CLIENT : BHEL

PROJECT : BHEL MAITREE CONVEYOR PACKAGE AT BANGLADESH

DRIVE POWER CALCULATION FOR CONV. NO. EAC-15A / 15B AS PER CEMA 6

INPUT
1.00 L : Length of the conveyor m 343.5
ft 1127
2.00 H : Lift m 9.30
ft 31
Flight 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
n
Loading Carrying Loading Carrying Loading Carrying Loading Carrying Active Snub Pulley Bend Pulley Bend Pulley Gravity Take Bend Pulley Bend Pulley Return Return Return Return Return Return Return Return Tail Pulley
Head Pulley up Pulley
3.00 Flight length (ft) ft 25 252 16 264 16 253 16 253 253 16 253 16 264 16 252 25

4.00 Hn (ft) = Lift or drop (-H) over the length Ln of flight n. ft 0 0 0 0 0 0 0 31 -31 0 0 0 0 0 0 0

5.00 Q(Rated): Rated Capacity TPH 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250
Q(Design): Design Capacity TPH 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375 1375

6.00 Material Handled Coal

Maximum Lump Size mm (-)100
φs : Surcharge Angle of the material deg. 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
radian 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
7.00 γm : Bulk Density t/m3 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80
lbf/ft3 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04 50.04
8.00 BW : Belt Width mm 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400
in 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55
Ws (in) = Skirtboard spacing. Figure 6.39 in 37 37 37 37
Bc (in) = Idler center roll length. Figure 6.39 21 21 21 21

9.00 V : Belt Speed m/sec 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60 2.60
fpm 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68 511.68
10.00 θin (deg) = Uniform or average angle of incline(+) or decline (-) in direction of degree 0.00 0.00 0.00 0.00 0.00 0.00 0.00 7.00 -7.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
movement over the flight length Ln.
β : Troughing angle deg. 35 35 35 35 35 35 35 35 20 20 20 20 20 20 20 20
radian 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

11.00 Wb : Weight of belt (kg/m) kg/m 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84 26.84
Wb : Weight of belt (lb/ft) lbf/ft 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00

12.00 Wm : Material weight (kg/m) kg/m 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94 146.94
Wm : Material weight (lb/ft) lbf/ft 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99
= (2200 . Q) /(60 . V)
13.00 Wb + Wm (kg/m) kg/m 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78 173.78
Wb + Wm (lb/ft) lbf/ft 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53 116.53

14.00 TF ( °F) = Operating ambient temperature

KiT : Temperature Correction Factor 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33
= 1.114 x 10^(-8) x TF^4 - 3.763 x 10^(-6) x TF^3
+ 4.458 x 10^(-4) x TF^2 - 2.136 x 10^(-2) x TF + 1.333

15.00 IDLER SELECTION

Step No. 1 : Troughing Idler Series Selection

CIL : Calculated Idler Load (lbf ) 592.34
= ((Wb + (Wm x K1)) x Si) + IML
K1 = Lump adjustment Factor (Table 5.23 of CEMA - 6)
IML = (D x T) / (6 x Si)
D = Misalignment , T = Belt Tension

ILR : Idler Load Rating 1116

CEMA Idler Class selected D6

16.00 μss = Sliding friction coefficient between belt and seal rubber. 1.00 1.00 1.00 1.00
Fss = Effective normal force between belt and seal lbff / ft 3.00 3.00 3.00 3.00
Kis = seal torsional resistance per roll at 500 rpm-see Table 6.19 in x lbff 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000 4.000
KiV = torsional speed effect-see Table 6.19 in x lbff/rpm 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004
nr = number of rolls per idler set 3 3 3 3 3 3 3 3 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
CiW = Torsional load effect, Table 6.21 in x lbff/lbff 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185 0.00185
Dr = Idler roll diameter mm 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0 159.0
in 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3
hb = Belt cover thickness mm 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
in 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197 0.197
E0 = Rubber stiffness property, Table 6.28 psi 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644 1644
wi = Load distribution factor, Table 6.26 [ BELT AND MATERIAL ] 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28 1.28
wi = Load distribution factor, Table 6.26 [ BELT ONLY ] 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265 1.265
Csb = Sliding Friction Factor, Table 6.36. 0.650 0.650 0.650 0.650

17.00 Si : Idler spacing m 0.4 1.0 0.4 1.0 0.4 1.0 0.4 1.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0
ft 1.31 3.28 1.31 3.28 1.31 3.28 1.31 3.28 9.84 9.84 9.84 9.84 9.84 9.84 9.84 9.84
n : Idler rpm rpm 312 312 312 312 312 312 312 312 312 312 312 312 312 312 312 312
Three Roll Carrying Idler (Roll dia. x Shell thickness x bearing dia.), 35 deg. mm 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x 159 x 4.85 x
Troughing angle 35 35 35 35 35 35 35 35 25 25 25 25 25 25 25 25

