4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant

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Power plant and calculations

Power plant and calculation site basically includes the detailed study of power plant operation and maintenance, its related all
calculations and thumb rules. It also involves detailed troubleshooting guides for operation and maintenance of power plant proc
and equipments.
Transformer Transformer
winding winding
machine machine
Winco Winco
8/12/16 spindles, 8/12/16 spindles,
High Quality High Quality
Reasonable price, Reasonable price,
Max output Max output

wincowire.com wincowire.com

OPEN 40 important question & answers on belt OPEN

conveyor for power plant engineers &

operators Transformer
1-What
are the equipments used in coal handling plant (CHP)?
Starting
from coal shed winding
Coal elevator
Coal grizzly hopper
machine
Coal vibro feeder Winco
Coal conveyors (belt conveyor) 8/12/16 spindles, High
Coal vibro screen Quality Reasonable
Coal crusher price, Max output
Coal dust extraction system
Shuttle conveyor wincowire.com
2-Name
the various parts of the belt conveyors?

Belt
Carrying idlers
Return idlers
Impact idlers OPEN
Transoms
Pulleys
Vertical gravity take up system
Power transmission system (Motor, Gear box,
couplings)
Main structure & trestles
Tools & tackles used in power plant maintenance

3-How
do you specify the conveyor belt?
Belt is
specified based on
Its material of composition
Number of ply
Belt rating
Belt width

4-What
are the various materials used for manufacturing of belts
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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators
Nylon,
Polyester, Aramide, Polyester-Nylon, Steel fabric
5-What
are the various pulleys used in belt conveyors?
CLOSE ADS Head pulley CLOSE ADS

Tail pulley
Snub pulley
Bend pulley
Transformer
Take up pulley winding
6-Which is the largest and smallest pulley among above all pulley?

Transformer Largest pulley : Head pulley machine Transformer

winding winding
Smallest pulley : Snub pulley
Winco
machine 7-What are the different troughing angles used for transoms?
machine
Winco Depending
on application and load carrying capacity, different troughing angles 8/12/16 spindles, High Winco
transoms
are used namely Quality Reasonable
8/12/16 spindles, 8/12/16 spindles,
High Quality 180 degree: For flat belts and low loads price, Max output High Quality
Reasonable price, Reasonable price,
45 degree: Higher capacity
Max output wincowire.com Max output
35 degree: Medium capacity
wincowire.com 20 degree: Low capacity wincowire.com
10 and 15 degrees.
8-What are the different protection systems provided for belt
conveyors?

Pull Cord Switch (PCS): Used for emergency stopping of

the belt.
Belt Sway Switch (BSS): Protects belt from swaying or
restricts over OPEN
side movement
Zero Speed Switches (ZSS): This arrangement is fitted to
tail pulley
or snub pulley to protect the belt from further damage during belt
cut. 
OPEN OPEN
TOP-6 BEST POWER PLANT O&M BOOKS

9-What  do you mean by the transoms in belt conveyors?

Transoms: Transoms are the brackets

on which idlers are fitted to locate them properly.
Following types of
transoms are noticed in general belt conveyor system.

Carrying
idler transom 8, 12, 16
spindles
Return
idler transom
Self
aligning carrying transom
Self
aligning return transom
Coil winding
Garland
idler transom (refer below image)
machine
10-What are the functions of carrying idler, return idler, impact
idler & side guide idler

Carrying
idlers: Fitted
on carrying side of the belt (top side of the Integrated in
belt) production to get
Return
idler: Fitted
on return side of the conveyor (bottom side). It is fully automatic line
the largest idler among all
the idlers used in conveyors
Impact
idlers: It
is same as carrying idler, it is fitted on carrying side wincowire.com
of the conveyor below
the discharge chute of preceding conveyor
Side
guide idler: Fitted to the self aligning transoms to avoid the
belt
swaying at one side
Practical QnA for power plant maintenance team

OPEN
10a-What
are the various grades of belts, explain their applications

M Grade: Heavy duty resistant to abrasion, sharp and rugged

materials. Work in
normal atmosphere temperature. Generally used for
coal, bagasse and other
biomass fuel applications.
N Grade: Used for coal, bagasse and biomass, low resistant to
abrasion, sharp and
rugged materials.
B (G) Grade: Work in normal temperature used only for low duty.
HRS: Used for high temperature applications up to 100 °C surface
temperature
and 200 °C material temperature.
HRE Grade: Used for high temperature applications up to 150 °C
surface temperature and 400 °C material temperature.
11-List
down the various problems that you face in belt conveyors.

