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

2
3
 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.

4
 Size specification
• Size depends on the requirement :

– Speed
– Cost
– Efficiency
– Maximum load it takes
– Material transferred per hour

5
 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.
6
 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.

7
 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.

8
 CONVEYORS

On Ground Conveyor Above Ground Conveyor

9
 COMPONENTS
Upper Belt
Hopper/Funnel Unloader
idlers
Take up pulley

Drive
pulley
SupportingUnloading
Frame funnel
Side Belt
Elevation cleaner
Lower idlers Drive
motor
Cross
Sections

10
Plan
 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) take-
up which are used
for adjusting tension
in the belt. 12
 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.
13
 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.

14
 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.

15
 ARRANGEMENTS
OF
BELT COVNEYORS
• Double /multi layer system

• Parallel system

• Single system

16
 SINGLE CONVEYOR
DOUBLE LAYER CONVEYOR

PARALLEL CONVEYOR 17
 INDUSTRIAL APPLICATION
• Production
• Mining
• Shipping companies
• Food and beverage companies (with
specializations like fruits and vegetables,
meat, poultry and seafood)
• Automobiles industry

18
 Cont…
• Electronics
• Pharmaceutical and medical
• Printing
• Packaging
• Cement industry

19
20
• 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.

21
• 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.

22
23
• 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 24

25
• 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.

26
• The conveyor systems are designed for:
1. Double layer system
2. Parallel system
• The framing is designed by using following
alternative: -
Sr. No. Columns Beams Framing
1 STEEL STEEL STEEL
2 CONCRETE STEEL COMPOSITE
3 CONCRETE CONCRETE CONCRETE

• Detailing of sample members with connections

27
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.
28
29
 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 =1m
• Spacing of return idlers =3m

30
 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)

31
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

32
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

33
EARTHQUAKE LOAD
• The earthquake load is taken as per IS:
1893-2002 (I).
• Location – Dahej (bharuch)
• zone - III

34
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.

35
 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

36
• 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

37
 LOADING
SHORT SUPPORTS

BELT

4.55 m

TRUSS
38
 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

39
 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

40
 STAAD MODEL
SINGLE CONVEYOR

3-D VIEW

SECTION
ELEVATION 41
 STAAD MODEL
STEEL DOUBLE CONVEYOR

ELEVATION

PLAN

Cross
section
42
3-D VIEW
CONCRETE DOUBLE CONVEYOR

ELEVATION

PLAN

43
3-D VIEW
COMPOSITE DOUBLE CONVEYOR

ELEVATION

PLAN

44
3-D VIEW
 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

45
STEEL PARALLEL CONVEYOR

ELEVATION

PLAN

Cross46
section
3-D VIEW
CONCRETE PARALLEL CONVEYOR

ELEVATION

PLAN

47
3-D VIEW
COMPOSITE PARALLEL GALLERY

ELEVATION

PLAN

3-D VIEW 48
 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

Steel Composite Concrete

50.00

40.00
Disp. (mm)

30.00

20.00

10.00

0.00
Steel Composite Concrete
Type of Material

49
 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.

50
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) 51
are designed to be fully rigid
Cont…
• The different steel frame
connections are
– Simple connection
– Moment Resisting
connection
• The one of loading of
parallel steel gallery is
shown below, Simple connection
• P= 25.1 kN
• M= 57.1 kN
• Beam = ISMB 450
• Column = ISMB 500

52
Moment resisting connection
 Cont…
• The design results are as 12 mm 6 mm fillet weld
follows, clearence

• Provided top plate =

130 mm x 6 mm 450
(6 mm fillet weld) ISMB 500 ISMB 450
Beam
• Design bottom seat plate Column
=
170 mm x 77 mm x 6 mm Bottom plate

(6 mm fillet weld) Elevation

100 70

130

Plan from Top

53
 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.
54
Thk. of strata Description of strata Notation Capacity of soil

(m) (T)

0-2 Dark brown med. Dense SP-SM 20

fine sand
2-3 Dark brown dense fine SM 20
silty sand
3-5 Dark grey stiff med. CI 20
plastic silt and clay

5-7 Dark grey med. Dense fine SM 30

silty sand
7-8 Dark grey very stiff sandy CL 30
clayey silt
8-12 Dark grey very stiff med. CI 40
Plastic silt and clay
12-15 Brown very stiff plastic CH 40
silt and clay
15-19 Brown very stiff med. CI 60
Plastic silt and clay
19-21 Brown very stiff plastic CH 80
silt and clay
55
 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,
P+W Mx My n
F= ± ± n
n I y I x
56
Cont…
F1 = 290.14 kN
F2 = 475.42 kN
F3 = 12.23 kN
F4 = 197.51 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 57
58
• The Conveyor Gallery is
analyzed for the assumed C O M P A R IS O N O F H O R IZ O N T A L L O A D
sectional property and it is
checked for the design in O F E Q A N D W IN D L O A D
STAAD-Pro. 800
D L + 0 .5 L L + E Q Z
D .L + L .L + W .L
600

• The wind load combination

LOAD (kN)
400
is governing than 200
earthquake load. 0
244 46 45 60 537
BEAM NOS.
• The DL+ LL combinations
give governing result with
compared to DL+LL+WL.

RESULTS FOR
PARALLEL STEEL 59
CONVEYORS
• 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.

60
 Option kN Rate (Rs. In lakhs)

1 37.43 1.50
2 39.76 1.59
1 2
1 .6 0
40.00
39.50
1 .5 5
39.00
Rs. in lakhs

38.50
1 .5 0

Wt. (kN)
38.00
37.50
1 .4 5 37.00
36.50
1 2
36.00
T r u s s o p ti o n 1 2
P r o file T y p e

Cost comparison Wt. comparison 61

 WEIGHT COMPARISON OF GALLERIES
Steel Galleries
•

Type (steel) kN
Double 1174.51
Parallel 796.35

62
• Concrete Galleries

Type (conc.) Conc. (m3) Steel (kN)

Double 342.79 211.08
Parallel 253.74 153.70

Concrete Steel

600.00

500.00

400.00
wt. (kN)

300.00

200.00

100.00

0.00
1 2
Concrete conveyor gallery

63
• Composite Galleries
Type (comp.) conc. (m3) steel (kN)
(Reinf + members)
Double 94.00 869.00
Parallel 58.00 709.00
concrete steel
1200.00

1000.00

800.00
wt. (kN)

600.00

400.00

200.00

0.00
Double Parallel

Composite conveyor gallery

64
 COST COMPARISON
Rate of steel = Rs. 40/ kg Rate of Concrete = Rs. 3500/ m3
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
Double Parallel

50.00
Rs. in Lakhs

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

65
• 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.

66
67
• Optimum distance between the trestles for
belt conveyor

• Optimum truss pattern for belt conveyor

• Conveyor on jetty

• Analysis and Design of Cable conveyor

68
 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. 69
• 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

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.S-456-
1978”, Bureau of Indian Standard, New-Delhi.

71
 LIST OF WEBSITES
• www.conveyorchain.com
www.kamandirect.com •www.inventorypos.com
•
www.hasler-int.com •www.conceptengineer.com
•
•www.hic-india.com
• www.bandt.com
•www.ise.ncsu.edu
• www.tranterphe.com
•www.martin-eng.com
• www.cemanet.org
•www.interroll.com
• www.kwsmfg.com
•www.pro-belt.com
• www.armax-conveyors.co.uk
•www.interquip.com.au
• www.patentstorm.com
•www.ingenieriatecnica.cl

72