Document No.

conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA
INPUT DATA : EL. 12.0M (RL 35.25 M)
P3
P1
EL. 0.0 (GL 27.0 M)
PRIMARY SECONDARY P2 EXISTING PLANT
SCRAPER SCRAPER
EL. 0.0 (FFL 23.25 M) EL. (-)6M (RL 21.0 M)
NEW PLANT LEVEL
V PLOW SCRAPERS
P2
473.974 (27A)
476.324 (27B)

PROFILE OF CONVEYORS 27A / 27B

Conveying Capacity (Q) 650 TPH

Belt Width (b) 1000 mm
Horizontal Belt Length c/c of Pulley (L) 49.000 m
Lift (H) 5.700 m
Developed length of belt (L1) 49.330 m
Average angle of Inclination of Belt Conveyor 2 Degrees
Percent Slope 3 %
Belt Speed (v) 2.90 m/sec
Material Coal
Bulk Density of Material (r) 0.8 T/m3
Lump Size of Material (Minus) 30 mm
Angle of Surcharge 20 Degrees
Idler Diameter 152.4 mm
Carrying Idler Spacing (Si) 1.0 m
Troughing Angle 35 Degrees
Acceleration due to gravity (g) 9.807 m/sec2
Nos. of Drive Pulley (P1) 1
Nos. of Tail/ Take up/ Bend Pulleys (P2) 7
Nos. of Snub Pulley (P3) 1
Nos. of Belt Scrapers (Ns) 3

Conversion Factors
1 Pound 0.4536 Kgs.
1 Meter 3.2808 Feet
1 Feet 0.304801 Meters
1 inch 25.4 mm
Speed 100 Ft/ Min 0.50813 Mtr/Sec
1 FT3/hr 0.028317 M3/hr

Page 1 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA

CALCULATIONS :
BELT SPEED CHECK :
CAPACITY AS PER TABLE 4.3 PAGE 53 OF CEMA
Width of 1000 mm wide conveyor belt in inches 39.37 inch
Speed - 100 Ft per Minute 0.508 m/sec
Capacity of Conveyor (with standard edge distance) as
per table 4.3 for 36 inch belt, 20 deg surcharge angle at 5886.0 FT3/hr
0.508 mtr. /sec

Capacity of 39.37 inch (1000 mm) wide belt (By interpolating

7168.2 FT3/hr
36 inch & 42 inch capacity of table 4.3) at 0.508 m/sec
Capacity at 1 m/sec 14107.02 FT3/hr
Capacity in M3/ hr 399.47 M3/hr
Capacity in TPH ( M3/hr * Density) at 1 m/sec (q) 319.57 TPH
Capacity required to be conveyed (Q) 650 TPH
Min. Belt speed required (Q/q) v' 2.03 m/sec
Belt speed considered (v) 2.90 m/sec
Filling factor (v' / v) 0.7014 %
HENCE BELT SPEED SELECTED IS O.K.

VALUE OF FACTORS USED IN CALCULATION :

1). Weight Of Material , Wm = Q/(3.6*v) = 62.26 Kg/m

2). Weight Of belt , Wb as per Phoenix Yule catalogue page

8 & 9 for selected rating of 500/4-HD with Top cover 5mm 16.772 Kg/m
and bottom cover 3mm
Carcass unit weight for given rating 3.1 Kg/ m2
Unit weight of rubber per mm of thickness 1.11 Kg/ m2
Belt weight (Wb)= Belt width*(Unit carcass wt.+ (Top cover
thk+ Bottom cover thk)*Unit rubber wt.)

3). Ambient Temp. correction factor from page 89 of CEMA, Kt 1.0

=

4). Idler Friction Factor, Kx = 0.00068(Wb+Wm)+Ai/Si

Force to overcome Frictional Resistance & Rotate Idlers(Ai)
for 152.4mm (6 inch) idlers as per page 91 of CEMA (5% 1.575 lbs
extra for V type return Idlers)
Kx = 0.00068(22.106+130.72)+(1.575* 0.4536)/1.2 = 0.768

5).Factor for Resistance to Flexure of Belt & Load (Ky)

Length of conveyor in feet =(L1* 3.2808) 161.843 Feet
(Wb+Wm) / (0.4536* 3.2808) in lbs/ feet 53.107 lbs/feet

Page 2 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA
Value of Ky for given length, wt. & slopes as per table 6.2
0.0250
Page 93

CALCULATION OF EFFECTIVE TENSION AT DRIVING

PULLEY (Te)