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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators
Belt
running off at head pulley due to improper alignment of troughing
idlers near
head pulley.
CLOSE ADS Belt
running off at tail pulley due to build up of material on return CLOSE ADS

idlers.
Excessive
wear on bottom side of belt. Transformer
Excessive
wear on carrying and return side of belt.
Overstretch
of belt due to excessive tension. winding
Transformer
Belt
slipping on tail pulley.
Pulley
hub key way damage.
machine Transformer
winding winding
Belt
moving on one side only. Winco
machine Fuel
leakage and spillage due to improper arrangement of scrapers
machine
Winco
8/12/16 spindles, High Winco
and skirting.
Quality Reasonable
8/12/16 spindles, Conveyor
Drive Problem: Vibrations in gear box and motors, abnormal 8/12/16 spindles,
High Quality price, Max output High Quality
sound in gear box,
coupling bolts loose.
Reasonable price, Reasonable price,
Max output 12-What are the reasons for operating ZSS?
wincowire.com Max output

wincowire.comZero speed switches operate on following

conditions: wincowire.com
Belt cut
Belt slip on
head pulley

13-What are the reasons

for excessive wear out of belt on carrying side?

Excessive wear out on carrying side of belt is due to:

OPEN
Dirt,
frozen or misaligned return idlers
Excessive
sag between troughing idlers causing load to move and
shift on belt as it
passes over idlers
OPEN Abrasive
skirt boards OPEN
Poor
loading
14-What is the reason for
excessive wear on bottom side of belt?

Slippage Between Belt and Drive Pulley or Pulleys: Check the wear out of
pulley
rubber lagging.

Transformer
Sticking Troughing Idlers: Check the operation of belt cleaners
(scrapers).
Material Ground
Between Pulley and Belt: Arrest fuel leakage and remove the
collected fuel
regularly.
15-What are the
possible reasons for belt running off at head pulley?
winding
Build up of material on return idlers.
Unequal loading.
machine
Improper alignment of head pulley.
Winco
Not working of
self aligning transums situated near head pulley.
16-What is the reason for a conveyor belt runs to
one side for some distance along 8/12/16 spindles, High
conveyor length?
Quality Reasonable
It is due to
Improper loading of belt and failure of self aligning transoms. price, Max output
 17-What actions will you take if you found conveyor
carrying side wearout occurs
continuously? wincowire.com
Following actions should be taken to avoid wear
out:
Install belt-cleaning plows at head end and tail end.
Clean, repair and align return idlers.
Increase belt tension if too low.
Reduce idler spacing.
Repair and inspect skirt board rubbers regularly.
OPEN
Feed load on
belt in same direction at same speed.

Most likely asked Questions with answers on bearings

18-What actions will you take if belt has excessive
tension?

If belt has excessive tension, then following

actions shall be taken:
Decrease the belt tension by lagging on drive pulleys.
Increase arc of contact of drive pulley.
Increase speed, if possible, keeping shift tonnage the same.
Reduce tonnage at slower speed.
Tighten screw take-up just enough to keep belt from slipping.
On a gravity
take-up reduce counter weight to minimum amount sufficient to keep
belt from
slipping.

19-What
is the preferred speed of coal belt conveyors in power plants?

