CONVEYOR CALCULATION

L&T CONSTRUCTION
EDRC-BMH-MMH IC
DOCUMENT NO DATE REV
PROJECT: MHS FOR DEVELOPMENT OF DRY BULK
AKBTPL:KDL-12/E101.007/M013/DN-C0201 05.09.13 A
TERMINAL AT TUNA NEAR KANDLA
L&T : O13074-M-BM-CS-DC-0005 31.07.13 2
TITLE: TYPICAL MANUAL DETAIL CACULATION OF Designed Checked SHEET
CONVEYOR KC-1C (AS PER IS:11592) MNS SAI 1 OF
INDEX
S.NO DESCRIPTION SHEET NO
A POWER & TENSION CALCULATION FOR CONV. KC-1C
B BELT/PULLEY DIA SELECTION FOR CONV. KC-1C
C CONCAVE/CONVEX RADIUS CALCULATION FOR CONV. KC-1C
D GEAR BOX & COUPLING SELECTION FOR CONV.KC-1C
E COASTING TIME CALCULATION FOR CONV KC-1C
ANNEXURE-1 POWER CALCULATION CONSIDERING MAX BULK

F
DENSITY OF MATERIAL
Refer CONVEYOR GA- KDL-12/E101.007/M013/DN-C 02 01 for

Conveyor related dimensions
LARSEN & TOUBRO LIMITED
EDRC-BMH-MMH IC
PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

TERMINAL NEAR TEKRA, KANDLA AKBTPL:KDL-12/E101.007/M013/DN-C0201 REV. NO. : A DT 05.09.13
L&T : O13074-M-BM-CS-DC-0005 REV. NO. : 2 DT 31.07.13
TITLE: TYPICAL MANUAL DETAIL CACULATION OF CONVEYOR KC-1C (AS PER DESIGNED CHECKED SHEET : OF
IS:11592) MNS SAI
A) POWER AND TENSION CALCULATION FOR CONVEYOR KC-1C
Sl. No. Description Nomenclature / Formula / Equation Unit Numerical value Remarks
1 Rated capacity R TPH 3200
2 Design Capacity C TPH 3600
3 Material - - COAL
4 Max Bulk Density ρ1 Kg/m3 1200
5 Min Bulk Density ρ2 Kg/m 3

800
6 Surcharge Angle SA Degree 20
7 Belt Width B mm 1600
8 Troughing angle BT Degree 45 Standard 3 Roll troughed
9 Conveyor Length L m 248.057 Refer attached conveyor profile
HC Refer attached conveyor profile. Head Pulley

10 Conveyor Lift m 2.595
Transition Lift of 175mm Added.
11 Lift due to tripper if any HT m -
12 Conveyor Inclination θ deg 4.56 Refer attached conveyor profile
13 Head pulley dia assumed Dh mm 800
14 Lagging thickness LT mm 16 Diamond grooved Rubber lagging
15 HP dia with lagging D1 m 0.832
16 Wrap angle q Degree 210
17 Belt Rating assumed - 1250/4 NN-HEAVY DUTY,Max RMBT 140 KN/M
18 Type of Take up & Location - - HGTU AT TAIL END
19 No of Type A pulley A - 1 Drive pulley
20 No of Tripper discharge pulley A' 0 No tripper

21 No of Type B pulley B - 1 Tail pulley
22 No of Type C pulley C - 1 Snub pulley

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IS:11592) MNS SAI
SPEED CALCULATION (WITH MAX BULK DENSITY)
23 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 2.92 C=DESIGN CAPACITY

For 1600 BW. 3 Roll, 45° troughed with 20°
Maximum cross sectional area of load on
24 A m2 0.324 Surcharge angle (Refer Page no. 11 of IS-
belt(A)
11592:2000)
For 6° conveyor inclination (max.)
25 Slope factor(K) K - 0.98
(Refer page no.13 of IS 11592:2000)
26 Filling factor(Kf) Kf - 0.9
Considering Maximum bulk density of conveyed

27 Bulk density(ρ) ρ T/m3 1.2
material
28 Belt speed as per Spec(V1) V1 m/sec 4.6
29 Motor RPM - RPM 1490
30 Motor RPM Available at GB input shaft Nm = Motor RPM*0.97 RPM 1445 (Considering fluid coupling slip as max.3%)
31 Gearbox ratio required G = (π x D1 x Motor RPM)/(60 x Belt Speed) - 13.68

32 Referring ELECON Helical gearbox catalogue, selected nominal reduction ratio - 14
33 Belt speed with gear box nominal ratio V2= (π x D1 x Motor RPM)/(60 x reduction ratio) m/sec 4.50
HENCE BELT SPEED V2 IS ADEQUATE TO CATER FOR DESIGN CAPACITY AS THE SELECTED SPEED OF 4.5 m/s IS MORE THAN REQUIRED SPEED OF 2.92 m/s (WITH MAX BULK
DENSITY OF MATERIAL). THEREFORE CHOSEN REDUCTION RATIO IS CORRECT.
EDRC-BMH-MMH IC

IS:11592) MNS SAI
SPEED CALCULATION (WITH MIN BULK DENSITY)
33A Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 4.37 C=DESIGN CAPACITY
33B A m2 0.324 Surcharge angle (Refer Page no. 11 of IS-
belt(A)
11592:2000)
33C Slope factor(K) K - 0.98
33D Filling factor(Kf) Kf - 0.9
Considering Minimum bulk density of conveyed

33E Bulk density(ρ) ρ T/m3 0.8
material
33F Belt speed as per Spec(V1) V1 m/sec 4.0
33G Motor RPM - RPM 1490
33H Motor RPM Available at GB input shaft Nm = Motor RPM*0.97 RPM 1445 (Considering fluid coupling slip as max.3%)
33I Gearbox ratio required G = (π x D1 x Motor RPM)/(60 x Belt Speed) - 13.68

33J Referring ELECON Helical gearbox catalogue, selected nominal reduction ratio - 16
33K Belt speed with gear box nominal ratio V2= (π x D1 x Motor RPM)/(60 x reduction ratio) m/sec 4.50
EDRC-BMH-MMH IC

