PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 1of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.






























VER 1 2 3 4 5 6
DATE 22-03-12
PPD.BY VEMU
APPD.BY GVKR







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NN B
BBA
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FF B
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CCK
KKE
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TT W
WWH
HHE
EEE
EEL
LL S
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TTA
AAC
CCK
KKE
EER
RR R
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FOR INFORMATION
PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 2of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
INDEX
CONTENTS



1.0 BASIC DATA .................................................................................................................................................................. 3
2.0 ENVIRONMENT, DUTY & DESIGN PARAMETERS .............................................................................................. 3
3.0 APPLICABLE CODES & STANDARDS ..................................................................................................................... 5
4.0 LOAD CASES & COMBINATIONS ........................................................................................................................... 5
4.1 ALLOWABLE STRESSES ............................................................................................................................................ 6
5.0 MATERIAL OF CONSTRUCTION / MATREIAL SPECIFICATION ....................................................................... 6
6.0 MAIN LOADS ................................................................................................................................................................. 7
6.1 DEAD LOADS ................................................................................................................................................................ 7
6.2 MATERIAL LOAD ......................................................................................................................................................... 7
6.3 ADDITIONAL LOADS ................................................................................................................................................ 9
6.4 SPECIAL LOADS ........................................................................................................................................................ 9
7.0 WHEEL LOAD LIMITAIONS .................................................................................................................................... 10
8.0 TRAVELING GEAR ARRANGEMENT ....................................................................................................................... 10
9.0 UNDERCARRIGE ......................................................................................................................................................... 10
10.0 SLEW BEARING ............................................................................................................................................................ 11
11.0 SLEWING ARRANGEMENT ........................................................................................................................................ 11
12.0 LUFFING ARRANGEMENT ......................................................................................................................................... 11
13.0 BOOM CONVEYOR DRIVE ........................................................................................................................................ 11
14.0 BUCKET & BUCKET WHEEL DRIVE ........................................................................................................................ 13
15.0 COUNTER WEIGHT BOOM ...................................................................................................................................... 13
16.0 TRIPPER ......................................................................................................................................................................... 13
17.0 INTERMEDIATE CONVEYOR ................................................................................................................................... 14
18.0 STABLITY ..................................................................................................................................................................... 14



PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 3of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
1.0 BASIC DATA

MATERIAL AND PILE DATA

Material to be handled ............................................... Coal
Bulk density ............................................................... 0.8 t/m
3
for capacity.
1t/m
3
for power calculation
1.2t/m
3
for structural calculation
Lump size (max) ........................................................ 100mm
Angle of repose .......................................................... 37
Moisture ..................................................................... ~12%

DESIGN DATA OF STACKER CUM RECLAIMER

Type ................................................................................. Uni-directional.
Stacking ............................................................................ 4000 TPH (rated) / 4400 TPH (design)
Reclaiming ........................................................................ 2000 TPH (rated) / 2400 TPH (design)
Height of stockpile ............................................................ 16 m
Width of stockpile ............................................................. 45 m
Rail CRS 8 m.
Rail profile CR-80
Wheel Diameter 630mm.
Long travel speed ............................................................. 0-40m/min.(20m/min for operation &
40m/min for traversing)
Boom conveyor length ...................................................... 41000mm
(from pivot to centre line of bucket)
Luffing angle ..................................................................... +8 Deg/-14.5 Deg
Slewing angle ................................................................... 90 Deg (working) / 105 deg (for slew
buffer stopper)
Duty Condition.................................................................. 24 hrs per day 365 days per year

2.0 ENVIRONMENT, DUTY & DESIGN PARAMETERS:

LOCATION

Country .....................................................................India
Region ........................................................................ Jaigarh



PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 4of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
WIND

Ref IS: 875 Part-3
Normal operating Condition:

Basic wind speed for normal operating Condition [Vb] 20 m/s
Risk Coefficient [K1] .................................................1.05
Height & structure size factor [K2] ........................... ref table-1
Topography factor [K3] .............................................1

Restricted condition: (Permitting travel to the parking position)
Basic wind speed for restricted operating Condition [Vb].26 m/s
Risk Coefficient [K1] .................................................1.05
Height & structure size factor [K2] ........................... ref table-1
Topography factor [K3] .............................................1

