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Analysis And DesignOf
Belt Conveyor Gallery System
GUIDED BY :
Mr. T.S.DHOLAKIA
(PMC PROJECT. PVT. LTD)
BY:
SHAH PREYASH R.
(06MCL018)
2
FLOW OF PRESENTATION
• INTRODUCTION
• LITERATURE REVIEW
• OBJECTIVE OF STUDY
• SCOPE OF WORK
• WORK CARRIED OUT
• CONCLUSION
• FUTURE LINE OF ACTION
3
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.
5
Size specification
• Size depends on the requirement :
– Speed– Cost– Efficiency– Maximum load it takes– Material transferred per hour
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.
7
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.
9
CONVEYORS
On Ground Conveyor Above Ground Conveyor
10
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
BeltUnloader
11
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).
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.
13
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.
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.
15
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.
16
ARRANGEMENTS OF
BELT COVNEYORS
• Double /multi layer system
• Parallel system
• Single system
17
SINGLE CONVEYOR
PARALLEL CONVEYOR
DOUBLE LAYER CONVEYOR
18
INDUSTRIAL APPLICATION
• Production• Mining • Shipping companies • Food and beverage companies (with
specializations like fruits and vegetables, meat, poultry and seafood)
• Automobiles industry
19
Cont…
• Electronics• Pharmaceutical and medical • Printing• Packaging• Cement industry
20
21
• 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.
23
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.
FLOW DIAGRAM OF SYSTEM
25
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.b. To frame the Design philosophy.
27
• The conveyor systems are designed for:1. Double layer system2. Parallel system
• The framing is designed by using following alternative: -
• Detailing of sample members with connections
Sr. No. Columns Beams Framing1 STEEL STEEL STEEL
2 CONCRETE STEEL COMPOSITE
3 CONCRETE CONCRETE CONCRETE
28
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 connections.
29
30
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• Spacing of return idlers = 3 m
31
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
(short supports and idler connection)
32
LIVE LOADLoad 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
33
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
34
EARTHQUAKE LOAD• The earthquake load is taken as per IS:
1893-2002 (I).• Location – Dahej (bharuch)• zone - III
35
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.
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– Transverse Load = 1.8 kN
37
• 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 Conveyor Gallery = 1.2 kN/m2 (lower truss)
– For Parallel Conveyor Gallery = 1.3 kN/m2
38
LOADINGSHORT SUPPORTS
BELT
TRUSS
4.55 m
39
LOAD COMBINATION
• Load Combination is taken from I.S.875 (part V)
• They are as follow:
1. DL+LL
2. DL+LL+WL
3. DL+0.5LL+EQ
40
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
f) End portal of conveyor gallery girder : Height / 325
41
STAAD MODEL SINGLE CONVEYOR
3-D VIEW
ELEVATIONSECTION
42
STAAD MODEL STEEL DOUBLE CONVEYOR
3-D VIEW
ELEVATION
PLAN
Cross section
43
CONCRETE DOUBLE CONVEYOR
ELEVATION
PLAN
3-D VIEW
44
COMPOSITE DOUBLE CONVEYOR
3-D VIEW
ELEVATION
PLAN
45
DISPLACEMENT COMPARISON FOR DOUBLE LAYER CONVEYOR GALLERY
Type Max Disp (mm) Permissible
Def. (mm)
Steel 45.35 48.00
Composite 35.87 48.00
Concrete 41.23 48.00
46
STEEL PARALLEL CONVEYOR
ELEVATION
PLAN
3-D VIEW
Cross section
47
CONCRETE PARALLEL CONVEYOR
ELEVATION
PLAN
3-D VIEW
48
COMPOSITE PARALLEL GALLERY
ELEVATION
PLAN
3-D VIEW
49
DISPLACEMENT COMPARISON FOR PARALLEL CONVEYOR GALLERYType Max. Disp (mm) Permissible
Def. (mm)
Steel 46.80 48.00
Composite 45.30 48.00
Concrete 36.24 48.00
0.00
10.00
20.00
30.00
40.00
50.00
Steel Composite Concrete
Type of Material
Dis
p. (m
m)
Steel Composite Concrete
50
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.
51
• 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 above) are designed to be semi-rigid
• Fully-Restrained moment connections (D and E above) are designed to be fully rigid
Steel Frame Connection Types
(AISC)
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
Moment resisting connection
53
• 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)
450ISMB 450ISMB 500
130
70100
6 mm fillet weld
Column
Beam
Bottom plate
Elevation
Plan from Top
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.
55
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
15-19 Brown very stiff med. Plastic silt and clay
CI 60
19-21 Brown very stiff plastic silt and clay
CH 80
56
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 MyP+WF= ± ±
n I I
57
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:• 8 mm# @ 56 mm c/c• Lateral ties at top:• 8 mm# @ 37 mm c/c
DETAILING OF PILE
F1 = 290.14 kN
F2 = 475.42 kN
F3 = 12.23 kN
F4 = 197.51 kN
58
59
• 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.
LOAD
(kN)
DL+0.5LL+EQZ
D.L+L.L+W.L
RESULTS FOR PARALLEL STEEL CONVEYORS
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.
• The option1 profile proves to be economical than option2.
61
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
Rs. in
lakh
s
36.0036.5037.0037.5038.0038.5039.0039.5040.00
1 2
Profile Type
Wt.
(kN
)
1 2
Wt. comparisonCost comparison
62
WEIGHT COMPARISON OF GALLERIES
• Steel Galleries
Type (steel) kN
Double 1174.51
Parallel 796.35
63
• Concrete Galleries
Type (conc.) Conc. (m3) Steel (kN)
Double 342.79 211.08
Parallel 253.74 153.70
0.00
100.00
200.00
300.00
400.00
500.00
600.00
1 2
Concrete conveyor gallery
wt.
(kN
)
Concrete Steel
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
wt.
(k
N)
concrete steel
65
COST COMPARISON
Type ofRate
(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
0.00
10.00
20.00
30.00
40.00
50.00
(steel) (concrete) (composite)
Conveyor Galleries
Rs.
in L
akhs
Double Parallel
Rate of steel = Rs. 40/ kg Rate of Concrete = Rs. 3500/ m3
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 galleries.
67
68
• Optimum distance between the trestles for belt conveyor
• Optimum truss pattern for belt conveyor
• Conveyor on jetty
• Analysis and Design of Cable conveyor
69
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 (vol-I) - Civil Engineering and Construction Review-1988-91.
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
71
• 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 Indian Standard, New-Delhi, June-2002.
• Sp-16,”Design Aids for Reinforced Concrete to I.S-456-1978”, Bureau of Indian Standard, New-Delhi.
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