IS:11592) MNS SAI
A) POWER AND TENSION CALCULATION FORDRIVING
CONVEYOR KC-1C
FORCE CALCULATION CONSIDERING THE MIN BULK DENSITY OF 800 KG/CU.M
INPUTS
[ For 3 ROLL φ152.4, 5.4mm Shell Thickness

34 Mass of rotating parts on carrying side(Mc) Mc Kg/m 42 idler Suitable for 1.6 m belt width and at 1.1m
spacing]. Average weight/m
Mass of rotating parts on return side(Mr) [ For 2 ROLL φ139.7, 4.85mm Shell Thickness
35 Mr Kg/m 10
Idler for 1.6 m belt width and at 3.3m spacing].
Mass of material remains same for both the

density of material because when density
36 Mass of material Mg= C/(3.6xV2) Kgs/m 222.22 increases by 1.5 times (800 to 1200 kg/cu.m),
area decreases by 1.5 times, since the speed of
4.5 m/s is constant.
[As per Belt Manufacturer’s catalogue, carcass
37 Carcass weight - Kg/m2 6 weight of 1250/4 Heavy duty belt. Catalogue
copy enclosed
[As per Belt Manufacturer’s catalogue cover

38 Cover weight - Kg/m²/mm 1.11 weight for M-24 grade]. Catalogue copy
enclosed
Thickness of top cover = 8 mm Thickness

39 Total cover thickness - mm 11
of bottom cover = 3 mm
Mb= (carcass wt x belt width)+(cover wt x total cover

40 Mass of belt(Mb) kg/m 29.136 0
thk x belt width)
41 Artificial Co efficient of friction f - 0.022
Min. bulk density of material is considered as

42 Volumetric conveying capacity(Q) Q= C/(3600 xρ ) cu.m/sec 1.250
density is in denominator
43 Coefficient of Friction between material & Belt µ1 - 0.6 Refer page 17 of IS-11592:2000
Co-efficient of friction between material and
44 µ2 0.6 Refer page 17 of IS:11592 – 2000
skirt plates
45 Acceleration length at loading area La = V22/(2 x g x µ1) M 1.7202
EDRC-BMH-MMH IC

IS:11592) MNS SAI
46 Inter-skirt plate width b1 M 1.1 b1= 2/3 x Belt width
Wrap Resistance for Type A Pulley (Drive, Assumed. To be checked after pulley
47 Rwa N 200
HT Bend) calculations
Wrap Resistance for Type B Pulley (Tail,Take Assumed. To be checked after pulley
48 Rwb N 175
up) calculations
Wrap Resistance for Type C Pulley (Snub,LT Assumed. To be checked after pulley
49 Rwc N 140
Bend) calculations
Pulley brg. Resistance(Rb) for Type A Pulley Assumed. To be checked after pulley
50 Rba 300
(Drive, HT Bend) calculations
Pulley brg. Resistance(Rb) for Type B Pulley Assumed. To be checked after pulley
51 Rbb N 200
(Tail,Take up) calculations
Pulley brg. Resistance(Rb) for Type C Pulley Assumed. To be checked after pulley
52 Rbc N 150
(Snub,LT Bend) calculations
Including The Length of Acceleration at Loading
53 Length of skirt plate(Lsk) Lsk M 8
Area
54 No of loading points - - 2 Since fed by 2 nos Mobile hopper
55 No. Of Internal belt cleaners 1

Length of contact of each internl belt cleaner
56 1.414 x b M 2.2624
blade
57 Internal belt cleaner blade thickness M 0.02
58 No. of External belt cleaners 2
Length of contact of each external belt cleaner
59 1xb M 1.6
blade
60 External belt cleaner blade thickness M 0.01
A1= No. Of Internal belt cleaners x Length of each
Area of contact between belt and belt
61
cleaner(A1)
belt cleaner blade x internal belt cleaner blade M2 0.077
thickness + No. of External belt cleaners x Length of
62 Pressure between belt and belt cleaner(P) P N/M2 65000 [Refer page 17 of IS:11592 – 2000]
Co-efficient of friction between belt and belt
63 µ3 0.65 [Refer page 17 of IS:11592 – 2000]
cleaner(µ3)
EDRC-BMH-MMH IC

IS:11592) MNS SAI
With out Tripper, where
Te1 = Carry Side frictional resistance from Tail to Head
64 Effective Tension Te Te= Te1 + Te2 + Te3 N
Te2 = Return Side frictional resistance from Takeup to Tail Te3 =
Return Side frictional resistance from Take up to head
RESISTANCES - (FULLY LOADED)

CARRY SIDE RESISTANCES FROM TAIL TO
65 Te1 = Rm + Rsl+Rs+Rsp N 34218.59
HEAD
66 Total Inclined Length Carry Lc m 248.07
67 Total Lift Hc m 2.60
68 Main Resistance Carry (Rm) Rm= f x Lc x g x [ Mc+ (Mb + Mg)] N 15705.87
69 Slope Resistance Carry (Rsl) Rsl= (Mb+Mg) x Hc x g N 6398.76
70 Secondary Resistance Carry(Rs) Rs = Ra + Rska + Rw + Rb N 6941.14
Inertial and frictional resistance at the loadng in the acceleration area between the handled
71 Ra = Q x 1000 x ρ x V2 N 4500.00
point and material and the belt
between handled material and the skirt plate in
72 Frictional resistance at the loadng point and Rska = (µ2 x Q2x1000x ρ x g x La)/((V22/4) x b12) N 2066.14
acceleration area
73 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 175.00 For 1 No Tail Pulley
74 Pulley bearing resistance Rb = Rb x (A'+B+C) N 200.00 For 1 No Tail Pulley
75 Special Resistance carry(Rsp) Rsp = Ri + Rsk +Rbs N 5172.83
76 Drag resistance due to forward tilt Ri= g x Ci x µ0 x L x { Mb + Mg } x Cos δ x Sin i N 0

2
Resistance due to friction between material Rsk= (µ2 x Q x1000 x ρ x g x (Lsk-La) x No.of loading
77 N 3771.34
and skirt plates points)/(V22 x b12)
Resistance due to friction between belt and
78 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1401.49
skirt plates
RETURN SIDE RESISTANCES FROM TAKE
79 Te2 0
UP TO TAIL
EDRC-BMH-MMH IC

