Manual Detail Calculation of Conveyor KC

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 - C 06 01 09.07.13 A
TERMINAL AT TUNA NEAR KANDLA
L&T : O13074-M-BM-CS-DC-0007 09.07.13 2
TITLE: TYPICAL MANUAL DETAIL CACULATION OF Designed Checked SHEET
CONVEYOR KC-4AA (As per IS:11592) MNS SAI 1 OF
INDEX
S.NO DESCRIPTION SHEET NO
A POWER & TENSION CALCULATION FOR CONV. KC-4AA
B BELT/PULLEY DIA SELECTION FOR CONV. KC-4AA
C CONCAVE/CONVEX RADIUS CALCULATION FOR CONV. KC-4AA
D GEAR BOX & COUPLING SELECTION FOR CONV.KC-4AA
E COASTING TIME CALCULATION FOR CONV KC-4AA
F FLYWHEEL SELECTION FOR CONV KC-4AA
ANNEXURE-1 POWER CALCULATION CONSIDERING MAX BULK DENSITY OF

G
MATERIAL
Refer Attached Sketch No- KDL-12 / E101.007 / M013 / DD - C 06 02 for

Conveyor Profile
LARSEN & TOUBRO LIMITED
EDRC-BMH-MMH IC
DOCUMENT NO :
PROJECT: MATERIAL HANDLING SYSTEM FOR DEVELOPEMENT OF BULK AKBTPL : KDL-12 / E101.007 / M013 / DN - C 06 01 Rev. No: A DT: 09.07.13
TERMINAL NEAR TEKRA, KANDLA L&T : O13074-M-BM-CS-DC-0007 Rev. No: 2 DT: 09.07.13
TITLE: TYPICAL MANUAL DETAIL CACULATION OF CONVEYOR KC-4AA (As per DESIGNED CHECKED SHEET : OF
IS:11592) MNS SAI
A) POWER AND TENSION CALCULATION FOR CONVEYOR KC-4AA
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
ρ1 3
4 Max Bulk Density Kg/m 1200
ρ2 3
5 Min Bulk Density Kg/m 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 115.388 Refer attached conveyor profile

Refer attached conveyor profile. Head Pulley
10 Conveyor Lift HC m 20.20
Transition Lift of 175mm Added.
11 Lift due to tripper if any HT m -
12 Conveyor Inclination θ deg 12 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 - - VGTU
19 No of Type A pulley A - 2 HT Pulleys
20 No of Tripper discharge pulley A' 0 No tripper

21 No of Type B pulley B - 2 Tail pulley + Take up
22 No of Type C pulley C - 4 3 LT Bend + 1 No Snub pulley

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
SPEED CALCULATION WITH MIN DENSITY
23 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 4.15 C=DESIGN CAPACITY

For 1600 BW. 3 Roll, 45° troughed with 20°
24 Maximum cross sectional area of load on belt(A) A m2 0.324 Surcharge angle (Refer Page no. 11 of IS-
11592:2000)
For 12° conveyor inclination (max.)
25 Slope factor(K) K - 0.93
(Refer page no.13 of IS 11592:2000)
As Design Capacity is used to calculate required
26 Filling factor(Kf) Kf - 1.0
belt speed
Considering Minimum bulk density of conveyed
27 Bulk density(ρ) ρ T/m3 0.8
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 RATED CAPACITY.THEREFORE CHOSEN REDUCTION RATIO IS CORRECT.
EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
SPEED CALCULATION WITH MAX DENSITY
33A Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 2.77 C=DESIGN CAPACITY
33B Maximum cross sectional area of load on belt(A) A m2 0.324 Surcharge angle (Refer Page no. 11 of IS-
11592:2000)
33C Slope factor(K) K - 0.97
As Design Capacity is used to calculate required
33D Filling factor(Kf) Kf - 1.0
belt speed
Considering Maximum bulk density of conveyed
33E Bulk density(ρ) ρ T/m3 1.2
material
33F Belt speed as per Spec(V1) V1 m/sec 4.6
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 - 14
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
DOCUMENT NO :
IS:11592) MNS SAI
DRIVING FORCE CALCULATION
INPUTS
[ For 3 ROLL φ152.4, 4.85mm 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
42 Volumetric conveying capacity(Q) Q= C/(3600 xρ ) cu.m/sec 1.250 Min. bulk density of material is considered
43 Coefficient of Friction between material & Belt µ1 - 0.6 Refer page 17 of IS-11592:2000
Co-efficient of friction between material and skirt
44 µ2 0.6 Refer page 17 of IS:11592 – 2000
plates
45 Acceleration length at loading area La = V22/(2 x g x µ1) M 1.7202
EDRC-BMH-MMH IC
DOCUMENT NO :
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 350
HT Bend) calculations
Wrap Resistance for Type B Pulley (Tail,Take Assumed. To be checked after pulley
48 Rwb N 250
up) calculations
Wrap Resistance for Type C Pulley (Snub,LT Assumed. To be checked after pulley
49 Rwc N 200
Bend) calculations
Pulley brg. Resistance(Rb) for Type A Pulley Assumed. To be checked after pulley
50 Rba 500
(Drive, HT Bend) calculations
Pulley brg. Resistance(Rb) for Type B Pulley Assumed. To be checked after pulley
51 Rbb N 350
(Tail,Take up) calculations
Pulley brg. Resistance(Rb) for Type C Pulley Assumed. To be checked after pulley
52 Rbc N 300
(Snub,LT Bend) calculations
53 Length of skirt plate(Lsk) Lsk M 6.5 Total skirt length (13m) is divided as 6.5m & 2
loading points. Including The Length of
54 No of loading points - - 2 Acceleration at Loading Area
55 No. Of Internal belt cleaners 2

