Conveyor Design

Analysis And Design

Of

Belt Conveyor Gallery System

GUIDED BY : Mr. T.S.DHOLAKIA

BY:

SHAH PREYASH R.

(06MCL018)

2

FLOW OF PRESENTATION

• INTRODUCTION

• LITERATURE REVIEW

• OBJECTIVE OF STUDY

• SCOPE OF WORK

• WORK CARRIED OUT

• CONCLUSION

4

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.

Size specification

• Size depends on the requirement :

– Speed

– Cost

– Efficiency

– Maximum load it takes

6

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.

8

Cont…

• The belt supporting system has supporting

structure with two pulleys arranged at its

ends: the driving pulley at the head and the

take-up pulley at the rear end.

• A belt bends around these pulleys and is

supported along its entire length by rollers

supports or idlers, which are fastened to

the frame.

• The Gallery supports the belt system with

its supports, and gallery is supported on

columns which transfer the load to the

foundations.

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COMPONENTS

Take up pulley Hopper/Funnel Supporting Frame Drive pulley Unloading funnel Drive motor Lower idlers Upper idlers Belt cleaner

Side

Elevation

Cross

Sections

Plan

Belt Unloader

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

12

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) take-up which are used for adjusting tension in the belt.

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

14

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 cross-pieces. The height of the frame is usually 400 to 500 mm; the spacing between the uprights is 2 to 3.5 m.

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

16

ARRANGEMENTS

OF

BELT COVNEYORS

• Double /multi layer system

• Parallel system

SINGLE CONVEYOR

18

INDUSTRIAL APPLICATION

• Production

• Mining

• Shipping companies

• Food and beverage companies (with

specializations like fruits and vegetables,

meat, poultry and seafood)

Cont…

• Electronics

• Pharmaceutical and medical

• Printing

• Packaging

• V. Afanasyev, The book is based on the various national code such as Indian (I.S 11592-2000), British standards, Russians standards and American standards. The book gives idea about conveying machines and some of the conveyors which are used in the industries. It gives description about the mechanical parts of the conveyer and show the different parts of the conveyer system.

• Wilbur G. Hudson, describes different conveyors with their schematic diagram and gives important tables for the design of conveyor components. It also gives description and design for the elevators and crushers units.

22

• Dr. Ram Chandra and Virendra Gehlot,The book is based on the analysis and design of some of the special steel structure. It is based on the Indian standard for the analysis and design.

• IS 11592-2000, is an Indian code of practice by

BIS, for the selection and design of belt conveyors. Its reference is made for belt speed, inclinations of idlers, width of the belt, spacing of idlers and for the use of the tables for the load calculations on conveyor.

• Joseph E. Bowels, gives the analysis of the

different foundation. The different techniques for soil exploration are suggested by him. The different tests on soil are also shown.

24

• The conveyor system to be

designed has a site located at Dahej (Bharuch) and is approximately 7 Km long. • The objective of the study

is to model, analyze and design the conveyor

gallery J2C1 and J2C2 by using different options of the material. Moreover the study also involves the

economical aspect of the conveyer galleries of

different materials, and does the parametric study of column by using steel and concrete as material for double and parallel conveyer system.

26

• To understand and design the conveyer belt

supporting system by using the alternatives

of steel/concrete columns and steel beams.

• Also to show the cost effectiveness of

conveyer system.

• The parametric study involves the

following:-

a.

Review and design of base structure

having pile foundation.

• The conveyor systems are designed for:

1.

Double layer system

2.

Parallel system

• The framing is designed by using following

alternative: -

• Detailing of sample members with

Sr. No. Columns Beams

Framing

1 STEEL STEEL STEEL

2 CONCRETE STEEL COMPOSITE

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d.

Analysis: For the system analysis and

design STAAD-Pro software will be

used as required

e.

Economics: To review with system.

f.

Detailing of sample members with

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MECHANICAL DATA

• Rated Capacity = 4200 t/h

• Bulk Density of Coal for structural calculation =12.0 kN/m3

• Angle of surcharge = 20°

• Angle of Repose = 37°

• Belt width = 1800 mm

• Belt speed = 4.35 m/s

• Wt of belt = 0.46 kN/m

• Wt. of rotating mass carrying side (carrying idlers) = 0.62 kN/m

• Wt. of rotating mass return side (return idlers) =0.155 kN/m

• Troughing angle = 45°

• Friction factor = 0.03

• Impact factor = 1.2

• Spacing of carrying idlers = 1 m

LOADINGS

DEAD LOAD

•Self weight of the gallery and trestle.

