conveyor No.

27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA
INPUT DATA :

REV.

Dated 07.12.06

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

EL. 12.0M (RL 35.25 M)

P3
P1
EL. 0.0 (GL 27.0 M)
PRIMARY
SCRAPER

SECONDARY

P2

EXISTING PLANT

SCRAPER

EL. 0.0 (FFL 23.25 M)

EL. (-)6M (RL 21.0 M)

NEW PLANT LEVEL

V PLOW SCRAPERS
P2

473.974 (27A)
476.324 (27B)

PROFILE OF CONVEYORS 27A / 27B

Conveying Capacity (Q)
Belt Width (b)
Horizontal Belt Length c/c of Pulley (L)
Lift (H)
Developed length of belt (L1)
Average angle of Inclination of Belt Conveyor
Percent Slope
Belt Speed (v)
Material
Bulk Density of Material ()
Lump Size of Material (Minus)
Angle of Surcharge
Idler Diameter
Carrying Idler Spacing (Si)
Troughing Angle
Acceleration due to gravity (g)
Nos. of Drive Pulley (P1)
Nos. of Tail/ Take up/ Bend Pulleys (P2)
Nos. of Snub Pulley (P3)
Nos. of Belt Scrapers (Ns)
Conversion Factors
1 Pound
1 Meter
1 Feet
1 inch
Speed 100 Ft/ Min
1 FT3/hr

650
1000
49.000
5.700
49.330
2
3
2.90
Coal
0.8
30
20
152.4
1.0
35
9.807
1
7
1
3

0.4536
3.2808
0.304801
25.4
0.50813
0.028317

Page 1 of 7

TPH
mm
m
m
m
Degrees
%
m/sec
T/m3
mm
Degrees
mm
m
Degrees
m/sec2

Kgs.
Feet
Meters
mm
Mtr/Sec
M3/hr

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA

REV.

Dated 07.12.06

CALCULATIONS :
BELT SPEED CHECK :
CAPACITY AS PER TABLE 4.3 PAGE 53 OF CEMA
Width of 1000 mm wide conveyor belt in inches
Speed - 100 Ft per Minute

5886.0 FT3/hr

Capacity of 39.37 inch (1000 mm) wide belt (By

interpolating 36 inch & 42 inch capacity of table 4.3)
at 0.508 m/sec
Capacity at 1 m/sec
Capacity in M3/ hr
Capacity in TPH ( M3/hr * Density) at 1 m/sec (q)
Capacity required to be conveyed (Q)
Min. Belt speed required (Q/q) v'
Belt speed considered (v)
Filling factor (v' / v)
HENCE BELT SPEED SELECTED IS O.K.

2). Weight Of belt , Wb as per Phoenix Yule catalogue

page 8 & 9 for selected rating of 500/4-HD with Top
cover 5mm and bottom cover 3mm
Carcass unit weight for given rating
Unit weight of rubber per mm of thickness
Belt weight (Wb)= Belt width*(Unit carcass wt.+ (Top
cover thk+ Bottom cover thk)*Unit rubber wt.)
3). Ambient Temp. correction factor from page 89 of CEMA,

PRP. BY: AV
CHD BY: AV
APP BY:
AV

39.37 inch
0.508 m/sec

Capacity of Conveyor (with standard edge

distance) as per table 4.3 for 36 inch belt, 20 deg
surcharge angle at 0.508 mtr. /sec

VALUE OF FACTORS USED IN CALCULATION :

1). Weight Of Material , Wm = Q/(3.6*v)

Document No.
GID-064-CHP1152

7168.2 FT3/hr
14107.02
399.47
319.57
650
2.03
2.90
0.7014

FT3/hr
M3/hr
TPH
TPH
m/sec
m/sec
%

62.26 Kg/m

16.772 Kg/m
3.1 Kg/ m2
1.11 Kg/ m2

1.0

4). Idler Friction Factor, Kx = 0.00068(Wb+Wm)+Ai/Si

Force to overcome Frictional Resistance & Rotate
Idlers(Ai) for 152.4mm (6 inch) idlers as per page 91
of CEMA (5% extra for V type return Idlers)
Kx = 0.00068(22.106+130.72)+(1.575* 0.4536)/1.2

1.575 lbs
= 0.768

5).Factor for Resistance to Flexure of Belt & Load (Ky)

Length of conveyor in feet =(L1* 3.2808)
(Wb+Wm) / (0.4536* 3.2808) in lbs/ feet

Page 2 of 7

161.843 Feet
53.107 lbs/feet

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA

REV.