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
Area of contact between belt and belt A1= No. Of Internal belt cleaners x Length of each belt
61
cleaner(A1) cleaner blade x internal belt cleaner blade thickness + M2 0.122
62 Pressure between belt and belt cleaner(P) No. of External belt cleaners
P x Length of each belt 2
65000 [Refer page 17 of IS:11592 – 2000]
N/M
Co-efficient of friction between belt and belt
63 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
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
EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
RESISTANCES - (FULLY LOADED)
CARRY SIDE RESISTANCES FROM TAIL TO
65 Te1 = Rm + Rsl+Rs+Rsp N 67511.72
DRIVE VIDE DISCHARGE
66 Total Inclined Length Carry Lc m 117.14
67 Total Lift Hc m 20.20
68 Total Inclined Length return up to drive Lrd 50.54
69 Total Lift return up to drive Hrd -10.55

Rm= f x Lc x g x [ Mc+ (Mb + Mg)]+f x Lrd x g x [
70 Main Resistance Carry (Rm) N 7843.46
Mr+ (Mb)]
71 Slope Resistance Carry (Rsl) Rsl= (Mb+Mg) x Hc x g + (Mb) x Hrd x g N 46792.91
72 Secondary Resistance Carry(Rs) Rs = Ra + Rska + Rw + Rb N 8866.14
Inertial and frictional resistance at the loadng in the acceleration area between the handled
73 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
74 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
75 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 950.00 1 no Tail & 2 no. HT Bend pulleys
76 Pulley bearing resistance Rb = Rb x (A'+B+C) N 1350.00 1 no Tail & 2 no. HT Bend pulleys
77 Special Resistance carry(Rsp) Rsp = Ri + Rsk +Rbs N 4009.22
78 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 and Rsk= (µ2 x Q x1000 x ρ x g x (Lsk-La) x No.of loading
79 N 2870.51
skirt plates points)/(V22 x b12)
Resistance due to friction between belt and skirt
80 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1138.71
plates
RETURN SIDE RESISTANCES FROM TAKE
81 Te2 1205
UP TO DRIVE
82 Total Inclined Length Return Lr1 m 5.65
83 Total Lift Hr1 m -1.20

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
84 Main Resistance Return Rm= f x Lr1 x g x [ Mr+ (Mb)] N 47.69
85 Slope Resistance Return Rsl= (Mb) x Hr1 x g N -342.99
86 Secondary Resistance Return Rs = Rw + Rb N 1500.00
87 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 600.00 2No LT Bend + 1 No Snub
88 Pulley bearing resistance Rb = Rb x (A'+B+C) N 900.00 2No LT Bend + 1 No Snub

89 Te3 4925.07
UP TO TAIL
93 Slope Resistance Return Rsl= (Mb) x Hc x g N -2367.20
95 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 650.00 1 No Take up + 1 No LT Bend
96 Pulley bearing resistance Rb = Rb x (A'+B+C) N 950.00 1 No Take up + 1 No LT Bend
97 Special Resistance Return Rsp = Rbc N 5175.46

Resistance due to friction between belt and belt
98 Rbc= A1 x P x µ3 N 5175.456 [Refer page 17 of IS-11592:2000]
cleaner(Rbc)
99 Hence,Effective Tension Te Te= Te1 + Te2 + Te3 N 73641.50