•Wt. of belt = 0.46 kN/m

•Wt. of the carrying idlers = 0.62 kN/m

•Wt. of the retrun idlers = 0.155 kN/m

•Wt. of technological str. = 0.80 kN/m

32

LIVE LOAD

Load on Walkway = 3 kN/m2

Dust Load = 1 kN/m2

L.L on conveyor belt = 1.6 x design wt. of the material carried over the belt

= 7.95 kN/m

Load due to motion of belt = 1.8 kN (longitudinal) Load due to outward = 1.8 kN (transverse) movement of stringers

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

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EARTHQUAKE LOAD

• The earthquake load is taken as per IS:

1893-2002 (I).

• Location – Dahej (bharuch)

• zone - III

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

36

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

• Design Wind pressure

– For Single Conveyor

Gallery = 1.2 kN/m2

– For Double Layer

Conveyor Gallery = 1.3 kN/m2 _{(upper truss)}

– For Double Layer

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LOADING

SHORT SUPPORTS BELT TRUSS 4.55 m

LOAD COMBINATION

•

Load Combination is taken from I.S.875

(part V)

•

They are as follow:

1. DL+LL

2. DL+LL+WL

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DEFLECTION

• The deflection is taken as per IS 11592-2000:-

a) Conveyor galleries : Span/500

b) Trestle supporting gallery in transverse : Height/1000

Direction

c) Gallery crosses beams directly supporting : Span/500

Conveyor short posts

d) Walkway beams of conveyor galleries :Span/325

e) Floor beams directly supporting drive : Span/500

Machinery, motor and gear boxes

STAAD MODEL

SINGLE CONVEYOR

42

STAAD MODEL

STEEL DOUBLE CONVEYOR

3-D VIEW ELEVATION

PLAN

Cross section

CONCRETE DOUBLE CONVEYOR

ELEVATION

44

COMPOSITE DOUBLE CONVEYOR

3-D VIEW

ELEVATION

DISPLACEMENT COMPARISON FOR

DOUBLE LAYER CONVEYOR GALLERY

10.00 20.00 30.00 40.00 50.00 D is p. ( m m )

Steel Composite Concrete

Type Max Disp (mm) Permissible

Def. (mm)

Steel 45.35 48.00

Composite 35.87 48.00

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STEEL PARALLEL CONVEYOR

ELEVATION

PLAN

3-D VIEW

Cross section

CONCRETE PARALLEL CONVEYOR

ELEVATION

48

COMPOSITE PARALLEL GALLERY

ELEVATION

PLAN

DISPLACEMENT COMPARISON FOR

PARALLEL CONVEYOR GALLERY

Type Max. Disp (mm) Permissible

Def. (mm) Steel 46.80 48.00 Composite 45.30 48.00 Concrete 36.24 48.00 10.00 20.00 30.00 40.00 50.00 D is p. ( m m )

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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.

• All connections have a certain amount of rigidity

• Simple connections (A above) have some rigidity, but are assumed to be free to rotate

• Partially-Restrained moment connections (B and C

Steel Frame Connection Types

52

• 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

Cont…

Simple connection

• 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) 450 ISMB 450 ISMB 500 130 70 100 6 mm fillet weld Column Beam Bottom plate Elevation

Cont…

12 mm clearence

54

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.

Thk. of strata Description of strata Notation Capacity of soil

(m) (T)

0-2 Dark brown med. Dense

fine sand SP-SM 20

2-3 Dark brown dense fine

silty sand SM 20

3-5 Dark grey stiff med.

plastic silt and clay CI 20

5-7 Dark grey med. Dense

fine silty sand SM 30

7-8 Dark grey very stiff

sandy clayey silt CL 30

8-12 Dark grey very stiff

med. Plastic silt and clay CI 40

12-15 Brown very stiff plastic

silt and clay CH 40

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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,

n n y x Mx My P +W F = ± ± n I I

Cont…

• Pile diameter = 0.6 m

• Pile length = 18 m

• No. of pile in group = 4 nos.

• Cover provided to pile = 40 mm

• Main reinforcement:

• 8-20 mm# having area of 2512

mm2

• Lateral ties:

• 8 mm# @ 300 c/c

• Lateral ties at bottom:

F1 = 290.14 kN

F2 = 475.42 kN

F3 = 12.23 kN

• The Conveyor Gallery is analyzed for the

assumed sectional property and it is

checked for the design in STAAD-Pro.

• The wind load combination is governing than earthquake load.

• The DL+ LL

combinations give

governing result with compared to

DL+LL+WL.