IS:11592) MNS SAI
80 Total Inclined Length Return Lr1 m 0.00
As Take up is HGTU At Tail End
81 Total Lift Hr1 m 0.00
82 Te3 4907.30
UP TO HEAD
84 Total Lift Hr2 m -2.60
85 Main Resistance Return Rm= f x Lr1 x g x [ Mr+ (Mb)] N 2095.29
86 Slope Resistance Return Rsl= (Mb) x Hc x g N -741.71
87 Secondary Resistance Return Rs = Rw + Rb N 290.00
88 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 140.00 For 1 No Snub Pulley
89 Pulley bearing resistance Rb = Rb x (A'+B+C) N 150.00 For 1 No Snub Pulley
90 Special Resistance Retun Rsp = Rbc N 3263.73

91 Rbc= A1 x P x µ3 N 3263.728 [Refer page 17 of IS-11592:2000]
belt cleaner(Rbc)
92 Hence,Effective Tension Te Te= Te1 + Te2 + Te3 N 39125.90

EDRC-BMH-MMH IC

IS:11592) MNS SAI
POWER CALCULATION AT FULLY LOADED CONDITION
93 Belt Power P = (Te x V2)/1000 kW 176.07

94 Power loss due to drive pulley Dp=(Rwa + Rba)x no of Drive pulley x V2 /1000 kW 2.25 No of Drive pulley is 1
95 Power absorbed at gear box output(Pa) Pa = Belt power + Power loss due to drive pulley kW 178.32
(For Triple Reduction Gearbox as per
96 Gear box efficiency - 0.965 catalogue)
- (For SCOOP type Fluid coupling, considering a
97 H.S. Coupling efficiency 0.97
max. slip of 3%)
98 Overall drive efficiency(η0) η0= Gear box efficiency x coupling efficiency X 0.99 0.927 Considering Gear Coupling Efficiency of 99%
99 Required power at motor shaft(Pm) Pm= Pa/η0 192.43

100 Motor power With 10% Margin Pm X 1.1 211.7
101 SELECTED MOTOR POWER MP kW 230 HT MOTOR
Absorbed power @ Motor shaft with rated
101 A Pmr kW 174.6
capacity
101 B Available Motor Margin on the above Mp/Pmr - 31.73 > 20%. Hence O.K
RESISTANCES - (EMPTY)
102 Te1 = Rm + Rsl+Rs+Rsp N 6326.72
HEAD
105 Main Resistance Carry (Rm) Rm= f x Lc x g x [ Mc+ (Mb)] N 3808.52
106 Slope Resistance Carry (Rsl) Rsl= (Mb) x Hc x g N 741.71
108 Ra = Q x 1000 x ρ x V2 N 0.00
between handled material and the skirt plate in
109 Frictional resistance at the loadng point and Rska = (µ2 x Q2x1000x ρ x g x La)/((V22/4) x b12) N 0.00
acceleration area
EDRC-BMH-MMH IC

IS:11592) MNS SAI

2
114 N 0
and skirt plates points)/(V22 x b12)
115 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1401.49
skirt plates
116 Te2 0
UP TO TAIL
119 Te3 4907.30
UP TO HEAD

belt cleaner(Rbc)
EDRC-BMH-MMH IC

IS:11592) MNS SAI
POWER CALCULATION AT EMPTY CONDITION

max. slip of 3%)
135 Overall drive efficiency(η0) η0= Gear box efficiency x coupling efficiency X 0.99 0.927
Considering Gear Coupling Efficiency of 99%
136 Required power at motor shaft(Pm) Pm= Pa/η0 56.98 At Empty Condition
TENSION CALCULATION
Minimum belt tension required from belt sag
137 T'sag = (Sc x (Mb + Mg) x 9.81)/(8 x S) N 16952.39 At carrying side (with material)
consideration(T'min)
138 Carrying idler spacing(Si) Sc m 1.1
139 Belt sag(S) S 0.02 [Refer page 20 of IS-11592:2000]
Minimum belt tension required from belt sag
140 T''sag = (SR x (Mb) x 9.81)/(8 x S) N 5895.12 At Return side (without material)
consideration(T''min)
141 Return idler spacing(SR) SR m 3.3
coefficient of friction between Head pulley and
142 µ - 0.30
belt,(µ)
Ratio of T1/T2 at any Loading/dynamic
143 Maximum Wrap Ratio Allowable (T1/T2) T1/T2 = e µθ - 3.0
condition shall not exceed this value
144 drive co-efficient(ξ) ξ - 1.3 For scoop type fluid coupling
145 Starting Force Fs = ξ x Te N 50863.7 To be controlled by Scoop Type fluid coupling
146 Assumed Take up Tension T take up N 46600.0

EDRC-BMH-MMH IC

IS:11592) MNS SAI
FULLY LOADED CONDITION
Force Available for Acceleration for the entire

147 Fa = Fs - Te N 11737.8
belt conveyor system Including Drive
Total mass of the Belt conveyor system
148 We1 kg 103218.9 Refer Coasting Time Calculation
Including Drive & fully Loaded
Excluding Drive
150 Force availabe for acceleration at the belt line F = Fa N 11737.8
151 Acceleration during fully Loaded a = F/We3 m/s2 0.136
152 Starting Time during fully loaded t = V/a s 33.0
153 Total Mass at Carry Side Mc kg 74506.3 Refer Coasting Time Calculation
Total Mass at Return Side (From Tail to Take
154 Mr1 kg 0.0 Refer Coasting Time Calculation
up)
Total Mass at Return Side (From Take up to
Head)
STARTING CONDITION FULLY LOADED
156 Tail Tension Tt = T take up N 46600.0
157 Slack Side Tension T2s = Tt - Te3 - (mr2 x a) N 40122.2
158 Tight Side Tension T1s = T2s + Te + F N 90985.9
159 WRAP CHECK T1s/T2s N 2.3 < 3, Hence Safe
RUNNING CONDITION FULLY LOADED
161 Slack Side Tension T2 = Tt - Te3 N 41692.7
162 Tight Side Tension T1 = T2 + Te N 80818.6
163 WRAP CHECK T1/T2 N 1.9 < 3, Hence Safe