18.00 Location / Type of Drive Single

19.00 Drive pulley Lagging Yes
θn : Wrap angle at drive pulley deg. 210
radian 3.67
f : Co-efficient of friction 0.35
20.00 Cw : Wrap factor = 1/(efθ - 1) 0.38
21.00 W (lbf) = Pulley weight lbf 3850 2640 2640 2640 3300 2640 2640 2640.00
22.00 Cs : Skirt board friction factor 0.0754 0.0754 0.0754 0.0754

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23.00 Belt Speed and Conveyor Capacity Check
Per Table 4.5 (CEMA - 6 th edition) - 35ᴼ troughed belt cross section of load ft2 2.404
(Asc) :
72 inch BW @ 20ᴼ Surcharge = 4.197 ft2
84 inch BW @ 20ᴼ Surcharge = 5.766 ft2
78 inch BW @ 20ᴼ Surcharge = 4.982 ft2 (by interpolation)
Full belt load: Asc x Bulk density lbf/ft3 120
Percent Full Load : (< 100) = 100 x (Wm / Full belt load) 82
Since this has been identified a Peak Load, the belt width, belt speed, and
trough angle shown are good selections .

24.00 SUMMARY OF INITIAL TENSION CALCULATIONS

Flight 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
n
Loading Carrying Loading Carrying Loading Carrying Loading Carrying Active Snub Pulley Bend Pulley Bend Pulley Gravity Take Bend Pulley Bend Pulley Return Return Return Return Return Return Return Return Tail Pulley
Head Pulley up Pulley

ΔTHn (lbf ) = Change in belt tension to lift or lower the material and belt lbf 0 0 0 0 0 0 0 3612 -558 0 0 0 0 0 0 0
= Hn x (Wb +Wm)
ΔTamn (lbf ) = Tension added in loading to continuously accelerate lbf 202
material to belt speed
= Q x (V - V0.sin θi ) / (g x 108)
ΔTssn (lbf ) = Tension change due to the belt sliding on skirtboard seal lbf 148 98 98 98
= 2 x μss x Fss x Ln
ΔTisn (lbf ) = Change in tension from idler seal friction lbf 78 319 52 334 52 319 52 319 71 5 71 5 74 5 71 7
= [(3.82 x V / Dr - 500) Kiv + Kis] x 1/(Dr/ 2) x (KiT x nr/ Sin ) x Ln

ΔTiWn (lbf ) = Change in tension from idler load friction lbf 16.68 170.37 11.07 178.16 11.07 170.42 11.07 170.42 170.42 11.07 170.42 11.07 178.16 11.07 170.37 16.68
= Ciw x (Wb + Wm)/(Dr/2) x Ln
ΔTbin (lbf ) = Tension increase from visco-elastic deformation of belt lbf 15 248 12 259 12 248 12 248 358 23 358 23 374 23 357 35
= KbiR x Pjn x (Wb + Wm) x wi x Ln
Pjn = Cover indentation parameter (dimensionless) 0.032 0.044 0.032 0.044 0.032 0.044 0.032 0.044 0.063 0.063 0.063 0.063 0.063 0.063 0.063 0.063
= [ (Wb + Wm) x Sin x hb / (Eo.(Dr/2)^2 x BW) ] ^(1/3)
KbiR = Viscoelastic characteristic of belt cover rubber 0.122 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150
= b0 + b1 x [1 + tanh [b2 + b3 x (log V + aTexp)]]
aTexp = a0 +a1 x TF + a2 x TF^2 + a3 x TF^3 + a4 x TF^4 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026 -0.026
+ a5 x TF^5
ΔTimn (lbf ) = Tension loss from idler misalignment lbf 20 138 13 144 13 138 13 559
= Cim x Ln x (Wb + Wm)
Cim = Design factor for frictional resistance due to idler misalignment 0.0070 0.0047 0.0070 0.0047 0.0070 0.0047 0.0070 0.0190 -0.0028 0.0047 0.0047 0.0047 0.0047 0.0047 0.0047 0.0047
= Cbi x eim
Cbi = Friction factor for sliding between belt cover and idler material 0.75 0.50 0.75 0.50 0.75 0.50 0.75 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50

eim = Average misalignment of idler axis to belt longitudinal axis in / in 0.009 0.009 0.009 0.009 0.009 0.009 0.009 0.038 -0.006 0.009 0.009 0.009 0.009 0.009 0.009 0.009
= ∆Ae / As
∆Ae = Effective total deviation from perpendicular to belt travel in 0.600 0.600 0.600 0.600 0.600 0.600 0.600 2.437 -0.355 0.600 0.600 0.600 0.600 0.600 0.600 0.600
= ∆Aei + ∆Aem + ∆Aet
∆Aet = 2 x ( Awc / Asc ) x δit x tanβ x As in 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.837 -0.955 0.000 0.000 0.000 0.000 0.000 0.000 0.000
As = Distance between idler support points in the direction in 64 64 64 64 64 64 64 64 64 64 64 64 64 64 64 64
of belt width
= BW + 9.0
ΔTsbn (lbf ) = Drag due to Slider Beds lbf
= Csb x (Wb +Wm) x Ln
ΔTsn (lbf ) = Tension change due to bulk materials sliding on skirtboards lbf 0.851 0.565 0.565 0.565
= Cs x dms^2 x Ln
dms = Contact depth of material on skirting in 0.676 0.676 0.676 0.676
= [ Am x 144 - 0.25.(Ws^2 - Bc^2) x tan β
- 0.25.Ws^2 ( φs / sin φs^2 - cot φs ) ] / Ws
Am = material cross section area in sq. ft sq. ft 1.79 1.79 1.79 1.79
= (Q x 2000) / (V x γm x 60)
ΔTmzn (lbf ) = Tension change due to bulk materials moving between the lbf 16 182 10 191 10 182 10 182 81 5 81 5 84 5 81 8
idlers
= (Wmzn x Ln) / Sin^2

