SL.

# DESCRIPTION UNITS BC-1

1 Material -- Coal
2 Min. Capacity TPH 700.00
3 Max. Capacity TPH 700.00
4 Min. Bulk Density KG/M³ 800.00
5 Max. Bulk Density KG/M³ 800.00
6 Belt Width MM 1200
7 Conveyor Hor. Crs. MTS 24.00
8 Lift Due to Conveyor MTS 6.50
9 Lift Due to Tripper MTS 0.00
10 Total Lift MTS 6.5
11 Conv. Inclination Degrees 16.000
12 Troughing Angle Degrees 35
13 Surcharge Angle Degrees 25
14 Max. Section of the Handled Matl. (A) M² 0.1771
15 Material Height MM 264.9
16 Slope Factor (K) -- 0.85
17 Filling Factor (K1) 0.85
18 Required Speed (For Min.Cap) M/Sec 1.8998
19 Required Speed (For Max.Cap) M/Sec 1.8998
20 Max.Required Speed M/Sec 1.8998
21 Provided Speed M/Sec 1.9
22 Material Weight (Mg) Kg/M 102.34
23 Belt Top Cover Thickness MM 5
24 Belt Bottom Cover Thickness MM 2
25 Carcass Weight Kg/m² 5.8
26 Belt Designation -- 500/4
27 Selected Belt Rating KN/M 55
28 Nominal Carcass Thickness mm 5.5
29 Belt Weight (Mb) Kg/M 17.04
30 No. of Carrying Ider Rollers -- 3
31 Carrying Idler Spacing (Si) M 1
32 Carrying Idler Roller Dia MM 139.7
33 Carrying Idler Brg. Dia MM 25
34 Mass of C.I. (Rotating) Parts (Mc) Kg/M 27
35 Return Idler Spacing M 3
36 Return Idler Roller Dia MM 139.7
37 Return Idler Brg. Dia MM 25
38 Mass of R.I. (Rotating) Parts (Mr) Kg/M 8
39 Length Factor (a) -- 1
40 Anti-Friction Co-efficient (f) -- 0.025
TENSION CALCULATION
41 Main Resistance ( R ) N 977.87
42 Slope Resistance (Rsl) N 6525.71
43 Volumetric conveying Capacity (Q) M³/Sec 0.2431
44 Inertial and frictional resistance at the loadng point and N 369.51
45 Acceleration length at loading area (la) M 0.3067
46 Inter skirt plate width (b1) M 0.8
47 Frictional resistance between handled material and the N 147.76
48 Type of Takeup -- SCREW
49 No of Tripper Drive/Discharge Pulley Nos 0
50 No of Tail/Takeup Pulley Nos 1
51 No of Bend Pulley Nos 0
52 No of Snub Pulley Nos 1
53 Wrap resistance between belt and pulley (Rw) N 315
54 Pulley bearing resistance (Rb) N 100
55 Secondary resistances (Rs) =Ra+Rska+Rw+Rb N 932.27
56 Angle of Tilt of the Idler Axis (i) Degrees 0
57 Coeff. depending upon trough angle (Ci) -- 0.5
58 Resistance due to idler tilting (Ri) N 0
59 Length of Skirt Plate (Lsk) M 5
60 No. of Loading Points -- 1
61 Resistance due to friction between handled material N 1204.46
62 Type of Internal Scrapper -- V-Plough
63 No of Internal Scrapper -- 1
64 Thickness of Internal Scrapper mm 10
65 Type of External Scrapper -- SPRINGLOADED
66 No of External Scrapper -- 2
67 No of Blades -- 2
68 Thickness of External Scrapper mm 10
69 No. of Pulley Scrapper -- 0
70 Thickness of Pulley Scrapper mm 0
71 Pressure between belt cleaner and belt (P) N/M² 65000
72 Area of contact between belt and belt cleaner (A1) M² 0.072
73 Frictional resistance due to the belt cleaners (Rbc) N 3042

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 SL.# DESCRIPTION UNITS BC-1
Resistance due to pull of material from hopper = b1² x
74 N 0
A x r x 0.6 x 9.81
75 No. of Plough -- 0
76 Resistance due to plough (Rp) N 0
77 Special resistance (Rsp) = Ri+Rsk+Rbc+Rp N 4246.46
Peripheral force on the driving pulleys without tripper
78 N 12682.31
(TE')
79 No. of Trippers -- 0
