TRIPPER POWER CALCULATION FOR DMW DESIGN (HNPCL)

Sl No DESCRIPTION SYMBOL VALUE UNIT REMARK

1 Belt width B 1600 mm
2 Tripper length L 18.7 m
3 Vertical lift of material on tripper H 5 m
4 Design capacity Cd 1680 tph
5 Belt speed Vb 2.8 m/s
6 Tripper speed V 9.42 m/min Minimum 10% of belt speed if not specified
7 Weight of material mg 166.67 kg/m
8 Weight of belt mb 24.35 kg/m
9 Belt tension at tripper Th1 3315 kg
10 Belt inclination at discharge pulley 1 14 degrees
11 Belt inclination at bend pulley 2 2.2 degrees
12 Bend pulley resistance Rb 882.9 N Consider a resistance of 200lbs.
13 Belt sealing roller resistance Rbs 441.45 N Rbs=Rb/2
14 Number of bend and discharge pulleys Nt 2
15 Number of belt sealing rollers Nbs 4
16 Wheel axle diameter at bearing Db 0.14 m
17 Estimated total weight of tripper W 22000 kg
18 Wheel diameter Dw 0.3 m
19 Length of skirt board on the tripper Lb 6 m
20 Skirt board friction factor Cs 0.0754
21 Depth of material touching skirtboard hs 6.3 inch Consider 10% of the belt width
22 Coeficient of friction for bearing m 0.015
23 Coefficient of rolling friction k 0.0005
Factor for friction between rail and wheel
24 flange f 2.5
25 Coefficient of adhesion fa 0.15 NTPC stipulation
26 Acceleration value of tripper a 0.0314 m/s Considering an acceleration time of 5 secs
POWER CALCULATION
27 Tripper resistance Te1 568.33 kgf Te1= (f x W) x (2 x k + m x Db))/Dw
28 Resistance due to bend pulley Te2 180 kgf Te2= Rb x Nt/9.81
29 Resistance due to belt sealing Te3 180 kgf Te3=Nbs x Rbs/9.81
30 Approx pull due to CRD Te4 0 kgf Cable festoon envisaged

31 Force required to lift the material and belt Te5 955.1 kgf Te5= (Wb+Wm) x H

32 Resistance due to belt tension difference Te6 96.03 kgf Te6=Th1 x (cos2- cos 1)
33 Resistance due to tripper acceleration Te7 70.42 kgf Te7= W x a/9.81
34 Skirt board resistance Te8 80.44 kgf Te8= Lb x ( Cs x hs + 6 )/2.2
35 Total tripper resistance F 2130.32 kgf F=Te1+Te2+Te3+Te4+Te5+Te6+Te7+Te8
36 Motor power required Pr 4.101318693 kW Pr=F x V/60000/.8
37 Taking 20% margin, power required Pm 4.921582432 kW
38 Motor Power selected P 2 x 3.7 kW Hence Ok
 TRIPPER POWER CALCULATION FOR ELECON DESIGN (GIPCL)

Sl No DESCRIPTION SYMBOL VALUE UNIT REMARK

1 Belt width B 1400 mm
2 Tripper length L 18.07 m
3 Vertical lift of material on tripper H 5.308 m
4 Design capacity Cd 1500 tph
5 Belt speed Vb 2.65 m/s
6 Tripper speed V 15 m/min Minimum 10% of belt speed if not specified
7 Weight of material mg 157.23 kg/m
8 Weight of belt mb 24.35 kg/m
9 Belt tension at tripper Th1 6600 kg
10 Belt inclination at discharge pulley 1 9.626 degrees
11 Belt inclination at bend pulley 2 0 degrees
12 Bend pulley resistance Rb 882.9 N Consider a resistance of 200lbs.
13 Belt sealing roller resistance Rbs 441.45 N Rbs=Rb/2
14 Number of bend and discharge pulleys Nt 2
15 Number of belt sealing rollers Nbs 4
16 Wheel axle diameter at bearing Db 0.14 m
17 Estimated total weight of tripper W 25000 kg
18 Wheel diameter Dw 0.75 m
19 Length of skirt board on the tripper Lb 6m
20 Skirt board friction factor Cs 0.0754
21 Depth of material touching skirtboard hs 5.51 inch Consider 10% of the belt width
22 Coeficient of friction for bearing m 0.015
23 Coefficient of rolling friction k 0.0005 Referring to NITC publication
Factor for friction between rail and wheel
24 flange f 2.5
25 Coefficient of adhesion fa 0.15
26 Acceleration value of tripper a 0.05 m/s Considering an acceleration time of 5 secs
POWER CALCULATION
27 Tripper resistance Te1 258.33 kgf Te1= (f x W) x (2 x k + m x Db))/Dw
28 Resistance due to bend pulley Te2 180 kgf Te2= Rb x Nt/9.81
29 Resistance due to belt sealing Te3 180 kgf Te3=Nbs x Rbs/9.81
30 Approx pull due to CRD Te4 100 kgf Cable festoon envisaged

