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Of
Belt Conveyor Gallery System
BY:
SHAH PREYASH R.
(06MCL018)
GUIDED BY :
Mr. T.S.DHOLAKIA
(PMC PROJECT. PVT. LTD)
FLOW OF PRESENTATION
INTRODUCTION
LITERATURE REVIEW
OBJECTIVE OF STUDY
SCOPE OF WORK
WORK CARRIED OUT
CONCLUSION
FUTURE LINE OF ACTION
2
CONVEYORS
Are used for handling
materials
Used in all industries
Consists of several
components, like frames,
trusses, legs (adjustable if so
required), wires, pulleys,
rollers, belts, chains, bearings,
sprockets, V-belts, guards,
electricals, speed controls,
weighing mechanism and belt
cleaning arrangements.
4
Size specification
Size depends on the requirement :
Speed
Cost
Efficiency
Maximum load it takes
Material transferred per hour
BELT CONVEYOR
Belt Conveyor is one of the
most important equipment for
the material handling and
plays an important part in
industrial growth and
economy.
The belt conveyor is an endless
moving belt for transporting
materials horizontally or on an
incline up or down. They are
employed for conveying
various bulk and unit loads
along horizontal or slightly
inclined paths and transporting
articles between various
operations in production flow
lines.
Cont
Conveyor is very cost effective and the easy
expandability and reconfiguration makes it
ideal for growing operations.
A belt conveyer consists of
1.Gallery with its supporting system,
2.belt supporting system.
Cont
CONVEYORS
On Ground Conveyor
COMPONENTS
Hopper/Funnel
Unloader
Upper
Belt
idlers
Take up pulley
Drive
pulley
SupportingUnloading
Frame
funnel
Belt
Side
Elevation
Lower idlers
Cross
Sections
Plan
Drive
motor
cleaner
10
Cont
BELT:
The belt conveyor has textile
belt made from camel hair,
cotton, duck cotton and
rubberized material. The
rubberized belts are most
commonly used as belt in
conveyor. They are
manufactured in standard
width from 300 to 3000 mm.
IDLERS:
Generally the belt is supported by idler
rollers. According to their location on
the conveyor, idlers are classified as
upper or carrying (supporting the
loaded strand of the belt) and lower or
return (supporting the unloaded return
strand of the belt).
11
Cont
CENTERING DEVICE:
To prevent the belt from
running off the rollers, special
belt training idlers of
various designs are used.
These idlers automatically
maintain belt alignment.
TAKE-UP:
A belt conveyor may
have a mechanical
(screw-type) or
counterweighted
(gravity-type) takeup which are used
for adjusting tension
in the belt.
12
Cont
DRIVE UNIT:
In belt conveyors motive
power is transmitted to the
belt by friction as it wraps
around the driving pulley
rotated by an electric motor.
The drive comprises the
following parts: the pulley,
motor and the transmission
gear between the motor and
pulley.
BELT CLEANER:
Wipers or scrapers serve to
clean the outer belt surface of
dry particles sticking to it. For
wet and sticky material
revolving brushes are used.
13
Cont
CONVEYOR FRAME:
The supporting structure of
the conveyor intermediate
section is made of angle iron
or channel bar, and consists of
longitudinal beams and crosspieces. The height of the
frame is usually 400 to 500
mm; the spacing between the
uprights is 2 to 3.5 m.
14
CONVEYOR GALLERY
The main supporting structure of the
conveyor system consists of conveyor gallery
and trestle. The conveyor gallery includes
truss system (through or deck type which
conveyor frame is supported) and trestle
which supports gallery.
The gallery is designed as steel structures,
concrete structures (in some cases e.g. in
Cement Industries) or as composite
structures (i.e. steel and concrete).
The structural design is carried out as per
Codal standards.