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
POWER CALCULATION AT FULLY LOADED CONDITION
100 Belt Power P = (Te x V2)/1000 kW 331.39

101 Power loss due to drive pulley Dp=(Rwa + Rba)x no of Drive pulley x V2 /1000 kW 3.83 No of Drive pulley is 1
102 Power absorbed at gear box output(Pa) Pa = Belt power + Power loss due to drive pulley kW 335.22
(For Triple Reduction Gearbox as per catalogue)
103 Gear box efficiency - 0.965
- (For SCOOP type Fluid coupling, considering a

104 H.S. Coupling efficiency 0.97
max. slip of 3%)
105 Overall drive efficiency(η0) η0= Gear box efficiency x coupling efficiency X 0.99 0.927 Considering Gear Coupling Efficiency of 99%
106 Required power at motor shaft(Pm) Pm= Pa/η0 361.74

107 Motor power With 10% Margin Pm X 1.1 397.9
108 SELECTED MOTOR POWER MP kW 400 HT MOTOR
108 A Consumed power with rated capacity Pmr kW 327.5
108 B Available Motor Margin on the above Mp/Pmr % 22.14 > 20%. Hence O.K
RESISTANCES - (EMPTY)
CARRY SIDE RESISTANCES FROM TAIL TO
109 Te1 = Rm + Rsl+Rs+Rsp N 8770.48
HEAD
110 Total Inclined Length Carry Lc + Lrd m 117.14
111 Total Lift Hc + Hrd m 20.20

Mr+ (Mb)]
117 Ra = Q x 1000 x ρ x V2 N 0.00
acceleration area
EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
119 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 950.00
120 Pulley bearing resistance Rb = Rb x (A'+B+C) N 1350.00

2
Resistance due to friction between material and Rsk= (µ2 x Q x1000 x ρ x g x (Lsk-La) x No.of loading
123 2 2 N 0
skirt plates points)/(V2 x b1 )
Resistance due to friction between belt and skirt
124 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1138.71
plates
125 Te2 1244
UP TO HEAD

133 Te3 4925.07
UP TO TAIL

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
141 Special Resistance Retun Rsp = Rbc N 5175.46

Resistance due to friction between belt and belt
cleaner(Rbc)
EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
POWER CALCULATION AT EMPTY CONDITION

(For Triple Reduction Gearbox as per catalogue)
147 Gear box efficiency - 0.965
-
- 0 (For SCOOP type Fluid coupling, considering a
max. slip of 3%)
-
150 Required power at motor shaft(Pm) Pm= Pa/η0 - 76.68 At Empty Condition
TENSION CALCULATION
Minimum belt tension required from belt sag
151 T'sag = (Sc x (Mb + Mg) x 9.81)/(8 x S) N 16952.39 At carrying side (with material)
consideration(T'min)
152 Carrying idler spacing(Si) Sc m 1.1
153 Belt sag(S) S 0.02 [Refer page 20 of IS-11592:2000]
Minimum belt tension required from belt sag
154 T''sag = (SR x (Mb) x 9.81)/(8 x S) N 5895.12 At Return side (without material)
consideration(T''min)
155 Return idler spacing(SR) SR m 3.3
coefficient of friction between Head pulley and
156 µ - 0.30
belt,(µ)
Ratio of T1/T2 at any Loading/dynamic condition
157 Maximum Wrap Ratio Allowable (T1/T2) T1/T2 = e µθ - 3.0
shall not exceed this value
158 drive co-efficient(ξ) ξ - 1.45 For scoop type fluid coupling
159 Starting Force Fs = ξ x Te /(Gear box eff x L/S coup eff) N 111770.7 To be controlled by Scoop Type fluid coupling
160 Assumed Take up Tension T take up N 60000.0

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
FULLY LOADED CONDITION
Force Available for Acceleration for the entire

161 Fa = Fs - Te/ (Gear box eff x L/S coup eff) N 38129.2
belt conveyor system Including Drive
Total mass of the Belt conveyor system
162 We1 kg 449388.2 Refer Coasting Time Calculation
Including Drive & fully Loaded
excluding motor & primary of fluid coupling.
164 Force availabe for acceleration at the belt line F = Fa N 38129.2
165 Acceleration during fully Loaded a = F/We3 m/s2 0.091
166 Starting Time during fully loaded t = V/a s 49.7
167 Total Mass at Carry Side Mc kg 38897.9 Refer Coasting Time Calculation
Total Mass at Return Side (From Discrage to

