Wagon Tippler LMI Approved Note, LMI PDF

FUEL HAND.
- MECH MAINT Department

SIMHADRI
Date:
Ref:SMTPP/FUEL HAND.-/2020-21/LMI WT/219175
19/06/2020(18:31:43)
Subject:Approval Note for Location Management Instructions of Wagon
Tippler, LMI/OGN/OPS/SYST/037
Sub: Approval Note for Location Management Instructions of Wagon Tippler LMI/OGN/OPS/SYST/037.
A statin specific LMI for safe operation of Wagon tipplers is prepared based on the OGN Ref. No: COS-
ISO-00-OGN/OPS/SYST/037, Rev.0, June'2020 and is enclosed herewith.
Kindly review and accord approval for implementation.
Submitted by:
Vasamsetty Srinivasa Rao - 008155 (DY. GENERAL MANAGER ,FUEL HAND.- MECH MAINT)
,Simhadri
On:19/06/2020(18:31:43) Ref:SMTPP/FUEL HAND.-/2020-21/LMI WT/219175
Submitted by:
ABDUL HASSAN SHAIK - 101949 (MANAGER ,FUEL HAND.- MECH MAINT) ,Simhadri
Submitted by:
Syam Naga Kumar Pydi - 062045 (SENIOR MANAGER , FUEL MANAGEMENT)
On:19/06/2020(18:44:00) Ref: SMTPP/FUEL HAND.-/2020-21/LMI WT/219175
Submitted by:
V RAJKUMAR - 035088 (SENIOR MANAGER ,ELECT MAINT- MAIN PLANT) ,Simhadri
LMI revised with respect to the inputs/suggestions received vide telecon/mail. Revised LMI enclosed
herewith.
Kindly review the LMI and accord approval for implementation.
Submitted by:
,Simhadri
Submitted by:
Makala Nageswara Rao - 007521 (DY. GENERAL MANAGER ,ELECT MAINT- MAIN PLANT)
,Simhadri
The Mismatch in the List of Annexures as Described in the LMI document Page No-9/Point-1.14 wrt the
attached Anneuxer nos. shall be corrected during final modification , after all stake hoders review &
comments.
Submitted by:
ANNADA SHANKAR DASH - 035085 (DY. GENERAL MANAGER ,FUEL MANAGEMENT)
,Simhadri
Submitted by:
Annapragada Rama Koteswararao - 047211 (ADDL. GENERAL MANAGER ,FUEL HAND.- OPN)
,Simhadri
LMI checked from C&I and found in order.
Forwarded for further approval.
Submitted by:
G H Rao - 006589 (ADDL. GENERAL MANAGER ,C & I MAINT- BOILER) ,Simhadri
LMI checked and found in line with OGN guidelines
Submitted by:
ITIKYALA LAXMA REDDY - 032235 (ADDL. GENERAL MANAGER ,FUEL HAND.- MECH
MAINT) ,Simhadri
Forwarded for approval.
Submitted by:
Dasari Srinivasa Rao - 005507 (ADDL. GENERAL MANAGER ,FUEL HAND.- MECH MAINT)
,Simhadri
LMI checked and found in line with OGN guidelines.
Recommended fro approval please.
Submitted by:
Maruvada Nvs Bhaskar - 005494 (ADDL. GENERAL MANAGER ,FUEL MANAGEMENT) ,Simhadri
Reviewed,SAC position indication diagram one correction is required (both sides SREL is written) Pl refer
Appendix-1
Submitted by:
Kadali Venkateswara Rao - 003725 (ADDL. GENERAL MANAGER ,ELECT MAINT- MAIN PLANT)
,Simhadri
Appendix-I, SAC end positions corrected to SREL – SAC return end limit and SFEL – SAC forward end
limit. May kindly review and accord approval please.
Submitted by:
,Simhadri
reviwed and for further perusal pl
Submitted by:
Kadali Venkateswara Rao - 003725 (ADDL. GENERAL MANAGER ,ELECT MAINT- MAIN PLANT)
,Simhadri
May be approved.
Submitted by:
Harish Chandra Verma - 001660 (GENERAL MANAGER ,O & M) ,Simhadri
Approved & Submitted by:
Velivala Sudharshanbabu - 004073 (EXECUTIVE DIRECTOR ,HEAD OF PROJECT) ,Simhadri
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Location Management Instructions
LMI/OGN/OPS/SYST/037
Issue No.1, Revision No.0, Date: June’2020
(Ref: COS-ISO-00-OGN/OPS/SYST/037, Rev No: 0)
LMI
Operating Procedures for
Wagon Tipplers
Approved for
Implementation
...............................................................................
Executive Director, Simhadri
Date: ....................
NTPC LIMITED
SIMHADRI SUPER THERMAL POWER STATION
COAL HANDLING PLANT – FUEL MANAGEMENT DEPARTMENT