15
ARRANGEMENTS
OF
BELT COVNEYORS
Double /multi layer system
Parallel system
Single system
16
PARALLEL CONVEYOR
SINGLE CONVEYOR
17
INDUSTRIAL APPLICATION
Production
Mining
Shipping companies
Food and beverage companies (with
specializations like fruits and vegetables,
meat, poultry and seafood)
Automobiles industry
18
Cont
Electronics
Pharmaceutical and medical
Printing
Packaging
Cement industry
19
20
21
22
23
24
25
Sr. No.
Columns
Beams
Framing
STEEL
STEEL
STEEL
CONCRETE
STEEL
COMPOSITE
CONCRETE
CONCRETE
CONCRETE
29
MECHANICAL DATA
Rated Capacity
Bulk Density of Coal for structural calculation
Angle of surcharge
Angle of Repose
Belt width
Belt speed
Wt of belt
Wt. of rotating mass carrying side (carrying idlers)
Wt. of rotating mass return side (return idlers)
Troughing angle
Friction factor
Impact factor
Spacing of carrying idlers
Spacing of return idlers
= 4200 t/h
=12.0 kN/m3
= 20
= 37
= 1800 mm
= 4.35 m/s
= 0.46 kN/m
= 0.62 kN/m
=0.155 kN/m
= 45
= 0.03
= 1.2
=1m
=3m
30
LOADINGS
DEAD LOAD
Self weight of the gallery and trestle.
Wt. of belt
= 0.46 kN/m
= 0.62 kN/m
= 0.155 kN/m
= 0.80 kN/m
31
LIVE LOAD
Load on Walkway
= 3 kN/m2
Dust Load
= 1 kN/m2
= 1.8 kN (longitudinal)
= 1.8 kN (transverse)
movement of stringers
32
WIND LOAD
As. Per I.S. 875-1987(part 3)
Basic wind speed
= 44 m/s (Dahej)
The probability factor (k1)
= 1.08
The terrain category
=2
The class of the building
=C
The terrain, height and structure
size factor (k2)
= from Tb-2 of I.S.875
topography factor (k3)
=1
The structure having two or more parallel frames where the
windward frames may have a shielding effect upon the
frames to leeward side. So shielding factor is calculated from
Tb-29 of I.S 875
33
EARTHQUAKE LOAD
The earthquake load is taken as per IS:
1893-2002 (I).
Location Dahej (bharuch)
zone - III
34
IMPACT FACTOR
Impact factor due to moving hoists etc.
shall be 1.2 for electrically operated hoist
and 1.1 for hand operated hoists. For floor
beams directly supporting drive machinery
like head end / tail end / drive pulleys,
motor, gear boxes etc. an impact factor of
1.5 shall be considered.
35
LOADING ON GALLERY
Dead Load= Self weight of Gallery,
supporting beams, columns and bracings.
Normal Load at mid support = 3.1 kN
Normal Load at end support = 1.55 kN
Live Load =
Normal Load at mid support = 11.9 kN
Normal Load at end support = 5.95 kN
Longitudinal Load
= 1.8 kN
Transverse Load
= 1.8 kN
36
LOADING
SHORT SUPPORTS
BELT
4.55 m
TRUSS
38
LOAD COMBINATION
39
DEFLECTION
a) Conveyor galleries
: Span/500
: Height/1000
: Span/500
:Span/325
: Span/500
: Height / 325
40
STAAD MODEL
SINGLE CONVEYOR
3-D VIEW
SECTION
ELEVATION
41
STAAD MODEL
STEEL DOUBLE CONVEYOR
ELEVATION
PLAN
Cross
section
42
3-D VIEW
ELEVATION
PLAN
3-D VIEW
43
ELEVATION
PLAN
44
3-D VIEW
Permissible
Def. (mm)
Steel
45.35
48.00
Composite
35.87
48.00
Concrete
41.23
48.00
45
ELEVATION
PLAN
3-D VIEW
Cross
46
section
ELEVATION
PLAN
47
3-D VIEW
ELEVATION
PLAN
3-D VIEW
48
Permissible
Def. (mm)
Steel
46.80
48.00
Composite
45.30
48.00
Concrete
36.24
48.00
49
CONNECTIONS
In general the cost of the design, fabrication and
erection of the structural frame in a steel framed
building is approximately 30% of the total cost of
construction. Of these three items, fabrication and
erection account for approximately 67%.