EDRC-BMH-MMH IC

IS:11592) MNS SAI
EMPTYCONDITION
Force Available for Acceleration for the entire

164 Fa = Fs - Te N 39629.6
belt conveyor system Including Drive
Including Drive & Empty
Excluding Drive
167 Force availabe for acceleration at the belt line F = Fa N 39629.6
168 Acceleration during empty Loaded a = F/We3 m/s2 1.283
169 Starting Time during Empty loaded t = V/a s 3.5
170 Total Mass at Carry Side Mc kg 19380.1 Refer Coasting Time Calculation
Total Mass at Return Side (From Tail to Take
up)
Total Mass at Return Side (From Take up to
Head)
STARTING CONDITION EMPTY
173 Tail Tension Tt = T take up N 46600.0 As HGTU at Tail End
174 Slack Side Tension T2s = Tt - Te3 - (mr2 x a) N 26927.5
175 Tight Side Tension T1s = T2s + Te + F N 77791.1
176 WRAP CHECK T1s/T2s N 2.89 < 3, Hence Safe
RUNNING CONDITION EMPTY
178 Slack Side Tension T2 = Tt - Te3 N 41692.7

EDRC-BMH-MMH IC

IS:11592) MNS SAI
179 Tight Side Tension T1 = T2 + Te N 52926.7
180 WRAP CHECK T1/T2 N 1.3 < 3, Hence Safe
B) BELT AND PULLEY DIA SELECTION

Breaking strength of our selected belt Tb
1 1250
1250/4 HEAVY DUTY KN/m
2 Factor of safety considered FOS - 9 As per spec.
3 Allowable Belt tension Ta=Tb/FOS KN/m 138.89
4 Maximum allowable belt tension for 1250/4 HD Tb= Ta*b KN 222.22
5 % Loading of the belt at running condition T1 /Tb 36.37 < 90%. So, selected belt is O.K.
T1max/Tb < 150%. Therefore, selected belt is safe during

6 % Loading of belt during starting 40.94
starting also.
HENCE SELECTED BELT IS NN-1250/4 Heavy duty. Maximum width for satisfactory load support is 2000mm > BW.
As per belt manufacturer with pulley lifted by
6A Minimum Transition distance required - mm 2040
half trough distance
6B Transition Height provided - mm 175
Drive pulley(Type – A)
= 500 mm
As per PHOENIX YULE catalogue, for the
Tail/Take-up pulley(Type – B)
7 Min Required pulley dia selected belt minimum required diameters of
= 400 mm
various types of pulleys
Snub / LT Bend pulley(Type– C)
= 315 mm
Drive pulley
(Type – A) = 800 mm
Tail/Take-up pulley
8 Selected diameter for different pulleys - For heavy duty belt.
(Type – B) = 630 mm
Snub / LT Bend pulley
(Type – C) = 500 mm
HENCE SELECTED PULLEY DIAMETER ARE O.K

EDRC-BMH-MMH IC

IS:11592) MNS SAI
C. CONVEX/CONCAVE RADIUS CALCULATION
1) Convex curvature at I.P- 2
1 Belt modulus(E) E KN/m 8125.00 As per belt manufacturer data sheet enclosed
2 Maximum Recommended belt tension(Tm) Tm = RMBT of belt KN/m 140 As per belt manufacturer data sheet enclosed
distance of drive pulley from IP point of convex

3 Lp2 m 13.20
curve(Lp1)
Lift of drive pulley from IP point of convex
4 Hp2 m 0.00
curve(Hp1)
Belt tension at the IP point of convex curve for Tcs fully = T1s - Main Resistance for Lp2 -
5 N 89621.75
fully loaded conditions at starting (Tcsfully) Acceleration for Lp2
Belt tension at the IP point of convex curve for

6 Tc fully = T1 - Main Resistance for Lp2 N 79982.87
fully loaded conditions at running (Tcfully)
Belt tension at the IP point of convex curve for Tcs empty = T1s - Main Resistance for Lp2 -
7 N 76383.75
Empty conditions at starting (Tcsempty) Acceleration for Lp2
Belt tension at the IP point of convex curve for

8 Tc empty = T1 - Main Resistance for Lp2 N 52724.07
Empty conditions at running (Tcempty)
9 Maximum of the above Tension Tc N 89621.75
As per IS-11592:2000,Where, b= belt width in

Minimum Radius to prevent overstress of
Re = (b x E sinλ) / (4.5 x (Tm-Tc/b)) metres, λ = Troughing angle in degrees,
10 m 24.32
belt edge(Re) E = Belt modulus
Tm = Maximum Recommended belt tension
11 Minimum of the above Tension Tcmin N 52724.07
Minimum Radius to prevent lack of tension

RL = b x E x sinλ / 9x (Tcmin/b-4.5) b= belt width , λ = Troughing angle ,
12 m 35.90
at belt centre(RL) E = Belt modulus
Hence Required Radius to be provided
13 R m 35.90
Minimum
14 Provided Radius Rp m 75.00

EDRC-BMH-MMH IC

IS:11592) MNS SAI
A) POWER curvature
2)Concave AND TENSION CALCULATION FOR CONVEYOR KC-1C
at I.P-1 As per IS-11592:2000
Distance of drive pulley from IP point of
15 Lp1 m 43.559
concave curve(Lp1)
Lift of drive pulley from IP point of concave
16 Hp1 m 2.42
curve(Hp1)
19 Belt modulus(E) E KN/m 8125.00 As per belt manufacturer
20 Maximum Recommended belt tension(Tm) Tm KN/m 140 As per belt manufacturer
Belt tension at the IP point of concave curve Tcs fully = T1s - Main Resistance for Lp1 - Slope
21 N 80517.08
for fully loaded conditions at starting (Tcsfully) Resistance for Hp1 - Acceleration for Lp1
Belt tension at the IP point of concave curve Tc fully = T1 - Main Resistance for Lp1- Slope
22 N 72093.54
for fully loaded conditions at running (Tcfully) Resistance for Hp1
Belt tension at the IP point of concave curve Tcs empty = T1s - Main Resistance for Lp1 - Slope
23 N 72455.20
for Empty conditions at starting (Tcsempty) Resistance for Hp1 - Acceleration for Lp1
Belt tension at the IP point of concave curve Tc empty = T1 - Main Resistance for Lp1- Slope
24 N 51566.29
for Empty conditions at running (Tcempty) Resistance for Hp1
25 Maximum of the above Tension Tc N 80517.08
26 Minimum of the above Tension Tcmin N 51566.29