168 Mr1 kg 3711.4 Refer Coasting Time Calculation
drive)
169 Total Mass at Return Side (Drive to take up) Mr2 kg 1687.6 Refer Coasting Time Calculation
170 Total Mass at Return Side (take up to tail) Mr3 kg 4928.0
STARTING CONDITION FULLY LOADED
170 Tail Tension Tt N 65371.3
171 Slack Side Tension T2s = Tt - Te3 - (mr2 x a) N 58642.5
172 Tight Side Tension T1s = T2s + Te + F N 170413.2
T3 = T1s - Resistance from Drive to Discharge - mr1 x

173 Tension at Discharge pulley N 164584.8
a
174 WRAP CHECK T1s/T2s N 2.91 < 3, Hence Safe
RUNNING CONDITION FULLY LOADED
175 Tail Tension Tt = T take up N 64925.1
176 Slack Side Tension T2 = Tt - Te3 N 58795.3

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
177 Tight Side Tension T1 = T2 + Te N 132436.8
178 Tension at Discharge pulley T3 N 126944.5
178 WRAP CHECK T1/T2 N 2.3 < 3, Hence Safe
EMPTYCONDITION
Force Available for Acceleration for the entire

179 Fa = Fs - Te N 96831.5
belt conveyor system Including Drive
Including Drive & empty Loaded
excluding motor & primary of fluid coupling.
182 Force availabe for acceleration at the belt line F = Fa N 96831.5
183 Acceleration during empty Loaded a = F/We3 m/s2 0.245
184 Starting Time during empty loaded t = V/a s 18.4
185 Total Mass at Carry Side Mc kg 12866.4 Refer Coasting Time Calculation
Total Mass at Return Side (From Discrage to

186 Mr1 kg 3711.4 Refer Coasting Time Calculation
drive)
187 Total Mass at Return Side (Drive to take up) Mr2 kg 1687.6 Refer Coasting Time Calculation
188 Total Mass at Return Side (take up to tail) Mr3 kg 4928.0

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
STARTING CONDITION EMPTY
189 Slack Side Tension T2s = Tt - Te3 - (mr2 x a) N 58342.6
190 Tight Side Tension T1s = T2s + Te + F N 170113.4
T3 = T1s - Resistance from Drive to Discharge - mr1 x

191 Tension at Discharge pulley N 164011.1
a
191 WRAP CHECK T1s/T2s N 2.92 < 3, Hence Safe
RUNNING CONDITION EMPTY
193 Slack Side Tension T2 = Tt - Te3 N 58756.3
194 Tight Side Tension T1 = T2 + Te N 73695.5
195 WRAP CHECK T1/T2 N 1.3 < 3, Hence Safe

EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
B) BELT AND PULLEY DIA SELECTION
Breaking strength of our selected belt
1 Tb 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 59.60 < 80%. So, selected belt is O.K.
< 150%. Therefore, selected belt is safe during
6 % Loading of belt during starting T1max/Tb 76.69
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 half
6A Minimum Transition distance required - mm 2040
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
DOCUMENT NO :
IS:11592) MNS SAI
C. CONVEX/CONCAVE RADIUS CALCULATION
2)Concave curvature at I.P-1 As per IS-11592:2000
Distance of drive pulley from IP point of concave

15 Lp1 m 73.5
curve(Lp1)
Lift of drive pulley from IP point of concave
16 Hp1 m 15.623
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 for Tcs fully = T1s - Main Resistance for Lp1 - Slope
21 N 125283.99
fully loaded conditions at starting (Tcsfully) Resistance for Hp1 - Acceleration for Lp1
Belt tension at the IP point of concave curve for Tc fully = T1 - Main Resistance for Lp1- Slope
22 N 89260.13
fully loaded conditions at running (Tcfully) Resistance for Hp1
Belt tension at the IP point of concave curve for Tcs empty = T1s - Main Resistance for Lp1 - Slope
23 N 163237.86
Empty conditions at starting (Tcsempty) Resistance for Hp1 - Acceleration for Lp1
Belt tension at the IP point of concave curve for Tc empty = T1 - Main Resistance for Lp1- Slope
24 N 68101.70
Empty conditions at running (Tcempty) Resistance for Hp1
25 Maximum of the above Tension Tc N 163237.86
26 Minimum of the above Tension Tcmin N 68101.70