1). Tension due to Idlers Friction, Tx = L1*Kx*Kt 37.89 Kgs

2). Tension due to resistance of Belt to Flexure for carrying

Idlers, Tyc = L1*Ky*Wb*Kt 20.68 Kgs

3). Tension due to resistance of Belt to Flexure for return

Idlers, Tyr = L1*0.015*Wb*Kt 12.41 Kgs

4). Tension due to resistance of Material to Flexure ,

Tym = L1*Ky*Wm 76.78 Kgs

5). Force needed to Lift the Material, Tm = H*Wm 354.89 Kgs

6). Force to accelerate the Material,Tam =

53.39 Kgs
1000*Q*v/(3600*g)

7)Tension due to Belt Scraper resistance (Tbc):-

Tension due to each scraper (Nsc) = 3 lbs/ inch(considered

0.053575 Kgs/ mm
for half material removal from belt) as per table 6-6
Tbc= Nsc* Belt Width* No. of Scrapers=Nsc*B*4 160.724409 Kgs

8)Tension due to Skirtboard Friction, Tsb = Lb(Cshs2+6)

Length of skirtboard Lb 5000 mm
Skirtboard Friction Factor as per table 6.7 (Cs) 0.0754
Depth of Material touching Skirtboard (10% of Belt width)as
per page 101 (hs) 100 mm

Tsb = Lb(Cshs2+6) =
53.342 Kgs
0.4536(12000/(25.4*12)*(0.0754*(140/25.4)2+6)

9). Tension due to Pulleys resistance as per Appendix C page

405, Tp (For non-drive pulleys)
Resistance of belt to flex over each pulley Tp(1)
Tp(1) =
9b(0.8+0.01Tav/b)*(Bt/Dp)
Resistance of each pulley brg, seal etc Tp(2)
Tp(2) = 0.01*(ds/Dp)*R

Page 3 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA
where
b=width of belt (1400mm) 55.12 inch
Bt= Conveyor Belt thickness (6+3+5.2) mm 0.56 inch
Dp= Pulley Diameter 658 mm -considering Dia of drive
25.90 inch
Pulleys
ds= Pulley shaft Dia 150 mm (assumed)-considering Dia of
6.00 inch
drive Pulley
Tav = Average tension at pulley as per following:-:-

For calculating the wrap average Tension all the tensions

calculated above Tav
1697.78 lbs
=(Tx+Tyc+Tyr+Tym+Tm+Tam+Tbc+Tsb) can be added
and divided by factor 0.4536 to get average tension in lbs

R= Resultant radial load (Vector sum of Average belt tension

(Tav) & pulley weight (Wp))
Weight of pulley assumed (Wb)- considering appx. wt. of
1500 lbs
drive pulley

R = ((Tav)2+(Wp)2)1/2 2265.495865344 lbs

Tp(1) =
9b(0.8+0.01Tav/b)*(Bt/Dp) for Single pulley 11.86458688831 lbs
Tp(1) for single. non drive pulley in Kgs. 5.381776612538 Kgs
Tp(1) for 7Nos. non drive pulleys in Kgs. 37.672436288 Kgs

Tp(2) = 0.01*(ds/Dp)*R for single pulley 5.2482529699 lbs

Tp(2) for single non drive pulley in Kgs. 2.380607547151 Kgs
Tp(2) for 7 Nos. non drive pulleys in Kgs. 16.66425283 Kgs

Total pulley resistance for non drive pulleys Tp=Tp(1) +

54.34 Kgs
Tp(2)

HENCE TOTAL EFFECTIVE TENSION

Te = Tx+Tyc+Tyr+Tym+Tm+Tam+Tbc+Tsb+Tp 824.45 Kgs

MOTOR POWER CALCULATION :

Belt Kw , Pb = Te*v*g/1000 = 23.45 Kw
where Te is effective tension, v is belt speed & g is
acceleration due to gravity

Drive pulley power Pd=N*(Tp(1)+Tp(2))*v*g/1000 0.22 Kw

Page 4 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA
where N is no. of drive pulleys, Tp(1) & Tp(2) pulley
resistance, v is beltspeed & g is acceleration due to gravity

Add 5% extra for speed reduction loss on Pb& Pd=

2.60 Kw
1.05(Pb+Pd)
Power at motor shaft, Pm = Pb+Pd+5% reducer
26.27 Kw
margin =
Design margin on motor required as per tender 20 %
Motor Power with 20% margin=Pm*1.2 31.53 KW
SELECTED MOTORS 36.00 KW

BELT TENSION CALCULATIONS:-

SLACK SIDE TENSION CALCULATION :
Minimum Tension for 2% Sag, To = 6.25*Si(Wb+Wm) at tail
493.95 Kgs
end close to loading point

Slack side Tension T2 as per formula T2=To+(H*Wb)-Tyr

Weight of return belt =H*Wb 95.60 Kgs
Resistance of return belt Tyr= 0.015*L1*Wb*Kt 12.41
Hence T2 577.14 Kgs.