Strom condition :( Non operating)
Basic wind speed for non operating Condition[Vb]..44 m/s
Risk Coefficient [K1] .................................................. 1.07
Height & structure size factor [K2] ............................ ref table-1
Topography factor [K3] ...............................................1

As per IS: 875 Part-3 the design wind speed [Vz]. Vb x K1 x K2 xK3 [m/s]

Height [m] K2
10 0.98
15 1.02
20 1.05
30 1.10
Table 1


TEMPERATURE
Ambient temperature ................................................. 40C


PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 5of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
3.0 APPLICABLE CODES & STANDARDS

The design and calculation are based on following standards and regulations:

S.NO Description CODES
1 Structures ISO: 5049-1
2 Conveyor calculation IS 11592-2000
3 Idlers IS: 8598,IS 9295
4 Conveyor Belt IS: 1891

4.0 Load cases / Combinations

The, additional and special loads mentioned in clause 3 shall be combined in load cases I, II
and III.

Table 1 - Load combinations
Sub - Type of load
M
a
i
n

l
o
a
d
s

M
a
i
n

a
n
d

a
d
d
i
t
i
o
n
a
l

l
o
a
d
s

Main, additional and special loads
E
r
e
c
t
i
o
n

l
o
a
d

Clause

I II III III III III III III
1)
III III III
1 2 3 4 5 6 7 8 9
3.1.1 Dead Loads X X X X X X X X X X X
3.1.2
Material loads on conveyors, reclaiming
devices and hoppers X X X X X X X X X X
3.1.3 Incrustation X X X X X X X X X X
3.1.4 Normal digging and lateral resistances X X X X
3.1.5 Forces on the conveyor X X X X X X X X X X
3.1.6 Permanent dynamic effects X X X X X X X X X
3.1.7 Loads due to inclination of machine X X X X X X X X X X
3.2.1 Wind load during operation
2)
X X X X X X X X
3.2.2 Snow and ice (possibly)
3.2.3 Temperature (possibly)
3.2.4 Abnormal digging + lateral resistances X
3.2.5 Resistances due to friction and travel X
3.2.6 Reactions perp. to the rail X
3.2.7 Non-permanent dynamic effects X
3.3.1 Blockage of chutes / chutes clogging X
3.3.2 Bucket wheel resting X
PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 6of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
3.3.3 Failure of safety devices X
3.3.4 Locking of travelling devices X
3.3.5
Lateral collision with the slope (bucket
wheel) X
3.3.6 Wind out of operation (perp. / parallel) X X
3.3.7 Buffer effects (Not Applicable) X
3.3.8 Loads due to earthquakes X
3.3.9
Erection loads (dead loads in particular
situations) X

4.1 Allowable stresses[
a]


The
a
for IS: 2062 grade B is specified to be 240 N/mm
The
a
for S 355 J2G3 is specified to be 360 N/mm

Cases Case I Case II Case III
Safety factor* 1,5 1,33 1,2
Allowable stress
IS: 2062 grade B
160 N/mm 180 N/mm 200 N/mm
Allowable stress
S 355 J2G3

240 N/mm 270 N/mm 300 N/mm

*Safety factors are as per ISO 5049-1: 1994 Clause 5.3


5.0 Material of construction / material specification

1. Plate IS: 2062 grade B (E250B)
2. Guy plate S 355 J2G3 St 52/Sailma 350hi
3. Pin 42CrMo4V / EN 19
4. Shaft En 19/ C-45 /42crMo4 V
5. Bucket body IS: 2062 Grade B/ Sailhard
6. Bucket teeth lips Hardox-400.
7. Chute plate IS: 2062 Grade B/ Tiscral
8. Ring Chute liners Stainless steel
9. Transfer chute liners Stainless steel
10. Middle chute liners Stainless steel
11. Wheel 42CrMo4 V



6.0 Main Loads

6.1 Dead Loads:

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 7of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
Dead loads are the load forces of all fixed & movable construction parts always present in
operation of mechanical & electrical were considered as dead loads.

