802-TSL-DO-M0166

POWER CALCULATION OF BELT CONVEYOR BCN-10C

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29/12/2009

First Submission

REV

DATE

DESCRIPTION OF REVISION

SK INL

VD SIGN

PREPARED

PROJECT

OWNER

OWNER’S CONSULTANT

INL

SKM SIGN

CHECKED

INL

SIGN

PROJECT MANAGER

KORBA WEST THERMAL POWER PROJECT 1X500 MW [EXTENSION STAGE III] KORBA (DIST), CHHATTISGARH CHHATTISGARH STATE POWER GENERATION COMPANY LTD (A SUCCESSOR COMPANY OF C.S.E.B) DEVELOPMENT CONSULTANT PVT LTD CONSULTING ENGINEERS, KOLKATA

BOP CONSORTIUM

TECPRO SYSTEMS LIMITED TECPRO ASHTECH LTD

VA TECH WABAG LTD

GAMMON INDIA LTD

BOP CONSORTIUM’S CONSULTANT

FICHTNER CONSULTING ENGINEERS (INDIA) PVT LIMITED, CHENNAI

DOCUMENT NUMBER 0802-TSL-DO-M0166

Tecpro Systems Ltd. Power Calculation for Belt Conveyor (Ref. IS:11592:2000) Conveyor No: BCN-10C

Project Input

Document No. App By Date Rev No/Description

0802-TSL-DO-M0166 SKM 21-Dec-09 By Date

Symbol B H V Cr Cd Vb

Value

External Coal Handling Plant for 1x500MW KorbaThermal Power Station

Description Belt width Horizontal crs Lift Rated Capacity Capacity Assumed Belt speed material Handled Sized/Unsized Max. Lump Size Bulk density Surcharge angle Troughing angle Max. Allowable Belt Tension of rated belt tension

Tripper Slope No of Trippers Conveyor Inclination Angle(Max.) Conveyor length along belt Material Transportation length Skirt Board length Carrying idler spacing Return Idler spacing C i idler idl Di Carrying Dia Return idler dia ERW Pipe thickness of CI(IS9295) ERW Pipe thickness of RII(IS9295) No of Rolls per set in CI No of Rolls per set in RI Artificial friction coefficient Tight side pulleys (wrap angle 150-240 deg) Slack Side Pulleys (wrap angle 150-240 deg) Other Pulleys( deflector/snub) Permissible sag Wrap Angle Coeffecient of friction betwee pulley & belt Coeffecient of friction between CI & belt Coeffecient of friction between materail & belt Coeffecient of friction between materail & skirt board Coeffecient of friction between belt & belt cleaner Coeffecient for Idler tilting No of scrapers(External & Internal ) Thickness of cleaning tip of Scraper Angle of Carrying Idler tilting in forward dirn Angle of Return Idler tilting in forward dirn Material speed component in belt direction Motor rpm Ambient Temp

Ls d As At Bt Tra nt Ai L Lt Lsk Pc Pr Dci Dri Tci Tri Nci Nri f Ntsp Nssp Ndef s Aw μ μ0 μ1 μ2 μ3 Ci Ns tc i ir Vo Nm Ta

1200 760.000 3 1000 1000 3 COAL Sized 75 0.8 20 35 80.0% 15 0 6.00 760 758 5 1.2 3 152 4 152.4 139.7 4.5 4.5 3 2 0.03 1 6 1 2.0% 210 0.3 0.35 0.6 0.6 0.65 0.5 3 20 0 0 0 1490 50

Unit mm m m TPH TPH m/sec

mm 3 t/m degree degree

degree m m m m m mm mm mm mm

degree

mm degree degree m/sec rpm degree C

Page 1 of 3

Document No. App By Date Rev No/Description

Tecpro Systems Ltd. Power Calculation for Belt Conveyor (Ref. IS:11592:2000) Conveyor No: BCN-10C

Project External Coal Handling Plant for 1x500MW KorbaThermal Power Station Belt Tension & Power Calculation c Edge Clearence on Belt p Material on troughed portion of belt A1 Water level fill Area A2 Surchage angle Fill Area K1 Slope Reduction Factor for Area A2 Ac Area of crosssection Lci Roller Length for CI Lri Roller Length for RI mb Weight of Belt (Refer Phoenix Yule Catalogue) Belt spped considering GB ratio as16:1 drive pulley dia as Vba

