FIELD OF THE INVENTION
The present invention generally relates to a large spanned single conveyor
gallery structure of a coal handling plant in thermal power plants. More
particularly, the present invention relates to a weight optimized large spanned
single conveyor gallery system for coal handling plant.
BACKGROUND OF THE INVENTION
The single conveyor gallery is one of the important systems in coal handling
plant. The conveyor gallery allows transportation of the material from port to
bunker or storage yard and then to the boiler. The storage yard is normally
located far away from the thermal power station for safety purpose. So, the coal
needs transportation for long distances along conveyor galleries. These galleries
can be of various lengths supported by the trestles and transfer towers where a
conveyor has to change its direction. In general, a single conveyor gallery
comprises one conveyor belt and its supporting arrangements, space for
walkways, provision for fire fighting pipes including potable water pipes, cable
trays, lighting arrangements. The gallery is covered by roof sheeting and side
sheeting to protect the coal from any transmission loss due to wind or rain.
Although the prior art documents CN202080735U and CN202080669U disclose
system having a portal-rigid frame substructure positioned inside a truss main
structure, the primary object of these prior art is to prevent the system from fire
hazards and corrosion effects rather than focusing on optimizing the structural
member and joining process to reduce the weight of the system.
The structural configuration of prior art single conveyor galleries consists of only
standard rolled sections (flat members) and are not optimized from techno
economic consideration. It contains a large number of built-up and heavy

sections. Under-utilization of these heavy material sections increases total weight
of the structure, and presence of built-up sections in the construction increases
welding requirements which in turn extends the fabrication time. Thus, the prior
art fails to address the problems of optimizing a single conveyor gallery system
to ensure maximum utilization of material, reduction in welding requirement,
minimizing the number of built up sections, and reducing the overall weight of
the system.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to propose a weight optimized
large spanned single conveyor gallery system for coal handling plants, which
eliminates the disadvantages of prior art.
Another object of the present invention is to propose a weight optimized large
spanned single conveyor gallery system for coal handling plants, which enables
selection of the constituting structural members including the joining sequence to
produce a system with reduced weight.
A still another object of the invention is to propose a weight optimized large
spanned single conveyor gallery system for coal handling plants, which can
withstand heavy wind load conditions.
A further object of the present invention is to propose a weight optimized large
spanned single conveyor gallery system for coal handling plants, which can
operate at various heights from ground.
A still another object of the present invention is to propose a weight optimized
large spanned single conveyor gallery system for coal handling plants, which
prevents excessive deflection of the system and limit the stresses to an

acceptable safe limits under severe wind load conditions.
SUMMARY OF THE INVENTION
Accordingly there is provided a weight optimized large spanned single conveyor
gallery system for coal handling plants, the system comprises two end portal
frames one each located at a first and a second end of the conveyor gallery and
a plurality of intermediate portal frames each placed in-between the first and
second end at equi-distance spacing.
The present invention is based on a parametric optimization of one such
standard single conveyor gallery. The present invention of single conveyor
gallery structure per se constitutes two end portal frames, plurality of
intermediate portal frames, walkway beams, lattice girders, purlins, side runners,
rafters and bracings. The present invention bridges the gap of optimized design
from conventional design for a single conveyor gallery.
According to the invention, standard pipe sections are introduced in the
proposed design of conveyor galleries. Almost 20% of the structural components
of the gallery are made of pipe sections. Pipe sections are preferred over
standard flat sections because of the following reasons,
i. The force coefficient of circular sections are almost 30% less when
compared to flat sections which results in huge reduction in wind load
acting on the structure.
ii. The load carrying capacity increases because of increase in moment of
inertia.
iii. Circular section may have as much as 30 to 40% less surface area than
that of an equivalent rolled shape and thus reduces the cost of
maintenance, cost of painting.
iv. There is no better section than the tubular one for torsional resistance.

v. Tubes are of special interest from structural to aesthetics view point,
vi. The external surface of the tube does not permit collection of moisture
and dust thus reducing the possibility of corrosion
These portal frames per se constitute a plurality of vertical side members,
several horizontal beams at the top and bottom, and multiple inclined roof
members and stiffeners. Similarly the intermediate frames constitute a plurality
of vertical side members, several horizontal beams at the top and bottom,
multiple inclined roof members (rafters), and a plurality of truss members at top
and bottom. The portal frames and the intermediate frames are connected by
bottom chord members for example, walkway beams, lattice girders and bracings
at the bottom; and top chord members for example, lattice girders and bracings
at the top, side runners at the sides, purlins and roof bracings at the top of the
inclined members.
According to the present invention, the input technical parameters for the
proposed system are processed in a module incorporated in an apparatus. The
values of load acting on the system is further incorporated in the module so as to
optimize the constituent members including development of the forming process
such that the overall weight of the system is reduced, and code provisions
including the stability of the structure is maintained. The system is then used for
fabrication of the structure.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The accompanied drawings describe the invention in detail and illustrate the
features; aspects, and advantages of the present invention. Reference numerals
are used for locating the component of the system. The invention may be readily
understood and carried into practical effect based on the following description
taken the conjunction with the accompanying drawings, wherein:

Figure 1 - shows a side view of a large spanned weight optimized single conveyor
gallery system according to the invention
Figure 2 - shows a front view of a large spanned weight optimized single
conveyor gallery system of Figure-1.
Figure 3 - shows an expanded view of end portal frame (A) of the single
conveyor gallery system of Figure-1.
Figure 4 - shows an expanded view of an intermediate portal frame (B) of the
system of Figure-1.
Figure 5 - shows an enlarged view of a bottom chord member (C) of the system
of Figure-1.
Figure 6 - shows an enlarged view of a top chord member (D) of the system of
Figure-1.
Figure 7 - shows a magnified view of side members (E) of the system, and as
marked in figure-2
Figure 8 - shows a magnified view of roof top members (F) of the system, and
as marked in figure 2.
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiment(s) is merely exemplary in
nature and is in no way intended to limit the invention, its application, or uses.
For purposes of clarity, the same reference numbers will be used in the drawings
to identify similar elements. As used herein, the term module, apparatus refers

to an application specific integrated module (ASIC), an electronic module, a
processor (shared, dedicated, or group) and memory that execute one or more
software or firmware programs, a combinational logic module, and/or other
suitable components that provide the described functionality.
Figure 1 shows the side view of the single conveyor gallery in accordance with a
preferred embodiment of the invention. Two end portal frames (A) which are
placed at the beginning and at the end of the conveyor gallery structure are
connected by a plurality of intermediate frames (B). At the bottom, a plurality of
bottom chord members (C) connects both the end portals frames (A) and the
intermediate portals frames (B) in a longitudinal direction. At the top, the top
chord members (D) connect both the end portal frames (A) and the intermediate
portals frames (B) in the longitudinal direction. At the sides, the side bracing
along with side runners (E) (figure 7) connects the frames on both sides. At the
roof top (F), the purlins and roof bracing connections are shown in figure 8.
According to the invention, the portal frames (A) as shown in figure 3 consists of
a horizontal bottom beam (1) connected to the side vertical of the end portals
(2a and 2b) which is associated with the inclined roof members (3a and 3b). The
horizontal top beam (5), inclined stiffeners at top (4a, 4b) are provided for
additional stability along with the other members. At the bottom of the side
verticals (2a and 2b) of end portals, the supporting members (6) are connected.
More of the sections in the end portal frame (A) are made up of standard I
sections except at some high stress regions, where built-up I sections are
provided.
The intermediate portal frames (B) (see figure 4) are placed at an equi-distance
in between both the end portal frames (A). It consist of a plurality of horizontal
bottom member (7) fastened to the intermediate side vertical (8a and 8b) and at

the top with inclined roof member (rafter) (9a and 9b) and horizontal top
member (11). The inclined roof member (9a and 9b) and the horizontal top
member (11) are linked with a plurality of truss members (10a, 10b, 10c, and
lOd). The inclined roof member and the truss members are made up of pipe
sections. The side verticals (8a and 8b), horizontal top members (11) and
horizontal bottom members (7) are all made up of standard channel sections.
The bottom chord member (C) (see figure 5) consists of a plurality of connecting
members attaching the bottom part of the frames. It consists of lattice girder
(12a, 12b) on both sides. In between, the walkway beams (13a, 13b, 13c, and
13d) are provided to support the walkway floors and the conveyor belt supports.
These are again standard channel sections but of lower size than the lattice
girder. Horizontal bottom beams (7) and lattice girders (12a, 12b) are interlinked
by bottom bracings (14) made up of pipe sections. The top chord member (D)
consists of a plurality of connecting members attaching the top plane of the
frames. The lattice girder (15a, 15b) consists of box sections made up of
standard channel sections. The lattice girders and the horizontal top members
(11) at the top chord are inter-connected by bracings (16) made up of pipe
sections.
At the sides (E) (see figure 7) the side bracings (17a and 17b) are used to
connect the end portals and the first intermediate portal frames. The side
bracings are made up of standard pipe sections. The side runners (18a, 18b, 18c
and 18d) hold the side sheeting and are supported by the portal frames in the
longitudinal direction. These side runners are made up of standard channel
sections.
At the roof top (F) (see figure 8) the purlins (19a, 19b, 19c, 19d, 19e, 19f) are
connected along the longitudinal direction. The purlins are used to hold the roof
sheeting and are supported at the inclined roof level at certain intervals. The roof

bracings (20a, 20b) at the roof top as shown in figure 1, and these bracings are
made up of pipe sections.
In order to account for the high stress levels side bracings (17a, 17b) and
inclined roof member or rafters (9a, 9b) employed at the end of gallery span are
provided with heavier sections than those at the intermediate locations.
For example, a single conveyor gallery at the range of 22 to 26 m span can be
taken to explain the process of this proposed system. The dimensional
parameters that were considered are as follow;


The logic generated takes into account the above parameters and place the
frames at the respective locations and connect accordingly. The members are
grouped according to their function and location and the logic to select the
property is given in such a way that each group has a particular section size.
The parameters considered for load application are as follows



The following table gives a comparison between prior art and weight optimized
single conveyor gallery system of the invention constructed with pipe sections for
a given set of aforementioned parameters.