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
S.A.Hassan Manager (CHP-O)
P. Syam Naga Kumar Sr. Manager (FC)
V. Raj Kumar Sr. Manager (EMD)

Prepared By
V Srinivasa Rao DGM (CHP-MM)
M. Nageswara Rao DGM (EMD)
A S Dash DGM (FC/FT)
Checked By A.R. Koteswara Rao AGM (CHP-OPN)
Checked By G. Hari Narayana Rao AGM (C&I)
Checked By I.Laxma Reddy AGM (CHP-MM)
Checked By D.Srinivasa Rao AGM I/c (CHP)
Checked &
M.N.V.S. Bhaskar HOD (FM)
Reviewed By
Checked &
K V Rao HOD (EMD)
Reviewed By
Reviewed By H.C.Verma GM (O&M)

Rev.0.0, Page | 1
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

Rev.0.0, Page | 2
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 Simhadri. 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.
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

Rev.0.0, Page | 3
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 of
placement. 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 Simhadri 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 300-
hose. 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 lamp
Charger personnel by to disable any SAC movement when
Operation SAC/Wagon the personnel is performing any of the
during following activities:
Rev.0.0, Page | 4
following • Decoupling/ Coupling at
operations: 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
Motion barricaded to avoid uncontrolled
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 Coupler,
at wagon tippler table weekly preventive maintenance shall
(Position SWCPL in be done.
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.
Rev.0.0, Page | 5
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 Wagon i) Healthiness & Cleanliness of Rack and
Tippler during Pinion should be ensured.
tippling operation. ii) Pressure in hydraulic circuit should be
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.
Formation b) Impact / Hit by Operation of EPB with lock should be
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.
Rev.0.0, Page | 6
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.
Rev.0.0, Page | 7
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 wagon tippler CHP-Oprn.
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 involved
1.3
in unloading operations.
1.4 Location Manpower – 4 member per shift (2 Skilled + 2 Unskilled) CHP-Oprn

FC/FT
JCBs for Boulders clearing from grills. They should be fitted with
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 FC/FT
wedges/other suitable durable material should be provided if there
1.9
are any issues of gradient. These wedges should be placed with
the help of operating handles from adequate distance of rail 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/CHP-Oprn.
1.11 mask and Reflective Jackets should be ensured for Personal
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
Rev.0.0, Page | 8
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 / TPMs. Rly. Exp. Person/
2.6
Upon completion of the break release, written clearance / SCE – TH CR
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
Rev.0.0, Page | 9
4. Operational Procedure:
S.No Work Description Responsibility

