Analysis And Design Of Belt Conveyor Gallery System

BY:
SHAH PREYASH R. (06MCL018)
GUIDED BY : Mr. T.S.DHOLAKIA (PMC PROJECT. PVT. LTD)

FLOW OF PRESENTATION
INTRODUCTION LITERATURE REVIEW OBJECTIVE OF STUDY SCOPE OF WORK WORK CARRIED OUT CONCLUSION FUTURE LINE OF ACTION
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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.
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Size specification
Size depends on the requirement :
Speed Cost Efficiency Maximum load it takes Material transferred per hour

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.

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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CONVEYORS

On Ground Conveyor

Above Ground Conveyor

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COMPONENTS
Hopper/Funnel Upper Unloader idlers Belt

Take up pulley
Drive pulley SupportingUnloading Frame funnel Belt Drive motor cleaner

Side Elevation
Lower idlers

Cross Sections

Plan

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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). 11

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) takeup which are used for adjusting tension in the belt.

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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.
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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.

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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.
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ARRANGEMENTS OF BELT COVNEYORS

Double /multi layer system

Parallel system
Single system

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DOUBLE LAYER CONVEYOR

SINGLE CONVEYOR

PARALLEL CONVEYOR

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INDUSTRIAL APPLICATION
Production Mining Shipping companies Food and beverage companies (with specializations like fruits and vegetables, meat, poultry and seafood) Automobiles industry

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Cont
Electronics Pharmaceutical and medical Printing Packaging Cement industry

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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.

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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.
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 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

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 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.
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 The conveyor systems are designed for: 1. Double layer system 2. Parallel system The framing is designed by using following alternative: -

Sr. No.
1 2 3

Columns
STEEL CONCRETE CONCRETE

Beams
STEEL STEEL CONCRETE

Framing
STEEL COMPOSITE CONCRETE

Detailing of sample members with connections

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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 connections.

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MECHANICAL DATA
Rated Capacity Bulk Density of Coal for structural calculation Angle of surcharge Angle of Repose Belt width Belt speed Wt of belt Wt. of rotating mass carrying side (carrying idlers) Wt. of rotating mass return side (return idlers) Troughing angle Friction factor Impact factor Spacing of carrying idlers Spacing of return idlers = 4200 t/h =12.0 kN/m3 = 20 = 37 = 1800 mm = 4.35 m/s = 0.46 kN/m = 0.62 kN/m =0.155 kN/m = 45 = 0.03 = 1.2 =1m =3m

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LOADINGS
DEAD LOAD
Self weight of the gallery and trestle. Wt. of belt Wt. of the carrying idlers Wt. of the retrun idlers Wt. of technological str. = 0.46 kN/m = 0.62 kN/m = 0.155 kN/m = 0.80 kN/m

(short supports and idler connection)

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LIVE LOAD
Load on Walkway Dust Load L.L on conveyor belt = 3 kN/m2 = 1 kN/m2 = 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

movement of stringers

= 1.8 kN (transverse)

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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
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EARTHQUAKE LOAD
The earthquake load is taken as per IS: 1893-2002 (I). Location Dahej (bharuch) zone - III

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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.
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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

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 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
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LOADING
SHORT SUPPORTS BELT

4.55 m TRUSS
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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

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DEFLECTION
The deflection is taken as per IS 11592-2000:: Span/500 : Height/1000 a) Conveyor galleries b) Trestle supporting gallery in transverse Direction

c) Gallery crosses beams directly supporting Conveyor short posts

d) Walkway beams of conveyor galleries

: Span/500
:Span/325

e) Floor beams directly supporting drive Machinery, motor and gear boxes
f) End portal of conveyor gallery girder

: Span/500
: Height / 325
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STAAD MODEL SINGLE CONVEYOR

3-D VIEW

SECTION ELEVATION
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STAAD MODEL STEEL DOUBLE CONVEYOR

ELEVATION

PLAN

Cross section 42

3-D VIEW

CONCRETE DOUBLE CONVEYOR

ELEVATION

PLAN

3-D VIEW

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COMPOSITE DOUBLE CONVEYOR

ELEVATION

PLAN

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3-D VIEW

DISPLACEMENT COMPARISON FOR DOUBLE LAYER CONVEYOR GALLERY

Type Steel Composite Concrete Max Disp (mm) 45.35 35.87 41.23
Steel
50.00 40.00 30.00 20.00 10.00 0.00 Ste e l Composite Concre te

Permissible

Def. (mm)
48.00 48.00 48.00
Composite Concrete

Disp. (mm)

