haul
output.
Out haul
SWUL
SWCPL
SNRL
SFEL
SREL
2 SAC-Arm proxies Vertical proxy
Horizontal Limit
3 SAC-Coupler proxies Engage-

Release
4 Clamp-I
Clamps Apply feed back
Clamp-II
Clamp-III

5 Clamps Release feed Clamp-I

back Clamp-II
Clamp-III

6 Hydraulic power pack Control pressure

Boosting pressure
Tippling pressure
Return pressure
Clamping current
Tippling current
Oil Temp. guage deg C
Oil level gauge
7 Coupling EPB & Railway
Safety push button clearance
protection
Decoupling EPB
Poking EPB
8 Tippler Tippler OT limit-1
Photocell IN
OUT
9 Tippling Tilt angles "0" deg / "3" deg
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"80" deg 40 deg/10 deg
10 Dribble conveyor
Down Conv.- interlock for AF
interlock/Permissive Availability & Inter lock
with AF
11 Control room
Emergency pushbuttons
SAC
Local panel
12 Hooter
13 Sampling EPB

14 Other Observations

CHP-MM EM C &I CHP Operation

(Name & Sign) (Name & Sign) (Name & Sign) (Name & Sign)
 कनिहा / KANIHA
LMI - Operating Procedures for Wagon Tipplers
LMI/OGN/OPS/SYST/037
Hazard Identification, Risk assessment and Control
Rev.0.0, P a g e | 18
Appendix-IV

Type of Risk Control Measures in place Objective/ Risk

Work Risk Assessment Risk Assessment Remarks
Harm Code OCP Code
SL. NO Activity/Human Type of Hazard
Injury/ Ill
behavior Severity Probability Severity Probability
Health
Placement of Hitting of a person by A. Warning Siren Provided
1. Rake wagon / run over in B. Following interlocks have been
track during rake Injury I D 8 SOP-WT IV D 19
provided for or placement of
placement. rake.
Derailment due to Plant i) Table Down at 0 degree & rails
IV C 18 alignment SOP-WT IV D 19
cradle Misalignment. Outage
ii) SAC Arm Up
Collision of Empty
standing wagon with Plant iii) All Clamps in released position. Installed a Signaling
II D 10 If all above permissive from B (i-iv) SOP-WT IV E 20
Incoming loaded Outage system.
wagon. are clear then wheel gripper in
Fouling of Loco/ haul will be released for loaded
Wagon with Side Arm wagon.
Charger/ Wagon Safety Indication Boards
Tippler Plant displayed indicating “DO NOT
II D 10 SOP-WT IV E 20
Outage CROSS TRACKS” to avoid hitting
of personnel by rake.

2. Brake Release Roll Over of Wagon Injury II D 10 i) Gradient of 1:1000. SOP-WT IV D 19

Incomplete brake ii) Wheel grippers at in haul, on
table & out haul are provided.
release.
Injury II D 10 Wheel stopper at Puller pusher SOP-WT IV D 19
in haul and out haul are also
provided.
Hit by wagon during iii) Adequate illumination ensured
manual adjustment of at brake release area.
hose. iv) Safe approaches ensured on
both sides along the rail line.
Regular Housekeeping of the
approaches is being done.
v) Only experienced persons are
Injury I D 8 being engaged for monitoring SOP-WT IV E 20
the brake release process and
ensuring safety of personal.
vi) Brake release clearance (in
written) by FT to WT Control
Room to avoid
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LMI - Operating Procedures for Wagon Tipplers

Hazard Identification, Risk assessment and Control LMI/OGN/OPS/SYST/037
Rev.0.0, P a g e | 19

Fall of Person while at miscommunication is initiated.

work Injury III D 14 _ IV D 19

3. Side Arm a) Hitting of i) Protection and Interlocks

Charger Unloading provided with EPB/ LOCAL
Operation personnel by ACK BUTTON and LED glow
SAC/Wagon lamp linking with SAC
during movement when personnel is
performing the following
 Arm Up activities:
 Arm Down  Decoupling/ Coupling at
 Forward inhaul/outhaul side.
 Sampling at wagon top.
Motion
ii) SAC Movement area
 Reverse barricaded to avoid
Injury II D 10 SOP-WT IV D 19
uncontrolled movement of
Motion personnel.
 Coupling iii) Manual interventions of
 Decoupling coupling / decoupling are
being done with the help of
 Hose operating handles / L-Rods by
connection. standing at a suitable distance
from tracks.
iv) EPB’s interlocking with the
SAC movement provided for
going inside the tracks in case
it is unavoidable.
Sudden opening of Areas embarked for standing and Emergency EPB
loose performing the coupling /decoupling provided for any
Wagon door / Bulged Injury III C 11 activities. SOP-WT IV C 18 exigencies.
wagon hitting the
person.
SAC festoon trolley Weekly checking is being done for DRAG CHAIN
fouling & entanglement Plant healthiness of Festoon Trolley in PROVIDED INSTEAD OF
IV C 18 IV E 20 FESTOON TROLLY.
Outage Wagon Tippler-II /Energy Chain in
Wagon Tippler-I.
Decoupling of Wagon i. Scheduled preventative Emergency EPB
from SAC before maintenance. provided for any
reaching the ii. Monthly protections checking exigencies.
designated point i.e. at Injury IV A 13 SOP-WT IV D 19
wagon tippler table
(Position SWCPL in
Appendix-II)
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Rev.0.0, P a g e | 20

