Bulk Conveying, Elevating, Hoisting, Aerial Ropeways and Related Equipment Sectional Commitee, ME 06 FOREWORD This indian Standard (Fist Revision) was adopted by the Buresu of Indian Stondards, alter the draft finalized by the Butk Conveying, Elevating, Hoisting, Aerial Ropeways and Relaxed Equipment Sectional Committse had been approved by the Meekznical Engineering Divisional Coutcil Belt conveyors play an important role in the key seetors of the economy such as mines, stec! plants, thermal power sitions ete. Accordingly, the design of the belt conveyors has to take care of various parameters. This Standard has beet prepared to help the engineers and technocrats and industry for making. use of uniform practice for selection and design of belt conveyors in India, This standard was frst publishad in 1985 and has been revised to bring itin line with ISO S048 which has since been revised. In sedition, the reference of Indian standards referred in the standard is also being up-dated. Further the errors noted during the implementation of the etandarde are also being corrected. ‘This standaed has basically covered the conveyor system using belts from 300 mm to 2 000 mun belt widths vonfcrming to 18 1891 (Part 1) : 1994 ‘Conveyor and elevator teatile belting : Pari | General purpose belting ourih revision)’, At present belts of widih upto 3 000 mun are also being used in Indian industries. ‘This siandard can be made applicable t0 belts of all widibs subject to availability of technical dats fn the preparation of this standznd assistance has been derived from the following: 180 5048 : 1989 Continuous mechanical handling equipment — Belt conveyors with carrying Jdlers — Calculations of operating power and teasile forces 150 5049 (Pari 1) 1994 Mobile equipment for continuous handling of bulk materials ~ Part: Rules for design of steel scructures 150 5293: 1982 Conveyor tetts — Formula for transition distance on three equal length idler rolls ISO/TR 10357: 1989 Conveyor belts — Formula for transition distance on three equal lengti ide rollers (new method) DIN 22101 : 1979 Continuous mechanical iaadling equiprcat, bell conveyors fer bulk materials: bases for calculation and design BS 2890; 1973, ‘Troughed belt conveyors BS 5934 - 1980 Method for calculation of operating power and teasile forces ia belt conveyors with carrying idlers on continuous meckanical handling equipment er the parpose of deciding whether a particular requirement of this standard is compied with the final value, ‘observed oF calculated, expressing the result of a test or analysis, shall be rounded off in accordance wilt 152. 1960 "Rules for rounding off numerical values (revised*, The number of significant p roan ff value should be Sime as thst of the specified value in this standard.BS 1isy2 : 2005 Indian Standard SELECTION AND DESIGN OF BELT CONVEYORS CODE OF PRACTICE ( First Revi ESCOPE, 11 This standin provides guidance for selection and design practices to be adopted for belt conveyors, 1.2 This standard applics to stationary and shiftable andicr extendable conveyors baadling loose bulk tna (erial and such material, which behave as solids. For guidance, classification and properties of such mate- ‘ial are covered in TS 8730, 41.3 This standard covers the conveyors withbblt wicths ranging from 300 mm to 2.000 mm as currently in ogue in conformity with relevant Indian Standards bot eactating special purpose conveyors, Noms 1 Comeyor.rotgovtel under hs sope wn special pupae conveys, foe exemple, feces package Somvesery etn be ‘uaeeel na separate stn 2 Th stele aa covers conveyors wings ed beg 235i aqitoment fer eneyos for wc unde onl eal tues sla ceveredy then, 4 tos standard doo not inclade certain date on sec end ‘conyers andoonveyer foruntergiound ines Where eran nas tants ee see {4 Attention s deawn tothe many varied factors‘which ‘ofluence the driving force onthe drive pulley and whic rake it extremely difficuk (0 redirect the power re- ‘quisemem exactly. This India Standaed ig imtended to ive 2 simple method of conveyor design calculation. Consequently i is limited in terms of precision bat is sufficient in the majority of cases, Many factors are not ‘ken inlo account inthe formule but deisils are pro- ‘vided on their nature and theic effect, In simple cases, sshich are the most frequent, itis possible to progress easily fmom the calculation of power requirements 10 !bose ofthe necessary ard the coal tensions in the belt, ‘shih are critical in the selection of the bet and in the esiga of the mechanical equipment. Howeves, certain conveyors present mare complicated problem, for ex- ample those with moulliple drives, of with an undulat- ing profile in vertical eR-vation, For these calculations, which age not covered in this Indian Standard, ulvisable to consulta competent expert, 1.5 The recommendations given in this standart shall ve applied bod 10 individual conveyor, av welt as conveyor systems consisting of more than one gy ewer tomemiesionCstosia Be pose itiaslcy eal ateeite tees omy Sa Uahspeceaenerts Lowspetrenieest OD ee ay a size oC material with — Relatwvely higher angie repose oe iz £Trghioganele strts cen egos vihtrenen tepecrstemienett, 1D A Alglevanccrscessothewngbetcayng, lage Recast deci = sity Pann ERE Le cela rerampres Wil or witout venical cervaure Without vetleat curve me oun Saale ede Meniniindeel tf f, 15. ay Giefaieotticion arecensaryingiers — {raat in sone wits 19 8730. 