Confirm brake release of wagons from TH-Control room Wagon tippler
4.1
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 completion
SCE – TH CR /
4.8 of the activity the SAC Rev. Permissive EPB should be
Wagon tippler
released. (Decoupling person should not go inside the track
operator
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 in Wagon tippler
4.9
OWS, the operator gives command for SAC REV-2 movement Operator
from SBL to SWL for coupling with the loaded wagon.
Rev.0.0, Page | 10
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 and
Wagon tippler
4.11 obtaining the permissive, Forward command to be given from
Operator
OWS to move SAC from SWL to SWUL.
The loaded wagon is to be decoupled from the rake (at inhaul
Rly. Exp. Person/
side) and EPB is to be pressed for granting permissive to
SCE – TH CR /
4.12 advance the side arm charger from OWS. Wagon decoupling
Wagon tippler
activity to be monitored by the WT operator through camera
Operator
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 given Wagon tippler
4.19
from SNRL to SBL for coupling with next loaded wagon. operator
Tippling continues up to 137 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 starting Wagon tippler
4.21
of clamping motors at 80 deg and release of clamps at 3 deg. operator
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 on Operator
the grills.
Rev.0.0, Page | 11
Rly. Exp. Person/
JCB to be engaged for removal of boulders. Poking EPB to be SCE – TH CR /
4.24
operated while clearing the boulders form hopper grill area. Wagon tippler
Operator
Rly. Exp. Person/
Poking EPB shall be released only after all the persons come SCE – TH CR /
4.25
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 inhibit Rly. Exp. Person/
4.26
the permissive for Side arm charger by keeping the push button SCE – TH CR
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 by Rly. Exp. Person/
4.28
coordinating with the TPM and Loco pilot to facilitate the next SCE – TH CR
rake unloading to start.
Additional provisions.
• Camera views are provided in the WT control room/Track Hopper CR for
4.29
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
Rev.0.0, Page | 12
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.
5.0 REVIEW
The HOP Simhadri shall be responsible for reviewing this LMI on a three yearly basis
or as necessary.
Rev.0.0, Page | 13
Appendix-I
SAC POSITIONS DURING WAGON TIIPPLER OPERATION
Rev.0.0, Page | 14
Appendix-II
Protections and Interlocks for SAC & Wagon Tippler operation
Equipment/ End of
Start Permissive for Protections & Interlock Modification
S.No Operation Command/
Command Trips incorporated
sequence Operation
• Overload
Manually stops after
• Module ON • Motor EPB
Tippling hydraulic motor completion of rake
• No Overload • Pr Filter Clogged • EPB provided in Power pack Room
1 Start - Manual Command
• Motor EPB released • Return Filter Clogged • Operator desk EPB (provided
(for the first time of rake) • Oil Temp >70 Deg Trip near work station) for emergency
• Oil Level Low stop of all operations.
• Module ON • Power pack EPB