Slack side Tension T2 as per formula T2=Te*Cw

Cw is Wrap factor as per Table 6.8
For Manual (screw take up) for lagged pulley 0.7
For automatic takeup Single with snub, 200 Deg & with lagging 0.42
For Dual Lagged Pulley 0.11

As these conveyors are provided with single drive use Cw 0.42

T2 = Te*Cw 346.27 Kgs

Taking Higher of the above three Values, T2 633.64 Kgs

TIGHT SIDE TENSION CALCULATION :

Tight Side Tension at Pulley, T1 = Te+T2 1458.09 Kgs
BELTING SELECTION :
Maximum operating Tension in Belt,
Tmax = T1/(b)
T1 as calculated above 1458.09 Kgs
T1 in KN = T1*g/ 1000 14.30 KN/M
b = belt width in Mtr. 1.00 Mtr
Tmax = T1/(b) 14.30 KN/M

Select Belting from Phoenix Yule Catalogue 400/3 Nylon-Nylon

Page 5 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA
Heavy-Duty FR Grade
Recommended Maximum allowable Belt Working Tension
for selected Belting from Phoenix Yule Catalogue (Tall) = 40 KN/M

Ratio of Max Tension to all tension = Tmax/ Tall 35.7488 %

As this ratio is less than 85 % allowed in NIT selected rating is OK

Max. belt width for satisfactory Load Support considering 1000 mm

the given Belt rating as per Phoenix Yule Catalogue

Minimum Belt Width required for satisfactory Troughing

for selected Belting as per Phoenix Yule Catalogue 500 mm

Hence selected Belt Width OK

MINIMUM PULLEY DIAMETERS REQUIRED AS PER PHOENIX YULE CATALOGUE :

- Drive Pulley Diameter (P1) 315 mm
- Tail/Take Up/ Bend Pulley Diameter (P2) 200 mm
- Snub Pulley Diameter (P3) 250 mm
PULLEYS SELECTED :
- Drive Pulley Diameter + 14 thk Lagging (P1) 508 mm
- Tail/Take Up/ Bend Pulley Diameter+ 10 thk lagging (P2) 520 mm
- Snub Pulley Diameter + 10 thk lagging (P3) 420 mm

GEAR BOX REDUCTION RATIO :

-Drive Motor RPM N 1440 rpm

- Drive Pulley RPM, n = v*60000/(p*diameter of Drive Pulley) 109.03 rpm
- Gear Box Reduction Ratio required ,i = N/n 13.21
Gear ratio selected 20.00
- Final Belt Speed as per Selected Gear Box Reduction Ratio 1.92 m/sec
-Gear box KW rating = 1.25 * Motor KW 45 KW

OUTPUT :
Motor Power Selected 36 KW
Slack Side Tension (T2) 633.64 Kgs
Tight Side Tension (T1) 1458.09 Kgs
Belt Rating Selected 400/3 HD- N/N
Recommended Maximum Belt Working Tension 40.00 KN/M
Selected Drive Pulley Diameter (P1) 508 mm
Selected Tail/Take Up/ Bend Pulley Diameter (P2) 520 mm
Selected Snub Pulley Diameter (P3) 420 mm
Selected Gear Box Reduction Ratio 20

Page 6 of 7
 Document No.
conveyor No.
GID-064-CHP-
27A/27B 1152

Project : Vijayawada Thermal Power Station, PRP. BY: AV

REV. 2 CHD BY: AV
Stage-IV Unit#7 (500 MW)
APP BY: AV
Subject : Conveyor Design Calculation as per 5th
Dated 07.12.06
edition of CEMA

REVISION-1
REVISED AS PER M/S DESEIN COMMENTS REF NO. 438 DATED 25.09.2006.
ALSO REVISED AS PER REVISED CONVEYOR LAYOUT DUE TO RL DIFFERENCE OF NEW
PLANT & EXISTING PLANT.

REVISION-2
CONVEYOR LENGTH REVISED DUE TO SHIFTING OF JT-11 AS PER REVISED PLOT PLAN NO.
GID-064-CHP-1157 REV 1.
M/S DESEIN COMMENTS REF NO. 559 DATED 10.11.2006. ALSO INCORPORATED.

Page 7 of 7