For
medium capacity power plants 10 to 50 MW : 0.9 to 1 m/sec
For
Higher thermal power plants = 0.9 to 1.5 m/sec
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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators
20-What
is meant by transition distance?
Transition
distance is traditionally defined as the distance from the center line of
the
first fully troughed idler roll to the centre line of either the head or tail
pulley
CLOSE ADS CLOSE ADS
21-Tell
briefly about belt cleaners/scrapers.
Belt cleaning techniques are aimed at removing the greatest possible
percentage of carryover at the source i.e. at the head/discharge pulley. Belt
cleaners must not however cause damage to the belt in the course of operation. Transformer
winding
Types of Belt Cleaners:
Contact Type:
Generally primary, secondary and tertiary belt cleaners are used.
Transformer Primary belt scraper is installed inside the head chute at a point below
the
natural material trajectory where the belt is in contact with the pulley.
Primary
machine Transformer
winding scrapers are usually contact scrapers. winding
Winco
machine Secondary belt scraper is usually installed within the head chute however
this
scraper is positioned to contact the belt once it leaves the head pulley.
machine
Winco Secondary scrapers are usually contact scrapers and are either blade-type 8/12/16 spindles, High Winco
scrapers or rotating brushes although the latter is not common. Quality Reasonable
8/12/16 spindles, 8/12/16 spindles,
High Quality
Tertiary scrapers are sometimes installed although this is not common price, Max output High Quality
practice. In this case the scraper is outside the head chute and scrapings must
Reasonable price, Reasonable price,
Max output
be returned to the head chute by a mechanical chain conveyor or similar. Max output
Tertiary scrapers are usually contact scrapers. wincowire.com
wincowire.comBelt
washing systems are also used in cases where the material carried over wincowire.com
is
extremely difficult to remove from the belt and/or where the disposal or
handling of the washing water plus spillage can be done easily or conveniently.
Washing systems are usually considered to be non-contact cleaners in as much
as
water is used to clean the belt and squeeze rollers provide a drying function.
 22-What
is the function of Take up unit (TU)?
The role
of the take-up device is to create and maintain adequate pre-tension to OPEN
allow
the conveyor drive pulley to drive the belt under all running conditions
(empty
or loaded).
23-What
are the main two types of Take up unit (TU)?
1-Fixed
type : screw take up unit (STU)
OPEN OPEN
2-Vertical
gravity take up (VGTU)
24-What
is the percentage of belt tension adjustment in normal running
condition?
It is 0.8
to 1.2% of total length
25-What
is the minimum length of the take up system ?
Minimum
length of take up is  the 1.5% of Conveyor length (Center to
Center)  
26-A
belt conveyor of length 100 meter need to install VGTU system
calculates the
minimum length of take up.
Minimum length of take up = 1.5% X 100 = 1.5 X 100/100 =1.5 meters Transformer
27-A
conveyor length is 200 meters and speed is 1 meter/sec, then
calculate the time
taken for this conveyor for one complete rotation
Total
appx.length of the belt = 2 X conveyor length + Conveyor length X 1.5%
winding
 
                     
                      =2 X 200 + 200 X
1.5% = 403 meters machine
Winco
Time
taken for one complete rotation of the belt 

= 403 m X 1 sec =403 seconds =403/60 = 6.71 minutes. 8/12/16 spindles, High
Quality Reasonable
28-What is meant by transition distance?
price, Max output

wincowire.com

OPEN
Transition distance is defined as the distance from the
centre line of the
first fully troughed idler roll to the centre line of either
the head or tail
pulley.

29-Explain
VGTU system in belt conveyors.

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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators

CLOSE ADS CLOSE ADS

Transformer Transformer
winding winding
machine machine
Winco Winco
8/12/16 spindles, 8/12/16 spindles,
High Quality The role of the take-up device is to create and maintain adequate
pre- High Quality
Reasonable price,tension to allow the conveyor drive pulley to drive the belt under all Reasonable price,
Max output running conditions (empty or loaded). Generally there are two main Max output
types of
take-up. The fixed type normally referred to as a screw take-
wincowire.comup STU and the
automatic or Gravity take-up (GTU). The screw take- wincowire.com
up is normally used on short
conveyors up to a length of 50 meters.
Over 50 meter an automatic take-up
system should be used to ensure
constant pre-tension. The length of the take-up
depends on the both
the center distance of the conveyor and the type of belt.
The screw
take-up on shorter belts is normally located at the tail end.
Tracking of
the belt with the screw take-up should only be performed as a last
resort as it may cause permanent belt stretch.

OPEN The GTU performs best located close to the drive pulley. The GTU OPEN
bend
pulleys will have a minimum diameter based on the belt
specification. Movement
of the GTU on both the vertical and horizontal
axis should be limited to avoid
excessive movement and associated
tracking problems. The GTU should be
protected with a return belt
plough and must be adequately guarded.