Minimum Radius for empty belt to avoid belt lift
27 Res= (Tcsempty x1000) / (9.81 X Mb) m 571.11
off,(Res )
Minimum Radius to prevent overstress of belt
28 Ro= (b x E sinλ) / (9 x (Tm-Tcmax/b)) m 26.90
edge(RO)
Minimum Radius to prevent lack of tension at
29 RL = b x E x sinλ / 4.5x (Tcmin/b-4.5) m 53.67
belt centre(RL)
Hence Required Radius to be provided
30 R =Max of Res, R0,RL m 571.11
Minimum
31 Provided Radius Rp m 566.00
EDRC-BMH-MMH IC
DOCUMENT NO :
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 335.22
2 Motor power selected Pm kW 400
3 Required Mechanical rating of Gearbox Max. value of power (1.6 times of Motor Power) kW 640
4 so, Required mechanical rating of Gearbox kW 640

5 Required Nominal Reduction Ratio iN 14
From ELECON catalogue, for KBN 450 & 14:1

6 From ELECON catalogue, for 400 kW power and 14:1 gearbox ratio, required Gear Box size = KBN 450 (Bevel Helical)
gearbox ratio Mechanical Rating = upto 780 KW
7 Thermal capacity available with natural cooling PG1 kW 420 for KBN 450 As per ELECON catalogue
As per ELECON catalogue, for 45º C ambient

temperature & considering 24 hours continuous
8 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 289.80
natural cooling sufficient
So, natural cooling is not sufficient
10 Thermal capacity available with fan cooling PG2 kW 990

As per ELECON catalogue, for 45º C ambient
temperature & considering 24 hours continuous
11 fw 0.75 for Gear box with fan cooling
operation of gearbox,
Ambient temperature factor
Therefore, available thermal cap. for gearbox
12 fw x PG2 kW 742.500 > motor power
with fan cooling
Hence, selected gearbox size is KBN 450 with fan cooling. Since the conveyor is inclined, Holdback is to be provided integral to input shaft of gearbox.
EDRC-BMH-MMH IC
DOCUMENT NO :
IS:11592) MNS SAI
COUPLING SELECTION
HIGH SPEED COUPLING:
Required motor power at motor shaft (excluding
1 P kW 361.74
drive margin)
2 Motor rating P kW 400
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 11A (Fluidomat or Equivalent) with a rating of 500kW > Motor Power
LOW SPEED COUPLING:

Actual power required at drive pulley shaft
3 P kW 335.22
(considering drive pulley loss)
4 Motor rating P kW 400.00
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 800.00
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 7.75
9 Torque to be transmitted Tq da N/M 7401.53
Selected coupling model = ED 11500 of capacity 11500 da N/M

For selected gearbox KBN 450 of 14:1 reduction
10 d3 mm 190
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 TERMINAL NEAR
AKBTPL : KDL-12 / E101.007 / M013 / DN - C 06 01 Rev. No: A DT: 09.07.13
TEKRA, KANDLA
L&T : O13074-M-BM-CS-DC-0007 Rev. No: 2 DT: 09.07.13
DESIGNED CHECKED SHEET :
TITLE: TYPICAL MANUAL DETAIL CACULATION OF CONVEYOR KC-4AA (As per IS:11592)
MNS SAI OF
E) COASTING TIME CALCULATION

1 Motor GD2 value at motor rpm MG = Kg-m2 54
2 2
2 Fluid coupling primary side GD value at motor rpm FG1 = Kg-m 40.9
Input Coupling(Fluid coupling secondary side/Flexible To be confirmed after receipt
3 FG2 = Kg-m2 10.3
Coupling) GD2 value at motor rpm of the drawings from vendor
4 Gear box GD2 value at motor rpm GG = Kg-m2 2.03
5 Output Coupling (Gear coupling) 'GD2' value at pulley rpm CG1 = Kg-m2 5.39
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 - 2
150O to 240O (NPA)
Wt. of each of non-driving pulleys in tight side having wrap
14 WNPA = Kgf 2600
angle of 150O to 240O (WNPA)
No. of non-driving pulley in slack side having wrap angle of
15 NPB - 2
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 - 4
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 :
TEKRA, KANDLA
MNS SAI OF
20 Weight of rotating parts of each return idler W2 = Kg/m 10
21 Total belt length L1 = m 234
22 Length along belt from tail to discharge L2 = m 117
23 Length along belt from discharge to drive L3 m 51
24 Length along belt from drive to take up L4 m 6
25 Length along belt from take up to tail L5 m 61

Motor Output Power Reqd at Conv. Running With Reduced Coeffitient of
26 MOPR = Kw 314.19
condition(MOPR) 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 103.30

