POWER CALCULATION OF BELT CONVEYOR BCN-3C

0 29/12/2009 First Submission SK VD SKM

REV DATE DESCRIPTION OF REVISION
INL SIGN INL SIGN INL SIGN
PREPARED CHECKED
PROJ ECT
MANAGER
PROJ ECT
KORBA WEST THERMAL POWER PROJECT
1X500 MW [EXTENSION STAGE III]
KORBA (DIST), CHHATTISGARH
OWNER
CHHATTISGARH STATE POWER GENERATION COMPANY LTD
(A SUCCESSOR COMPANY OF C.S.E.B)
OWNERS
CONSULTANT

DEVELOPMENT CONSULTANT PVT LTD
CONSULTING ENGINEERS, KOLKATA
BOP CONSORTIUM

TECPRO SYSTEMS LIMITED


TECPRO ASHTECH LTD VA TECH WABAG LTD

GAMMON INDIA LTD

BOP CONSORTIUMS
CONSULTANT
FICHTNER CONSULTING ENGINEERS (INDIA) PVT LIMITED,
CHENNAI
DOCUMENT NUMBER
0802-TSL-DO-M0156

Document No.
App By SKM
Date 21-Dec-09
Rev No/Description By Date
Project
Input
Description Symbol Value Unit
Belt width B 1200 mm
Horizontal crs H 82.300 m
Lift V 15.68 m
Rated Capacity Cr 150 TPH
Capacity Cd 150 TPH
Assumed Belt speed Vb 1.5 m/sec
material Handled COAL
Sized/Unsized Sized
Max. Lump Size Ls 300 mm
Bulk density d 0.8
t/m
3
Surcharge angle As 20 degree
Troughing angle At 35 degree
Max. Allowable Belt Tension of rated belt tension Bt 80.0%
Tripper Slope Tra 15
No of Trippers nt 0
Conveyor Inclination Angle(Max.) Ai 14.0 degree
Conveyor length along belt L 84 m
Material Transportation length Lt 82 m
Skirt Board length Lsk 5 m
Carrying idler spacing Pc 1.2 m
Return Idler spacing Pr 3 m
C i idl Di Dci 152 4 mm
0802-TSL-DO-M0156
External Coal Handling Plant for 1x500MW KorbaThermal Power Station
Conveyor No: Rev. BCN-3C
Power Calculation for Belt Conveyor (Ref. IS:11592:2000)
Tecpro Systems Ltd.
Carrying idler Dia Dci 152.4 mm
Return idler dia Dri 139.7 mm
ERWPipe thickness of CI(IS9295) Tci 4.5 mm
ERWPipe thickness of RII(IS9295) Tri 4.5 mm
No of Rolls per set in CI Nci 3
No of Rolls per set in RI Nri 1
Artificial friction coefficient f 0.03
Tight side pulleys (wrap angle 150-240 deg) Ntsp 1
Slack Side Pulleys (wrap angle 150-240 deg) Nssp 4
Other Pulleys( deflector/snub) Ndef 1
Permissible sag s 2.0%
Wrap Angle Aw 210 degree
Coeffecient of friction betwee pulley & belt 0.3
Coeffecient of friction between CI & belt 0 0.35
Coeffecient of friction between materail & belt 1 0.6
Coeffecient of friction between materail & skirt board 2 0.6
Coeffecient of friction between belt & belt cleaner 3 0.65
Coeffecient for Idler tilting Ci 0.5
No of scrapers(External & Internal ) Ns 3
Thickness of cleaning tip of Scraper tc 20 mm
Angle of Carrying Idler tilting in forward dirn i 0 degree
Angle of Return Idler tilting in forward dirn ir 0 degree
Material speed component in belt direction Vo 0 m/sec
Motor rpm Nm 1475 rpm
Ambient Temp Ta 50 degree C
Page 1 of 3
Document No.
App By SKM
Date 21-Dec-09
Rev No/Description By Date
Project
0802-TSL-DO-M0156
External Coal Handling Plant for 1x500MW KorbaThermal Power Station
Conveyor No: Rev. BCN-3C
Power Calculation for Belt Conveyor (Ref. IS:11592:2000)
Tecpro Systems Ltd.
Belt Tension & Power Calculation
Edge Clearence on Belt c
=IF(B<2000,0.05*B+25,125)
85 mm
Material on troughed portion of belt p
=0.5*(B-2*c-Lci)
282.5 mm
Water level fill Area A1
=(p*COS(At)+Lci)*p*SIN(At)
112843
mm
2
Surchage angle Fill Area A2
=1/6*(Lci+2*p*COS(At))^2*TAN(As)
52221
mm
2
Slope Reduction Factor for Area A2 K1
=Sqr(((Cos(Ai))^2-(Cos(As))^2)/(1-(Cos(As))^2))
0.71