Type of Material

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STEEL PARALLEL CONVEYOR

ELEVATION

PLAN

3-D VIEW

Cross 46 section

CONCRETE PARALLEL CONVEYOR

ELEVATION

PLAN

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3-D VIEW

COMPOSITE PARALLEL GALLERY

ELEVATION

PLAN

3-D VIEW

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DISPLACEMENT COMPARISON FOR PARALLEL CONVEYOR GALLERY

Type Steel Composite Concrete Max. Disp (mm) 46.80 45.30 36.24 Permissible Def. (mm) 48.00 48.00 48.00

Steel 50.00 40.00

Composite

Concrete

Disp. (mm)

30.00 20.00 10.00 0.00 Steel Composite Type of Material Concrete

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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.
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Steel Frame Connection Types

(AISC)

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
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Cont
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

Simple connection

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Moment resisting connection

Cont
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)
12 mm clearence 6 mm fillet weld

450
ISMB 500 Column ISMB 450 Beam

Bottom plate
Elevation

100

70

130

Plan from Top

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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.
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Thk. of strata (m)

Description of strata

Notation

Capacity of soil (T)

0-2
2-3 3-5 5-7 7-8 8-12 12-15 15-19 19-21

Dark brown med. Dense fine sand

Dark brown dense fine silty sand Dark grey stiff med. plastic silt and clay Dark grey med. Dense fine silty sand Dark grey very sandy clayey silt stiff

SP-SM
SM CI SM CL CI CH CI CH

20
20 20 30 30 40 40 60 80 55

Dark grey very stiff med. Plastic silt and clay Brown very stiff plastic silt and clay Brown very stiff med. Plastic silt and clay Brown very stiff plastic silt and clay

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,
F= Mxn Myn P+W n Iy Ix
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Cont
F1 = F2 = F3 = F4 = 290.14 475.42 12.23 197.51 kN kN kN kN

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

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 The Conveyor Gallery is analyzed for the assumed sectional property and it is checked for the design in STAAD-Pro.
LOAD (kN)

COMPARISON OF HORIZONTAL LOAD OF EQ AND WIND LOAD

800 DL+0.5LL+EQZ D.L+L.L+W.L

The wind load combination is governing than earthquake load.

The DL+ LL combinations give governing result with compared to DL+LL+WL.

600 400 200 0 244 46 45 60 537 BEAM NOS.

RESULTS FOR PARALLEL STEEL CONVEYORS

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 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.

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Option 1

kN 37.43

Rate (Rs. In lakhs) 1.50

2
1.60 1.55 1.50 1.45 1 Truss option 2

39.76

1.59
1 40.00 39.50 39.00 38.50 38.00 37.50 37.00 36.50 36.00 1
Profile Type

Rs. in lakhs

Wt. (kN)

Cost comparison

Wt. comparison

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WEIGHT COMPARISON OF GALLERIES

Steel Galleries
Type (steel) Double Parallel
Double
1400.00 1200.00 1000.00 800.00 600.00 400.00 200.00 0.00 Double
Steel conveyor gallery

kN 1174.51 796.35
Parallel

wt. (kN)

Paralle l

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 Concrete Galleries
Type (conc.) Double Parallel Conc. (m3) 342.79 253.74
Concrete 600.00 500.00 Steel

Steel (kN) 211.08 153.70

wt. (kN)

400.00 300.00 200.00 100.00 0.00 1 Concrete conveyor gallery 2

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 Composite Galleries
Type (comp.) Double Parallel conc. (m3) 94.00 58.00
concrete 1200.00 1000.00 800.00
wt. (kN)

steel (kN) (Reinf + members) 869.00 709.00

steel

600.00 400.00 200.00 0.00

Double Parallel

Composite conveyor gallery

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COST COMPARISON
Rate of steel = Rs. 40/ kg Rate of Concrete = Rs. 3500/ m3

Type of conveyor Double Parallel

Rate (Rs.lakhs) (steel) 46.98 31.85

Rate Rate (Rs.-lakhs) (Rs.lakhs) (concrete) 20.44 15.03

Double Parallel

(composite) 38.05 30.39

50.00

Rs. in Lakhs

40.00 30.00 20.00 10.00 0.00 (steel) (concrete) Conveyor Galleries (composite)
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 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.

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 Optimum distance between the trestles for belt conveyor Optimum truss pattern for belt conveyor Conveyor on jetty Analysis and Design of Cable conveyor

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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.
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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 Designers 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 70

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.S456-1978, Bureau of Indian Standard, New-Delhi.

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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

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