4. Tippling a)Slipping of Wagon Plant I. Monthly Protection/Interlock

Operation III D 14 checking. SOP-WT IV D 19
Outage
II. Cleaning of Check rail should be
b) Wagon Derailment Plant
IV A 13 ensured at regular intervals. SOP-WT IV D 19
Outage
c) Clearing coal from i.Pocking EPB provided.
hopper grill Injury IV B 16 SOP-WT IV D 19
ii.Reverse horns ensured for grill
cleaning equipment.
d) Over Travel of Monthly Protection/Interlock checking. Limit switches provided
Plant on both sides. Along
Wagon III D 14 SOP-WT IV D 19 with encoders.
Outage
Tippler on both sides
e) Fall of wagon Bulged wagon detection system Emergency EPB
during tippling in case provided for deciding placement of provided for any
of Handling of Bulged Plant rake on WT-I/WT-II. exigencies.
III D 14 SOP-WT IV D 19
Wagon where clamps Outage Chain blocks arrangement are being Photo sensors
do not hold the wagon used to avoid damages to other provided.
properly. equipment.
f) Free Fall of Wagon i) Cleanliness of Rack and Pinion NASH value measurement
Tippler during tippling is ensured. done by chem. Dept.
operation. ii) Operation of system with
Design/OEM guidelines.
iii) Online oil filtration unit provided
Plant for maintaining the oil quality
III D 14 (NAS Value 7). SOP-WT IV D 19
Outage
iv) Preventive Maintenance of all
Hydraulic and associated
equipment.

g) Personnel being hit i. No personnel should be allowed

by Wagon during to stand in tippler table / track /
placement on WT Injury II C 6 pit. SOP-WT IV E 20
table. ii. Photocell protection provided
5. Empty Wagon / a) Derailment of empty Wheel grippers along with
Plant Table alignment inspection during the
IV D 19 IV D 19 rail stopper provided on
Rake Formation Outage table for restricting lateral
wagon scheduled protections checking.
and axial movement of
wagon on table
b) Impact / Hit by EPB with lock provided at Out Haul
wagon to operating Side to disable movement of SAC if
Injury II C 6 SOP-WT IV D 19
personnel. personnel working in empty Rake
formation.
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c) Run over by wagon Out haul rake formation

EPB with lock provided at Out Haul
of person engaged in done by Puller pusher and
hose pipe connection. Side to disable movement of SAC if shifter car. Local ack.
Injury I C 4 SOP-WT IV D 19 Button and wheel gripper
personnel working in empty Rake
plus rail stopper provided at
formation. out haul.
6. Associated a) Electrocution due PTW with isolation of OHE is being No OHE cable at site.
Activities to OHE cable fouling taken before start of work.
with boom of
Excavator/ Crane Injury I C 4 SOP-WT IV E 20
while movement of
equipment/ working
above hopper grills.
b) Housekeeping i. Reverse horn ensured in all
personnel being hit by vehicles
stone / boulder ii. EPB with Beacon provided
Injury II C 6 IV D 19
removal vehicle/
hopper cleaning
equipment.
c) Impact by falling Pit cleaning is not allowed during
coal due to Wagon tippling operation. It is being done
Tippling during Injury III D 14 with PTW. IV E 20
hopper cleaning / pit
area cleaning.
d) Fall of Gratings are being used while working
housekeeping near the pit areas with suitable
personnel in pit area/ Injury II D 10 barricaded. IV D 19
hopper grill during
cleaning.
e)Unloading i) Warning sign boards are being
personnel/ Vehicle displayed.
being hit by loco / Injury I D 8 ii) Audio warning systems IV D 19
wagon during rail provided
crossing.
f) Fall / Slip / i) Adequate Illumination provided.
Entanglement / Run ii) Working personal has been
Over of personal due Injury I D 8 ensured with IV C 18
to poor visibility/ Fluorescent/Reflective Jackets,
illumination. Helmets, and torch/flash lights.
 Severity Category People Costs

Death due to serious Plant outage > one week and/or

Catastrophic I
injuries or illnesses losses > Rupees 100 crores

Disabling injury or Facility outage upto one week

Critical II severe occupational and/or losses > Rupees 20 crores
illness but < Rupees 100 crores

Medical Aid Injury or Facility outage upto 2 days and/or

Marginal III minor occupational losses > Rupees 1 crore but <
illness Rupees 20 crores

Minor injury or illness Facility outage upto 1 day and/or

Negligible IV
(First Aid case) losses < Rupees 1 crore

Probability Level Frequency or Likelihood

Likely to occur frequently or at least once per
Frequent A
year or more frequently

Likely to occur several times in life of the

Probable B
system or at least once in 3 year period
Likely to occur sometime in life of the system
Occasional C or once in
6 years period

Unlikely, but possible to occur in the life of

Remote D
the system or once in 15 years period

Highly unlikely, but possible to occur in the

Improbable E lifecycle of the system or once in more than
15 years period.

SEVERITY
I II III IV
PROBABILITY CATASTROPHIC CRITICAL MARGINAL NEGLIGIBLE
FREQUENT A 1 3 7 13

PROBABLE B 2A 5 9 16
OCCASIONAL C 4 6 11 18
REMOTE D 8 10 14 19
IMPROBABLE E 12 15 17 20