6% Delimton mde Sai oe i 4 Otaauneinaenmainies — Gh inaveoaialenazeminaidtentcie pub oul i, aOmalee erin UR) MCL Sie) covered in 6.2, the following data is also required: 1K, Coniston tween Belew ele — ap Coa ES ong Sotseeres il b) Difference in levels betivoon the head and tal 50 Bakdeesy ote tee ends, Ge ene bosch c) Whether future extensions are required or not 12. praielgia ite Its, the proposed level ofthe head end ar til 14 @ Sochargeonele dege nd to be ater ie, hed Gentle aot ane st Tamora, Si Upper wiles 6} Location of discharge conveyorsin cus of pivot S,= lover & operation; s nas Whe ihe 0 Type of wi ep feeder movement a SELECTION (whether SeaWTe® mounted oF rail mounted) Table? lists the feanaes of eoughed and fat belt con and veyortand shall help in selecting the ypecofbeltcon 4g). Maximum allowable ground pressure “yer 6.2.2 For layont of system of conveyors and/or smu LAYOUT ‘yelual conveyor in underground (raining) installations, points such as compact drive head, flame poof 5.1 Forasingloconveyarthe centreto-centre distance pouors, fire etarding belting and recautions2vode ved alte gulls sou Iatronntd Losi (eh -gaibang to eani@ equa muenixed & ste wbIW 1196 oF noietsst (CF seustd) 2a niencereib A "sata quest maaan abiw anlbreasA (mes) 12h 2 sie ‘si andthe te) ‘aooianami(l mera) (osinatol! 0! a ‘we oot a Oe ast at oe, ott oor ou, oot at 209 oes at 2a ove O81 ot ote ost 0x ot vos oe oct wos 004 oat ees eo oce oe a 9a eae wet on cae ay oy orn O02 | 008 on oat ‘oe oF ont 90 1 008 oot se gel mic Yo noautiemahb doexs oT — BTUA ‘0 booge id lane angus! 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Bas "bosie" ew bovanty ad fila Ustotal 1.0.6 ‘ewollol zt Initsium anh no bse lainstein Ilo cena YW ansowg OE — bse) Ue 2LT souls ov ao rodgid o2u bos BLT bas EL mot uols2 oelA .noieno! gaiieroqo rauini xem stelualto 0} wnoienot gains murizern atsl jun ¢d aoiena! gaiteroqo murnixainxlgiluM D1 inioj lad to 2¢1t of onanctor dibw rots isha cee 9 qu-siet bas ccoona i signonte guiloord gnivad sod w foalo@ TLE shiv slueer eb apd DLT moa bonisido oulee To smurniean bas curinion bos mumixem bobaommoos1 -qu2 bar gaidguow rt 2g Yo arodemuncibiw sod ) Tena Tato o0cT rian 1 tne ar dove leon gown oy or ‘roi ei hoow qi teow gery oven tral gat lve fe oa > sven brug bras Aon aumgouge os de alerie ——_ loite Ms lace hte Soom te bua nod enh, se ts © garg me esa tne srt m quid eqn, sieaet ano node Joly) easy on ih ainsi) leant sali cd owes ing nolbaitt bia muney bas noize) aqole oteivole”) E1.5 rads aoiowgilnes wysves ou griba9geG BET 2b Yo HoiNaDOI noite seg AOlEAH!>eb\noHENITIN noienss sbie sale beniupen mumininn st sumqen0fs 11592 : 2000 ‘Table 7 Matxisum Section of the andled Material in m? for Triple Roller Trogubed Belts According to Fig, 2 with Equal Length Carrying Idlers (Clauses 7.6, 83.2, 84.3, 843.2 und 84.5) © @ one 9, 6624 0.05m FoR “2 —0.25m FoR 97 Fio. 2 Maxuntuw Secrion B oF Hanoteo MarexiaL rox TRirLé ROLLER TRouces Bets Bele Sarsharge ‘Trough A te wan kage ————— =m 20° 350 a “ ad cos 9020-39 ois oir cose cow? dole? ois 6 conta nee | eg ook gum gan oon 6 vou? aise | ww os 4 0mms 2 dams oom cow? oo} en oo ones toons x22 oor 1 oo 2809 ta dose? oss gow a oo 2 90? awa 8013 ates w oon > 9D Naa 0.0507 0023 bs wooo om? ome naa sous 0050 ast w cows oo ass ase 80603 sa » 0053 3 (Oost (a8 0.067 oon bone 0 oot og 263 vos oo? an bw oF ours ost? 99817 ore 0003s w oor ou as O33 om es | 2” oor 6 bse 6 tow an one e129 | ” 109 oat ae a5 one a6 mot goo oes 3 nom? oan ean o corso ne east ose east » ose asi ats a7 ote Fg oun ala 4030 1% en 00 oe oaze ose ost orn can 1 use as ist oan au » out 923 200 oan os | 0286 9253 1264 oan wan ven ase sas 0.208 208 date O09 aan 0.253 oan an 0251 0302 8.300 O31 ase oats 154 au 0360 136 venus 920 an 124 oan aa cs 26 92% ion oie bass a oa 936 ese oot outta o aaa oa) hate oat oss Jrww 021 ous oo 36a oats o 290 232 asi ans oan oso > 05% ans oat ate oan sta m0 as 0301 9538 ssa osh si18 1192 ; 2000 Table7— Concluded il Surcharge : “Trough An wine" Asgle powell ce et ‘ton Ea = o ~ | 220 vast eon 30s a0 0.6 oars ww bast oe ass Dave 0527 ose ” asi 0508 oss ota e410 vey m0" 0369 cy 269 ost 0.607 719 o 9303 oes owe o.as2 oss 0565 j co oan asa os o3t6 eas oss 20 9347 4 9683 0.504 ons os ao 9917 om om ace 830 oss Deo” og 360 a9 oste os cas oar wo 9302 sts oto 0.595 ona on 20 Dt ante ont om oso ass a» oso one oo 953 ose 099 2800" oe os13 oss osas 6.600 oz oma wo ose 0663 ont oso oes oxy 2 ons. ox ane 0.950 0993 toes so" 078 O98 1.963 Lice Lis7 Lass nore "Tinea gnerally notable theaSavy and mea i fematen ony 7.23 Finalized drive power considering transmission losses afier selecting machinery between drive pulley and the Source of power. 7.24 Finalise the drive element's specification like Cou pling, beichuin drive, gear box 7.25 Determine drive shaft diameter and other termi a) shattings. 