30-What
is the significance of counter weight?

The weight of the GTU should maintain a constant belt sag between
the
idlers (normally H/L 5 1–2% of length of take up) hence calculating
the correct
weight is important. A GTU underweight will lead to
excessive belt sag thus
increasing belt bend resistance and reducing
overall belt and idler life. A GTU
over weight will lead to excessive belt
tension resulting in belt and joint
stretch.
31-What is the significance of covers in
belt?
Covers are used in conveyor belt constructions in order to protect the
base conveyor belt carcass and to extend its service life. In addition,
covers
do provide the finished belt with a wide variety of desirable
properties,
including the following:
32-A belt conveyor of length 100 meter
need to install VGTU
system calculate the minimum length of take up.

Minimum length of take up = Conveyor length (centre to Centre) X

1.5%
                                              =
100 X 1.5/100 = 1.5 meters

33-A 200 metre length conveyor belt has a

drive pulley size OD
510 mm 3 Length 1800 mm, this pulley is directly coupled
to
planetary reduction gear box having reduction ratio 40:1 and 1475

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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators
rpm motor
is used to drive this gear box. Then calculate the time
required for conveyor
for one complete rotation.
CLOSE ADS CLOSE ADS
We have,
Conveyor length: 200 meters
Pulley OD: 510 mm = 0.51 m
Motor output speed = 1475 rpm
Gear box reduction ratio = 40:1
Gear box output speed N = 1475/40 = 36.87 rpm
Transformer
Head pulley speed = Gear box output speed (As head pulley is directly Transformer
coupled to gear box)
winding Pulley speed in m/sec. = V = Pi X D X N/60 winding
machine                                          
= (3.142 X 0.51 X 36.87/60) = 0.98 m/sec machine
Winco Winco
Belt speed is 0.98 m/sec, given that conveyor total length is 200
meters.
8/12/16 spindles,Then the length of the belt = 2 X conveyor C/C length + Conveyor C/C
length 8/12/16 spindles,
High Quality High Quality
X 2 X 1.5% (VGTU) + 0.5 X No. of pulleys (Pulley and belt contact radius
Reasonable price, Reasonable price,
Max output length is considered 0.5 meter for each pulleys) Max output
= 2 X 200 + 200 X 2 X (1.5/100) + 0.5 X 6 (6 Nos of pulleys)
wincowire.com= 409 meters wincowire.com
Time required for one complete revolution = Belt length/Speed
                   
                     
                     
     = 409/(0.98 X 60) = 6.95 minutes
34-A
conveyor of 7.5 KW having belt width 800 mm and speed 0.95
m/sec., calculate
the maximum tension at the start of the belt.

Belt rated power P = 7.5 KW

Belt speed V = 0.95 m/sec.
Belt width W = 800 mm = 0.8 meters
Maximum tension at the start of the belt = (3.2 X P)/(V X W)
OPEN                    
                     
                     
 = (3.2 X 7.5)/(0.95 3 0.8) OPEN
                   
                     
                     
 = 31.5 KN/M
About Me
Read SOP on CHP & Dust extraction system

35-A
1400 mm width inclined belt conveyor has its head pulley at the
elevation of 22
meter from ground, is used to convey 45 TPH coal. The
head pulley is coupled to
motor of RPM 1450 through planetary gear
box of efficiency 80%. Then calculate
the motor rated power to drive
Powerplant and calculations
the conveyor. Consider motor efficiency 90%.
View my complete profile
Belt width W =1400 mm
Vertical lift = L = 22 meter
► 
2022
(10)
Conveyor capacity Q = 45 TPH
Gear box efficiency = 80% ► 
2021
(45)
Motor efficiency = 90% ▼ 
2020
(58)
We have power required to drive the inclined belt P = 4.7 X L X Q/1000 December
(2)
                   
                     
                     
                   = 4.7 X 22
X 45/1000
November
(2)
                   
                     
                     
                   = 4.65 KW
Motor input power = 4.65/(Gear box eff. 3 Motor eff.) October
(4)
                   
           = 4.65/(0.8 X 0.9) = 6.45 KW September
(3)

