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Tippler Refurbishment & Upgrade Project // Majuba Power Station

Majuba Tippler
Refurbishment

Comprehensive refurbishment and upgrade of the coal tippler system at Eskom's Majuba Power Station — mechanical, hydraulic, electrical and control-system improvements to plant reliability, material flow, equipment availability and maintainability.

Majuba Power Station, Mpumalanga
Coal Tippler Refurbishment & Upgrade
PMAJ-27

Project Stats

Project IDPMAJ-27
ClientEskom
CategoryCoal Tippler Refurbishment
LocationMajuba Power Station, Mpumalanga

Project Overview

RULA delivered an integrated mechanical, hydraulic, electrical and control-system refurbishment — from structural and trunnion refurbishment to a full hydraulic drive conversion of the positioner, upgraded monitoring, dust suppression and material flow — engineered, procured, fabricated, installed, tested and commissioned while maintaining compatibility with the original tippler operating philosophy.

// Specifications

Detailed Project Scope

Structural & Mechanical
  • Refurbishment of the tippler side beams and replacement of structural fasteners
  • Replacement and refurbishment of wagon clamping components, slide rails and cushioning springs
  • New spillage shields and upgraded flooring within the tippler table
  • Replacement of trunnion wheels, bearings and assemblies, with realignment of the tippler and rail system
  • Trunnion wheel deflector plates and corrosion protection to refurbished structures
  • Replacement and upgrading of the automatic lubrication system
  • Installation of additional lifting and maintenance facilities
Hydraulic System
  • Replacement of the positioner long-travel drive with new hydraulic drives
  • New hydraulic power packs, pumps, reservoirs, filtration, cooling, instrumentation and pipework
  • Upgrade of the train positioner and pusher-arm systems
  • Replacement and rerouting of hydraulic hoses, with improved access and maintainability
  • Recommissioning of the complete hydraulic system
Material Flow & Monitoring
  • Upgraded dust suppression system with improved spray nozzles and air cannon arrangements
  • Modification of the tippler hoppers to improve coal flow and reduce material bridging
  • Upgraded hopper level detection and operator monitoring, including CCTV integration
  • Upgraded extraction belt feeder system to achieve required material-handling capacity
  • Installation of a tramp-iron removal magnet to protect downstream conveyor equipment
Electrical & Control
  • PLC programming
  • Motor control systems
  • Instrumentation and position feedback
  • System integration across mechanical, hydraulic and electrical disciplines

Project Outcomes

Reduced Structural & Mechanical Wear
Modern Hydraulic Drive Technology
Downstream Equipment Protected From Unwanted Scrap Iron
Improved Material Flow & Reduced Bridging
Capabilities Delivered
Mechanical Refurbishment Hydraulic Design & Installation Electrical & Control Systems PLC Programming Fabrication & Installation Testing & Commissioning

Need A Tippler Or Positioner Refurbishment?

RULA delivers brownfield mechanical, hydraulic and electrical upgrades for train tippler and positioner systems.

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