=IF(B<2000,0.05*B+25,125) =0.5*(B-2*c-Lci) =(p*COS(At)+Lci)*p*SIN(At) =1/6*(Lci+2*p*COS(At))^2*TAN(As) =Sqr(((Cos(Ai))^2-(Cos(As))^2)/(1-(Cos(As))^2)) =(A1+K1*A2)/(1000*1000)

Considering 800/4NN-HD 5mm/3mm

=PI()*Dp/1000*Nm/(In*60)

0802-TSL-DO-M0166 SKM 21-Dec-09 By Date

85 282.5 112843 52221 0.95 0.163 465 700 18.70 3.07

mm mm mm2 mm2 m2 mm mm Kg/m m/sec

630mm

Weight of rotating parts of CI Weight of rotating parts of RI Skirt Boar width Acceleration length at loading area Recommended filling factor(7.4.5.1) Actual filling factor Length correction factor (For conv. less then 80m) Volume of the material Weight of material on belt Main Resistance(With material) Main Resistance(Without material) Slope Resistance Inertial & friction resistance at the loading point in acceleratione zone between belt & material Friction resistance at skirt board Belt Thickness

mc mr b1 La Ff Af α Q mg R Ro RSL Ra

=0.667*B/1000 =(Vba2-Vo2)/(2*9.81*μ1) =Cd/(3600*d*Ac*Vba) =Cd/(3600*d*Ac*Vba*Sfc) =Ac*Vba*Af =Cd/(3.6*Vba) =f*9.81*((mc+mr+2*mb)*L+mg*Lt) =f*9.81*((mc+mr+2*mb)*L) =mg*V*9.81 =Q*1000*d*(Vba-Vo)

Rska =µ2*Q2*1000*d*9.81*La/((((Vba+Vo)/2)2)*b12) t Av. tension at slack side Pulley(assumed for wrap resist.) Tavt Wrap resistance between belt & pulley (Except drive pulley)(Ref:IS:11592Rw =9B*(140+.01*(Tavt/B)*t/D*(Nssp+Ndef) =(Nssp+Ndef)*50 Pulley bearing resistance(Considering 50N for each non Rb drive pulley) =Ra+Rska+Rw+Rb Secondary Resistance Rs Secondary Resistance(Without material) Rso =Rw+Rb =Ric+Rir Ri Resistance due to idler tilting Rsk =μ2*Q2*1000*d*9.81*Lsk/(Vba2*b12) Resistance betn material & skirt plate Rbc =50000*Ns*B*tc*1E-6*μ3 Resistance due to belt Cleaners Special resistance Rsp =Ri+Rsk+Rbc Special resistance(Without material) Rspo =Ri+Rbc Factor for extra power for tripper βtp =(R+RSL+Rs+Rsp)*(nt*btp) Tripper Resistance Rt =R+RSL+Rs+Rsp+Rt Effective Tension(With Material) Te Effective Tension(Without Material) Teo =Ro+Rso+Rspo+Rt Power Reqd to overcome these resistance for loaded belt =Te*Vba/1000 PDP

22.1 7.8 0.80 0.802 90% 69.5% 1 0.347 90.43 35219.3 15047.2 2661.2 853.3

m3/ sec Kg/m N N N N

301.1 14.1 31000.0 849.2 350

N mm N N N

2353.6 1199.2 0.0 469.5 2340 2809.5 2340.0 0.1 0.00 43043.67 18586.38 132.23

Kg/m Kg/m m m

N N N N N N N Ref Table-13 N N N kw

Power Reqd to overcome these resistance for empty belt

PDPo

=Teo*Vba/1000

Resistance at Drive Pulley Bearing

Rdb Tavd

(Considering 100 N for each)

100 N 62000.0 N

Rdw Pa Pao Cw Tcmin Trmin T2T

=9B*(140+.01*(Tavd/B)*t/Dp

158.7 133.00 57.89 0.499 8028.6 3438.9 25789.6

T2 T1

=IF(T2T>Trmin,T2T,Trmin)

Average Tension drive Pulley(assumed for wrap resistance)

Drive Pulley wrap resistance Absorbed power at GB o/p shaft for Loaded Belt Absorbed power at GB o/p shaft for empty belt Wrap factor Min tensile force to limit the belt sag at Carrying side Min tensile force to limit the belt sag at return side Slack side tension at drive pulley for transmission Effective Slack side tension required Tight side tension