7.26 Select proper bearings for the duty ednditions and service life, 7.27 Consider location and type ef take-up and find ul the amount of take-up tension and the take-up. 7.28 Cateulate coasting time of individual conveyors and comree ie coasting times forthe conveyor systetn 7.29 Consider if hold back and brake are required Simulaneously or one will be sufficient, Detormine the type and location ef hetd back"braks, 7.30 Calculate the braking force and torque required, 8 DESIGN ASPECTS 4.1 Characteristics of Material Affecting Conveyor Design 8.1.1 The proper design of a belt conveyorieoaveyor system 18 greatly influenced by the characteristics of the material to be haadted. Generally, the materia’ is classified as showe ii (8 $750 8.1.2 Care sball be eaken for the inclination of any Inchinedideelined conveyor, carrying lunips of material, as these ane fkely tu'slide down, wherever Sulubtesjestsa may de madein case oer ales ofsuchageangle and vewphing angle __| Possible. Actua! inclination of the conveyor shall not exceed the maximum, allowable value (see IS 8730) In case of declination, the angle of declination shell fof exceed 12° in any egap 8.1.3 Table 6 shows the maximum recommended belt speeds for different sizes of belts based on specd fnc> ‘or (speed factor = lump size factor + abrasivencss factor). For systsms with ploughs and trippers, lower speeds of belt shall be adopted 8.1.4 Physical Condition of Materia Care shall be taken to analyse the physical condition of the material to be conveyed which ere classified as follows: 4) ily oF liable to reace with rubber products, d) High temperature, 9) Nowabrasive, ©) Mildly ebrasive, ©) Abrasive, 1) Very abrasive, 2) Sharp abrasive, hy Easily degradable, 1) Mildly corrosive, 1) Highly corrosive, «) Explosive or creating iareutul vase 8) Very dusty, ) loflammable, ) Hygroscopic, and 1) Sticky,1p 11592 : 2000, ‘Toble 8 Maainiuw Section B of the Handled Material in m for Two Lqual idler Troughed Betts ‘According Co Fig. 3 and for Flat Belts According to Fig. 4 (Clouses 7.6,83.2, 843, 84.3.2 and 8.43) 020.9 ~0.08m FORB £2m )= 9 =0.25m FOR B 72m Fro, 3 Maxunu Section B oe HaNpLeD MATERA ic. 4 Maxmun Sscrien B of Haste Foe Two Fquat [ouee TrovanED Bear Materuat tor Puar Bett [iia Serchanae Toller Tewgied Bal Fader } mm | Angle [ee ee NR i is a a | 00 . | = : w = = = 014 » = 7 = 29 ae x 7 ES 008 6 oo * 00059 0.0092 ae 1 ops ours uw 2 ou oon8 ‘0857 a doit 0153 a0 509 o ooo aoa a toe 00183 0002 ooo? we oon oon ones rg 0a oor bows “0 o 00179 oor i os box? bea a. 3 2” | oon oust s caves a0 | eat O08 6 pos so ” | oom7 oon 9 = wo | pi» buss 6 0:39 eS s+ 068 7 bores soe 00556 0073 Ke + 000 ° oo» 00090 = toe 544 fens 2 oo j a 038 5 O08 oon? sas 0106 a3 10853 0 ” 0563 10 ze so 00950 our ooins 20 bas ois, 050 we | nase ost 095 8 | 200 a = = 10° 2 z | oe = 9.9560 Ba = e bane we = ous NOTE: —_ Sule aujusmensrioy bermade in esa of other vabiex of surchargeangle and voughingangle. 1015 11592 : 2000 ‘Table 9 Slope Factor ‘(Clauses 76,832, 8.44 and Fig. 99 Conveyor | ‘Sope. ‘Conveyer ‘Slope Conveyor ‘Slope Incnstion Factor x Incintien, Prcor 5 Tintin, racic Depvees ‘beerees Degreet a |e 25 5 4 Dae Te a Ea 0 6 Doe 1 Oss 2 os a ney | a om 36 Dot 0 095 ey ware 2 | 2 Dos 23 on © 086 i 194 2 on 1a pt | | HEEFFRRKA Foo} | + § a | TE 08 —~ a 1 is 8 ie ae SLOPE ANGLE, —— ie. $ Factor K as 4 Function or 5 ror Ascenpins Converos [S41 Selecouu of various components of the con veyor system stall be made taking the relevant ohysi- cal conditions of material inwo secount B.L5 Flowability Abrasion and Other Miscellaneous Characteristics of Materials 8.1.5.1 Based on size, shape, angle of repose ancl angle ‘of Sarcharge, the lowsbility of bulk materials is given in 1S 8730, 8.1.5.2 Due consideration shatl be given to abrasion and other miscellaneous chasacteristies of material in selection of belts. These properties of material are lasitied int 1S 8730, 8.2 Belt Speed 8.2.1 Belt speed depends on the following fasts 2) Capacity required ard belt jickt: ») Loading and unloading conditions, ©) Size, shapes. llowability and other eharieseas ties of the material conveyed; 4) Belt consirnction; ©) Inclination of bett conveyor, and 9) Wler constavetion and diameter, 82.2 Bel speed shall be selected From the secon dluion givea ia Table 6. Higher belt speeds may be considered under spevial design conditionsiS 11392: 2000 ‘able 10 Maximum Capcity of a Belt Conveyor in tonnesvhour (Clauses 76,832, 83.3 ond 84.3) Cape bet om Duirdersiy of mera p= | Ovex® Bekspeed Y= Omi Slopetixtor K-= 1.00 sex | Sursunse “re Fal a Rote roughed Welt, Trngh Ange vwiain | angie -——___ = vn |= = ” as o ow | 4s a 50 56 @ or so | ow a se 6 70 » a © 28 « ss ® o | es a se 96 19 12 105 } ° 6 *0 3 108 16 bs «co | ow | 48 161 ns uo 9 14s w/o has 6 156 1 1 w | is 16s 2, 135 2 i eo a3 a 10s 180 we wu we) tas 68 186 an a » 2 | im 2 na 28 235 2s so fou 260 m4 281 25 an ° | om 208 wa m so » vg | ae | aaa m x 336 » rs w fo at ma 2° a7 a se | om a “6 68 “a a © | as san a0 03 * a vow | we | ass ar 433 on 2 so we | a su sst 37 as o se | st as «5 as 7s mm © | oan os so s as ea fe séo «0 a a4 70 we | ou 108 10 oo 89 az | se | as “9 ou 30 © on wo | ass a «6 40 20 78 tow | ue | sss ast 9 on om 108 i we | oss 10 10 10 166 we | cose visa na 1386 1296 vn { ce fom at 3 on viz van | oe sie as 103 16 aes 137 aw | cor 3202 199 te 1a 199 we | 1346 151 107 13 ose 1085 foe fw ou 10st vis re) to van bow | vou vis 1m st 1 12 jw fiss v4 163 us Ls is we | use va 1908 1998 20s 201 NOTE Suan aajsinen say benase mene of oles anes achageangleand onphngangle st 007-01 foecen:Table 11 Maximum Capacity of « Belt Conveyor in tonneshours (Clauses 7.6, 83.2, 83.3 ond 8.43) Capeciy based 04 Bulk dees of materal, p= | yn! Belspees v= ios Sbyeticer X= 100 Is nisez : 2000 Belnwet| Suresaree “Two ler Trosghed Boke Flat Bes am ‘Angle “Trough Arete 1s ES a ’ ~ a a a 300 oe = = a se ES = = mt os ae 2 = = sa o a n 2 = 09 lo 30 36 “u oe Ea 0 as 6 05 a 2 ss s 3 ° a 46 ss = 30 We 3 6 6 a a 6 % 2 4 aw as 2 oe 2 * 6 a 98 - 0 toe 86, 10» v3 30 2» ot a Me ao 11 165 v5 3 o » ne 134 = | o to 3 m1 193 a 20 is 24 23 83 woe 235 2se 24 16 o 1 28 28 = +000 toe at Zs 310 fa me 206 a a4 1 ae 3 a7 3 as o 2s 308 367 = 4200 rs at ao 37 un 2 359 504 So ns ae 361 ez sat ses ‘ = * i a | 400 we S = = 13 a = = = m a = a = os 200 ww 7 & 7 201 20 = x = 410 i = = ea 630 i NOTE — Suitable adjustments may be made ia ease of other values of surcharge angle nd roughing angleist 2000 8.2.3 Higher belt speeds may be adopted after taking ‘nto consideration the rcsultan: effect arising out of; 4) creation of turbulence at leading points anc b) encouraging of low density material t become air borne; ©) increase product size degradation; and 4) reduction in Life of chutes and transfer devices. 