sarnath-profile-at lnt
TRANSCRIPT
CLIENTS WORKED WITH AT L&T
M/s. ADANI LTD.,
M/s. NTPC
M/s. SAIL INDIA
M/s. M N DASTUR
M/s. BMT WBM AUSTRALIA
M/s. NINE DOT SOUTH AFRICA
MACHINE DESIGN AND
ENGINEERING CAPABILITIES:
STACKER AND RECLAIMER Bucket Wheel Stacker cum Reclaimer
Bucket Wheel Reclaimer
Slewing and Non-Slewing Stacker
Twin Boom Stacker
Tripper, Elevator and Tail house.
Design Process for Stacker,
Reclaimer and Ship Unloader
Design Basis (ISO, FEM, AS)
Input Design Document (Design
Specification)
Preliminary Calculations
FEA
Input Document
BASIC DATAS
ENVIRONMENT, DUTY & DESIGN PARAMETERS
STANDARDS, RULES & LOADS
LOAD CASES / COMBINATIONS
MATERIAL
MECHANICAL PROPERTIES
ALLOWABLE STRESSES
MATERIAL LOADS
LIVE LOADS ON BOOM CONVEYOR
INCRUSTATION (DIRT ACCUMULATION) ON BOOM
BELT TENSIONS
RESISTANCES DUE TO FRICTION AND TRAVEL
WIND LOAD
DEAD LOADS
LIVE LOADS
LATERAL COLLISION
SEISMIC LOAD
Standards
ISO 5049 & ISO 5048
FEM Section II
IS 800
BS 2573 part 1 & 2
AS 4324,AS4100, AS 1170
DIN ISO 281
CALCULATIONS
Slew Bearing Calculation
Wheel and Rail Calculation
Bucket Wheel / Screw Calculation
Drive Calculation (conveyor, Travel, Bucket Wheel, Slew)
Conveyor Calculation
Pin, Shaft, Bearing Calculation
Wheel Load Calculation
Stability Calculation
Cylinder Calculation
Guy and Boom Calculation
Splice Joint Calculation
Weld Calculation
POST FEA CALCULATION
Fatigue Calculations
Buckling Calculation –Plate and Column
Pin Calculation
Joint calculation
Bearing Calculation
Buffer Calculation
LOAD CASES & LOAD COMBINATIONS
Load combinatio
n Ref No
ISO 5049 Load
combination Case
DESCRIPTION OF LOAD COMBINATION
& LOADS
Case type
Stress Factor
FEA Req'd
Luff Angle
Boom Slew Posn
FEA Load Case
1 I DEAD LOADS ONLY
(A+I) STRENG
TH 1.5 YES
Fully Raised
2 1
2 I NORMAL DIGGING
(A+B1+C1+C3+D+E+I+Fu+Fs+G+N1)
STRENGTH
1.5 YES Fully
Lowered
2 2
2.1 I NORMAL DIGGING
(A+B1+C1+C3+D+E+I+Fu+Fs+G+N1)
STRENGTH
1.5 YES Horizo
ntal 2 2.1
3 I NORMAL STACKING (A+B2+X+D+E+I+G)
STRENGTH
1.5 YES Fully
Lowered
2 3
4 I
FATIGUE ANALYSIS (Load Comb'n rf.No.1 - Load Comb'n rf.No.2)
OR (Load Comb'n rf.No.1 - Load Comb'n rf.No.3)
FATIGUE NA NA NA NA NA
5 II
ABNORMAL DIGGING + TAIL WIND
(A+B1+C1+C3+D+E+I+G+H4+Ju+Js+K+L+N2)
STRENGTH
1.333 YES Fully
Lowered
2 4
5.1 II
ABNORMAL DIGGING + SIDE WIND
(A+B1+C1+C3+D+E+I+G+H1+Ju+Js+K+L+N2)
STRENGTH
1.333 YES Horizo
ntal 2 4.1
6 III/1
BLOCKED CHUTE + TAIL WIND
(A+B1+M1+C1+D+E+I+Fu+Fs+G+H4+N3)
STRENGTH
1.2 YES Fully
Lowered
2 5
7 III/2
BW RESTING + HEAD/TAIL WIND
(A+B2+X+D+E+I+G+H4+BR)
STRENGTH
1.2 YES Fully
Lowered
2 6
8 III/5
BW LATERAL COLLISION WITH STOCKPILE
(A+B1+C1+D+E+I+Fu+Fs+G+H1+N1+R+R2)
STRENGTH
1.2 YES Horizo
ntal 2 7
9 III/6 TRAVEL TO STORM TIE STRENG 1.2 YES Fully 1 8
LOAD CASES & LOAD COMBINATIONS
Load combinatio
n Ref No
ISO 5049 Load
combination Case
DESCRIPTION OF LOAD COMBINATION
& LOADS
Case type
Stress Factor
FEA Req'd
Luff Angle
Boom Slew Posn
FEA Load Case
1 I DEAD LOADS ONLY
(A+I) STRENG
TH 1.5 YES
Fully Raised