Wmzn = Belt work required to cause material movement from one ft-lbf 1.101 7.759 1.101 7.759 1.101 7.759 1.101 7.759 30.910 30.910 30.910 30.910 30.910 30.910 30.910 30.910
idler to the next
= (1/12) x dm^3 x γm x Cmz x BW x [exp[(Wb + Wm) x
Sin/Tn] - 1 ] x exp[(-1/2) x (Wb + Wm) x Sin/Tn ] x Rmz
Rmz = Correction between actual sag and catenary sag 4.34 12.23 4.34 12.23 4.34 12.23 4.34 12.23 16.24 16.24 16.24 16.24 16.24 16.24 16.24 16.24
= (1/12)e^[4.181-1.572 x (BW/(Sin x 12))^1.5-1.0827 ∆ysn^0.5]

for Fabric carcass

= (1/12)e^[4.966-4.071x(BW/(Sin x 12))^5-1.062x10^(-2)∆ysn^(-1.0)]

Δysn (%) = Average catenary belt sag for flight

fornSteel
as a cord
percentage
carcass 1.5
of the idler spacing = Sin x [ (Wb + Wm) / 8 x Tn ] x 100
ΔTpxn (lbf ) = Tension change due to belt bending on the pulley lbf 31 13 13 14 14 14 14 19.07
= 9 x BW [ 0.8 + 0.01xTn / BW ] x tb / Dpn for fabric carcass
= 12 x BW [ 1.142 + 0.01xTn / BW ] x tb / Dpn for steel cable belts

ΔTprn (lbf ) = Tension change due to pulley bearings lbf 46 18 15 16 23 20 20 38

= 0.01 x (dsn / Dpn) x Rpn
Rpn (lbf ) = Resultant radial load (vector sum of belt tensions and 22262 8657 7431 7634 10943 9669 9424 18137
pulley weight) of pulley ‘n’
ΔTbcn (lbf ) = Tension added due to belt cleaners and plows lbf 551
= BW x Σ Cbc
ΔTdpn (lbf ) = Tension added due to discharge plow lbf 882

Initial dT (lbf) lbf 497 1057 198 1105 198 1057 198 5091 628 31 29 29 37 34 34 122 44 680 44 710 44 679 948 57
Initial Step Tension lbf 4433 4930 5987 6185 7290 7488 8545 8743 13834 911 942 971 1000 1037 1071 1104 1226 1270 1950 1994 2704 2748 3428 4376
Update Belt to 4 ply, 630 / 4 Rating, 4.9 kg/m2 carcass weight fabric belt lbf 4458 4954 5838 6020 6944 7126 8010 8193 12500 911 942 971 1000 1037 1071 1104 1377 1419 2061 2102 2773 2815 3456 4401
Update to 1.5% Sag Limit lbf 3184 3680 4564 4746 5670 5853 6737 6919 11226 -363 -332 -303 -274 -237 -203 -169 103 145 787 828 1499 1541 2182 3127
Update to Drive Tmin (lbf) lbf 7993 8489 9373 9555 10479 10662 11546 11728 16035 4446 4477 4506 4535 4572 4606 4640 4912 4954 5596 5637 6308 6350 6991 7936
∆Ten : Effective Tension lbf 11589
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 Tm1 (lbf ) = Minimum tension to meet 1.5 % sag lbf 3184
= 12.5 x Si1 x (Wb + Wm) / ∆ys
Drive Tmin = Te x Cw lbf 4446

Belt Rating
The peak tension in the loop lbf 13834
N 62882
So belt rating needed = Peak tension / BW kN / m 45
Selecting 4 ply, 630 / 4 Rating, 4.9 kg/m2 carcass weight fabric belt
changes the tension balance so that the tension loop to be recalculated

Drive Required
a Pbn (hp) = linear power seen by the belt at pulley n hp 180
= (∆Ten x V) / 33000
b Pdn (hp) = minimum rotary power required of a drive component to hp 212
pulley n = (Pbn x SFd) / En
En = Efficiency or power loss between drive and belt (dimensionless ratio). 0.93

SFd = Safety Margin for active pulley for various considerations described 1.1
below.
c Power required for Drive pulley friction loss at pulley n hp 12
= [ (∆Tpn + ∆Tbcn) x V / 33000 ] x SFd / En
Pn (hp) = Power required at motor shaft at pulley n hp 224
= b+c
Drive power in KW at motor shaft at pulley n kW 167

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