Clamping hydraulic motor Manually stops after • Local station EPB (at inhaul side)
2 Start - Manual Command • No Overload completion of rake
• Motor EPB released • Operator desk EPB
(for the first time of rake)
(provided near work station)
• Operator Local station EPB
SAC motor Protections:
After reaching SWL • SAC EPB
position • Over Load
• SBL Position
3 SAC Rev-2 (from SBL to (Here coupling • EPB provided on the top of Coal
• Arm Down Position • Oil Level Low
SWL) Manual Command takes place and sampling arrangement.
• SAC Rev Permissive (EPB • Oil Temp >70 Deg Trip
after Coupling
release) • Pressure Switch
gives Engage-2
• Main Filter clogged
proxy feedback) • Return Filter Clogged
• Table 0 Deg. • AF motor current limited from 60-95
• Tippling Hyd Motor ON Amp., to restrict next tipple so as to
• Clamp Motor ON feedback avoid overload on Apron feeder.
• Tippling stops at • Tippling halts at 80 deg • ZSS provided for AF.
• AF motor ON feedback &
150 Deg  If any clamp APPLY
Current (60- 95A range) • VFD installed for AF and also DBU
Tippler “TIPPLE” Manual • Clamps start feedback misses
4 (interlock with DC motor (Dynamic Braking Unit)
Command at 0 deg applying from 0  Clamp motor ON feedback
running feedback) commissioned.
deg. misses
• Photocell - 1&2 clear • Clamp motor ON feedback
• Clamp motor • Tippling stops when
• SAC at SNRL Position incorporated in permissive.
stops in auto at  Extra LL2 Limit Switch
• SAC Arm UP proxy operated (for over • All clamps APPLY & RELEASE in
80 deg
feedback tippling) 4/4 logic incorporated.
• EPB at Power Pack Room  Any clamp APPLY feedback • Extra LL2 Limit Switch operated (for
Released missing (after 80 deg) over tippling)
• Railway permissive EPB • Additional Limit switches provided on
Clamps for APPLY feedback for
height boxes.
• Railway permissive EPB provided at
Outhaul side for emergency stop by
Railway TPMs.
Rev.0.0, Page | 15
Equipment/ End of
Start Permissive for Protections & Interlock Modification
S.No Operation Command/
Command Trips incorporated
sequence Operation
• Clamping motor • Any clamp RELEASE Limit Limit switch relocated from Drive pit
• Hyd. Motor ON
5 Tippler “RETURN” Manual starts in Auto at switch feedback missing. to Tippler side for Table 0 deg
• Table at 150 deg.
Command at 150 Deg 80 deg. and feedback
• All clamps APPLY feedback • Table 0 deg feedback
Clamps start
missing
releasing.
• Tippling RETURN
stops at 0 Deg
• Table "0" Deg Position
• All Clamps Release
SAC FWD-1 Manual feedbacks
6 Command (from SWL to • SAC Arm Down feedback At SWUL Position • SFEL feedback
SWUL) • Coupling Engage – 1 & 2
feedback
• Sampling EPB Release
feedback
• Railway Permissive Button
• Table "0" Deg Position
SAC FWD-2 Manual
7 • SAC at SWUL Position At SWCPL Position • SFEL feedback
Command (from SWUL to
• Wagon Uncouple feedback
SWCPL)
SAC FWD-3 Auto
8 Command (from • Coupler Release Proxy At SNRL Position
SWCPL to SNRL)
SAC REV-1 Manual • SNRL Position • At SBL Position (&

9 • SREL feedback
Command (from SNRL to • Arm not Down gives permissive to
SBL) Coupler Engage-1)
• SBL Position (which further
gives permissive for Auto • By Sensing Arm Proxy replaced with Limit switch as
10 Arm Down Manual
command for Engage- 1) Down Limit switch proxy was malfunctioning due to its
Command
location.
11 Arm UP Manual Command • SNRL Position • By Sensing Arm

Vertical Proxy
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 SBL
SWL
SWUL
SWCPL
SNRL
SFEL
SREL
2 SAC-Arm proxies Vertical proxy
Horizontal Limit
3 SAC-Coupler proxies Engage-1
Engage-2
Release
4 Clamp-I
Clamps Apply feed back
Clamp-II
Clamp-III
Clamp-IV
5 Clamps Release feed Clamp-I
back Clamp-II
Clamp-III
Clamp-IV
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
Rev.0.0, Page | 17
"80" 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)
Hazard Identification, Risk assessment and Control LMI/OGN/OPS/SYST/037
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
behavior Injury/ Ill
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
Injury I D 8 SOP-WT IV D 19
track during rake 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
Collision of Empty
ii) SAC Arm Up
standing wagon with Plant iii) All Clamps in released position. Installed a Signaling
II D 10 SOP-WT IV E 20
Incoming loaded Outage iv) No empty rake in Outhaul side system.
wagon. (Railway signal permissive)
Fouling of Loco/ If all above permissive from B (i-iv)
Wagon with Side Arm are clear then signal will be
Charger/ Wagon “YELLOW” otherwise it should be
Tippler Plant
II D 10 “RED”. SOP-WT IV E 20
Outage
Safety Indication Boards displayed
indicating “DO NOT 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) Contoured wedges / fix skids
release. are being placed under the
Injury II D 10 wagon wheels from suitable SOP-WT IV D 19
distance with the help of long
operating handle.
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.
Injury I D 8 v) Only experienced persons are SOP-WT IV E 20
being engaged for monitoring
the brake release process and
ensuring safety of personal.
vi) Brake release clearance (in
written) by FT to WT Control
Room to avoid
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 and LED
Operation personnel by glow lamp linking with SAC
SAC/Wagon movement when personnel is
during performing the following
• Arm Up activities:
• Arm Down • Decoupling/ Coupling at