Minimum Radius for empty belt to avoid belt lift
27 Res= (Tcsempty x1000) / (9.81 X Mb) m 253.50
off,(Res )
Minimum Radius to prevent overstress of belt
28 Ro= (b x E sinλ) / (9 x (Tm-Tcmax/b)) m 11.39
edge(RO)
Minimum Radius to prevent lack of tension at
29 RL = b x E x sinλ / 4.5x (Tcmin/b-4.5) m 73.67
belt centre(RL)
Hence Required Radius to be provided
30 R =Max of Res, R0,RL m 253.50
Minimum
31 Provided Radius Rp m 375.00
EDRC-BMH-MMH IC

IS:11592) MNS SAI
D.GEAR BOX & COUPLING SELECTION
Actual power required at drive pulley shaft
1 (considering drive pulley loss) Pa= Belt power + Power loss due to drive pulley kW 178.32
2 Motor power selected Pm kW 230
3 Required Mechanical rating of Gearbox Max. value of power (1.6 times of Motor Power) kW 368
4 so, Required mechanical rating of Gearbox kW 368

5 Required Nominal Reduction Ratio iN 14
From ELECON catalogue, for KBN 355 & 14:1

6 From ELECON catalogue, for 230 kW power and 14:1 gearbox ratio, required Gear Box size = KBN 355 (Bevel Helical)
gearbox ratio Mechanical Rating = upto 465 KW
7 Thermal capacity available with natural cooling PG1 kW 265 for KBN 355 As per ELECON catalogue
As per ELECON catalogue, for 45º C ambient
temperature & considering 24 hours
8 continuous operation of gearbox, fw 0.69 As per ELECON catalogue
Ambient temperature factor for gear box with
natural cooling
Available thermal capacity for gearbox with < Motor Power, So, natural cooling is not
9 PG1 x fw kW 182.85
natural cooling sufficient
So, natural cooling is not sufficient
10 Thermal capacity available with fan cooling PG2 kW 600
As per ELECON catalogue, for 45º C ambient
temperature & considering 24 hours
11 fw 0.75 for Gear box with fan cooling
continuous operation of gearbox,
Ambient temperature factor
Therefore, available thermal cap. for gearbox
12 fw x PG2 kW 450 > motor power
with fan cooling
Hence, selected gearbox size is KBN 355 with fan cooling. Since the conveyor is inclined, Holdback is to be provided integral to input shaft of gearbox.
EDRC-BMH-MMH IC

IS:11592) MNS SAI
COUPLING SELECTION
HIGH SPEED COUPLING:
Required motor power at motor shaft
1 P kW 192.43
(excluding drive margin)
2 Motor rating P kW 230
As per Design basis, Scoop type fluid coupling shall be provided since motor power requirement is greater than 160 kW
Selected High Speed Coupling model SC 10 (Fluidomat or Equivalent) with a rating of 350kW > Motor Power
LOW SPEED COUPLING:

Actual power required at drive pulley shaft
3 P kW 178.32
(considering drive pulley loss)
4 Motor rating P kW 230.00
5 Coupling RPM(N2) N2=Motor RPM/ Reduction Ratio 103.21
Referring GEAR Coupling catalogue of ELECON (attached),
6 Design power for low speed coupling Motor Powerx S.F kW 460.00
Refer catalogue enclosed. (As per design basis)
7 Service Factor(S.F.) S.F. 2.00
8 Power to be transmitted per RPM Design Power / Coupling RPM kW/1/Min 4.46
9 Torque to be transmitted Tq da N/M 4255.88
Selected coupling model = ED 11500 of capacity 11500 da N/M

For selected gearbox KBN 355 of 14:1
10 d3 mm 140
reduction ratio, output shaft dia(d3)
Assumed. To be verified after finalization of
11 Required pulley shaft dia at coupling(d4) d4 mm 200
Pulley calculation.
Therefore, selected coupling model ED 11500 Where Max Bore can be made up to 240mm & hence is adequate.
ECC Division - EDRC
DOCUMENT NO :
PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK
AKBTPL:KDL-12/E101.007/M013/DN-C0201 REV. NO.: A DT 05.09.13
TERMINAL NEAR TEKRA, KANDLA
L&T : O13074-M-BM-CS-DC-0005 REV. NO.: 2 DT 31.07.13
DESIGNED CHECKED SHEET :
TITLE: TYPICAL MANUAL DETAIL CACULATION OF CONVEYOR KC-1C
MNS SAI OF
E) COASTING TIME CALCULATION
1 Motor GD2 value at motor rpm MG = Kg-m2 24
2 FG1 = 2
2 Fluid coupling primary side GD value at motor rpm Kg-m 26.2
Input Coupling(Fluid coupling secondary side/Flexible To be confirmed after
3 FG2 = Kg-m2 6.33 receipt of the drawings
Coupling) GD2 value at motor rpm
from vendor
4 Gear box GD2 value at motor rpm GG = Kg-m2 1.075
5 Output Coupling (Gear coupling) 'GD2' value at pulley rpm CG1 = Kg-m2 3.72
6 Motor rpm MR = RPM 1485
7 Belt speed (BS) BS = m/min 270.00
8 Weight of belt (WB) WB = Kg/m 29.14
9 Capacity of conveyor (T) C= TPH 3600
10 Drive pulley diameter PD = m 800
11 No. of drive pulley DP = - 1
12 Actual weight of drive pulley (AW) Aw = Kgf 2600