8.2.3.1 Lis important also to check the adequacy of ihe lype of belting, its joining, and safety devices for the conveyors. 8.2.4 Fntreme core shall be exercised while selecting speed, as lower speed will make the installation costly ‘but on the other hand a higher speed is likely wo create problems of spillage, dust generation and loss of fine pondery materials. 83 Widths of Belt 8.3.1 The width of bet is predorninantly governed by ‘ovo fectors the hump size of the material conveyed ang the eapacity requirements ofthe conveyor. 832 Tables 7, 8, 9, 10 and II give cross-sectional area, slope fiter and carrying capacity respectively offbelt conveyors, 8.3.3 The width of belt for the capacity requirement fean be read off from Tables 10 and 11, This shall, however be checked for minimur belt wieth from Table 6 for given lump size factor. The preater of the tuxo values shall be adopted, 8.3.4 The standard width of belts in millimetres as specified in IS 1894 (Part |) areas follows: 300, 400, 500, 600, 450, 800, 1 000, 1 200, 1400, 1 600, 1 800 and 2 000. 8.4 Capacity of Belt Conveyor 8.4.1 The capacity of a belt conveyor is determined primarily by the following three factors: 48) Cross-section of load on the belt —The eross- sectional lead on the belt will vary with the With of bel, the type of carrying idlera uscd which dewezinines ihe amount of woughing, fe tothe bel, and che nxture ofthe material being handled, which dsicrmincs the quantity lof material that ean be safely losded on 10 a en o10s5-seation by Sposd of belts and ©) Slop 81.2 General Foren for 6 of all types of belt conveyors shall be as follows: C=3.600 pA VK, Mae a 8.43 Figures 2 16 4 show she most sual trough sections for which the cross-sectional atca. of the ‘material is given in Tables 7 nd 8 which are esloulated ‘onabelt width, filled with material, of width 6 (below 2.000 mui 9B 005 (2) 8.4.3.1 For belis of width greater ten 2.000 mm, b-B-025 (3) 8.4.3.2 Tables 7 and 8 indicate eress-sectional area from materials having succhargo angles of 0, 10°, 20° and 30°. The ehoice of right surcharge angle depends on the conveyed material and the distance it hhasto travel. For orally Cowing material, surcharge angle of 20° shall generally be chasen as standard valve, Easily flowing or almost fluid materials, how- ‘over attain surcharge angle of less than 20° and may drop down to 6°. Surcharge angle higher than 20° occur only for materials featuring a very high internal fiction, 84d The slope factor, K, in equation (1) takes into ‘aczount the decrease of the section ofthe handed ina terial onthe bait when a gradient is involved. Table 9 read with Fig. 5 gives walus of the slope factor, for different inclinations of 2 conveyor. 8.458 Tables 10 and 11 give he bel: conveyor capaci ties for herizontal conveyors, hats, A= 1.0 based on the load cross-section as piven in Tables T and & fora material of bulk density of 1.0 tha, and belt speed of 1.0 mis. To ealelate the capacity ofa specific con- veyex, the corresponding valu given in Table 10 and Table LI shall bemulkplied by the actual bulk density ‘of the material, he belt speed and the slope facta. 8.4.5.1 To take surges and unevenness in loading ‘operations into account, the capacity of belt conveyor calenlated according to 8:4.5 shall be generally limited 40 90 percent. In ease of conveyors with belt widths up {0 600 mm, the capacity shall be reduced to 15 percent 85 Driving Foree and Power Calewlation 8.5.1 Peripheral Force Required on the Driving Pulleys). 85.1.1 The requiced peripheral force, T, on the driv ing palley(s) of abelt conveyor is obisined by adding upall the resistances, Rt Ry + Raat Ry, @ go fa, tm, + Qn, +g) ces 3) + RF Ry ER Ry © + ef bee fm, +m, + (ty + me) 09 5] 4g Bot Ry +Ryy © 21, ag = uriving force on the draving pulleys én N; main resistances inN comprising of. 1) rotational resistance of the carrying and reium idless due to the frition Jn idler bearings and seals, and bolt advancement resistance, result- ing font the impression of the idlers on the belt, the recurrent flexing of the beltand of the material, = secondary resistances in N comprising of i) the inertial and fritional resistances due to the acceleration of the material atthe loading area, resistance due fo the Fitton on the side walls of the skirt board a: the loading area, pulley bearing resistance with the exception of the driving pulley earings, ané the resistance dc to weapping of the belt on the pulleys; ii) 4) wi) wy special main resistances in N comprising oe i) drag resistance due wo forward th of the idler inthe direction of movement of the belt, and resistance duet friction ageinst chute aps or skict plates, when these are present over the fll length of the belts special secondary resistance in N comprising of i) resistance duet friction with belt and palley cleaners, resistance due to Mristion with the chute flaps or skitt plates, when fesent over a part of the cenveyor length, resistance due to inverting the return strand to the belt, ») wit) iv) resistance