Challenge

The primary challenge in this project was dismantling key components of a rotary-type wagon tippler, particularly the platform (weighing approximately 20 tonnes), end ring (21 tonnes), and crossbar (28 tonnes). The platform, situated at a significant height above the hopper, served as the main working surface for personnel. Its considerable weight and elevated position introduced substantial risks and complexities, requiring precise planning to ensure safety and operational efficiency.

One of the most critical aspects was locking the platform, end ring, and crossbar securely during dismantling operations. Despite various efforts, achieving a satisfactory locking mechanism proved difficult. The absence of a reliable locking system could have posed severe risks to personnel and the integrity of the operations.

Solution: TCE developed a comprehensive dismantling scheme for the wagon tippler components to address these challenges. This scheme included pre-requisite checks, step-by-step dismantling procedures, and equipment usage guidelines. Key solutions included:

Implementation:

The implementation phase involved collaboration between the structural and electrical teams. Adjustments to the dismantling sequence were made based on-site conditions, and particular attention was paid to salvaging components for reuse.

Key areas of implementation included:

Results:

The dismantling of the rotary-type wagon tippler components was executed successfully with minimal operational disruption and enhanced safety. The use of lifting lugs, combined with strategic gas cutting, allowed for efficient component removal. No accidents occurred, and the project was completed on time.

Conclusion:

This case study highlights the successful dismantling of the wagon tippler through meticulous planning, collaboration, and innovative solutions. By prioritising safety and operational efficiency, the team was able to address the project’s significant challenges and achieve its objectives. This project stands as an example of our commitment to delivering high-quality industrial solutions while maintaining safety and client satisfaction.