No. of non-driving pulleys in tight side having wrap angle of
13 NPA - 0
150O to 240O (NPA)
Wt. of each of non-driving pulleys in tight side having wrap
14 WNPA = Kgf 0
angle of 150O to 240O (WNPA)
No. of non-driving pulley in slack side having wrap angle of
15 NPB - 1
150O to 240O (NPB)
Wt. of each of non-driving pulley in slack side having wrap
16 WNPB = Kgf 1600
angle of 150O to 240O (WNPB)
No. of all other non-driving pulley except those mentioned in
17 NPC - 1
12 & 14 (NPC)
WT. of each of all other non-driving pulley except those
18 WNPC = Kgf 1100
mentioned in 12 & 14 (WNPC)
19 Weight of rotating parts of each carrying idler W1 = Kg/m 42
ECC Division - EDRC
DOCUMENT NO :
MNS SAI OF
20 Weight of rotating parts of each return idler W2 = Kg/m 10
21 Total belt length L1 = m 496
22 Length along belt L2 = m 248
Motor Output Power Reqd at Conv. Running With Reduced Coeffitient

23 MOPR = Kw 139.66
condition(MOPR) of Friction (0.012)
24 Weight of material WM =1000 x T / (3600 x BS / 60) kg/m 222.22
25 Pulley rpm (PR) PR =BSx1000 /(π x PD) RPM 107.43

2 2 2
26 Gear coupling 'GD ' value at motor rpm CG2 = CG1 x (PR / MR) kg-m 0.019
27 Total 'GD2' value of drive system at motor rpm TG2 =MG + FG2 + FG1 + GG + CG2 kg-m2 57.624
28 Equivalent weight of drive system (ED) at belt line :-
a)Total GD2 of Drive System with Motor & Primary side of

ED2 =(TG2/4) x (2 x π x MR / BS)2 = Kgf 17204.10
fluid coupling
b)Total GD2 of Drive System without Motor & Primary side of

ED2' =(TG2'/4) x (2 x π x MR / BS)2 = Kgf 2216.62
fluid coupling
29 Equivalent weight of drive pulley (EW) EW = (2/3) x AW x DP Kgf 1733.33
Total equivalent weight of drive system including drive

30
pulley :-
a) considering GD2 of motor & primary side of HS coupling TED2 =EW + ED2 Kgf 18937.44
2
b) Without considering GD of motor & primary side of HS TED2' =EW + ED2' Kgf 3949.95
coupling
31 Total weight of non-drive pulley (NW) NW =NPB x WNPB + NPC x WNPC Kgf 2700
32 Equivalent weight of non-drive pulley (ENW) = (2/3) x NW = Kgf 1800.00

ECC Division - EDRC
DOCUMENT NO :
MNS SAI OF
33 Total weight of belt (TB) TB =TB1 + TB2 Kgf 14455.57
Belt Mass at Carry side TB1 =WB x L2 = Kgf 7227.78
Belt Mass at Return side TB2 =WB x L2 = Kgf 7227.78
34 Total weight of material (TM) TM =WM x L2 Kgf 55126.24 At Carry Side Only
35 Total weight of idlers (IW) IW =IW1 + IW2 Kgf 12899.670
Idler Mass at Carry side IW1 =L2 x W1 Kgf 10418.964
Idler Mass at Return side IW2 =L2 x W2 = Kgf 2480.706

Total equivalent weight of moving parts including material
36 TMW =ENW + TB + TM + IW = Kgf 84281.481
(TMW)=
Total equivalent weight of the system including drive system

37
:-
a) considering GD2 of motor & primary side of HS coupling WE1 =TMW + TED2 = Kgf 103218.918
b) Without considering GD2 of motor & primary side of HS WE2 =TMW + TED2 = Kgf 88231.431
coupling
38 Belt speed of conveyor in running condition BS = m/min 270.0

ECC Division - EDRC
DOCUMENT NO :
MNS SAI OF
Case-I : When conveyor will be stopped by operator, entire system including conveyor system, drive unit and motor will start decelerating. However,
after 5 seconds secondary section of Scoop coupling shall be disengaged. Henceforth conveyor assembly, gear coupling, gearbox &
secondary section of fluid coupling will continue to decelerate till they come to standstill.
Therefore, Natural Coasting time of conveyor under this condition =
disengagement time of scoop coupling (i.e. 5 sec) + time required for conveyor assembly,
Gear coupling, gearbox and secondary section of scoop coupling to come to rest from a speed what the conveyor assembly and drive unit
including motor would have attained before secondary section of scoop coupling would be disengaged.
39 Scoop coupling disengagement time td S 5
Reduced belt speed when secondary section of scoop BSr = BS-(60 x1000 x MOPR x td)/
40 m/min 179.80
coupling is going to be disengaged (WE1x(BS/60))
Time required for conveyor system alongwith gearbox, low tr =WE2 x (BS/60) x (BSr/60) / (MOPR x
41 speed coupling and high speed coupling to come to rest S 8.519
1000)
from reduced belt speed
42 Natural stopping time CT1 = td + tr S 13.519
Case-II : When conveyor will be stopped due to power cut, secondary section of scoop coupling can not be disengaged as because no power
is there to take out scoop actuator. In that case entire system including conveyor system, drive unit and motor will decelerate till it comes to rest
from belt speed at running condition.
43 Natural stopping time CT2 =WE1 x (BS/60)2 / (MOPR x 1000) S 14.966
G) BRAKE REQUIREMENT CHECK
1 Stopping Time of Succeeding conveyor CT3 S 28 For Conv KC-2C
<0 Hence No brake is

2 Time Difference CT2-CT3 S -13.03
required
EDRC-BMH-MMH IC

IS:11592) MNS SAI
ANNEXURE - 1 POWER CALCULATION CONSIDERING MAXIMUM BULK DENSITY OF MATERIAL
1 Rated capacity R TPH 3200
2 Design Capacity C TPH 3600
3 Material - - COAL
CONSIDERING MAX BULK DENSITY OF THE
4 Max Bulk Density ρ Kg/m3 1200
MATERIAL
5 Surcharge Angle SA Degree 20
6 Belt Width B mm 1600
7 Troughing angle BT Degree 45 Standard 3 Roll troughed
8 Conveyor Length L m 248.057 Refer attached conveyor profile
HC Refer attached conveyor profile. Head Pulley

