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206-Operating Procedures For Wagon Tippler Operations PDF
206-Operating Procedures For Wagon Tippler Operations PDF
LMI/OGN/OPS/SYST/037/206
Released on 28Jul20
Date:
Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
11/07/2020(16:20:42)
Subject:Approval Note for Location Management Instructions of Wagon
Tippler,SAC & puller cum pusher, LMI/OGN/OPS/SYST/037.
Sub: Approval Note for Location Management Instructions of Wagon Tippler, SAC & puller cum pusher,
LMI/OGN/OPS/SYST/037.
A statin specific LMI for safe operation of Wagon tipplers, SAC & puller cum pusher is prepared based on
the OGN Ref. No: COS-ISO-
00-OGN/OPS/SYST/037, Rev.0, June'2020 and is enclosed herewith.
Submitted by:
AMIT BALASO SHINDE - 091089 (DY. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:11/07/2020(16:20:42) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Chengala Vijay Kumar - 007180 (ADDL. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:16/07/2020(09:56:12) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Necessary changes done in LMI. Forwarded for approval of the competent authority.
Submitted by:
AMIT BALASO SHINDE - 091089 (DY. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:22/07/2020(11:42:44) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Verified the LMI, in order, put up for forward approval.
Submitted by:
Chengala Vijay Kumar - 007180 (ADDL. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:22/07/2020(15:42:26) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Sisir Kumar Nayak - 032239 (ADDL. GENERAL MANAGER ,FUEL HAND.- MECH MAINT) ,Talcher
Kaniha
On:22/07/2020(17:55:38) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Subrat Kumar Dash - 005623 (ADDL. GENERAL MANAGER ,MGR) ,Talcher Kaniha
On:25/07/2020(10:28:26) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Brajaraj Rath - 095521 (ADDL. GENERAL MANAGER ,ELECT MAINT) ,Talcher Kaniha
On:25/07/2020(12:06:50) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Murari Lal Agarwal - 020447 (ADDL. GENERAL MANAGER ,C & I MAINT) ,Talcher Kaniha
On:25/07/2020(15:48:04) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
AS DISCUSSED NECESSARY CORRECTION IS TO BE DONE CONSULTING WITH AGM
(MGR).
Submitted by:
Karunakar Das - 003823 (GENERAL MANAGER ,FUEL MANAGEMENT) ,Talcher Kaniha
On:27/07/2020(10:23:24) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
As discussed necessary changes made in documets in consultation with AGM/MGR. Forwarded through
AGM/MGR for check.
Submitted by:
AMIT BALASO SHINDE - 091089 (DY. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:27/07/2020(11:56:02) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
submitted
Submitted by:
Subrat Kumar Dash - 005623 (ADDL. GENERAL MANAGER ,MGR) ,Talcher Kaniha
On:27/07/2020(12:17:10) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Sisir Kumar Nayak - 032239 (ADDL. GENERAL MANAGER ,FUEL HAND.- MECH MAINT) ,Talcher
Kaniha
On:27/07/2020(12:51:32) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
As discussed LMI sent for necessary correction.
Submitted by:
Karunakar Das - 003823 (GENERAL MANAGER ,FUEL MANAGEMENT) ,Talcher Kaniha
On:28/07/2020(10:03:12) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
As discussed LMI document updated & uploaded. Forwarded for approval of the competent authority.
Submitted by:
AMIT BALASO SHINDE - 091089 (DY. GENERAL MANAGER ,FUEL HANDLING) ,Talcher Kaniha
On:28/07/2020(10:31:11) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
New LMI on operating procedure of Wagon Tippler, SAC & Puller Cum Pusher
(LMI/OGN/OPS/SYST/037) was prepared and reviewed by concerned departments.
Submitted by:
Karunakar Das - 003823 (GENERAL MANAGER ,FUEL MANAGEMENT) ,Talcher Kaniha
On:28/07/2020(11:01:44) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
Submitted by:
Nasaka Srinivasa Rao - 004542 (GENERAL MANAGER ,O & M) ,Talcher Kaniha
On:28/07/2020(12:20:25) Ref:TSTPP/FUEL HAND./2020-21/LMIWTCHP/280522
LMI
Operating Procedures for
Wagon Tipplers, SAC &
Puller cum Pusher.
Approved for
Implementation
...............................................................................
Shree.Sudip Nag
Chief General Manager, TSTPS, Kaniha
Date: ....................
NTPC LIMITED
KANIHA SUPER THERMAL POWER STATION
LMI NO : LMI/OGN/OPS/SYST/037
Checked By
S K Nayak AGM (MGR)
Checked &
Karunakar Das HOD (FM)
Reviewed By
LMI/OGN/OPS/SYST/037
INDEX
1.0 Introduction 1
5.0 Review 15
1.0 INTRODUCTION
NTPC Talcher Wagon unloading facility includes two wagon tipplers supplied and
erected by ThyssenKrupp Industries India Ltd 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. (Track hopper#1)
This control philosophy for NTPC, Talcher wagon tipplers and conveyor package
consists of two parts as follows
Nil
Nil
MAIN DOCUMENT
This LMI consists of two sections:
4.10: Section A:
4.20: Section B:
4.20 (A): Operating Procedures for WT Operation and Resources for facilitating safe
unloading operations through wagon tipplers and side arm chargers with transform
platform & puller cum pusher .