due to diseharge ploughs, and » ~ slope resistance io N, chat is, the resistance Aue to lifting or lowering the material in clined conveyors; and resistance cue to tipers; =m Hg 0 1g tkeon 98 postive for aacending installation ive far descending iatallation = tibia eoctticieat of fiction, dieaension: less comprising ofratling resisance ofthe ilers along the cerrying and seturn Is uus92 060 sides of belt and the belt advancement ~ 0,020,is abasic value for normally alignee belt conveyors; nd = 0.012, is a basie value for down hill ‘conveyors requiring a brake-motor. NOTES 1 Under fyouable cone iv as xed anc peep aignae inallons wit ely roll ers and hw lle ition eater /may be as fow 02016 (hase value 0.030 euced +620 percent) snd fr anferourabio candions such es pool algnel bei canveyor wth ily ling ilo aah neal ‘heionateraljmxy be athighas 0.130 (baie wal of 9.020 Increase by 30"peren. The base value 0.920 sonferms te jer ofc, 2 Thebaic value. 002001/ 8 only applicable to ines ed af avand 70 9 L1 erwet of ther nom ec, ‘conveying padacts with anaverage ema leon coeff quipped withthe rol earryiagilersferibe upper sie of bolts 30° sige woughing engl, bolt pce ef abuut 3 ns srtouning tempertaer of abou! 20° and 103 te 158 gen dame carrying les mth aby rate el, togater with faker spacing oft 3 mor he earying seo the bel and oF vou forex return sie of Bl 3 The vai, may meee shove the valve 0.020 range up te (0030 mie filywing cases: 2) formed materiale with = high internal fistog foes yfortoushing ngieof aver ‘ferbettspeeésoFnver Ses ‘Qlorcamyingidler dara: lover tan te ate stone S\forsuecindingtempeninesofies tan 20°C, ‘Pfoea decease ofthe bet onion, ferlexblecweasbels and owe with hickand Nex 1) forpoely aignedinctinins .) wen oping onions ave dy a wet anor seky = 1) for ilerspung of markedly more tha (5m fr te ‘aryng side upp snl of th bck ata en fF the Yo, de (omer atrand}of heel, “4 The ail ction cet, decease thebaic sales af 20 ie enltion stated a Note3 severed ‘5 Wien theinsallaion scundngundeo-eadcondons, he sale of foun be eter lower or higies Un eee fF ‘penting condone copeningonthe nas ofthe oving pte and onthe conveyor bls enor, Dewail cre eyora which ‘rauirets te baketby brkeamolr, salle aly ease brcalevlate witha value lower hy 40 pereet han wed fo the ‘sleulanordiivenbettcoaveyers. Therese fa ¢absie vlueoF f= 0012, 6 Valuect/ima ineesse above thevahie nf. 050 aver ein rene conditions and/onypelualaen a forename nese Fone, 1! = numerical coefficient, being a function of conveyor length LZ (see Fig, 6) ‘Total resistance without slope resistance and ‘without special resistance ‘Main eesistance * Fer coneyors wit centecistnes issthan 80 ye value & ‘sunrise by Detached o¢ Fi, Wher esr secondary sistance at te grater wikis are pssivc espera) fersher highspeed fedeomeyer oflrgecapaics.1S uis9e: 2000 caerricent 30 05 [ 10 © mm 50 0 m0 ‘no0 seco cOnvEvoR LENGTH (ELANCE OFIWEEN ceNTmES},L Fea, 6 Vawues oF Conrrtcier @ As Function oF Converox Lenton E. 8 85:13 Calculation for secondary resisuance, tor 28 (9 symbols, see Table 1) img = mass per metre, of handled material in Rt Ry HRAR, ay en where 1000 10" ~O) = intetial and frictional resistance ut dhe where Joading point and in the acceleration area 2. = volumetric conveyer eapacity ina; betxcen the handled material and the belt ~ AP and (10) iaN MH = li of the conveyor between the discharze = 2.1000. p.(-¥) (2) aca in m, In case a belt wipper is wed Hy, = trietional resistance between handled stall include lit of the tipper ase material and the skit plates in the 5.5.2 Equation (6 is generally ws for determining sSeeee es EN the diving force Py the conveyor stope is Les than 18°, the factor cos 8 in equations (5) and (6) shall be Ha E1000 p.2.14 itted. Equation (5) is applicable for all conveyor lengths. However equation (6) can be used for approx. use eatcaations for conveyors length more than 80 (13)A = sup vesistunce between belt anc paile 1 N (not. be calculated for drive pulleys} tule wa| a0 +00): Se B i a for fabric carcass belt 120500 oor In} 2 ale iy forseel cord belt Hayle The values of wp reser A, all gonetally be edited in ocordance with ermal (14) and (15). For [banc lowing bie ves Ih ales of wrap reste: Leciowef—Degies of Woop Wrap Resistance ley Bele ¥ gotsce 130" 200 20 Shckside 130240" us Alls: pulleys — 10 A, = pulley bearing sesistance (not to be cal- culated for deiving pulleys) in N a ooos 4p, 416) 5 r (, = acceleration length at loading area m - Gene a7) 4; = copflicient of friction between material and bat ($1007 2 © ccefficien’ of friction between material and skirt plates: 051007 5.144 Calculation for special main and secondary resistances. Ry ANd Ryy R= special resistances in N Bay + Regd 8) FR, +R AR) 9) A, = sesstance due 1s idle thing = 4. C, sub, (ng +m) e058 sin 20) in case of carrying idlers equipped with uree equal leagih rollers, = Mbeki) 605 v6085sini 1) in case of reuirn lees equipped with wo colle A. © tesistance due to Friction between handled ‘material and skirt ates in N is.@? #000). 