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Conveyor Design Calculations
Conveyor Design Calculations
Designer JVP
Mormugao Port Second Coal
Project Name Company Roberts & Schaefer
Terminal
Conveyor Name CRD-2 Filename CRD-2_N(New)_1
Mormugao Port Second Coal
Location Date June 25, 2011
Terminal
Description
System Information Idler Set Data
Calculation method ................................................ CEMA Carry Return
Length / Height ............................................... 391 / 4.4 m Series name Series 40 Series 30
Material lift ............................................................ 18.0 m Bearing 6308 420206
Ambient temperature ................................................. 10 C Number of rolls 3 2
Trough angle (deg) 45 15
Material Properties Type Garland Inline
Type ............................................................... Unspecified Idler spacing (m) 1.20 3.60
Tonnage ............................................................... 5000 t/h Number of idler sets 362 108
Density .............................................................. 800 kg/m3 Roll diameter 152 140
Maximum lump size ............................................ 150 mm Roll rpm 578 627
Surcharge angle ...................................................... 20 deg Total drag (N) 9.0 6.0
Roll length 720 1080
Belt Properties Shaft diameter (mm) 40.0 30.0
Type ............................................................ Fabric (4-Ply) Dynamic capacity (kN) 42.3 22.8
Width ................................................................. 2000 mm L10 life1 (1000 hrs) 350.0 / 293.4 350.0
Rating............................................................. 1250 N/mm Shaft deflection (min) 0.90 / 3.09 3.27
Speed ................................................................... 4.60 m/s 1
L10 life above which 95% of idlers exceed
Top / bottom cover thickness ....................... 5.0 x 3.0 mm
Total thickness ....................................................... 16 mm Drive Station
Weight (new / worn) ............................... 34.2 / 26.4 kg/m
Type ...................................... Fluid coupling (VSFC-750)
Modulus ....................................................... 10,411 kN/m
Synchronous RPM ...........................................1500 RPM
Tape length ............................................................. 835 m
Motor quantity / rating .................................... 1 / 750 kW
Belt cycle time ...................................................... 182 sec
Total installed power ............................................ 750 kW
Tension Summary Running Momentary Nominal empty / full power ...... (20 / 72%) 149 / 541 kW
Maximum tension (kN) 207 293 Min / max demand power............ (10 / 78%) 73 / 583 kW
Minimum safety factor 12.09 8.52 Motor Voltage ....................................................... 3300 V
Minimum tension (kN) 93.7 37.0 Efficiency ................................................................... 92%
Maximum belt sag (%) 0.52 1.46 Maximum starting torque ......................................... 140%
Inertia - Motor .................................................. 16.7 kg·m²
Cross Sectional Loading Pulley lagging type ................................................ Rubber
Material mass (wm) ......................................... 302.1 kg/m Motor wrap angles....................................................... 194
Combined mass (wm + wb) .............................. 336.3 kg/m Lagging friction factor (run / accel) ................. 0.35 / 0.35
Edge distance (required / actual)................. 133 / 241 mm Reducer ratio .......................................................... 13.850
Cross sectional area ............................................ 0.378 m² Pulley shaft rpm ....................................................... 104.8
Cross sectional loading (utility / total) ........... 74 % / 55 %
Bed depth ............................................................. 390 mm Take-up Data
Type ...................................................................... Gravity
Location ................................................. Head / Pulley #8
Required belt line tension ..................................... 96.5 kN
Counterweight mass ........................................ 19.7 tonnes
Required pulley displacement ................................ 8.80 m
Dynamic displacement (incl thermal) .............. 2.02 m
Permanent elongation ...................................... 5.43 m
Splice length (1 included) ................................ 0.85 m
Clearance ......................................................... 0.50 m
Maximum Pulley Tensions for any Load Case & Maximum Resultant Force
Shaft Shaft Shaft Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Hub stress Center
Pulley Type Angle Resultant Resultant
Def. safety Def. T1 T2 T1 T2
(deg) Force Force
(min) factor (mm)
Pulley 1 4 180 2.74 4.35 0.68 177 357 258 520
Pulley 2 4 75 1.78 6.70 0.44 179 218 263 322
Pulley 3 4 90 1.72 6.95 0.43 176 249 264 375
Motor 1 - Brake
1 194 2.88 4.10 0.81 207 95.3 300 293 100 391
1 - Backstop 1
Pulley 5 3 30 1.13 10.00 0.31 95.3 49.5 100 51.6
Pulley 6 3 85 2.41 5.93 0.67 97.2 132 100 135
Pulley 7 3 90 2.07 6.90 0.58 96.1 136 97.7 137
Take-up Pulley 2 180 2.46 5.27 0.69 96.5 194 96.5 198
Pulley 9 3 90 2.10 6.80 0.59 97.4 138 102 147
Pulley 10 3 95 2.67 5.34 0.75 99.1 147 108 162
Tail Pulley 2 90 1.63 7.96 0.46 101 144 156 224
Note: T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
For this conveyor, there are five Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
3. Bypass
4. Stacking
5. Reclaiming
In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.