Area of crosssection Ac
=(A1+K1*A2)/(1000*1000)
0.150
m
2
Roller Length for CI Lci 465 mm
Roller Length for RI Lri 1400 mm
Weight of Belt (Refer Phoenix Yule Catalogue) mb
Considering 400/4NN-HD 5mm/3mm
15.62 Kg/m
Belt spped considering GB ratio as31.5:1 drive pulley dia as
630mm
Vb
a
=PI()*Dp/1000*Nm/(In*60) 1.54 m/sec
Weight of rotating parts of CI mc 22.1 Kg/m
Weight of rotating parts of RI mr 7.4 Kg/m
Skirt Boar width b1
=0.667*B/1000
0.80 m
Acceleration length at loading area La =(Vb
a
2
-Vo
2
)/(2*9.81*1) 0.203 m
Recommended filling factor(7.4.5.1) Ff 90%
Actual filling factor Af
=Cd/(3600*d*Ac*Vb
a
)
22.5%
Length correction factor (For conv. less then 80m)
=Cd/(3600*d*Ac*Vb
a
*Sfc)
1
Volume of the material Q
=Ac*Vb
a
*Af
0.052
m
3
/ sec
Weight of material on belt mg
=Cd/(3.6*Vb
a
)
26.98 Kg/m
Main Resistance(With material) R
=f*9.81*((mc+mr+2*mb)*L+mg*Lt)
2152.3 N
Main Resistance(Without material) Ro
=f*9.81*((mc+mr+2*mb)*L)
1501.3 N
Slope Resistance R
SL
=mg*V*9.81
4149.4 N
Inertial & friction resistance at the loading point in
acceleratione zone between belt & material
Ra
=Q*1000*d*(Vb
a
-Vo)
64.4 N
Friction resistance at skirt board Rska =2*Q
2
*1000*d*9.81*La/((((Vb
a
+Vo)/2)
2
)*b1
2
) 6.8 N
Belt Thickness t 11.8 mm
Av. tension at slack side Pulley(assumed for wrap resist.) Tavt 6000.0 N
Wrap resistance between belt & pulley (Except drive pulley)(Ref:IS:11592
Rw
=9B*(140+.01*(Tavt/B)*t/D*(Nssp+Ndef)
242.1 N
Pulley bearing resistance(Considering 50N for each non
drive pulley)
Rb =(Nssp+Ndef)*50 250 N
Secondary Resistance Rs
=Ra+Rska+Rw+Rb
563.3 N
Secondary Resistance(Without material) Rso
=Rw+Rb
492.1 N
Resistance due to idler tilting Ri
=Ric+Rir
0.0 N
Resistance betn material & skirt plate Rsk =2*Q
2
*1000*d*9.81*Lsk/(Vb
a
2
*b1
2
) 41.8 N
Resistance due to belt Cleaners Rbc =50000*Ns*B*tc*1E
-6
*3 2340 N
Special resistance Rsp
=Ri+Rsk+Rbc
2381.8 N
Special resistance(Without material) Rspo
=Ri+Rbc
2340.0 N
Factor for extra power for tripper tp 0.1 Ref Table-13
Tripper Resistance Rt
=(R+R
SL
+Rs+Rsp)*(nt*btp)
0.00 N
Effective Tension(With Material) Te
=R+RSL+Rs+Rsp+Rt
9246.75 N
Effective Tension(Without Material) Teo
=Ro+Rso+Rspo+Rt
4333.47 N
Power Reqd to overcome these resistance for loaded belt
P
DP
=Te*Vb
a
/1000
14.28 kw
Power Reqd to overcome these resistance for empty belt
P
DPo
=Teo*Vb
a
/1000
6.69 kw
Resistance at Drive Pulley Bearing Rdb
(Considering 100 N for each)
100 N
Average Tension drive Pulley(assumed for wrap resistance) Tavd 12000.0 N
Drive Pulley wrap resistance Rdw
=9B*(140+.01*(Tavd/B)*t/Dp
48.5 N
Absorbed power at GB o/p shaft for Loaded Belt Pa
=PDP+(Rdb+Rdw)*Vb
a
/1000
14.51 kw
Absorbed power at GB o/p shaft for empty belt Pao
=PDPo+(Rdb+Rdw)*Vb
a
/1000
6.92 kw
Wrap factor Cw =1/(e
m*Aw*pi()/180
-1) 0.499
Min tensile force to limit the belt sag at Carrying side Tcmin
=Pc*(mb+mg)*9.81/(8*s)
3134.3 N
Min tensile force to limit the belt sag at return side Trmin
=Pr*mb*9.81/(8*s)
2873.8 N
Slack side tension at drive pulley for transmission T
2T
=Fd*Te/(e
m*Aw*pi()/180
-1) 6925.2 N
Effective Slack side tension required T
2
=IF(T
2T
>Trmin,T
2T
,Trmin)
6925 N
Tight side tension T1
=Te*(Fd/(e
*Aw*PI()/180
)-1)+1)
16172 N
Component of Main Resistance R for upper belt-Loaded Rc
=f*9.81*((mc+mb)*L+mg*Lt)
1583.1 N
