1. SARNATH
CORPORATE PROFILE

2. 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

3. 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.

5. Design Process for Stacker,
Reclaimer and Ship Unloader
 Design Basis (ISO, FEM, AS)
 Input Design Document (Design
Specification)
 Preliminary Calculations
 FEA

6. BWSR MACHINE

7. 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

8. Standards
 ISO 5049 & ISO 5048
 FEM Section II
 IS 800
 BS 2573 part 1 & 2
 AS 4324,AS4100, AS 1170
 DIN ISO 281

9. 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

10. FEA Calculation
 Structural Analysis
 Buckling Analysis
 Modal analysis

11. POST FEA CALCULATION
 Fatigue Calculations
 Buckling Calculation –Plate and Column
 Pin Calculation
 Joint calculation
 Bearing Calculation
 Buffer Calculation

12. A
B
C

13. Fixed and Floating Bearings

14. Base Frame

16. Boom Structure

17. Bucket Wheel Assembly.

18. Slew Drive Assembly

19. LOAD CASES & LOAD COMBINATIONS
Load
combinatio
n Ref No
ISO 5049
Load
combinatio
n 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)
STRENG
TH
1.5 YES
Fully
Lowere
d
2 2
2.1 I
NORMAL DIGGING
(A+B1+C1+C3+D+E+I+Fu+
Fs+G+N1)
STRENG
TH
1.5 YES
Horizo
ntal
2 2.1
3 I
NORMAL STACKING
(A+B2+X+D+E+I+G)
STRENG
TH
1.5 YES
Fully
Lowere
d
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+H
4+Ju+Js+K+L+N2)
STRENG
TH
1.333 YES
Fully
Lowere
d
2 4
5.1 II
ABNORMAL DIGGING +
SIDE WIND
(A+B1+C1+C3+D+E+I+G+H
1+Ju+Js+K+L+N2)
STRENG
TH
1.333 YES
Horizo
ntal
2 4.1

20. 6 III/1
BLOCKED CHUTE + TAIL
WIND
(A+B1+M1+C1+D+E+I+Fu+
Fs+G+H4+N3)
STRENG
TH
1.2 YES
Fully
Lowere
d
2 5
7 III/2
BW RESTING + HEAD/TAIL
WIND
(A+B2+X+D+E+I+G+H4+BR
)
STRENG
TH
1.2 YES
Fully
Lowere
d
2 6
8 III/5
BW LATERAL COLLISION
WITH STOCKPILE
(A+B1+C1+D+E+I+Fu+Fs+
G+H1+N1+R+R2)
STRENG
TH
1.2 YES
Horizo
ntal
2 7
9 III/6 TRAVEL TO STORM TIE STRENG 1.2 YES Fully 1 8

21. 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

22. Link Type S/R

23. High Capacity S/R
Nodes:
51290
Elements:
54506

24. High Capacity S/R

25. Boom Girder with Rear Luff
cylinder

26. Tripper Structure
Nodes:
95481
Elements:
93346

27. Tripper Structure

28. C Frame Type S/R
Nodes:
91842
Elements:
96432

29. C Frame Type S/R

30. Stress Plots

31. Stress Plots

32. LARSEN & TOUBRO
LTD
MACHINE DESIGN AND
ENGINEERING

33. 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

34. Adani Mundra Phase II

35. 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

39. ADANI VIZAG

40. 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

41. Achievement
 India’s first C-Frame machine
 The C-Frame Design of Stacker Reclaimer
is realized in Adani Vizag and in Dhamra

45. 10000TPH BWSR
DEVELOPMENT
Technology provider :
Ashton Bulk UK

46.  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

47. 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

52. KHARGONE

53. 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

54. 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.

57. Tripper , Elevator and Tail
House

58. Thank You