Motor rated power = Motor input power X 1.15 = 6.45 X 1.15 = 7.42 KW August
(5)
(Take 15% margin) July
(11)
Select 7.5 KW motor
June
(8)
36-Calculate
the length of a 3 ply 1600 mm width conveyor belt, May
(23)
which is coiled on a 100 mm
pipe. The thickness of the belt is 10
mm and belt is coiled around 65 turns.
Labels
We have,
AVR
Diameter of centre hole of coiled belt, d = 100 mm X 0.1 m Boiler

Thickness of the belt T = 10 mm = 0.01 m Efficiency & performance

Electrical & Instrumentation

No. of turns N = 65
energy conservation & thumb rules in power
plant
Outer diameter of belt, D= 2 X 65 X 0.01 = 1.9 m
ESP
Length of belt = (d + (D - d)/2) X π X N fuel handling

                   
    = (0.1 + (1.9 - 0.1)/2) X 3.142 X 65 Mechanical Engineering

pmg
                   
    = 204.23 meters
power generation

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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators

power plant
37-Write a short note on
operation checks of conveyor belt? Power plant best operation & maintenance
CLOSE ADS Belts: books CLOSE ADS
Watch out for spillage of material onto the return strand, where it can power plant maintenance
get between the belt and pulleys.
power plants
See that the belt is properly aligned and does not contact steel
structure. This is especially important on the return strand that is pumps/compressors/fans

generally
not as easy to see. safety and energy
Mark breaks, damaged and worn spots and report them for early steam turbine
Transformer repair. Water treatment plant Transformer
winding Keep large lumps (coal lumps, stones, other foreign materials) of winding
material off belts. If they do get on, remove them carefully.
machine Idlers and Pulleys: Report Abuse machine
Winco Note and mark “frozen” or damaged idlers for repair or replacement. Winco
8/12/16 spindles,Check troughing and return training/self aligning idlers for proper Home 8/12/16 spindles,
High Quality operation. High Quality
Reasonable price, Boiler Reasonable price,
Check scrapers and plows for proper operation.
Max output Turbine Max output
Watch for material to build up on decking or floor under idlers or
wincowire.compulleys. This is especially important at training/self aligning idlers. Maintenance
wincowire.com
 Chutes and Hoppers: Fuel handling
Note and correct clogged or “bridged” material.
Efficiency&Performance
Prevent large lumps from dropping onto unprotected belt.
WTP
Check to see that the material is centred on the belt and that the belt
is E&I
not overloaded. Pumps/compressors/fans
Replace all damaged impact idlers; do not replace impact idlers with
regular idler.
38-What is the significance of pulley
lagging? Home Search This
OPEN Lagging is done to improve Pulley traction, either bolt or vulcanize the Boiler Blog OPEN
lagging to the pulley face. The lagging will prevent slipping at the head Turbine Search
pulley and also cushion the wear between the belt and the pulley
Maintenance
surface. In
wet conditions, grooved lagging works best.
Fuel handling
39-What is the function of hold back
device in conveyor belts? Efficiency&Performa
Hold back is a device used to restrict the reverse/back movement of nce
belt
during sudden stop or trip of conveyor. WTP

40-What is belt splicing? What are the

different types of splicing? E&I
Pumps/compressors
Splicing is the
process of joining up of two trimmed ends of a conveyor /fans
belt utilizing a
defined chemical or mechanical procedure. Disclaimer

Vulcanized Splicing (cold and hot) and Mechanical Splicing are Privacy policy
generally
used for belt jointing. About us

Contact us

Available @ Flipcart/Amazon/Notion press

Factors considered for Boiler Engineering/Design

Power plant maintenance calculations

Turbine oil and transformer oil standard testing parameters

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4/10/22, 3:19 PM Power plant and calculations: 40 important question & answers on belt conveyor for power plant engineers & operators

at
June 10, 2020

CLOSE ADS Labels:

fuel handling CLOSE ADS

1 comment:
Unknown 21 August 2021 at 19:14

Transformer Nice but i want information in conveyor belt BHS system

Transformer
winding Reply
winding
machine machine
Winco Enter your comment... Winco
8/12/16 spindles, 8/12/16 spindles,
High Quality High Quality
Reasonable price, Reasonable price,
Max output Comment as:
Google Accoun Max output

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