inhaul/outhaul side.
• Forward
• Sampling at wagon top.
Motion ii) SAC Movement area
• Reverse barricaded to avoid
Injury II D 10 uncontrolled movement of SOP-WT IV D 19
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 enmarked for standing and Emergency EPB
loose performing the coupling /decoupling provided for any
Wagon door / Bulged Injury III C 11 activates. SOP-WT IV C 18 exigencies.
wagon hitting the
person.
SAC festoon trolley Weekly checking is being done for
fouling & entanglement Plant healthiness of Festoon Trolley in
IV C 18 IV E 20
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)
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 ensured at regular intervals.
IV A 13 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.
Wagon III D 14 SOP-WT IV D 19
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
do not hold the wagon used to avoid damages to other
properly. equipment.
f) Free Fall of Wagon i) Cleanliness of Rack and Pinion
Tippler during tippling is ensured.
operation.
ii) Operation of system with
Design/OEM guidelines.
Plant iii) Online oil filtration unit provided
III D 14 for maintaining the oil quality SOP-WT IV D 19
Outage
(NAS Value 7).
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 SOP-WT IV E 20
pit.
table.
ii. Photocell protection provided
5. Empty Wagon / a) Derailment of empty Table alignment inspection during the
Plant
Rake Formation IV D 19 IV D 19
wagon Outage scheduled protections checking.
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.
Rev.0.0, P a g e | 21
c) Run over by wagon EPB with lock provided at Out Haul

of person engaged in
hose pipe connection. Side to disable movement of SAC if
Injury I C 4 SOP-WT IV D 19
personnel working in empty Rake
formation.
6. Associated a) Electrocution due PTW with isolation of OHE is being
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.
Rev.0.0, P a g e | 22
Severity Category People Costs Probability Level Frequency or Likelihood
Death due to serious Plant outage > one week and/or Likely to occur frequently or at least once per
Catastrophic I Frequent A
injuries or illnesses losses > Rupees 100 crores year or more frequently
Likely to occur several times in life of the

Probable B
Disabling injury or Facility outage upto one week system or at least once in 3 year period
Critical II severe occupational and/or losses > Rupees 20 crores
Likely to occur sometime in life of the system
illness but < Rupees 100 crores
Occasional C or once in
6 years period
Medical Aid Injury or Facility outage upto 2 days and/or
Marginal III minor occupational losses > Rupees 1 crore but < Unlikely, but possible to occur in the life of
illness Rupees 20 crores Remote D
the system or once in 15 years period
Minor injury or illness Facility outage upto 1 day and/or Highly unlikely, but possible to occur in the
Negligible IV
(First Aid case) losses < Rupees 1 crore 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
NTPC SIMHADRI
Installation of Audible Warning System with auto operation at Wagon Tippler area, Simhadri
“As a due service to the public, the assurance of the continuous improvement of one’s safety
within society to enhance the quality of life is vital”
Guided by : Executed by :
Sri M N V S Bhaskar, HOD-FM Syam Naga Kumar Pydi, Sr. Manager-FC/FT