Any savings in the fabrication and erection costs
can significantly reduce the overall cost of
construction.
The majority of the fabrication costs are absorbed by
the connections, and the choice of connection also
has a significant influence on the speed, ease, and,
therefore, the cost of erection.
50
(AISC)
51
Cont
The different steel
frame connections are
Simple connection
Moment Resisting
connection
The one of loading of
parallel steel gallery is
shown below,
P= 25.1 kN
M= 57.1 kN
Beam = ISMB 450
Column = ISMB 500
Simple connection
52
Cont
The design results are as
follows,
Provided top plate =
130 mm x 6 mm
(6 mm fillet weld)
Design bottom seat plate
=
170 mm x 77 mm x 6 mm
(6 mm fillet weld)
12 mm
clearence
ISMB 500
6 mm fillet weld
ISMB 450
450
Beam
Column
Bottom plate
Elevation
100
70
130
53
PILE FOUNDATIONS
Pile foundations are the part of a structure used to
carry and transfer the load of the structure to the
bearing ground located at some depth below
ground surface. The main components of the
foundation are the pile cap and the piles. Piles are
long and slender members which transfer the load
to deeper soil or rock of high bearing capacity
avoiding shallow soil of low bearing capacity.
The main types of materials used for piles are
Wood, steel and concrete. Piles made from these
materials are driven, drilled or jacked into the
ground and connected to pile caps.
BEARING CAPACITY OF SOIL
The capacities of soil at Dahej for different depths
are given in table in next slide.
54
Thk. of strata
Description of strata
Notation
(m)
Capacity of soil
(T)
0-2
SP-SM
20
2-3
SM
20
3-5
CI
20
5-7
SM
30
7-8
stiff
CL
30
8-12
CI
40
12-15
CH
40
15-19
CI
60
19-21
CH
80
55
LOADING ON PILE
The load from
column of double
composite gallery
to pile cap are,
P = 875.3 kN
Mx = 333.5 kNm
My = 540.5 kNm
The load per pile is
given by,
F=
Mxn
Myn
P+W
n
Iy
Ix
56
Cont
F1 =
290.14
kN
F2 =
475.42
kN
F3 =
12.23
kN
F4 =
197.51
kN
DETAILING OF PILE
57
58
59
60
Option
kN
37.43
Rate (Rs. In
lakhs)
1.50
39.76
1.59
Cost comparison
Wt. comparison
61
kN
Double
1174.51
Parallel
796.35
62
Concrete Galleries
Type (conc.)
Conc. (m3)
Steel (kN)
Double
342.79
211.08
Parallel
253.74
153.70
63
Composite Galleries
Type (comp.)
conc. (m3)
steel (kN)
(Reinf + members)
Double
94.00
869.00
Parallel
58.00
709.00
64
COST COMPARISON
Rate of steel = Rs. 40/ kg
Type of
Rate
(Rs.lakhs)
Rate
Rate (Rs.-lakhs)
(Rs.lakhs)
conveyor
(steel)
(concrete)
(composite)
Double
46.98
20.44
38.05
Parallel
31.85
15.03
30.39
65
66
67
68
REFERENCES
LIST OF WEBSITES
www.conveyorchain.com
www.kamandirect.com
www.hasler-int.com
www.bandt.com
www.tranterphe.com
www.cemanet.org
www.kwsmfg.com
www.armax-conveyors.co.uk
www.patentstorm.com
www.inventorypos.com
www.conceptengineer.com
www.hic-india.com
www.ise.ncsu.edu
www.martin-eng.com
www.interroll.com
www.pro-belt.com
www.interquip.com.au
www.ingenieriatecnica.cl
72