80 Tripper Inclination DEG. 0
81 Type of Tripper -- NA
82 Factor b -- 0
83 Peripheral force on the driving pulleys with tripper (TE) N 12682.31
POWER CALCULATION O/P RPM
84 Power required at driving pulley (PDP) kW 24.1
85 Power loss due to drive pulley kW 0.53
86 Absorbed Power (PA) kW 24.63
87 Efficiency of Gear Box -- 0.97
88 Efficiency of I/P Coupling -- 1
89 Motor output power at shaft (PM) kW 25.39
90 Extra % Considered for Motor Selection -- 10
91 Motor Power Reqd with Extra % kW 27.93
92 Motor Speed RPM 1480
93 Ambient Temperature ºC 50
94 Selected Motor Power kW 30
95 Selected Motor Frame Size -- 200M
96 Motor Shaft Dia MM 55
97 GD² Value of Motor Kg-M² 1.16
98 Motor Weight Kg 255
99 Ts/Tn Ratio of Motor -- 2
BELT SELECTION
100 Drive Co-Efficient x -- 2
101 Angle of Wrap Degrees 210
102 Max. Belt Tension under starting condition (Tmax) N 22412.54
103 Max. working Tension on belt KN/M 18.68
104 Actual % tensile force % 33.96
As per Belt Manufacturer Catalogue:
105 Head Pulley Dia Required MM 500
106 Tail/Takeup/B.P Dia Required MM 400
107 Snub Pulley Dia Required MM 323
As Per Tender/Specification
108 Head Pulley Dia Provided mm 508
109 Tail/Take-up/B.P Dia Provided mm 400
110 Snub Pulley Dia Provided mm 323
TENSION VALUES
111 Min. Slack Side Tension (T2) N 9730.23
112 Min. Belt Tension to limit belt sag (Tmin) N 7319.49
113 Min Slack Side Tension Required (T2) N 9730.23
114 Tail Tension (Tt) N 8791.06
115 Final Tail Tension based on Tmin (Tt) N 8791.06
116 Final Slack Side Tension based (T2) N 9730.23
117 Length of Takeup Pulley from Head End M 0
118 Lift of Bend Pulley from Head End M 0
119 Tension at Takeup (Ttu) N 8791.06
120 Counter weight required at take-up Kgs 0
GEAR BOX SELECTION
121 Type of Gear Box Required -- HELICAL
122 Make of Gear Box Considered -- GREAVES
123 Gear Ratio Selected -- 20.9
INPUT COUPLING SELECTION
140 Type of Input Coupling -- TYRE
141 Make of Input Coupling -- FENNER
142 Service Factor Value Considered -- 1.5
OUTPUT COUPLING SELECTION
152 Type of Output Coupling -- GEARED
153 Make of Output Coupling -- FENNER
154 Service Factor Value Considered -- 1.5
HEAD PULLEY SHAFT DESIGN
164 Max. Belt Tension (T1) N 22412.54
165 Max. Slack Side Tension (T2) N 9730.23
166 Weight of Head Pulley (Wp) N 3520.07
167 Conv. Inclination at Head Pulley Degrees 16.00
168 Horizontal Force (Fh) N 30985.52
169 Vertical Force (Fv) N 7343.85
170 Resultant Load on Drive Pulley (R) N 31843.91
171 Pulley Bearing Centres (I) Mts 1.75
172 Arm Length (a) Mts 0.25
173 Bending Moment (Mb) = Rxa/2 N-m 3980.49
174 Torque (Mt) N-m 4045.55
175 Kb Factor Considered -- 2
176 Kt Factor Considered -- 1.5
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 SL.# DESCRIPTION UNITS BC-1
177 Equivalent Torque (Teq) N-m 10010.08
178 Shear Stress N/M² 45000000
179 Allowable Deflection (d) Mts 0.001458
180 Allowable Angular Deflection Minutes 10
181 Shaft Dia at Hub Based on Equivalent Torque (Case-1) MM 104.25
182 Shaft Dia at Hub Based on Linear Deflection (Case-2) MM 99.65
183 Shaft Dia at Bearing Based on Angular Deflection MM 95.44
184 Shaft Dia Selected at Hub MM 110
185 Shaft Dia Selected at Bearing MM 100
186 Shaft Dia Selected at Coupling End MM 90