9.24 aS 11592 = 2000 frietinat resistance due to belt cleaners in = AP, (23) OTE —The frictional siatnce eo belt sleanens Bal Ue eolealaedin acordnace with formats (23) Fee gasdane, 2 Vale fetween S50 and S20 Nn length each snap may be et AR, = resistance due to friction at the discharge plough in N BLK, ea) 04 ough factor up 19 30° rough = 05 trough factor above 30” and up to 45° ough coofficient of friction between carrying, Idlers and belts = 031004 1, = coefficken: of friction between material anc skint plates 0507 = 0,6 10.0.7 between belt and belt cleanet Pressure between belt cleaner and belt 3 (10) to 10° Na? K, = scraping factor in N/m normally 1 500 Nim 85.2 The formulae given in 8.5.1 for the calculation ‘of the petipheral force at the diving palley ure suit- ‘able only for uniformly and continuously lezded in- stallations. For belt conveyors running over rough ‘ground with slope ehaniges oronly sloping inthe down Hill direction, for which paral loading of the belt is frequenlly the case, the computing of the peripheral Totce shall ke carried out For different operating con. ditions, for example: =e 4) empty conveyor; b) fully loaded throughout, ©) loaded on some sections of the conveyor with fising, level or slightly dropping run wheve cach section requires positive Force to move it and empty on the remaining sections which ‘would be regenerative if loaded; anid 1 loaded on regenerative sections and empty on sections with a rising, level or slightly descending run ‘3.2.1 The highest peripheral foree on the driving pub Jey, whether positive or negative. foun i this mater bail be used for the design of the driving eystem, 8S Belt Conveyor Operating Power Requirements 8.5.3.1 The power required atthe driving pulley(s) of a belteonyeyor shall be > ai 150 2Is isy2 2000 (26) after taking drive pulleys loss into acount Ras Wa stones wanen Bland pulley fo tive pul anc ois eines Pile bearing esac are pey sh nto be tlbiaad a ghee Oe, 45.2 The meio eu power (tal) sal be oe + @) @n sn for regenerative soaveyors noes | Eten of vcioas wansmistion lament all botken ne accouetwileadoptng te vakes a, Forgieace, Tate 1 ‘hay oe teed. Movever where aberay, te atl efciee) 2 \lakedciin one moar paver tealoptd, cereeion Shall given otheacual kel con nr sige isltion 37,7 10095 3 Adatitonol power required due to tipper 3) Tabett conveyor has, number of tippers she power requirement shall be: 1) > Bas Roa yy Tan as factor for extis power for each tipper and shall be taken from Table 13 or Table 14 as Uke case may be. Table 13 gives the values of factor tor atripper whieh is either fixed or separately driven and Table 14 is for belt propelled trippers and is restricted 10 those lengths and slopes where these are applicable » The lilt ofthe tipper shall be ineladed in the cconveyar Hilt (4) The peripheral force required on the ériving pulleys for abeli conveyor with" numbers of Uuiggers shall be 7,(1 + Bn) ‘and further calculations shall be'based on this force only. 354 Belt Forces 8.3.4.1 The temsile forces on the belt, being different at dilferest point on belt of the conveyer, depend upon: 8) the path of the conveyor; by the number and arrangement of the driving pulleys the characteristies of the driving and beating ts ‘Table 12 EMtcieney for Various ‘Transmission Units [Clause 8.53.2 (Note 1)} "Type of Brive Percentage ificeney Eneloved gearunis— ‘Se eluson eid et pee 98 Deabicredactonhecelstaignct Upto 96 “Tiplerscusionhlclien ght eat pcos Spal bese cientworm gow Usernarais Done euction Uptose Tasreducien pee ga Chain dives —Toulyenctcedango binicaeel Upie 88 V.Betidvee 33 “Tooth bel des 95.98 Fuudames servant sures notes 1 The percertage giver for gear wats ae based upon wal veel bones Tiled withthe maniac’ tscommenced beat, -2Muhiply oseerappeopnane percentage fr cach estos om ‘rime over to eal pulley 4 obtain overal felency cf 4) the type, location and arrangement of the belt tensioning devices; and ©) the load case of the installation: starting, nominal rating, braking, stopped either at 9 load or completely or partially loaded, 8.5.4.2 The tensile forces exerted on the belt shall be such that, at any rating, the periphecal focees applies to all the driving pulleys are transmitted ta the belt ny friction without slipping and the belt sug between the supporting idlets does net exceed a safe imi 854.3 Transmission of the peripheral force at the driving puiley(s) For the transmission of a peripheral force for T, from a driving pulley to the belt the minisnusn tensile force T,,,, om le retur belt shall be calculated trem the font 1 ot 1 9-1 Ts = Tena 00) 2 pe BD Mivcimura peripheral fore, in N, often foocurs when stamting up or when braking the completely loaded conveyor, For guidance, with ratio of T, and Ty, may be taken trom Table 15 dependis2 upon the characteristics of selected drive the coefficient of friction between the driving pulley and the belt and can be determined For Table 16.4S 11592 Table 13 Factor f for Extra Power Required for Separately Driven Tripper [Closes 8.5.3.3 (a) and 85.3.3 (b)] neyo “Tripper Slope © res en mea 1-20" 3 = ‘027 023) 0 = a 29 02 ow 1s, - 020 our os i a a oat an ont on { 0 st oy oat oun 008, “6 = ous 110 0s ous « pay oor 0.08 008 3 me i vos 008 ae Py pat p10 oe 008 04 a0 ony oo vos 008 ou 10 one dot oe 007 oor 1 on or oor 097 our 20 oa oor oor 07 our 250 oo oor oor oor oor 300 oo 07 no? oar oo 00 on our oor e own vox oor our oor = 0.96 ‘Table 14 Factor Bor Extra Power Required for Belt Propelled Trippers (Clauses 85.3.3 (a) and 85.3.3 (6)] LC ‘Tripper Spe ee ° oe ene cr 16-20" 3 ns = = 052 ae } 2 0st 06 038 6 as = 038 30 025 » ow 030 03 as 0 - ox. ot ou ws 4s om ow ons on @ = os on an | ox a1 ow on 0 | op on oz | ao ous ou ons 010, 1s on) oe ow = = i on ow | 20 ou 40 2 x, -Is risv2 : 2000 8544 Mi n tensile jorce wo lind the bel sag ‘The minionums tensile farce 7,,, which shall be exerted con the belt to limit the amount of bet sag between the two sets of iets shall be: fo, > lta mee ris Spo: for canying sige .. 