2 2 2
26 Gear coupling 'GD ' value at motor rpm CG2 = CG1 x (PR / MR) kg-m 0.026
27 Total 'GD2' value of drive system at motor rpm TG2 =MG + FG2 + FG1 + GG + CG2 kg-m2 107.256
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 32021.90
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 3688.98
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 33755.23
2
b) Without considering GD of motor & primary side of HS TED2' =EW + ED2' Kgf 5422.31
coupling
ECC Division - EDRC
DOCUMENT NO :
TEKRA, KANDLA
MNS SAI OF
31 Total weight of non-drive pulley (NW) NW =NPB x WNPB + NPC x WNPC Kgf 12800
32 Equivalent weight of non-drive pulley (ENW) = (2/3) x NW = Kgf 8533.33
33 Total weight of belt (TB) TB =TB1 + TB2 Kgf 6833.00
Belt Mass at Carry side TB1 =WB x L2 = Kgf 3413.07
Belt Mass at Return side for L3 distance TB2 =WB x L3 = Kgf 1472.65
34 Total weight of material (TM) TM =WM x L2 Kgf 26031.47 At Carry Side Only
35 Total weight of idlers (IW) IW =IW1 + IW2 Kgf 6093.777
Idler Mass at Carry side IW1 =L2 x W1 Kgf 4919.997
Idler Mass at Return side for L3 distance IW3 =L3 x W2 = Kgf 505.440
Total equivalent weight of moving parts including material
36 TMW =ENW + TB + TM + IW = Kgf 47491.576
(TMW)=
Total equivalent weight of the system including drive

37
system :-
a) considering GD2 of motor & primary side of HS coupling WE1 =TMW + TED2 = Kgf 81246.805
b) Without considering GD2 of motor & primary side of HS WE2 =TMW + TED2 = Kgf 52913.885
coupling
38 Belt speed of conveyor in running condition BS = m/min 270.0

ECC Division - EDRC
DOCUMENT NO :
TEKRA, KANDLA
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 12.19
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 0.154
1000)
from reduced belt speed
42 Natural stopping time CT1 = td + tr S 5.154
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 5.236
F) FLYWHEEL SELECTION. (as Preceeding conveyor has high stopping time)

1 Allowable Volume V m3 2.25
Allowable weight of material that can be accumulated inside
2 m kg 1800
skirt
3 Stopping time of Preceeding conveyor t2 S 31.300 for Conv KC-3B
4 Allowable time difference between the conveyors t3 S 3.60
5 Required Stopping time for the present conveyor At1 = t2- t3 S 27.70 Instead of CT2
Therefore, total Mass inertia require to increase the
6 WET = AT1x(MOPR x 1000)/ (BS/60)2 Kg 429780.889
conveyor stopping time.
ECC Division - EDRC
DOCUMENT NO :
TEKRA, KANDLA
MNS SAI OF
7 Mass inertia to be added extra We = WET - WE1 KG 348534.084 at Belt line
8 Selected Flywheed Dia D mm 1000
9 Selected Flywheel Thickness T mm 50
10 No of Flywheel Q - 8
11 Total Weight of flywheel at motor RPM Wef = 3.14*D2/4 X T/1000 X 7850 X Q KG 2466.150
11A Total Inertia of Flywheel I = MxR2/2 kg sqm 308.269 R = D/2
11B Equivalent Mass at the belt line Wef = (I) x (2 x π x MR / BS)2 = kg 368141.399
11C Equivalent mass of the entire drive system at the belt line We1 = Wef + EW + ED2 kg 401896.63
Total equivalent mass of the conveyor system including

11D We2 = W 1 + TMW kg 449388.2
drive
Total equivalent mass of the conveyor system including

11E We3 = W 2 -ED2 + ED2' kg 421055.3
drive excluding motor & primary of fluid coupling
11F Difference between required weight & Selected Weight Diff = W 2 - WET kg 19607.32 >0 Hence O.K
HENCE SELECTED FLYWHEEL DIA X THK X QTY = 950X50X6 (MS:IS2062)
Revised Stopping time of the conveyor with the selected Opening to Stock pile, Hence
12 CT=(We2) x (BS/60)2 / (MOPR x 1000) S 28.964
flywheel weight No brake is required.
EDRC-BMH-MMH IC
DOCUMENT NO :
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
ρ1 3
4 Max Bulk Density Kg/m 1200
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 115.388 Refer attached conveyor profile