Empty
Fully Loaded
Bypass
Stacking
Reclaiming
Takeup Details
1. Type ...................................................................................................................................................Gravity
2. Location .............................................................................................................................. Head / Pulley #8
3. Belt line tension ................................................................................................................................ 96.5 kN
4. Take-up pulley displacement range
a. Running ......................................................................................................................... -0.38 to 0.05 m
b. Momentary .................................................................................................................... -1.37 to 0.66 m
Pulley Details
Pulley Shaft Stress Analysis - Forces Based on Design Level 1 + 10%
Shaft Hub Hub Hub Von Fillet Fillet Fillet Von
Bearing Resultant Resultant
Deflection Safety Bending Torsion Mises Bending Torsion Mises
Pulley L10 Life Force Torque
at Hub Factor Stress Stress Stress Stress Stress Stress
1000 hrs (kN) (kN·m)
(min) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 2.74 4.35 929 402 1.31 25.0 0.2 25.0 30.7 0.5 30.7
2 1.78 6.70 1000 261 0.16 16.2 0.0 16.2 19.9 0.1 19.9
3 1.72 6.95 1000 252 0.16 15.7 0.0 15.7 19.2 0.1 19.2
4 2.88 4.10 1000 332 51.4 26.3 9.7 31.2 25.3 18.9 41.4
5 1.13 10.00 1000 74.2 0.13 8.8 0.0 8.8 7.1 0.1 7.1
6 2.41 5.93 1000 159 0.11 18.9 0.0 18.9 15.1 0.1 15.1
7 2.07 6.90 1000 137 0.11 16.2 0.0 16.2 13.0 0.1 13.0
8 2.46 5.27 1000 215 0.32 20.9 0.1 20.9 17.2 0.1 17.2
9 2.10 6.80 1000 139 0.15 16.5 0.0 16.5 13.2 0.1 13.2
10 2.67 5.34 1000 176 0.15 20.9 0.0 20.9 16.8 0.1 16.8
11 1.63 7.96 1000 142 0.20 13.9 0.0 13.9 11.4 0.1 11.4
The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt. If this ratio
is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and result in
resonance.
The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of the empty
belt under the normal friction case. The shaded pink areas should be avoided.
*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 7,060 t/h have also been included. This specific load case results in 102% nameplate motor power,
excluding any reducer losses. 140% starting tensions have also been included for this case. The maximum tension values
have been multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum
tensions have been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 7,060 t/h under high friction steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
Pulley Type Resultant Resultant
(deg) Def. safety Def. T1 T2 T1 T2
Force Force
(min) factor (mm)
Pulley 1 4 180 3.97 4.35 0.99 70.8 154 283 582
Pulley 2 4 75 2.56 6.70 0.64 69.8 107 289 376
Pulley 3 4 90 2.66 6.95 0.66 58.2 61.7 290 390
Motor 1 - Brake
1 194 3.89 3.99 1.10 53.1 83.6 137 338 110 448
1 - Backstop 1
Pulley 5 3 30 1.16 10.00 0.32 83.7 63.4 110 76.4
Pulley 6 3 85 2.46 5.93 0.69 86.4 132 110 162
Pulley 7 3 90 2.09 6.90 0.58 85.9 109 107 138
Take-up Pulley 2 180 2.51 5.27 0.71 86.9 175 106 219
Pulley 9 3 90 2.25 6.80 0.63 86.5 109 112 149
Pulley 10 3 95 2.93 5.34 0.82 87.1 143 119 193
Tail Pulley 2 90 2.63 7.96 0.74 78.3 95.2 171 230
The idler stringer loading should be based on the flooded belt surge capacity of 9,077 t/h and 753.975Kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Power Summary
Idler Specifications
Idler Specifications
Equal Roll
Type VEE
Trough
Number of rolls 3 2
Trough angle (deg) 45 15
Roll diameter (mm) 152 140
Roll length (mm) 720 1080
Shaft diameter (mm) 40.0 30.0
Bearing series 6308 420206
Maximum roll RPM 578 627
Min Life (1000 hrs) 350 / 291 350
95% life1 (1000 hrs) 350 / 293 350
Shaft deflection (min) 0.90 / 3.09 3.27
Mass (kg) 64.7 47.7
Rotating mass (kg) 39.5 34.9
Wk2 for set 204,893 155,567