187 Plummer Block Selected -- SNA-522
188 Bearing Size Selected -- 22222EK
189 Bearing Life Required Hours 30000
190 Bearing Life Calculated Hours 1471498.9
TAIL PULLEY SHAFT DESIGN
191 Tail Tension (Tt) N 8791.06
192 Tail Pulley RPM RPM 89.93
193 Weight of Tail Pulley (Wtp) N 2968
194 Conv. Inclination at Tail Pulley Degrees 16.00
195 Horizontal Force (Fh) N 16901.02
196 Vertical Force (Fv) N -1877.82
197 Resultant Load on Drive Pulley (R) N 17005.02
198 Bending Moment (Mb) = Rxa/2 N-m 2125.63
199 Shaft Dia at Hub Based on Bending Moment (Case-1) MM 78.36
200 Shaft Dia at Hub Based on Linear Deflection (Case-2) MM 85.18
201 Shaft Dia at Bearing Based on Angular Deflection MM 81.59
202 Shaft Dia Selected at Hub MM 100
203 Shaft Dia Selected at Bearing MM 90
204 Plummer Block Selected -- SNA-520
205 Bearing Size Selected (For 222 Series) -- 22220EK
206 Bearing Life Required Hours 30000
207 Bearing Life Calculated (For 222 Series) Hours 14767998.1
208 Bearing Size Selected (For 12 Series) -- N.A
209 Bearing Life Calculated (For 12 Series) Hours N.A
210 Bearing Size Selected (For 22 Series) -- 2220K
211 Bearing Life Calculated (For 22 Series) Hours 63864.7
BEND PULLEY SHAFT DESIGN
212 Tension at Takeup (Ttu) N 8791.06
213 Weight of Bend Pulley (Wbp) N 2968
214 Conv. Inclination at Bend Pulley Degrees 16.00
215 Horizontal Force (Fh) N 8450.51
216 Vertical Force (Fv) N 6913.24
217 Resultant Load on Drive Pulley (R) N 10918.06
218 Bending Moment (Mb) = Rxa/2 N-m 1364.76
219 Shaft Dia at Hub Based on Bending Moment (Case-1) MM 0.00
220 Shaft Dia at Hub Based on Linear Deflection (Case-2) MM 0.00
221 Shaft Dia at Bearing Based on Angular Deflection MM 0.00
222 Shaft Dia Selected at Hub MM #N/A
223 Shaft Dia Selected at Bearing MM #N/A
224 Plummer Block Selected -- #N/A
225 Bearing Size Selected (For 222 Series) -- #N/A
226 Bearing Life Required Hours 30000
227 Bearing Life Calculated (For 222 Series) Hours #N/A
228 Bearing Size Selected (For 12 Series) -- #N/A
229 Bearing Life Calculated (For 12 Series) Hours #N/A
230 Bearing Size Selected (For 22 Series) -- #N/A
231 Bearing Life Calculated (For 22 Series) Hours #N/A
SNUB PULLEY SHAFT DESIGN
232 Max. Slack Side Tension (T2) N 9730.23
233 Snub Pulley RPM RPM 111.4
234 Weight of Snub Pulley (Wsp) N 2393
235 Horizontal Force (Fh) N 0
236 Vertical Force (Fv) N 12123.18
237 Resultant Load on Drive Pulley (R) N 12123.18
238 Bending Moment (Mb) = Rxa/2 N-m 1515.40
239 Shaft Dia at Hub Based on Bending Moment (Case-1) MM 70.00
240 Shaft Dia at Hub Based on Linear Deflection (Case-2) MM 78.27
241 Shaft Dia at Bearing Based on Angular Deflection MM 74.97
242 Shaft Dia Selected at Hub MM 85
243 Shaft Dia Selected at Bearing MM 75
244 Plummer Block Selected -- SNA-517
245 Bearing Size Selected (For 222 Series) -- 22217EK
246 Bearing Life Required Hours 30000
247 Bearing Life Calculated (For 222 Series) Hours 11135978.7
248 Bearing Size Selected (For 12 Series) -- N.A
249 Bearing Life Calculated (For 12 Series) Hours N.A
250 Bearing Size Selected (For 22 Series) -- 2217K
251 Bearing Life Calculated (For 22 Series) Hours 30095.2

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