9 Conveyor Lift m 2.595
Transition Lift of 175mm Added.
10 Lift due to tripper if any HT m -
11 Conveyor Inclination θ deg 4.56 Refer attached conveyor profile

12 Head pulley dia assumed Dh mm 800
13 Lagging thickness LT mm 16 Diamond grooved Rubber lagging
14 HP dia with lagging D1 m 0.832
15 Wrap angle q Degree 210
16 Belt Rating assumed - 1250/4 NN-HEAVY DUTY,Max RMBT 140 KN/M
17 Type of Take up & Location - - HGTU AT TAIL END
18 No of Type A pulley A - 1 Drive pulley
19 No of Tripper discharge pulley A' 0 No tripper

20 No of Type B pulley B - 1 Tail pulley
21 No of Type C pulley C - 1 Snub pulley

EDRC-BMH-MMH IC

IS:11592) MNS SAI
SPEED CALCULATION (WITH MAX BULK DENSITY)
22 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 2.92 C=DESIGN CAPACITY

23 A m2 0.324 Surcharge angle (Refer Page no. 11 of IS-
belt(A)
11592:2000)
24 Slope factor(K) K - 0.98
25 Filling factor(Kf) Kf - 0.9
Considering Maximum bulk density of conveyed

26 Bulk density(ρ) ρ T/m
3
1.2
material
27 Belt speed as per Spec(V1) V1 m/sec 4.6
28 Motor RPM - RPM 1490
29 Motor RPM Available at GB input shaft Nm = Motor RPM*0.97 RPM 1445 (Considering fluid coupling slip as max.3%)
30 Gearbox ratio required G = (π x D1 x Motor RPM)/(60 x Belt Speed) - 13.68

31 Referring ELECON Helical gearbox catalogue, selected nominal reduction ratio - 14
32 Belt speed with gear box nominal ratio V2= (π x D1 x Motor RPM)/(60 x reduction ratio) m/sec 4.50
EDRC-BMH-MMH IC

IS:11592) MNS SAI
ANNEXURE - 1 POWER CALCULATION CONSIDERING MAXIMUM BULK DENSITY OF KG/CU.M
DRIVING FORCE CALCULATION CONSIDERING THE MAX BULK DENSITY OF 1200 MATERIAL
INPUTS
[ For 3 ROLL φ152.4, 5.4mm Shell Thickness

33 Mass of rotating parts on carrying side(Mc) Mc Kg/m 42 idler Suitable for 1.6 m belt width and at 1.1m
spacing]. Average weight/m
Mass of rotating parts on return side(Mr) [ For 2 ROLL φ139.7, 4.85mm Shell Thickness
34 Mr Kg/m 10
Idler for 1.6 m belt width and at 3.3m spacing].
Mass of material remains same for both the

density of material because when density
35 Mass of material Mg= C/(3.6xV2) Kgs/m 222.22 increases by 1.5 times (800 to 1200 kg/cu.m),
area decreases by 1.5 times, since the speed of
4.5 m/s is constant.
[As per Belt Manufacturer’s catalogue, carcass
36 Carcass weight - Kg/m2 6 weight of 1250/4 Heavy duty belt. Catalogue
copy enclosed
[As per Belt Manufacturer’s catalogue cover

37 Cover weight - Kg/m²/mm 1.11 weight for M-24 grade]. Catalogue copy
enclosed
Thickness of top cover = 8 mm Thickness

38 Total cover thickness - mm 11
of bottom cover = 3 mm
Mb= (carcass wt x belt width)+(cover wt x total cover

39 Mass of belt(Mb) kg/m 29.136 0
thk x belt width)
40 Artificial Co efficient of friction f - 0.022
Min. bulk density of material is considered as

41 Volumetric conveying capacity(Q) Q= C/(3600 xρ ) cu.m/sec 0.833
density is in denominator
42 Coefficient of Friction between material & Belt µ1 - 0.6 Refer page 17 of IS-11592:2000
Co-efficient of friction between material and
43 µ2 0.6 Refer page 17 of IS:11592 – 2000
skirt plates
2
44 Acceleration length at loading area La = V2 /(2 x g x µ1) M 1.7202
EDRC-BMH-MMH IC

IS:11592) MNS SAI
45 Inter-skirt plate width b1 M 1.1 b1= 2/3 x Belt width
Wrap Resistance for Type A Pulley (Drive, Assumed. To be checked after pulley
46 Rwa N 200
HT Bend) calculations
Wrap Resistance for Type B Pulley (Tail,Take Assumed. To be checked after pulley
47 Rwb N 175
up) calculations
Wrap Resistance for Type C Pulley (Snub,LT Assumed. To be checked after pulley
48 Rwc N 140
Bend) calculations
Pulley brg. Resistance(Rb) for Type A Pulley Assumed. To be checked after pulley
49 Rba 300
(Drive, HT Bend) calculations
Pulley brg. Resistance(Rb) for Type B Pulley Assumed. To be checked after pulley
50 Rbb N 200
(Tail,Take up) calculations
Pulley brg. Resistance(Rb) for Type C Pulley Assumed. To be checked after pulley
51 Rbc N 150
(Snub,LT Bend) calculations
Including The Length of Acceleration at Loading
52 Length of skirt plate(Lsk) Lsk M 8
Area
53 No of loading points - - 2 Since fed by 2 nos Mobile hopper
54 No. Of Internal belt cleaners 1

Length of contact of each internl belt cleaner
55 1.414 x b M 2.2624
blade
56 Internal belt cleaner blade thickness M 0.02
57 No. of External belt cleaners 2
Length of contact of each external belt cleaner
58 1xb M 1.6
blade
59 External belt cleaner blade thickness M 0.01
A1= No. Of Internal belt cleaners x Length of each
Area of contact between belt and belt 2
60 belt cleaner blade x internal belt cleaner blade M 0.077
cleaner(A1)
thickness + No. of External belt cleaners x Length of
61 Pressure between belt and belt cleaner(P) P N/M2 65000 [Refer page 17 of IS:11592 – 2000]
Co-efficient of friction between belt and belt
62 µ3 0.65 [Refer page 17 of IS:11592 – 2000]
cleaner(µ3)
With out Tripper, where