31 Force required to lift the material and belt Te5 963.82664 kgf Te5= (Wb+Wm) x H

32 Resistance due to belt tension difference Te6 92.93 kgf Te6=Th1 x (cos2- cos 1)
33 Resistance due to tripper acceleration Te7 127.42 kgf Te7= W x a/9.81
34 Skirt board resistance Te8 74.15 kgf Te8= Lb x ( Cs x hs + 6 )/2.2
35 Total tripper resistance F 1976.65664 kgf F=Te1+Te2+Te3+Te4+Te5+Te6+Te7+Te8
36 Motor power required Pr 6.059688012 kW Pr=F x V/60000/.8
37 Taking 20% margin, power required Pm 7.271625614 kW
38 Motor Power selected P 2 X 5.5Kw OK
 TRIPPER POWER CALCULATION FOR MBECL DESIGN (UKAI, CHANDRAPURA)

Sl No DESCRIPTION SYMBOL VALUE UNIT REMARK

1 Belt width B 1200 mm
2 Tripper length L 8 m
3 Vertical lift of material on tripper H 3.05 m
4 Design capacity Cd 960 tph
5 Belt speed Vb 2.5 m/s
6 Tripper speed V 15 m/min Minimum 10% of belt speed if not specified
7 Weight of material mg 106.67 kg/m
8 Weight of belt mb 24.35 kg/m
9 Belt tension at tripper Th1 6600 kg
10 Belt inclination at discharge pulley 1 12 degrees
11 Belt inclination at bend pulley 2 2.2 degrees
12 Bend pulley resistance Rb 882.9 N Consider a resistance of 200lbs.
13 Belt sealing roller resistance Rbs 441.45 N Rbs=Rb/2
14 Number of bend and discharge pulleys Nt 2
15 Number of belt sealing rollers Nbs 4
16 Wheel axle diameter at bearing Db 0.1 m
17 Estimated total weight of tripper W 25000 kg
18 Wheel diameter Dw 0.5 m
19 Length of skirt board on the tripper Lb 6 m
20 Skirt board friction factor Cs 0.0754
21 Depth of material touching skirtboard hs 4.72 inch Consider 10% of the belt width
22 Coeficient of friction for bearing m 0.015 NTPC stipulation
23 Coefficient of rolling friction k 0.0005 Referring to NITC publication
Factor for friction between rail and wheel
24 flange f 2.5
25 Coefficient of adhesion fa 0.15
26 Acceleration value of tripper a 0.05 m/s Considering an acceleration time of 5 secs
POWER CALCULATION
27 Tripper resistance Te1 312.5 kgf Te1= (f x W) x (2 x k + m x Db))/Dw
28 Resistance due to bend pulley Te2 180 kgf Te2= Rb x Nt/9.81
29 Resistance due to belt sealing Te3 180 kgf Te3=Nbs x Rbs/9.81
30 Approx pull due to CRD Te4 100 kgf Cable festoon envisaged

31 Force required to lift the material and belt Te5 399.611 kgf Te5= (Wb+Wm) x H

32 Resistance due to belt tension difference Te6 139.36 kgf Te6=Th1 x (cos2- cos 1)
33 Resistance due to tripper acceleration Te7 127.42 kgf Te7= W x a/9.81
34 Skirt board resistance Te8 68.7 kgf Te8= Lb x ( Cs x hs + 6 )/2.2
35 Total tripper resistance F 1507.591 kgf F=Te1+Te2+Te3+Te4+Te5+Te6+Te7+Te8
36 Motor power required Pr 4.621708659 kW Pr=F x V/60000/.8
37 Taking 20% margin, power required Pm 5.546050391 kW
38 Motor Power selected P 2 X 3.7 Kw OK
 TRIPPER POWER CALCULATION FOR L T DESIGN (CSEB KORBA)