Ramu Karri, Sr. Manager-EM
Sri K. Venkateswara Rao, HOD-EMD
Nageswara Rao. M, DGM-EM
A S Dash, DGM-FT
NTPC Simhadri gets coal from Coal India Subsidiaries through Indian Railway Coal Rakes
of BOBRN & BOXN type. BOBRN Rakes are directly placed & unloaded at Track Hopper. BOXN
coal rakes are unloaded at Wagon-Tipplers by tippling each wagon at a time onto a hopper. The
empty wagons are joined one by one on the other side (outhaul) and empty rake is composed.
Wagon Tipplers have Side Arm Chargers to place each wagon on to the Wagon Tippler
table and simultaneously push the empty wagon. Once loaded wagon is placed on the table, it is
tippled up to around 140 degrees to empty the coal. During tippling, the wagon is clamped by
hydraulic arms and controlled/monitored by various safety protections and interlocks.
Total Railway Track section at Simhadri is Over-Head Electrified except for the 100 metres
on inhaul & outhaul side of Wagon Tippler area for facilitating the tippling of wagon. An engine
escape line is available between the two wagon tipplers for movement of the Railway Electric
Locomotive (Diesel loco directly passes over the tippler table, in absence of empty rake on out-
haul side, subjected to permissive clearance) after reaching the wagon Tippler area. Railway
Locomotive, after detaching from the loaded rake, 100mts prior to Wagon tippler, passes through
the engine escape line and attaches to rear of the rake. The Loco then pushes the whole rake for
placement of the rake near to Side Arm Charger, with communication between points-man & loco
driver through walkie talkie. During back pushing, the rake moves at a very slow speed (@ 1 to 2
Km/hr speed), without any audible alarm. Till now, there was no audible signal available for giving
caution to the persons working at Wagon tippler area & also for Two Wheelers and Four wheeler
road users.
Page 1 of 7
NTPC SIMHADRI
With a view to enhance safety and give an audible caution to the people who are working
near Railway tracks & crossing the railway track at Wagon Tippler area road, an initiative is taken
for installation of a audible warning system using siren at the Wagon Tippler location,
which is totally operative on “AUTO”, without any human intervention.
This is an additional safety feature being put in place in addition to existing safety systems.
Inputs are taken from S&T system with installation of electrically operated Siren separately.
Automatic Siren would start to give audible caution during fulfilment of following conditions.
1. During Box-N Rake arrival at WT-1

2. During Box-N Rake arrival at WT-2
3. During Box-N Rake back pushing through Railway Loco at WT-1&2
4. During Empty Loco movements in Engine Escape line (Forward & Reverse)
Audible Siren works on Auto mode to alert all the persons those who are working in nearby
Wagon Tippler area & sub-road users near W/T, and also auto cut-off would occur after the rake
gets placed completely within the reach of Side Arm Charger of Wagon Tippler, through a timer
of 25 seconds.
Figure 1: Track Layout with installation of New Siren & New Control JB.
This idea is conceptualized and implemented at Simhadri

using wholly in-house material and services
Page 2 of 7
NTPC SIMHADRI
Figure 2: Schematic of Track circuits
Siren auto starts in all the following conditions:
Forward direction Whenever loco wheels cross point “A”, “C”, “D”, “E”, “G”, “I”
Reverse direction. Whenever loco wheels cross point “J”, “F”
Stabling point of load rake on WT-1 for detaching the loco, for onward movement over engine
escape line to get attached on the rear of the rake via C-F-I-J
Stabling point of load rake on WT-2 for detaching the loco, for onward movement over engine
escape line to get attached on the rear of the rake via E-F-I-J
Light engine movement either from WT-1 or WT-2 in reverse direction for back pushing the
rake via J-I-F-D.
Page 3 of 7
NTPC SIMHADRI
Logic Implementation:
Control logic scheme envisaged using existing Railway S&T system, ensuring no mixing of
voltages (i.e. 6v dc, 24v dc, 230v ac). To accomplish this, railway track monitoring voltage relay
contacts are multiplied using sub-relays. Track circuits are segregated to enable siren on each
operation of loco/rake movement.
Whenever engine/rake, comes on the track, corresponding Track monitoring voltage (6V DC)
gets shorted and the corresponding Track master relay (Related to Signalling system) will be
dropped.
Figure 3: Inside Rly. S&T cabin
Upon dropping of Track master relay, the NC (Normally closed) contacts will open and the
corresponding sub-relay (260AT etc) will be dropped.
Figure 4: Inside Rly. S&T cabin
Page 4 of 7
NTPC SIMHADRI
Upon dropping of sub relays (i.e. 260AT etc), corresponding timer shall be energized and picks
up the Power contactor C1 (Refer figure-5 below). The timer shall hold the power contactor up to
the predefined set value of 25sec. duration.
Figure 7: New Control JB