2 1
2 I NORMAL DIGGING
(A+B1+C1+C3+D+E+I+Fu+Fs+G+N1)
STRENGTH
1.5 YES Fully
Lowered
2 2
2.1 I NORMAL DIGGING
(A+B1+C1+C3+D+E+I+Fu+Fs+G+N1)
STRENGTH
1.5 YES Horizo
ntal 2 2.1
3 I NORMAL STACKING (A+B2+X+D+E+I+G)
STRENGTH
1.5 YES Fully
Lowered
2 3
4 I
FATIGUE ANALYSIS (Load Comb'n rf.No.1 - Load Comb'n rf.No.2)
OR (Load Comb'n rf.No.1 - Load Comb'n rf.No.3)
FATIGUE NA NA NA NA NA
5 II
ABNORMAL DIGGING + TAIL WIND
(A+B1+C1+C3+D+E+I+G+H4+Ju+Js+K+L+N2)
STRENGTH
1.333 YES Fully
Lowered
2 4
5.1 II
ABNORMAL DIGGING + SIDE WIND
(A+B1+C1+C3+D+E+I+G+H1+Ju+Js+K+L+N2)
STRENGTH
1.333 YES Horizo
ntal 2 4.1
6 III/1
BLOCKED CHUTE + TAIL WIND
(A+B1+M1+C1+D+E+I+Fu+Fs+G+H4+N3)
STRENGTH
1.2 YES Fully
Lowered
2 5
7 III/2
BW RESTING + HEAD/TAIL WIND
(A+B2+X+D+E+I+G+H4+BR)
STRENGTH
1.2 YES Fully
Lowered
2 6
8 III/5
BW LATERAL COLLISION WITH STOCKPILE
(A+B1+C1+D+E+I+Fu+Fs+G+H1+N1+R+R2)
STRENGTH
1.2 YES Horizo
ntal 2 7
9 III/6 TRAVEL TO STORM TIE STRENG 1.2 YES Fully 1 8
Machine Configurations
Boom Fully Raised - Slew Position 2 –
35 degrees to Main Track
Boom Fully Lowered - Slew Position 2 – 35 degrees to Main Track
Boom Horizontal - Slew Position 2 – 35 degrees to Main Track
Boom Fully Raised - Slew Position 1 – Zero degrees to Main Track
PROJECT ROLE TEAM SIZE MAN DAYS
ADANI VIZAG DESIGN REVIEW 2 200
ADANI MUNDRA PHASE II PROJECT LEAD 8 800
ADANI PARSAKENTE DESIGN REVIEW 2 100
10,000TPH BWSR DEVELOPMENT
DESIGN REVIEW 2 100
ADANI DHAMRA 45m DESIGN LEAD 8 100
ADANI DHAMRA 51m DESIGN LEAD 8 125
KHARGONE 41m BWR DESIGN LEAD 7 600
KHARGONE 41m BWSR & ELEVATOR, TRIPPER AND TAILHOUSE
DESIGN LEAD 8 900
RECLAIMER DEVELOPEMNT
DESIGN LEAD 3 200
Tech Spec
Material Handled : Coal
Stacking Capacity : 6800 TPH
Reclaiming Capacity: 3500 TPH
Boom Length : 41m
Stock pile : 44m x 15m
No of Wheels : 48+8
Tech Spec
Material Handled : Coal
Stacking Capacity : 3600 TPH
Reclaiming Capacity: 3350 TPH
Boom Length : 51m
Stock pile : 44m x 15m
No of Wheels : 36+10
Achievement India’s first C-Frame machine
The C-Frame Design of Stacker Reclaimer
is realized in Adani Vizag and in Dhamra
MAST CONSTRUCTION : C-FRAME WITH DETACHABLE
TOWED STRUCTURE
BOOM LENGTH : 60 M LATTICE GIRDER
CAPACITY : 10000 TPH STACKING
10000 TPH RECLAIMING
BOOM BELT WIDTH : 2500 MM
BOOM BELT SPEED : 4.7 M/S
BUCKET WHEEL : 11 M CUTTING DIAMETER, 10
NOS. OF BUCKETS EACH OF 3850 LITRE VOLUME
DESIGN STANDARD : AS-4324.1, AS-3990,AS-4100
Scope
Maintain Single point contact with AB
To Review Design of AB as per AS
standards
Codes used : AS4324, AS4100, AS1403,
AS1418, AS1170, BS 2573 1&2, FEM
Sec-II
Check the Loads, Load Cases and all
calculations
Tech Spec
MAST CONSTRUCTION : LINK TYPE
BOOM LENGTH : 41 M
STACKING CAP : 1760 TPH
RECLAIMING CAP : 2000 TPH (PEAK)
BELT SPEED : 3.2 m/s
MATERIAL HANDLED : COAL
Designed as per ISO 5049/1
Reviewed by: NTPC
Achievement
Reduced the weight of the Reclaimer
Machine by 30T, i.e., reduced weight of
structure by 15%.
Reduced Elevator, Tripper and Tail house
weight by 10T.