Dated 07.12.06

Value of Ky for given length, wt. & slopes as per

table 6.2 Page 93

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

0.0250

CALCULATION OF EFFECTIVE TENSION AT

DRIVING PULLEY (Te)
1). Tension due to Idlers Friction, Tx = L1*Kx*Kt

37.89 Kgs

2). Tension due to resistance of Belt to Flexure for carrying

Idlers, Tyc = L1*Ky*Wb*Kt

20.68 Kgs

3). Tension due to resistance of Belt to Flexure for return

Idlers, Tyr = L1*0.015*Wb*Kt

12.41 Kgs

4). Tension due to resistance of Material to Flexure ,

Tym = L1*Ky*Wm

76.78 Kgs

5). Force needed to Lift the Material, Tm = H*Wm

354.89 Kgs

6). Force to accelerate the Material,Tam =

1000*Q*v/(3600*g)

53.39 Kgs

7)Tension due to Belt Scraper resistance (Tbc):Tension due to each scraper (Nsc) = 3 lbs/
inch(considered for half material removal from belt)
as per table 6-6
Tbc= Nsc* Belt Width* No. of Scrapers=Nsc*B*4

0.053575 Kgs/ mm
160.724409 Kgs

8)Tension due to Skirtboard Friction, Tsb = Lb(Cshs2+6)

Length of skirtboard
Skirtboard Friction Factor as per table 6.7

Lb
(Cs)

Depth of Material touching Skirtboard (10% of Belt

width)as per page 101 (hs)
Tsb = Lb(Cshs2+6) = 0.4536(12000/
(25.4*12)*(0.0754*(140/25.4)2+6)

9b(0.8+0.01Tav/b)*(Bt/Dp)

Resistance of each pulley brg, seal etc Tp(2)

Tp(2) =

100 mm
53.342 Kgs

9). Tension due to Pulleys resistance as per Appendix

C page 405, Tp (For non-drive pulleys)
Resistance of belt to flex over each pulley Tp(1)
Tp(1)

5000 mm
0.0754

0.01*(ds/Dp)*R

Page 3 of 7

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA
where
b=width of belt (1400mm)
Bt= Conveyor Belt thickness (6+3+5.2) mm
Dp= Pulley Diameter 658 mm -considering Dia of
drive Pulleys
ds= Pulley shaft Dia 150 mm (assumed)-considering
Dia of drive Pulley

REV.

Dated 07.12.06

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

55.12 inch
0.56 inch
25.90 inch
6.00 inch

Tav = Average tension at pulley as per following:-:For calculating the wrap average Tension all the
tensions calculated above Tav
=(Tx+Tyc+Tyr+Tym+Tm+Tam+Tbc+Tsb) can be
added and divided by factor 0.4536 to get average
tension in lbs
R= Resultant radial load (Vector sum of Average belt
tension (Tav) & pulley weight (Wp))
Weight of pulley assumed (Wb)- considering appx.
wt. of drive pulley
R = ((Tav)2+(Wp)2)1/2

1500 lbs
2265.4958653 lbs

Tp(1) = 9b(0.8+0.01Tav/b)*(Bt/Dp) for Single

pulley
Tp(1) for single. non drive pulley in Kgs.
Tp(1) for 7Nos. non drive pulleys in Kgs.
Tp(2) =

1697.78 lbs

0.01*(ds/Dp)*R for single pulley

11.864586888 lbs
5.3817766125 Kgs
37.67243629 Kgs
5.24825297 lbs

Tp(2) for single non drive pulley in Kgs.

2.3806075472 Kgs

Tp(2) for 7 Nos. non drive pulleys in Kgs.

16.66425283 Kgs

Total pulley resistance for non drive pulleys Tp=Tp(1)

+ Tp(2)
HENCE TOTAL EFFECTIVE TENSION
Te = Tx+Tyc+Tyr+Tym+Tm+Tam+Tbc+Tsb+Tp
MOTOR POWER CALCULATION :
Belt Kw , Pb = Te*v*g/1000 =

54.34 Kgs

824.45 Kgs

23.45 Kw

where Te is effective tension, v is belt speed & g is

acceleration due to gravity
Drive pulley power Pd=N*(Tp(1)+Tp(2))*v*g/1000

Page 4 of 7

0.22 Kw

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA

REV.