Refer attached conveyor profile. Head Pulley
9 Conveyor Lift HC m 20.20
Transition Lift of 175mm Added.
10 Lift due to tripper if any HT m -
11 Conveyor Inclination θ deg 12 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 - - VGTU
18 No of Type A pulley A - 2 HT Pulleys
19 No of Tripper discharge pulley A' 0 No tripper

20 No of Type B pulley B - 2 Tail pulley + Take up
21 No of Type C pulley C - 4 3 LT Bend + 1 No Snub pulley

EDRC-BMH-MMH IC
DOCUMENT NO :
IS: 11592) MNS SAI
SPEED CALCULATION WITH MIN DENSITY
22 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 2.77 C=DESIGN CAPACITY

Maximum cross sectional area of load on 2
23 A m 0.324 Surcharge angle (Refer Page no. 11 of IS-
belt(A)
11592:2000)
24 Slope factor(K) K - 0.93
As Design Capacity is used to calculate
25 Filling factor(Kf) Kf - 1.0
required belt speed
Considering Minimum bulk density of conveyed
26 Bulk density(ρ) ρ T/m3 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
DOCUMENT NO :
IS: 11592) MNS SAI
DRIVING FORCE CALCULATION
INPUTS
[ For 3 ROLL φ152.4, 4.85mm 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].
35 Mass of material Mg= C/(3.6xV2) Kgs/m 222.22

[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

38 Total cover thickness - mm 11
Thickness 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
41 Volumetric conveying capacity(Q) Q= C/(3600 xρ ) cu.m/sec 0.833 Min. bulk density of material is considered
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
44 Acceleration length at loading area La = V22/(2 x g x µ1) M 1.7202
45 Inter-skirt plate width b1 M 1.1 b1= 2/3 x Belt width

EDRC-BMH-MMH IC
DOCUMENT NO :
IS: 11592) MNS SAI
Wrap Resistance for Type A Pulley (Drive, Assumed. To be checked after pulley
46 Rwa N 350
HT Bend) calculations
Wrap Resistance for Type B Pulley (Tail,Take Assumed. To be checked after pulley
47 Rwb N 250
up) calculations
Wrap Resistance for Type C Pulley (Snub,LT Assumed. To be checked after pulley
48 Rwc N 200
Bend) calculations
Pulley brg. Resistance(Rb) for Type A Pulley Assumed. To be checked after pulley
49 Rba 500
(Drive, HT Bend) calculations
Pulley brg. Resistance(Rb) for Type B Pulley Assumed. To be checked after pulley
50 Rbb N 350
(Tail,Take up) calculations
Pulley brg. Resistance(Rb) for Type C Pulley Assumed. To be checked after pulley
51 Rbc N 300
(Snub,LT Bend) calculations
52 Length of skirt plate(Lsk) Lsk M 6.5 Total skirt length (13m) is divided as 6.5m & 2
loading points. Including The Length of
53 No of loading points - - 2 Acceleration at Loading Area
54 No. Of Internal belt cleaners 2

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
Area of contact between belt and belt A1= No. Of Internal belt cleaners x Length of each
60
cleaner(A1) belt cleaner blade x internal belt cleaner blade M2 0.122
61 Pressure between belt and belt cleaner(P) thickness + No. of External P belt cleaners x Length of N/M
2
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
DOCUMENT NO :
IS: 11592) MNS SAI
RESISTANCES - (FULLY LOADED)
CARRY SIDE RESISTANCES FROM TAIL
64 Te1 = Rm + Rsl+Rs+Rsp N 65865.73
TO DRIVE VIDE DISCHARGE
65 Total Inclined Length Carry Lc m 117.14
66 Total Lift Hc m 20.20

Mr+ (Mb)]
72 Ra = Q x 1000 x ρ x V2 N 4499.82
acceleration area
74 Wrap resistance between belt and pulley Rw = (Rwa xA')+(RwbxB)+(RwcxC) N 950.00 1 no Tail & 2 no. HT Bend pulleys
75 Pulley bearing resistance Rb = Rb x (A'+B+C) N 1350.00 1 no Tail & 2 no. HT Bend pulleys

2
Resistance due to friction between material Rsk= (µ2 x Q x1000 x ρ x g x (Lsk-La) x No.of
78 N 1913.52
and skirt plates loading points)/(V22 x b12)
Resistance due to friction between belt and
79 Rbs =2*3*G*Lsk*2*3.2808/2.2046 N 1138.71
skirt plates
80 Te2 1205
UP TO DRIVE