6.2 MATERIAL LOADS:

Material load carried on the conveyor (as per ISO-5049-1:1994 Clause: 3.1.2.1)

Live loads in accordance with the ISO -standards are determined from the design capacity (in
cubic meters per hour) as follows:

6.2.1 Stacking rate:
Static Stacking rate = C/ (Vx3600) x L x (1.2)

C = Stacking Capacity in tph
V = Belt Speed in m/s
L = Boom center to center in m

Dynamic Stacking rate = 1.1 x static stacking rate
6.2.2 Reclaiming rate:
As per ISO-5049-1:1994 Clause 3.1.2.1.2 b units fitted with reclaiming device with automatic
capacity limiter

Reclaiming rate = C/ (Vx3600) x L x (1.2)

C = Reclaiming Capacity in tph
V = Belt Speed in m/s
L = Boom center to center in m

Dynamic load = 1.1 x reclaiming rate

The above material live load calculation procedure is followed for tripper ,intermediate &
belt feeder conveyors.
6.2.3 Loading in the Reclaiming Devices

To take into account the weight of the material to be conveyed in the reclaiming devices, it is
assumed that for bucket wheels one-quarter of all available buckets are 100% full. (As per
ISO 5049-1:1994 Clause: 3.1.2.2)

Loading of reclaiming devices = n x V x / 4

n = Number of buckets
V = Bucket volume in m3
= 1.2 t/m
3
density of material
6.2.4 INCRUSTATION

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 8of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
The degree of incrustation depends on the specific material and the operating conditions
prevailing in each given case. The data which follow shall be taken as guidance. The actual
values can deviate towards either higher or lower values.

Loads due to incrustation on the conveying devices shall be taken into account as 10% of the
material load (as per ISO 5049-1:1994 Clause: 3.1.3 a) calculated as before.


Incrustation during stacking = 0.1 x Static Stacking capacity

Incrustation for Bucket Wheels: (as per ISO 5049-1:1994 Clause: 3.1.3 b)
Loads due to incrustation for bucket wheels shall be taken into account as the weight of a 5
cm thick layer of material on the center of the bucket wheel, considered as a solid disc up to
the cutting circle.
Incrustation during reclaiming = d * Pi * t * y /4

d = Cutting circle diameter in m
= 1.2 t/m
3
Material density
t = Layer thickness: t = 0.05 m

6.2.5 Normal Tangential and lateral Digging Forces

As per ISO 5049-1: 1994 clause 3.1.4


6.2.6 Forces on conveyors (Belt Tensions)

Forces on conveyor & Belt tension shall be calculated as per IS 11592

6.2.6 Loads due to inclination of machine

Calculation of Slope load by considering 1:600 level gradient and it shall be increased to 20%
of level gradient as per ISO: 5049-1 1994 clause 3.1.7

6.2.7 Loads on gangways, stairs & platforms
As per ISO: 5049-1 1994 clause 3.1.8

Stairs ,gangways & platforms shall be constructed to bear 3 KN of concentrated load under
worst conditions & railings & gurads to with stand 0.3 kN of horizontal load.



6.3 Additional Loads:
6.3.1 Wind Loads:

Operating Wind Loads
PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 9of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.

P= A* q*c
P = Operating Wind load in KN
A = Wind area in m
2
Q = Vw
2
/1600 in kN/m
2

V
w
= Wind speed in operation in m/s
C = Aerodynamic coefficient (as per Table 1 of ISO-5049)

6.3.2 Abnormal Tangential and lateral Digging Forces

As per ISO 5049-1: 1994 clause 3.2.4

6.3.3 Resistances due to friction and travel
As per ISO 5049-1:1994 Clause 3.2.5

a) Frictional resistances need only be calculated as long as they influence
the sizes.
The friction coefficients shall be calculated as follows:
- for pivots and ball bearings: = 0,10
s - for structural parts with sliding friction: = 0,25

b) For calculating the resistances to travel, the friction coefficients are as
follows:
- on wheels of rail-mounted machines: = 0,03
- on wheels of crawler-mounted machines: = 0,10
- between crawler and ground: = 0,60


6.4 Special Loads:

6.4.1 Blocked Chute (Chute Clogging)
(As per ISO: 5049-1:1994 clause 3.3.1)

Chute Blockage = V x

V = Transfer Chute + Ring Chute volume m
3

= Material density = 1.2 t/m

6.4.2 Non-Operating Wind loads
P= A* q*c
P = Non Operating Wind load in KN
A = Wind area in m
2
Q = Vw
2
/1600 in kN/m
2

V
w
= Wind speed in non operation in m/s (as per Table 1 of ISO-5049)

6.4.3 Failure of safety devices
PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 10of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.