57.10 kw

=PDP+(Rdb+Rdw)*Vba/1000 =PDPo+(Rdb+Rdw)*Vba/1000 =1/(em*Aw*pi()/180-1) =Pc*(mb+mg)*9.81/(8*s) =Pr*mb*9.81/(8*s) =Fd*Te/(em*Aw*pi()/180-1)

=Te*(Fd/(e

μ*Aw*PI()/180

)-1)+1)

N kw kw N N N

25790 N 68833 N

Page 2 of 3

Document No. App By Date Rev No/Description

Tecpro Systems Ltd. Power Calculation for Belt Conveyor (Ref. IS:11592:2000) Conveyor No: BCN-10C

Project

0802-TSL-DO-M0166 SKM 21-Dec-09 By Date

External Coal Handling Plant for 1x500MW KorbaThermal Power Station

Component of Main Resistance R for upper belt-Loaded Component of Special Resistence Ri due to CI tilting-Loaded

Rc Ric

=f*9.81*((mc+mb)*L+mg*Lt)

Specific Resistance to Loaded Upper Belt without lifting force

Rcs Rco

=(Rc+Ric)/L =f*9.81*((mc+mb)*L)*IF(Ai<18,1,COS(Ai))

38.5 N/m 9120.4 N

Rico Rcso Rr Rir Rrs T3

=9.81*Ci*µ0*L*(mb)*COS(At* )*SIN(i)

0.0 12.0 5926.7 0.0 7.8 31167

Component of Main Resistance R for upper belt-empty Component of Special Resistence Ri due to CI tilting-empty

Specific Resistance to empty Upper Belt Component of Main Resistance R for return belt Component of Special Resistence Ri due to RI tilting Specific Resistance to Lower Belt Motion Tail Pulley Tension Belt & Pulley Selection & Starting Tension Type of Belt Duty Minimum Allowable Belt Working Tension Max. recommended working tension of selected Belt Recommended Belt for Tensile Strength Selected Belt Check the belt for satisfactory load support Top Cover Bottom Cover Pulley diameters(mm) Di P ll Drive Pulley Tail & Take-up Bend & Snub pulley Reduction ration of gear box Pulley rpm Equivalent mass of Belt & Belt Driven component-loaded

Bty Bd Brr Br Bre Bs Brls Ct Cb D Dp Tp Sp In Np Me

29292.6 N 0.0 N

=9.81*Ci*µ0*L*(mb+mg)*COS(At*)*SIN(i))

=(Rco+Rico)/L =f*9.81*((mr+mb)*L)*IF(Ai<18,1,COS(Ai)) =9.81*Ci*m0*L*(mb)*COS(At* )*SIN(ir) =(Rr+Rir)/L =T2+Rrs*L-9.8*mb*V

N N/m N N N/m N

NN HD =T1/(B*Bt)

considering FOS as 10

mm mm mm =Nm/In =((mc+mr+2*mb+mg)*L+Wndp)+Nmt/4*(2*PI()*Nm/(60*V ba))^2*(Mgd+Hsgd+Gbgd+Lsgd/(In^2))

71.7 90.0 NN800/4 NN800/4 OK 5 3.0 Selected 630 500 400 16.0 93 620732.9

KN/m KN/m

mm mm Recommended

630 500 400 16.38 91 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))

552009.4 Kg

Gd2 value of emtybelt (at motor rpm) Gd2 value of loaded belt (at motor rpm) Force available for acceleration at drive pulley Tight Side Tension (Starting) Tail Pulley Tension Starting)

=Me*(Dp/In)2*0.000001

962.4 855.8 33268.9 102102.2 32246.0 94.5%

Gd Gdo Fa T1s T3s

% Belt Tension at starting of the belt rated tension(Max. 150%)

Motor Selection Drive Efficency ng Drive Efficency ngc Motor derating Factor for 50 Deg. C ambient temp. Required Motor Power for Loaded Belt Reuire Motor Power for Empty Belt Motor selected No of Motors Available Service Factor

2

=Meo*(Dp/In) *0.000001 =(Fd*ng*Pmi*Nmt-Pa)/Vba*1000 =T1_+Fa

=T3_+Fa*(mb+mr)*L/Me =(T1s/B)/Br

ng ngc Ntm Pm Pmo Pmi Nmt

Kg-m2 Kg-m2 N N N OK

98% 97% 1.00 =PA/(ng*ngc*Ntm) =Pao/(ng*ngc*Ntm)

(Required Service Factor for Motor:1.1)

139.9 kw 60.9 kw 200 kw 1 1.43

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