02) » Ete for reim site 6) 85 8) = maximum showable bel: sag. = 0.005 to 0.02. ‘Values lower than these never be reached at any point ‘on the installafion. The maximum ekiowable belt sag [(S = hva),,)- 18 generally fixed at berween 0,005, and 0.02 85.4.5 Variation of the tensile forces and maxinaum ronsile force on the belt The necessary tensile force and its alteration along he conveying lenge stall he determined foreach load fave asa function ofthe number, the arrangement and characteristics ofthe driving and braking devices, and according to the type and location ef the tensioning vices, by suitably adding to or subtracting from the ‘minimum Forges exerced on te bel! the motion resis- tances, the fosces due to the weight ofthe belt and the conveyed products, and tie peripheral forces applied to oil the driving pulleys. The minimum necessary tems fore> ia fixed either by the ability of transauit- ting the peripheral force ata driving pulley or by the limitation of belt sag, This highest value ofthe neons- sary tensile force for a given load case is generally maintained with all the other load eaces even if they ‘do nok require it, as normally it fs not reasonable and not practicable to peaduce different make-up forces wil, ditierent load eases. The maximum tensile 970 Ty, cette on the bolt which hs to be used For the chatee and the dimensioning of the belt ean not be indiceted 1 ‘Table 15 Values of Drive Coefficient & (Clause 8.5.43) 5 Type of rive Thee phase see eae mows wits bash coupling and dice 4) Tse pase irl cage motor ih i coupling and daston elie rat iy) Thre pce equites! czpe motor with pci ad coupling with eager cher fring ivy Thee phate sqviel cage motor with = U2 {pest ld coup wihstayedchenbee Init pane and scoop ont ¥) Thioe phase aquired sage mitorwitk Be 12 ecoupling and saree tat pg north tp gesting con law22 iswis lamis bby. formula which it universally valid. tis only im the simple eases, which, however, occur relatively cefen, that is, in the ease of horizontal conveying ot ‘with a small gradient, and if there isa single driving pulley, andif low beaking forces for stopping the plant are required, that the maximum tensile force applied to the belt can be calculated, approximately, by using fornmula (34) (see Fig. 7): } ro) & Tow == Te Faas ae NOTE — The eaefficien: hes ito account de fxs ta {Me peripheral free should ‘when tating the Dat ap then won ats ncminl mang. According o the (Give chrecterien, the coeicient fr bebwees 12 and 22 8.6 BoltSpecifieation 8.6.1 A conveyor belt consists of two elements, the ‘pareass and the cover. The carcass is the reinforcing ‘member and may be of ether textile reinforcements or steel cords and supplies the tensile sirengih and the body to the belt to hold the shape. In case of textile t ANGLE OF WARE Ho. 7 Tussite Fusces Exneren ow Beir18 11592 : 2000 Table 16 Friction Cuefiiciemt Between Drivaiy Pulley and Rubber Helting (Clouse 85.4.3) ] Secchee [fits tases] Pvmmtane | Gonmctngaing T PNCDa Tp ") “Ringed” | winteragton: | Dusen | vinuaegine Tuley | Fatencd Crone | Getngione | PanenesGrrrs | tered Ges Dysmilinajeabs | 035w08 { —oswaae | —aiswar | oawoet imeos ce veremdien | ans «as ©5004 0150030 ter epson | Opmsionintireat || ad wai easioan | og as est an 0.25 Stary ayer | i clon Operation under very oa { 02 oa bas ‘einforcement, tae carcass is normally build up of plies oftviile fabric The strongth of fabric andthe numberof. plies in the carcass ofthe belt may be varies together to suite stength requirements. However, testrength of carease has a practical limit, IF the belt is to0 tough, woughing and treining the belt will be very difficult ‘Paerefore dn belt wih esser number of pies with iran. et labric is generally preferred beccuse i ig more flex ‘ble both in troughing and going round the terminal pul- Joys. "The stel cond betiing is used to meet the condition of sini] elongation and good troughoility in conjunc ‘ion with higher operating tensile forces, PVC belting is _generally selected for underground mining applications where the azard exis 8.6.2 Selection of Belt Carcass 8.6.2.1 Tensile forces calculated in accordance Witt Foninula (4) (see 8.5.4.5) és then used in selection of belt carcass based on full thickness tensile strength GFTTS) (belt type) 8.6.2.2 Full thiciness tensile strength (ETS) method ‘he value of tensile forces (see 8.6.2.1) multiplied by factor of safety gives the required value of full {hickness tensile strength of the required beh, The full, thickness tensile strength of belt fixes the “Type of bel! © be selecied. The foctor of safety may vary from 9 1012.5 in case of textile bel and 7 to 10 in case of steel cord belts depending upon the application, type ‘of belt joint type oF iakt~up device and ype of starting for converyers. Por general guidances factor of safety of 10 isnormally used for textile belts with vulcanized jpintsand on e conveyor with gravity take-up and 7 for steel cord helring, 8.6.2.3 After the solection, the selected eaccass shall be checked for tie following 10 constraints 4} Adequate “body to support the load of the material caricd for the spesifc width ofthe bet. This may be checked from manufacturers recommendatory tables providing either min 2 ‘mur numberof plies foradequate fond sapport ‘ormaximum width for adequate load support for \arious fypeslconstrustions as also impact load- ing. b) Adequate fleribility to trough on the specified ngle oilers. This wzay be checked from man facturers" recommendatory tables pro-viding ‘maximum number of plies for adequate woughing minima with for adequate toughing 1 various types/consimietions 8.6.2.4 The selected belting carcass shall subsequently eross-checked for compatibility with ty vertical curves oosurring onthe conveyor (ae 8.9).