Te1 = Carry Side frictional resistance from Tail to Head
63 Effective Tension Te Te= Te1 + Te2 + Te3 N
Te2 = Return Side frictional resistance from Takeup to Tail Te3 =
Return Side frictional resistance from Take up to head
EDRC-BMH-MMH IC

IS:11592) MNS SAI
RESISTANCES - (FULLY LOADED)
64 Te1 = Rm + Rsl+Rs+Rsp N 32272.28
HEAD
67 Main Resistance Carry (Rm) Rm= f x Lc x g x [ Mc+ (Mb + Mg)] N 15705.87
68 Slope Resistance Carry (Rsl) Rsl= (Mb+Mg) x Hc x g N 6398.76
70 Ra = Q x 1000 x ρ x V2 N 4499.82
2 2 2 between handled material and the skirt plate in
71 Frictional resistance at the loadng point and Rska = (µ2 x Q x1000x ρ x g x La)/((V2 /4) x b1 ) N 1377.31
acceleration area

2
76 2 2 N 2514.03
and skirt plates points)/(V2 x b1 )
77 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1401.49
skirt plates
78 Te2 0
UP TO TAIL
EDRC-BMH-MMH IC

IS:11592) MNS SAI
RETURN SIDE RESISTANCES FROMANNEXURE
TAKE - 1 POWER CALCULATION CONSIDERING MAXIMUM BULK DENSITY OF MATERIAL
81 Te3 4907.30
UP TO HEAD

belt cleaner(Rbc)

EDRC-BMH-MMH IC

IS:11592) MNS SAI
POWER CALCULATION AT FULLY LOADED CONDITION

max. slip of 3%)
97 Overall drive efficiency(η0) η0= Gear box efficiency x coupling efficiency X 0.99 0.927 Considering Gear Coupling Efficiency of 99%
98 Required power at motor shaft(Pm) Pm= Pa/η0 182.97

99 Motor power With 10% Margin Pm X 1.1 201.3
100 SELECTED MOTOR POWER MP kW 230 HT MOTOR
Absorbed power @ Motor shaft with rated
101 A Pmr kW 167.1
capacity
101 B Available Motor Margin on the above Mp/Pmr - 37.63 > 20%. Hence O.K

CONVEYOR CALCULATION

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L&T CONSTRUCTION

S.NO DESCRIPTION SHEET NO

A POWER & TENSION CALCULATION FOR CONV. KC-1C

B BELT/PULLEY DIA SELECTION FOR CONV. KC-1C

C CONCAVE/CONVEX RADIUS CALCULATION FOR CONV. KC-1C

D GEAR BOX & COUPLING SELECTION FOR CONV.KC-1C

E COASTING TIME CALCULATION FOR CONV KC-1C

ANNEXURE-1 POWER CALCULATION CONSIDERING MAX BULK

Refer CONVEYOR GA- KDL-12/E101.007/M013/DN-C 02 01 for

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

1 Rated capacity R TPH 3200

2 Design Capacity C TPH 3600

4 Max Bulk Density ρ1 Kg/m3 1200

5 Min Bulk Density ρ2 Kg/m 3

6 Surcharge Angle SA Degree 20

7 Belt Width B mm 1600

8 Troughing angle BT Degree 45 Standard 3 Roll troughed

9 Conveyor Length L m 248.057 Refer attached conveyor profile

HC Refer attached conveyor profile. Head Pulley

12 Conveyor Inclination θ deg 4.56 Refer attached conveyor profile

13 Head pulley dia assumed Dh mm 800

14 Lagging thickness LT mm 16 Diamond grooved Rubber lagging

15 HP dia with lagging D1 m 0.832

16 Wrap angle q Degree 210

17 Belt Rating assumed - 1250/4 NN-HEAVY DUTY,Max RMBT 140 KN/M

18 Type of Take up & Location - - HGTU AT TAIL END

19 No of Type A pulley A - 1 Drive pulley

20 No of Tripper discharge pulley A' 0 No tripper

22 No of Type C pulley C - 1 Snub pulley

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

23 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 2.92 C=DESIGN CAPACITY

26 Filling factor(Kf) Kf - 0.9

Considering Maximum bulk density of conveyed

31 Gearbox ratio required G = (π x D1 x Motor RPM)/(60 x Belt Speed) - 13.68

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

33D Filling factor(Kf) Kf - 0.9

Considering Minimum bulk density of conveyed

33I Gearbox ratio required G = (π x D1 x Motor RPM)/(60 x Belt Speed) - 13.68

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

[ For 3 ROLL φ152.4, 5.4mm Shell Thickness

Mass of material remains same for both the

[As per Belt Manufacturer’s catalogue cover

Thickness of top cover = 8 mm Thickness

Mb= (carcass wt x belt width)+(cover wt x total cover

41 Artificial Co efficient of friction f - 0.022

Min. bulk density of material is considered as

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

55 No. Of Internal belt cleaners 1

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

RESISTANCES - (FULLY LOADED)

67 Total Lift Hc m 2.60

68 Main Resistance Carry (Rm) Rm= f x Lc x g x [ Mc+ (Mb + Mg)] N 15705.87

69 Slope Resistance Carry (Rsl) Rsl= (Mb+Mg) x Hc x g N 6398.76

70 Secondary Resistance Carry(Rs) Rs = Ra + Rska + Rw + Rb N 6941.14

74 Pulley bearing resistance Rb = Rb x (A'+B+C) N 200.00 For 1 No Tail Pulley

75 Special Resistance carry(Rsp) Rsp = Ri + Rsk +Rbs N 5172.83

76 Drag resistance due to forward tilt Ri= g x Ci x µ0 x L x { Mb + Mg } x Cos δ x Sin i N 0

PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK DOCUMENT NO :

84 Total Lift Hr2 m -2.60

85 Main Resistance Return Rm= f x Lr1 x g x [ Mr+ (Mb)] N 2095.29

86 Slope Resistance Return Rsl= (Mb) x Hc x g N -741.71

87 Secondary Resistance Return Rs = Rw + Rb N 290.00

89 Pulley bearing resistance Rb = Rb x (A'+B+C) N 150.00 For 1 No Snub Pulley