Page 2 of 3
Document No.
App By SKM
Date 21-Dec-09
Rev No/Description By Date
Project
0802-TSL-DO-M0156
External Coal Handling Plant for 1x500MW KorbaThermal Power Station
Conveyor No: Rev. BCN-3C
Power Calculation for Belt Conveyor (Ref. IS:11592:2000)
Tecpro Systems Ltd.
Component of Special Resistence Ri due to CI tilting-Loaded Ric
=9.81*Ci*0*L*(mb+mg)*COS(At*)*SIN(i))
0.0 N
Specific Resistance to Loaded Upper Belt without lifting force
Rcs
=(Rc+Ric)/L
18.8 N/m
Component of Main Resistance R for upper belt-empty Rco
=f*9.81*((mc+mb)*L)*IF(Ai<18,1,COS(Ai))
932.1 N
Component of Special Resistence Ri due to CI tilting-empty Rico
=9.81*Ci*0*L*(mb)*COS(At* )*SIN(i)
0.0 N
Specific Resistance to empty Upper Belt Rcso
=(Rco+Rico)/L
11.1 N/m
Component of Main Resistance R for return belt Rr
=f*9.81*((mr+mb)*L)*IF(Ai<18,1,COS(Ai))
569.2 N
Component of Special Resistence Ri due to RI tilting Rir
=9.81*Ci*m0*L*(mb)*COS(At* )*SIN(ir)
0.0 N
Specific Resistance to Lower Belt Motion Rrs
=(Rr+Rir)/L
6.8 N/m
Tail Pulley Tension T3
=T2+Rrs*L-9.8*mb*V
5094 N
Belt & Pulley Selection & Starting Tension
Type of Belt Bty NN
Duty Bd HD
Minimum Allowable Belt Working Tension Brr
=T1/(B*Bt)
16.8 KN/m
Tension rating of selected Belt Br 40 KN/m
Recommended Belt for Tensile Strength Bre 400/3
Selected Belt Bs 400/4
Check the belt for satisfactory load support Brls OK
Top Cover Ct 5 mm
Bottom Cover Cb 3.0 mm
Pulley diameters(mm) Selected
Recommended
Drive Pulley Dp
mm
630 400
Tail & Take-up Tp
mm
500 315
Bend & Snub pulley Sp
mm
400 250
Reduction ration of gear box In 31 5 32 44 Reduction ration of gear box In 31.5 32.44
Pulley rpm Np
=Nm/In
47 45
Equivalent mass of Belt & Belt Driven component-loaded Me
=((mc+mr+2*mb+mg)*L+Wndp)+Nmt/4*(2*PI()*Nm/(60*V
ba))^2*(Mgd+Hsgd+Gbgd+Lsgd/(In^2))
13486.1 Kg
Equivalent mass of Belt & Belt Driven component-empty Meo
=((mc+mr+2*mb)*L+Wndp)+Nmt/4*(2*PI()*Nm/(60*Vba))^
2*(Mgd+Hsgd+Gbgd+Lsgd/(In^2))
11220.2 Kg
Gd2 value of emtybelt (at motor rpm) Gd =Me*(Dp/In)
2
*0.000001 5.4
Kg-m
2
Gd2 value of loaded belt (at motor rpm) Gdo =Meo*(Dp/In)
2
*0.000001 4.5
Kg-m
2
Force available for acceleration at drive pulley Fa
=(Fd*ng*Pmi*Nmt-Pa)/Vba*1000
11332.6 N
Time taken by motor to accelerate-loaded belt tm1
=Me*Vba/Fa
1.8 sec
Time taken by motor to accelerate-empty belt tm1o
=Meo*Vba/Fa
1.53 sec
Deacceleration time-loaded belt td =Me*Vba
2
/(1000*PA) 2.1 sec
Deacceleration time-empty belt tdo =Meo*Vba
2
/(1000*Pao) 3.6 sec
Deacceleration force to stop the conveyor in time tc Fad
=IF(Tc_>td, "NOT REQD.",PA*1000/Vb*(td-Tc_)/Tc_)
NOT REQD. N
Breaking Torque Required(at motor shaft) Btr
=IF(Tc_>td,"N/A",Fad*Dp/(2000*ng*In))
N/A Nm
Brake provided Btp_ 2789.1603 NM
Tight Side Tension (Starting) T1s
=T1_+Fa
27504.577 N
Tail Pulley Tension Starting) T3s =T3_+Fa*(mb+mr)*L/Me 6718.9 N
% Belt Tension at starting of the belt rated tension(Max. 150%) =(T1s/B)/Br 57.3% OK
Motor Selection
Drive Efficency ng ng 97%
Drive Efficency ngc ngc 100%
Motor derating Factor for 50 Deg. C ambient temp. N
tm
1.00
Required Motor Power for Loaded Belt Pm =PA/(ng*ngc*Ntm) 15.0 kw
Reuire Motor Power for Empty Belt Pmo =Pao/(ng*ngc*Ntm) 7.1 kw
Motor selected Pmi 22 kw
No of Motors
Nmt
1
Available Service Factor
(Required Service Factor for Motor:1.1)
1.47
Page 3 of 3