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LMI/OGN/OPS/SYST/037
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किनहा / KANIHA
LMI/OGN/OPS/SYST/037
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किनहा / KANIHA
LMI/OGN/OPS/SYST/037
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Notes:
Note-1: Monthly protection and interlocks checking should be done. Protection & Interlock
checklist is placed at Appendix-I.
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.
5|Page
किनहा / KANIHA
LMI/OGN/OPS/SYST/037
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 MGR
1.7 with Adequate nos of Walkie – Talkies / Handsets for seamless
communication.
Operating Handles, L-Rods, Shovels, Hammers, Rope etc. for MGR & CHP-
1.8 Oprn.
clearing the grills, Chutes and deck sheets.
Mechanical wedges, properly contoured fix skids/wooden Not applicable
wedges/other suitable durable material should be provided if there (Wheel gripper
1.9 & stopper
are any issues of gradient. These wedges should be placed with
the help of operating handles from adequate distance of rail tracks. provided.)
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 MGR/CHP-
1.11 mask and Reflective Jackets should be ensured for Personal Oprn.
working in wagon tippler areas.
MGR
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:
Protection Checking Protocol: Appendix-I
HIRAC WT: Appendix-II
1.14
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किनहा / KANIHA
LMI/OGN/OPS/SYST/037
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किनहा / KANIHA
LMI/OGN/OPS/SYST/037
4. Operational Procedure:
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. 1A/B.
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 PA System 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
Experienced
EPB before doing the adjustment of coupling. After completion
shunter / SCE –
4.8 of the activity the SAC Rev. Permissive EPB should be
MGR CR /
released. (Decoupling person should not go inside the track
Wagon tippler
after release of SAC Rev. Permissive EPB).
operator
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, local supervisor
and SAC Rev. Permissive provided in OWS, the operator gives Wagon tippler
4.9
command for SAC REV-2 movement Operator
from SBL to SWL for coupling with the loaded wagon.
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LMI/OGN/OPS/SYST/037
9|Page
किनहा / KANIHA
LMI/OGN/OPS/SYST/037
Rev.0.0
Wagon tippler
JCB to be engaged for removal of boulders. Poking EPB to be Operator
4.24
operated while clearing the boulders form hopper grill area.
Poking EPB shall be released only after all the persons come Wagon tippler
4.25 Operator
out of the grill.
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.
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LMI/OGN/OPS/SYST/037
Rev.0.0
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 rods at a suitable distance from tracks. During this activity it has to be ensured that puller
cum pusher does not move the wagon
When the personnel is adjusting the Wagon-Wagon coupling, he has to push the EPB with all commands for
puller cum pusher 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.
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.
Following safety interlocks must be ensured in Local / Auto / Manual modes of operation:-
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Rev.0.0
coupled to the wagon signal is received from the proximity switch mounted on the SAC de-coupler
mechanism.
5. 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.
6. 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.
SAC Interlocks:-
1. 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.
2. SAC arm must not be allowed to be lowered when traveling in arm rai se position in the WT Table
zone, similarly when in arm lowered position it must not be allowed to raise in the WT table zone.
3. SAC arm should be lowered at 400 mm before wagon coupled position at inhaul side. This is initial
waiting position.
4. 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.
5. SAC must not be allowed to travel in arm lowered position when tippler is in forward / reverse
rotation.
6. 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
all the three clamping cylinders.
7. 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:-
1. Tippler must work in close loop interlock with the SAC travel positions & Wagon positions. The
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Rev.0.0
starting/acceleration/constant speed/retardation shall be in accordance to the starting &
stopping positions based on the Tippling encoder feedbacks through PLC.
2. Tippler must not be allowed to tipple when diesel locomotives are being passed from inhaul side
to outhaul side. (Operator to check)
3. 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.
4. 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.
5. Tippler forward tippling must not be allowed when SAC is traveling in the WT Table zone with arm
lowered condition.
6. Table must not be raised unless it has all the Radar sensors (Inhaul & Outhaul) range is clear for
tippling.
7. 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.
8. 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:-
1. 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.
2. 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.
3. 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
shall be terminated if clamping OK signal is not received before 45 deg table rotation.
4. Dosing operation shall start at 45 Deg & shall stop at 85 Deg of the Wagon tippler position in
forward tippling cycle.
5. 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.
6. 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
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Rev.0.0
gripped to ensure against rolling.
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LMI/OGN/OPS/SYST/037
Rev.0.0
2. Apron feeder running /trip feedback to be interlocked with wagon tippler drive as explained under
WT drive interlock ; Cl.2.4.3
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.
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Rev.0.0
Appendix-I
Release
4 Clamp-I
Clamps Apply feed back
Clamp-II
Clamp-III
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LMI/OGN/OPS/SYST/037
Rev.0.0
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
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िकन ह ◌ा
/
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िकन ह ◌ा
/
c) Run over by wagon EPB with lock provided at Out Haul Out haul rake formation
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
personnel working in empty Rake Button and wheel gripper
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.
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किनहा / KANIHA LMI - Operating Procedures for Wagon Tipplers
Hazard Identification, Risk assessment and Control
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
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