Load due to failure of safety device = A x L x

A = Maximum cross section area of the boom conveyor belt
L = Boom centre to centre in m
= 1.2 t/m
3
density of material

6.4.4 Lateral Collision

The maximum lateral collosion or lateral resistance is determined by the kinetic energy of the
super structure.

6.4.5 EARTHQUAKE LOADS:

As per JSW specification the horizontal & vertical acceleration taken as 0.49m/s2

7.0 WHEEL LOADS LIMITATIONS

Max. Allowable Vertical : 30/37 Tonnes (operation/Strom)
Wheel load

8.0 TRAVELING GEAR ARRANGEMENT

Rail gauge : 8m

Travel speed : 0-20 m/min

Type of motor : VVVF controlled Gearedmotor

No of Automatic rail clamps : 2 nos

No of Manual rail clamps : 2 nos



9.0 UNDERCARRIAGE:

Type : 3 point 4 corner

Support of Tripper legs : on Traverse


10.0 SLEW BEARING

Make : Rothe erde, Germany

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 11of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
Type (Ring type) : Roller / Ball-Roller combinations


11.0 SLEWING ARRANGEMENT

No of drives : 2 nos

Type of drive : Hydraulic drive

Slewing speed : 0-0.15rpm at tip of Bucket wheel


12.0 LUFFING ARRANGEMENT

Type of Hoist : Hydraulic cylinder

Luffing speed at tip of Bucket wheel : 3 m/min (min)

No of Cylinders : 2 nos.

Type of cylinders : Double acting

Luffing angle : +8 Deg/-14.5 Deg



13.0 BOOM CONVEYOR DRIVE

Design standard : IS 11592

Length of the Boom
(luff centre to bucket wheel centre) : 41 m

Length of boom Conveyor : 43 m (approx)

Belt width : 2000 mm

Trough angle : 45 Deg

Angle of surcharge : 20 Deg

Belt speed : 4 m/s
BELT

Belt type : Steel cord

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 12of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
Rating : ST500

Grade : FR

Top/Bottom covers thickness (mm) : 6/5


IDLER:

No of roller(carrying) : 3 Roll

Dia, Spacing of carrying Idler : 152.4mm X 1.1 m

Dia, Spacing of impact Idler : 190.4 mm X 0.4 m

Dia, Spacing of return Idler : 152.4mm x 3.3 m

Spacing of SAIC Idler : 15 m



PULLEY:

Bearing for drive pulley : Heavy duty roller type

Material for pulley shaft : EN.8 Or Eqv

Deflection at hub limited to : 8 minute


Lagging of drive pulley : 16 thk diamond grooved
rubber Lagging

Lagging of non-drive pulley : 10 thk plain rubber
Lagging

Scrapers

Sprung blade type (primary) :2 nos (one at drive end & one at
tail end)
Torsion arm type ( secondary) :2 nos (one at drive end & one at
tail end)

Internal scraper (D-Plough) :2 nos (one at drive end & one at
tail end)

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 13of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
Belt weigh scale accuracy : + 1 %

No of Drives for boom conveyor : 1 nos

No of Drives for Intermediate conveyor : 1 nos

Motor : TEFC, SCIM

Brake : EHT Brake

Gear box : Helical/Bevel helical type


14.0 BUCKET & BUCKET WHEEL DRIVE

Type of Bucket wheel : Cell less

No of discharges : 55/minute (maximum)

No of Buckets : 9nos

Material of Bucket body : IS: 2062 Grade B/ Sailhard

Cutting lips : Hardox 400/eqvalent

Type of Drive : Hydraulic



15.0 COUNTER WEIGHT BOOM


Type of counter weight : Blocks placed on CW Boom

95% of counter weight material shall be RCC & remaining 5% shall be of MS/CI

16.0 TRIPPER

Maximum inclination : 16 Deg

Wheel Gauge : 8 m

17.0 INTERMEDIATE CONVEYOR

Maximum inclination : 16 Deg

PROJECT NAME JSW -JAIGARH PORT

CLIENT JSW JAIGARH PORT LIMITED

DESCRIPTION DESIGN BASIS OF BWSR

DOCUMENT NO 50055781 VER 1 PAGE: 14of 14




FLSmidth House,
34,Egatoor, Kelambakkam,
Chennai - 603103.
Belt width : 2000m m

Drive ; Electro mechanical.


18.0 STABILITY

Safety factor (stability) against overturning is based in Table-31 as per ISO 5049-1:1994.