From the above table it is seen that the structural arrangement with pipe section,
local stiffening arrangement and bracing pattern has lower structural weight and
reduced number of built-up sections, which inter alia reduces the welding
requirements. These make the present invention to be better than the existing
systems.
The inventive system can be used for any material handling plant like coal, steel,
lime etc., because the apparatus and module developed provide data irrespective
of the material being carried by the conveyor system.
While the illustrative embodiments of the disclosure has been described above, it
will be recognized and understood that various modifications can be made to the
embodiments and the appended claims are intended to cover all such
modifications which may fall within the spirit and the scope of the disclosure.

WE CLAIM
1. A weight optimized large spanned single conveyor gallery system for coal
handling plant, comprising:
- at least two end portal frames disposed at each end of the system;
- a plurality of intermediate portal frames connecting the end portal frames;
- a plurality of bottom chord members connecting the intermediate portal
frames and the end portal frames in a longitudinal direction at the bottom
portion of the system;
- a plurality of top chord members connecting the end portal frames and
the intermediate portal frames at the top portion of the system;
- a plurality of roof top members connected along the longitudinal direction;
and
- a plurality of side runners connecting the system at both sides,
wherein the intermediate portal frames are placed at an equi-distance
between both the end portal frames.
2. The system as claimed in claim 1, wherein the end portal frames are
enclosing a roof portion and plurality of side vertical members extending
downwards from the roof portion with a plurality of side stiffeners along
with horizontal bottom and top members with vertical stiffener in-
between, leaving an opening in the middle.
3. The system as claimed in claim 1, wherein the intermediate portal frames
consist of a plurality of frames, with each frame enclosing a roof portion
and plurality of side vertical members extending downwards from roof
portion with a plurality of truss members and horizontal top members,
leaving an opening in the middle.

4. The system as claimed in claim 1, wherein the bottom chord members
comprising a plurality of lattice girders wherein, the lattice girders, end
portal frames, intermediate portal frames, walkway beams are connected
with patterned bracings along the longitudinal direction to form a proper
support system at the bottom plane.
5. The system as claimed in claim 1, wherein the top chord members
comprising a plurality of lattice girders wherein, the lattice girders, the
end portal frame with patterned bracings are connected along the
longitudinal direction to form a proper support system at the top plane.
6. The system as claimed in claim 1, wherein the roof top members
comprising a plurality of purlins and wherein the roof top members, the
end portal frames and intermediate portal frames with patterned bracings
are connected along the longitudinal direction at the top plane of the
roof in order to support the roof sheeting placed on top of it.
7. The system as claimed in claim 1, wherein the side runners, in order to
support the side sheeting, provided with a plurality of side runners
connecting the end portal frames and intermediate portal frames in the
longitudinal direction with the proper bracing pattern at the side planes.
8. The system as claimed in claim 1 or 2, wherein the side verticals consist of
built-up I sections at the specified high stress region including the
supporting member, the rest of the side verticals being made up of
standard I sections.
9. The system as claimed in claim 1 or 2, wherein the horizontal bottom
members made up of standard I sections.

10. The system as claimed in claim 1 or 2, wherein the inclined roof portion
consists of standard I section connected with side stiffener which is made
up of standard I section cut beam.
11. The system as claimed in claim 1 or 2, wherein the horizontal top
members made up of standard channel section connected to side verticals
for more stability.
12. The system as claimed in claim 1 or 3, wherein the horizontal bottom
members consist of plurality of standard channel sections.
13. The system as claimed in claim 1 or 3, wherein the side verticals are made
up of a plurality of standard channel sections.
14. The system as claimed in claim 1 or 3, wherein the roof portion consists of
pipe sections connected by tubular truss members.
15. The system as claimed in claim 1 or 3, wherein the horizontal top beam is
made up of standard channel sections connected to the side verticals.
16. The system as claimed in claim 1 or 4, wherein the lattice girder consists
of built-up channel section connecting the frames in the longitudinal
direction.
17. The system as claimed in claim 1 or 4, wherein the walkway beam is
made up of standard channel section.
18. The system as claimed in claim 1 or 4, wherein the intermediate portal
frames and end portal frames are connected by bracings made of pipe

section.
19. The system as claimed in claim 1 or 5, wherein the lattice girder
connecting the intermediate portal frames and end portal frames are box
section made up of standard channel section.
20. The system as claimed in claim 1 or 5, wherein the intermediate portal
frames and end portal frames are connected by bracings made of pipe
section.
21. The system as claimed in claim 1 or 6, wherein the purlins are connected
on top of the roof members in order to support the roof sheeting and
constitute standard channel sections.
22. The system as claimed in claim 1 or 6, wherein the roof bracings are
connected at particular locations in order to provide stiffness in lateral and
longitudinal directions and constitute standard pipe sections.
23. The system as claimed in claim 1 or 7, wherein the side runners are
standard channel section.
24. The system as claimed in claim 1 or 7, wherein the bracings are
connected in longitudinal direction to provide rigidity in both longitudinal
and vertical directions which constitute standard pipe section.