= ae 8.6.3 Selection of Cover 863.4 The propaties seeded for the cover of bel ig” chide resistance to eutting, gauging, tearing, abtasiois, ‘ging, moisture absorption and in some conditions to ils, cheraical and beat, 8.6.3.2 The grace and thickness of top cover of belt depend upon a number of conditions, the most impostant of which are: a OF oR a) abrasivequalities ofthe material being handed, ) loading eyete, thats, the frequeney with which the belt eceives the loa. ©) lump sizeof the material 4) loading and unloading conditions, ©) temperature ofthe material ca be handle. 1) chemical activity ofthe material 8) contamination ofthe meterial with cil 1) fire resistant cover needed or not. 46.3.3 The back cover thickness ofa belt is generally $00 to 3,0 mm for textile rubber belts and 0.8 to 1.2 mun for PVC belts, In ease of steel cord belts, back cover thickness is minimum 4.0meand age up to fall thickness of fac> cover 8.6.3.4 Carestull be eiken for te determination of back cover thickness for belts on tandem drives and otherIs 11592: 2000 other special applications, where there is consider- ‘ble wear and tear in the back side of the belt. In such tases the back cover thickness may be increased 10 3 mm and above as may be necessary. R65 Thecover grade is determined by eharucteris- tics of the material handled. The recommended values af rubber cover grade selection are given in 1S 1891 (Part 1). 8.6.4 Standardisation of Belt Consoructions Where belting speciticaons are being selected for a number of conveyors in a plant i is worthwhile to consider standardization of carcass and covers for a porticular width of belting. This isto be looked into Jntcians of expected if and inventory. may be noted here that the adequacy of belting constructions with respect to actual service conditions that exist on each individwal insiallation should be ensured whilss standardizing 8.7 Pulleys 8.7.1 Based on percentage tensile force (rato between ‘he working tensile force and :uzximum allowable ten- sile force of the selected bait), diameters of pulleys, shall be selected from the recommended valves given in IS 1891 (Past 1) and shall couserm to IS 8531. 18.7.2 The drive pulleys may be lagged, wherever nec ‘sity, to increase the coefficient of fiction between. ths belt and the dive pulley 8.7.3 The logging thickness shall vary between 6 t0 12 taan and the durometer hardness on heed pulley shall be 55 to 65 Shore A scale, whilst on the stub, said bend polley shall be 35 to 45 Shore A seale. The softer rubber teuds co tesist the build up and allowing, of solid objects to get embeded in the rubber rather than damage the belt, X74 kn case of steed cor belting and PVC belting, special consideration shall be made in selection of pulley diameters and lagging, its type, thickness, ‘materia and application 88 Ldlers BAA Gewevel Types of ldlers 8.8.1.1 There are tw Das type of belteonveyor ier 4) Carrying idlets which sopport the loaded ran of the conveyor bel and 5) Return jdlers which support empty setara run of the soaveyor NBL Currsing faters Carrying fers cas hhave three types of general configuratic Ly Fe bree roll throughing idiers for » troughed bets (wee Fig. 2) cousisuny of fourrtwo ovter rolls, which ate inclined upward and a horizontal central rol 2) Two colt shrougking idlers for troughedt bells (see Fig. 3) consisting of two identical idler rolls, inélined upward 0 facilitate the belt to from a tough, 3) Horizontal caerying idle for supporting flat Joaded belis (see Fig. 4) consisting of a single horizontal idler roll positioned between brackels which attach directly 10 the conveyor frame ‘Type of carrying idiers 1) The most commonly used gype to carrying Idlers consists of thee in line idler rolls of ‘equal length. Fora given width of belt, rll inclination snd surcharge angle of the material, the three equal Jength roll ‘roughing idler forms the belt ita the best troughed shape to camry a maximum load cerass-seztion 2) Troughing idler arcangement having 4 relatively long horizontal coll and two shot upward inelined rolls does not forma given belt into a ough for maximum load cross- section but is useful under certain conditions, for instance where conveyor’s Joa! must be spread for manual inspection, picking up of sorting. The inclined end rolls. ‘um up the belt edges 10 prevert or greatly nniaimize spillage 3) In an offect troughing idler, the inclined rolls ((wo numbers on bot the sides) and the Rorizontal roll are located in two different vertical planes. 4) Catenary fype— Troughing idler consists of a fleaible catenary member on which integral small diameter rolls or mukipte rolk, assembly is mounted, ‘The rolls ean be ‘moulded either in the flexible member, which rotates as an assembly in fixed bearings atthe ends of the eaenary member or in the individual rolls which may rotate ‘on bearings supported by the flexible vatenary member. Garland type — This type of idlers are suspeaded from stringers by suitable suspension methods. This type of idlets voasist of rolls connected in between with flexible links and can be used for beth on carrying avd return side 6) Impact cushioned kdters — Impact \yve ‘diets having rolls made of resilient ‘material, ave used at loading points where the tumg sive and the weight of the handled