SARNATH-PROFILE-at LNT

SARNATH

CORPORATE PROFILE

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

BWSR MACHINE

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

FEA Calculation

Structural Analysis

Buckling Analysis

Modal analysis

POST FEA CALCULATION

Fatigue Calculations

Buckling Calculation –Plate and Column

Pin Calculation

Joint calculation

Bearing Calculation

Buffer Calculation

A

B

C

Fixed and Floating Bearings

Base Frame

Boom Structure

Bucket Wheel Assembly.

Slew Drive Assembly

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

Link Type S/R

High Capacity S/R

Nodes:

51290

Elements:

54506

High Capacity S/R

Boom Girder with Rear Luff

cylinder

Tripper Structure

Nodes:

95481

Elements:

93346

Tripper Structure

C Frame Type S/R

Nodes:

91842

Elements:

96432

C Frame Type S/R

Stress Plots

LARSEN & TOUBRO

LTD

MACHINE DESIGN AND

ENGINEERING

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

Adani Mundra Phase II

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

ADANI VIZAG

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

10000TPH BWSR

DEVELOPMENT

Technology provider :

Ashton Bulk UK

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

KHARGONE

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.

Tripper , Elevator and Tail

House

Thank You

SARNATH-PROFILE-at LNT

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