Dated 07.12.06

where N is no. of drive pulleys, Tp(1) & Tp(2) pulley

resistance, v is beltspeed & g is acceleration due to
gravity
Add 5% extra for speed reduction loss on Pb&
Pd= 1.05(Pb+Pd)
Power at motor shaft, Pm = Pb+Pd+5% reducer
margin
=
Design margin on motor required as per tender
Motor Power with 20% margin=Pm*1.2
SELECTED MOTORS

BELT TENSION CALCULATIONS:SLACK SIDE TENSION CALCULATION :

Minimum Tension for 2% Sag, To = 6.25*Si(Wb+Wm)
at tail end close to loading point

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

2.60 Kw
26.27 Kw
20 %
31.53 KW
36.00 KW

493.95 Kgs

Slack side Tension T2 as per formula T2=To+(H*Wb)-Tyr

Weight of return belt =H*Wb
95.60 Kgs
Resistance of return belt Tyr= 0.015*L1*Wb*Kt
12.41
Hence T2
577.14 Kgs.
Slack side Tension T2 as per formula T2=Te*Cw
Cw is Wrap factor as per Table 6.8
For Manual (screw take up) for lagged pulley
For automatic takeup Single with snub, 200 Deg & with lagg

For Dual Lagged Pulley

these conveyors are provided with single drive use Cw
T2 = Te*Cw
Taking Higher of the above three Values, T2
TIGHT SIDE TENSION CALCULATION :
Tight Side Tension at Pulley, T1 = Te+T2
BELTING SELECTION :
Maximum operating Tension in Belt,
Tmax = T1/(b)
T1 as calculated above
T1 in KN = T1*g/ 1000
b = belt width in Mtr.
Tmax = T1/(b)
Select Belting from Phoenix Yule Catalogue

Page 5 of 7

0.7
0.42
0.11
0.42
346.27 Kgs
633.64 Kgs

1458.09 Kgs

1458.09
14.30
1.00
14.30
400/3

Kgs
KN/M
Mtr
KN/M
Nylon-Nylon

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA

REV.

Dated 07.12.06

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

Heavy-Duty FR Grade
Recommended Maximum allowable Belt Working Tension
for selected Belting from Phoenix Yule Catalogue (Tall
40 KN/M
Ratio of Max Tension to all tension = Tmax/ Tall

35.7488 %
As this ratio is less than 85 % allowed in NIT selected rating is OK
Max. belt width for satisfactory Load Support consider
the given Belt rating as per Phoenix Yule Catalogue
Minimum Belt Width required for satisfactory Troughin
for selected Belting as per Phoenix Yule Catalogue

1000 mm

500 mm

Hence selected Belt Width OK

MINIMUM PULLEY DIAMETERS REQUIRED AS PER PHOENIX YULE CATALOGUE :
- Drive Pulley Diameter (P1)
315 mm
- Tail/Take Up/ Bend Pulley Diameter (P2)
200 mm
- Snub Pulley Diameter (P3)
250 mm
PULLEYS SELECTED :
- Drive Pulley Diameter + 14 thk Lagging (P1)
508 mm
- Tail/Take Up/ Bend Pulley Diameter+ 10 thk lagging (P2)
520 mm
- Snub Pulley Diameter + 10 thk lagging (P3)
420 mm

GEAR BOX REDUCTION RATIO :

-Drive Motor RPM N
- Drive Pulley RPM, n = v*60000/(*diameter of Drive Pulley)

- Gear Box Reduction Ratio required ,i = N/n

Gear ratio selected
- Final Belt Speed as per Selected Gear Box Reduction Ra
-Gear box KW rating = 1.25 * Motor KW
OUTPUT :
Motor Power Selected
Slack Side Tension (T2)
Tight Side Tension (T1)
Belt Rating Selected
Recommended Maximum Belt Working Tension
Selected Drive Pulley Diameter (P1)
Selected Tail/Take Up/ Bend Pulley Diameter (P2)
Selected Snub Pulley Diameter (P3)
Selected Gear Box Reduction Ratio

Page 6 of 7

1440
109.03
13.21
20.00
1.92
45

36
633.64
1458.09
400/3
40.00
508
520
420
20

rpm
rpm

m/sec
KW

KW
Kgs
Kgs
HD- N/N
KN/M
mm
mm
mm

conveyor No.
27A/27B

Project : Vijayawada Thermal Power

Station, Stage-IV Unit#7 (500 MW)
Subject : Conveyor Design Calculation as
per 5th edition of CEMA

REV.

Dated 07.12.06

Document No.
GID-064-CHP1152

PRP. BY: AV
CHD BY: AV
APP BY:
AV

REVISION-1
REVISED AS PER M/S DESEIN COMMENTS REF NO. 438 DATED 25.09.2006.
ALSO REVISED AS PER REVISED CONVEYOR LAYOUT DUE TO RL DIFFERENCE OF NEW
PLANT & EXISTING PLANT.

REVISION-2
CONVEYOR LENGTH REVISED DUE TO SHIFTING OF JT-11 AS PER REVISED PLOT PLAN NO.
GID-064-CHP-1157 REV 1.
M/S DESEIN COMMENTS REF NO. 559 DATED 10.11.2006. ALSO INCORPORATED.

Page 7 of 7