EDRC-BMH-MMH IC
DOCUMENT NO :
IS: 11592) MNS SAI

88 Te3 4925.07
UP TO TAIL
96 Special Resistance Return Rsp = Rbc N 5175.46

Resistance due to friction between belt and
belt cleaner(Rbc)

EDRC-BMH-MMH IC
DOCUMENT NO :
IS: 11592) MNS SAI
POWER CALCULATION AT FULLY LOADED CONDITION

(For Triple Reduction Gearbox as per
102 Gear box efficiency - 0.965 catalogue)
- (For SCOOP type Fluid coupling, considering a
max. slip of 3%)
105 Required power at motor shaft(Pm) Pm= Pa/η0 353.74

106 Motor power With 10% Margin Pm X 1.1 389.1
107 SELECTED MOTOR POWER MP kW 400 HT MOTOR
108 A Consumed power with rated capacity Pmr kW 321.8
108 B Available Motor Margin on the above Mp/Pmr % 24.30 > 20%. Hence O.K

Manual Detail Calculation of Conveyor KC

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Manual Detail Calculation of Conveyor KC

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L&T CONSTRUCTION

S.NO DESCRIPTION SHEET NO

A POWER & TENSION CALCULATION FOR CONV. KC-4AA

B BELT/PULLEY DIA SELECTION FOR CONV. KC-4AA

C CONCAVE/CONVEX RADIUS CALCULATION FOR CONV. KC-4AA

D GEAR BOX & COUPLING SELECTION FOR CONV.KC-4AA

E COASTING TIME CALCULATION FOR CONV KC-4AA

F FLYWHEEL SELECTION FOR CONV KC-4AA

ANNEXURE-1 POWER CALCULATION CONSIDERING MAX BULK DENSITY OF

Refer Attached Sketch No- KDL-12 / E101.007 / M013 / DD - C 06 02 for

1 Rated capacity R TPH 3200

2 Design Capacity C TPH 3600

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 115.388 Refer attached conveyor profile

12 Conveyor Inclination θ deg 12 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 - - VGTU

19 No of Type A pulley A - 2 HT Pulleys

20 No of Tripper discharge pulley A' 0 No tripper

22 No of Type C pulley C - 4 3 LT Bend + 1 No Snub pulley

23 Belt Speed required(V) V= C/(3600xA x ρ x K x Kf) m/sec 4.15 C=DESIGN CAPACITY

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

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

[ For 3 ROLL φ152.4, 4.85mm 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

46 Inter-skirt plate width b1 M 1.1 b1= 2/3 x Belt width

55 No. Of Internal belt cleaners 2

With out Tripper, where

67 Total Lift Hc m 20.20

68 Total Inclined Length return up to drive Lrd 50.54

69 Total Lift return up to drive Hrd -10.55

72 Secondary Resistance Carry(Rs) Rs = Ra + Rska + Rw + Rb N 8866.14

77 Special Resistance carry(Rsp) Rsp = Ri + Rsk +Rbs N 4009.22

78 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

83 Total Lift Hr1 m -1.20

84 Main Resistance Return Rm= f x Lr1 x g x [ Mr+ (Mb)] N 47.69

85 Slope Resistance Return Rsl= (Mb) x Hr1 x g N -342.99

86 Secondary Resistance Return Rs = Rw + Rb N 1500.00

88 Pulley bearing resistance Rb = Rb x (A'+B+C) N 900.00 2No LT Bend + 1 No Snub

91 Total Lift Hr2 m -8.28

92 Main Resistance Return Rm= f x Lr1 x g x [ Mr+ (Mb)] N 516.81

93 Slope Resistance Return Rsl= (Mb) x Hc x g N -2367.20

94 Secondary Resistance Return Rs = Rw + Rb N 1600.00

96 Pulley bearing resistance Rb = Rb x (A'+B+C) N 950.00 1 No Take up + 1 No LT Bend

97 Special Resistance Return Rsp = Rbc N 5175.46

99 Hence,Effective Tension Te Te= Te1 + Te2 + Te3 N 73641.50

100 Belt Power P = (Te x V2)/1000 kW 331.39

- (For SCOOP type Fluid coupling, considering a

106 Required power at motor shaft(Pm) Pm= Pa/η0 361.74

111 Total Lift Hc + Hrd m 20.20

112 Total Inclined Length return up to drive Lrd 50.54

113 Total Lift return up to drive Hrd -10.55

116 Secondary Resistance Carry(Rs) Rs = Ra + Rska + Rw + Rb N 2300.00

120 Pulley bearing resistance Rb = Rb x (A'+B+C) N 1350.00