COMPARISON OF HORIZONTAL LOAD

OF EQ AND WIND LOAD

0 200 400 600 800 244 46 45 60 537 BEAM NOS. L O A D ( k N ) DL+0.5LL+EQZ D.L+L.L+W.L

60

• The concrete conveyor gallery proves to be economical

than steel conveyor gallery, but steel is chosen for its durability, easy fabrication and easy further extension.

• Concrete galleries have large cross section than steel, and

hence concrete is generally not used.

Option

kN

Rate (Rs. In

lakhs)

1

37.43

1.50

2

39.76

1.59

1.45 1.50 1.55 1.60 1 2 Truss option R s. i n l a kh s 36.00 36.50 37.00 37.50 38.00 38.50 39.00 39.50 40.00 1 2 Profile Type W t. (k N ) 1 2

62

WEIGHT COMPARISON OF GALLERIES

• Steel Galleries

Type (steel) kN Double 1174.51 Parallel 796.35 0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00 Double Paralle l

Steel conveyor gallery

w t. (k N ) Double Parallel

• Concrete Galleries

Type (conc.) Conc. (m3_{) Steel (kN)}

Double 342.79 211.08 Parallel 253.74 153.70 100.00 200.00 300.00 400.00 500.00 600.00 w t. ( kN ) Concre te Ste e l

64

• Composite Galleries

Type (comp.) conc. (m3_{) steel (kN)}

(Reinf + members) Double 94.00 869.00 Parallel 58.00 709.00 0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 Double Parallel

Composite conveyor gallery

w t. (k N ) concrete steel

COST COMPARISON

Type of Rate (Rs.lakhs) Rate (Rs.-lakhs) Rate (Rs.lakhs) conveyor (steel) (concrete) (composite)

Double 46.98 20.44 38.05 Parallel 31.85 15.03 30.39 10.00 20.00 30.00 40.00 50.00 R s. in L ak hs Double Parallel

66

• From above graphs it is concluded that

Parallel Conveyor Galleries are economical

than Double Layer Conveyor Galleries.

Moreover Concrete Galleries are the most

economical one than the others two

68

• Optimum distance between the trestles for

belt conveyor

• Optimum truss pattern for belt conveyor

• Conveyor on jetty

REFERENCES

• V.Afanasyev,”Conveying Machines-I”, Mir Publishers Moscow-1985.

• Don Danemanis, ”Conveyors and Related

Equipments”,Peace Publishers, Moscow

• Wilbur G. Hudson,” Conveyor and Related

Equipment”, John Wiley and Sons-New York INC.

Chapman and Hall, Limited- London

• Dr.B.C.Punmia, and A.K.Jain,”Design of Steel

Structures”, Laxmi Publications Ltd.

• Dr.Ram Chandra and Virendra Gehlot,”Design of

steel structure-2”, Standard Publishers Distributors.

• Jerzy Antoniak, ”Resistance to the motion in Mining

Belt Conveyors” Russia-1992

• Jagman Singh,”Cross Country Conveyor System”, Construction Equipment and Machinery in India

70

• Ascalew Abebe and Dr. Ian GN Smith, “Pile

Foundation Design”, School of Build Environment ,

Napier University ,Edinburgh

• Dr. B.C.Punmia,” Soil Mechanics and Foundations”, Standard Book House, New-Delhi.

• A.S.Arya and J.L.Ajamani,” Design of Steel

Structures”, Nem Chand and Bros Publication,

Roorkee.

• James G Colin, “Timber Pile Design and

Construction Manual”, Timber Piling Council

American Wood Preservers Institute.

• Buick Davison and Graham W Owens, “Steel

Designer’s Manual”, Steel Construction Institute,

Blackwell Publication.

• Joseph E. Bowels, “Foundation Analysis and

Design”, McGraw-Hill company, New York, 1997

• H. J. Shah, “Reinforced Concrete – II”, Charotar Publication, Anand, 2005

• IS 456-2000 “Code of Practice for Plain and

Reinforced Concrete”, Fourth Revision, Bureau of

Indian Standard, New-Delhi, 2000

• IS 11592-2000,”Selection and Design of Belt

Conveyors-Code of Practice” First Revision, Bureau

of Indian Standard, New-Delhi, 2000

• IS 875-1987(part3),”Code of Practice for Design

Loads for Buildings and Structures”, Second

Revision, Bureau of Indian Standard, New-Delhi, November-1998

• IS 800-1984 “Code of Practice for General

Construction in Steel”, First Revision, Bureau of

Indian Standard, New-Delhi, May-1999

• IS 1893-2002 “Criteria For Earthquake Resistant

Design of Structures”, Fifth Revision, Bureau of

72

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