Sl No DESCRIPTION SYMBOL VALUE UNIT REMARK

1 Belt width B 1400 mm
2 Tripper length L 11.4 m
3 Vertical lift of material on tripper H 4.55 m
4 Design capacity Cd 1000 tph
5 Belt speed Vb 2.2 m/s
6 Tripper speed V 12.5 m/min Minimum 10% of belt speed if not specified
7 Weight of material mg 126.26 kg/m
8 Weight of belt mb 24.35 kg/m
9 Belt tension at tripper Th1 5854 kg
10 Belt inclination at discharge pulley 1 15 degrees
11 Belt inclination at bend pulley 2 2.2 degrees
12 Bend pulley resistance Rb 882.9 N Consider a resistance of 200lbs.
13 Belt sealing roller resistance Rbs 441.45 N Rbs=Rb/2
14 Number of bend and discharge pulleys Nt 2
15 Number of belt sealing rollers Nbs 4
16 Wheel axle diameter at bearing Db 0.14 m
17 Estimated total weight of tripper W 21200 kg
18 Wheel diameter Dw 0.3 m
19 Length of skirt board on the tripper Lb 6 m
20 Skirt board friction factor Cs 0.0754
21 Depth of material touching skirtboard hs 5.51 inch Consider 10% of the belt width
22 Coeficient of friction for bearing m 0.015 NTPC stipulation
23 Coefficient of rolling friction k 0.0005 Referring to NITC publication
Factor for friction between rail and wheel
24 flange f 2.5
25 Coefficient of adhesion fa 0.15
26 Acceleration value of tripper a 0.041666667 m/s Considering an acceleration time of 5 secs
POWER CALCULATION
27 Tripper resistance Te1 547.67 kgf Te1= (f x W) x (2 x k + m x Db))/Dw
28 Resistance due to bend pulley Te2 180 kgf Te2= Rb x Nt/9.81
29 Resistance due to belt sealing Te3 180 kgf Te3=Nbs x Rbs/9.81
30 Approx pull due to CRD Te4 0 kgf Cable festoon envisaged

31 Force required to lift the material and belt Te5 685.2755 kgf Te5= (Wb+Wm) x H

32 Resistance due to belt tension difference Te6 195.16 kgf Te6=Th1 x (cos2- cos 1)
33 Resistance due to tripper acceleration Te7 90.04 kgf Te7= W x a/9.81
34 Skirt board resistance Te8 74.15 kgf Te8= Lb x ( Cs x hs + 6 )/2.2
35 Total tripper resistance F 1952.2955 kgf F=Te1+Te2+Te3+Te4+Te5+Te6+Te7+Te8
36 Motor power required Pr 4.98750491 kW Pr=F x V/60000/.8
37 Taking 20% margin, power required Pm 5.985005892 kW
38 Motor Power selected P 2 x 5.5 kW Hence Ok
 POWER CALCULATION FOR TRF (AMARKHANTAK TPP)

Sl No DESCRIPTION SYMBOL VALUE UNIT REMARK

1 Belt width B 1000 mm
2 Tripper length L 12.9 m
3 Vertical lift of material on tripper H 5.375 m
4 Design capacity Cd 500 tph
5 Belt speed Vb 2 m/s
6 Tripper speed V 10 m/min Minimum 10% of belt speed if not specified
7 Weight of material mg 69.44 kg/m
8 Weight of belt mb 24.35 kg/m
9 Belt tension at tripper Th1 3000 kg
10 Belt inclination at discharge pulley 1 15 degrees
11 Belt inclination at bend pulley 2 2.2 degrees
12 Bend pulley resistance Rb 882.9 N Consider a resistance of 200lbs.
13 Belt sealing roller resistance Rbs 441.45 N Rbs=Rb/2
14 Number of bend and discharge pulleys Nt 2
15 Number of belt sealing rollers Nbs 4
16 Wheel axle diameter at bearing Db 0.115 m
17 Estimated total weight of tripper W 16000 kg
18 Wheel diameter Dw 0.3 m
19 Length of skirt board on the tripper Lb 6 m
20 Skirt board friction factor Cs 0.0754
21 Depth of material touching skirtboard hs 3.94 inch Consider 10% of the belt width
22 Coeficient of friction for bearing m 0.015 NTPC stipulation
23 Coefficient of rolling friction k 0.0005 Referring to NITC publication
Factor for friction between rail and wheel
24 flange f 2.5
25 Coefficient of adhesion fa 0.15
26 Acceleration value of tripper a 0.033333333 m/s Considering an acceleration time of 5 secs
POWER CALCULATION
27 Tripper resistance Te1 363.33 kgf Te1= (f x W) x (2 x k + m x Db))/Dw
28 Resistance due to bend pulley Te2 180 kgf Te2= Rb x Nt/9.81
29 Resistance due to belt sealing Te3 180 kgf Te3=Nbs x Rbs/9.81
30 Approx pull due to CRD Te4 100 kgf Cable festoon envisaged

31 Force required to lift the material and belt Te5 504.12125 kgf Te5= (Wb+Wm) x H

32 Resistance due to belt tension difference Te6 100.01 kgf Te6=Th1 x (cos2- cos 1)
33 Resistance due to tripper acceleration Te7 54.37 kgf Te7= W x a/9.81
34 Skirt board resistance Te8 64.14 kgf Te8= Lb x ( Cs x hs + 6 )/2.2
35 Total tripper resistance F 1545.97125 kgf F=Te1+Te2+Te3+Te4+Te5+Te6+Te7+Te8
36 Motor power required Pr 3.159578742 kW Pr=F x V/60000/.8
37 Taking 20% margin, power required Pm 3.791494491 kW
38 Motor Power selected P 1.5 + .75 kW Not OK