installed on existing Rly. Track
panel
Figure 5: Timer Logic
Figure 6: New Fuses installed in L9 JB Figure 8: Timer Control JB
Irrespective of the position of the rake, on each circuit, this logic will be operated on AUTO during
all conditions of Engine on Track as defined at Page No.2 (Various movements of rolling stock)
above. For example, although a rake is placed on WT#1, and second rake is about to be placed
on WT#2, this logic will be operated on AUTO mode and enables Siren.
*Timers will be de-energized once the rake/loco passes entire defined track circuit zone.
Page 5 of 7
NTPC SIMHADRI
Figure 10: Power JB of Siren
Figure 9: Power scheme of Siren Motor Figure 11: Electrical Siren installed at WT
Bill of Material: Along with the existing track circuit, the following material is used.
1. Timers (230V ac) - 4 nos (multi-mode using interval selection)

2. 3-ph MCB - 1no.
3. 3-ph Power contactor - 1 no.
4. Power cable (3Cx16 sq.mm) - 20mtrs.
5. Control cable - 20mtrs
6. Plug-in relays (sub-relays) - 4nos
7. Control fuses - 7 nos
8. 3-ph Siren - 1 no.
Page 6 of 7
NTPC SIMHADRI
With this “PATENT” conceptualisation, design & implementation of this project, we intent
to achieve complete safety for those who are working near Wagon tippler premises and
also the road users through the interconnecting road, during any movement of coal
rakes/Locos at Wagon tippler area.
Page 7 of 7

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Wagon Tippler LMI Approved Note, LMI PDF

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FUEL HAND.

- MECH MAINT Department

Kindly review and accord approval for implementation.

Kindly review the LMI and accord approval for implementation.

Forwarded for further approval.

LMI checked and found in line with OGN guidelines

Forwarded for approval.

LMI checked and found in line with OGN guidelines.

Recommended fro approval please.

reviwed and for further perusal pl

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COAL HANDLING PLANT – FUEL MANAGEMENT DEPARTMENT

Issue No. 1 Revision : 00 Date: 19.06.2020

Name Designation Signature

S.A.Hassan Manager (CHP-O)

P. Syam Naga Kumar Sr. Manager (FC)

V. Raj Kumar Sr. Manager (EMD)

M. Nageswara Rao DGM (EMD)

A S Dash DGM (FC/FT)

Checked By A.R. Koteswara Rao AGM (CHP-OPN)

Checked By G. Hari Narayana Rao AGM (C&I)

Checked By I.Laxma Reddy AGM (CHP-MM)

Checked By D.Srinivasa Rao AGM I/c (CHP)

Reviewed By H.C.Verma GM (O&M)

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

Appendix -I SAC Positions of WT 13

Protection & Interlocks of Wagon Tippler and Side Arm

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

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

2.0 SUPERSEDED DOCUMENTS

3.0 RECORD OF REVISION

4.0 MAIN DOCUMENT

Hazard Identification, Risk Assessment & Control Measures (HIRAC)

4.20 (B): Additional Protection & Interlocks

S. No Activity Hazards Control Measures

c) Clearing coal from Pocking EPB with beacon should be

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

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

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

S.No Work Description Responsibility

S.No Work Description Responsibility

vi) Auto warning Siren system for wagon placement:

vii) Direct placement railway signal lamp:

• Module ON • Power pack EPB

SAC REV-1 Manual • SNRL Position • At SBL Position (&

11 Arm UP Manual Command • SNRL Position • By Sensing Arm

MONTHLY WAGON TIPPLER PROTECTION CHECKING PROTOCOL FORMAT

CHP-MM EM C &I CHP Operation

Type of Risk Control Measures in place Objective/ Risk

Fall of Person while at miscommunication is initiated.

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

• Arm Down • Decoupling/ Coupling at

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