36.M111 Potasium Sulphate BW 750,1.67 m s

8/10/2019 36.M111 Potasium Sulphate BW 750,1.67 m s

1/27

Conveyor Design Summary17 Oct 2014 11:16 1/27Page

PT.PETROKIMIA GRESIK

Helix Technologies Pty Ltd

Project

Project No.

Conveyor No.

Client

Prepared By

Design Date

Sistem Reaktor 36.R-101

36.M111, 1.67 m/s

JSA

Material Description POTASSIUM SULPHATE

Conveyed Material

High Bulk Density 1040

1040Low Bulk Density kg/m3

kg/m3

Angle of Repose 46

30Surcharge Angle deg

deg

Material Lump size 3 mm

Conveyor Data

Nett Lift / Lower (-) 0.00

21.83Conveying Distance m

m

Design Capacity 1.4 tonnes/hr

Belt Speed 1.67 m/s

Belt Details

Belt Class & Run Safety Factor PN800/4

750Belt Width Selected mm Calculated Belt % Full 0.3 %

Top Cover Thickness 8 mm

Belt Total Length 52.7

90Belt Rated Tension kN/m

m

Bottom Cover Thickness 6 mm

Belt Mass 16.96 kg/m

Belt Tensions and Power Calculations CEMA

Maximum Tension Tmax 41.60

3.64Effective Tens. Fully Loaded kN Belt Power - Empty Belt 6.07 kW

Belt Power - Inclines Loaded 6.07 kW

Sag Tension 1.4

38.18Minimum Tension Tmin kN

kN

Belt Power - Declines Loaded 6.07 kW

Belt Power - Fully Loaded 6.07 kW1.5 %

kN

Takeup Type Fixed Centres

Takeup Mass 8100 kg Absorbed Power Fully Loaded 6.40 kW

Installed Motor Power 11 kW

Drive Efficiency 95.0 %

Carry and Return Idlers

Carry Idler Spacing 130Carry Idler Trough Angle 0

3 m

3 x 152Carry Idler No Rolls x Dia mm 1 x 152 mm

Return Idler SpacingReturn Idler Trough Angle

Return Idler No Rolls x Dia

m

Dynamics and Miscellaneous Data

Startup Factor - Empty 140

140Startup Factor - Fully Loaded 1.00

22.00 kNm

0.74Starting Time - Fully Loaded sec 0.06 sec

Total Braking Torque LSS

CEMA Temperature Factor Kt

Stop Time - Loaded, Braking

0.74Starting Time - Empty sec 1.08 secStop Time - Loaded, Coasting

%

%

Takeup Pulley Belt Tension 39.72 kN

14.42

Designers Comments

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering


2/27

Conveyor Sections - Input Data17 Oct 2014 11:16 2/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

FrictionFactorInputDescription

No. ofScrapers

SkirtLength

m

IdlerSpacing

m

Cap-acitytph

Y co-ord m

X co-ord mStation

SectionLiftm

SectionLength

m

Station / Sectio

Z co-ord m

TenAdj.kN

1 0.00 0.003.60 0.00 0 0.50Takeup 0.00000.00

2 3.60 0.001.40 0.00 1.4 0.35Hopper 2.00 0.00000.25 1.00

3 5.00 0.007.00 0.00 1.4 1.50Int. Pt 0.00000.25

4 12.00 0.002.00 0.00 1.4 1.50Hopper 2.00 0.00000.25 1.00

5 14.00 0.0011.43 0.00 1.4 2.00Int. Pt 0.00000.25

6 25.43 0.0025.43 0.13 0 2.00Drive 3 0.0000-0.07

Totals: 50.85 2.00 4.00 30.13

Designers Comments



3/27

Takeup & Drive Traction Calculation17 Oct 2014 11:16 3/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

%140 Takeup Mass 8100 kg

Takeup Pulley Belt Tension 39.72 kN

Running

DriveNumber

FullyLoaded

EmptyBelt

Starting Braking

FullyLoaded

EmptyBelt

FullyLoaded

EmptyBelt

1Drive No. Drive

Wrap Angle 180

Co-efficient of Friction 0.35

Drive Factor Cw

Calculated Belt Tension T1 kNCalculated Belt Tension T2

Minimum Required T2

Surplus T2 Tension (T1-T2)

0.499

kN

kN

kN

1.71

41.638.18

36.47

Lagging Type

180

0.35

0.499

1.71

41.638.18

36.47

Rubber

180

0.45

0.321

2.22

43.4536.53

34.31

180

0.45

0.321

2.22

43.4436.53

34.31

Rubber

180

0.45

0.321

13.8

16.9359.93

3.13

Rubber

180

0.45

0.321

13.79

1759.96

3.21

Pulley No. 6

Designers Comments



4/27

Tension Calculations - Summary Run / Start17 Oct 2014 11:16 4/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

140 % Takeup Mass 8100 kg

Running

StationNo

FullyLoadedTension

kN

EmptyTension

kN

InclinesLoadedTension

kN

DeclinesLoadedTension

kN

Starting

FullyLoadedTension

kN

EmptyTension

kN

Braking

EmptyTension

kN

FullyLoadedTension

kN

Coasting

FullyLoadedTension

kN

EmptyTension

kN

1 39.16 39.1639.16 39.16Takeup 39.40 39.4044.81 44.7938.74 38.74

2 39.43 39.4339.43 39.43Hopper 39.09 39.0933.84 33.8039.85 39.85

3 40.46 40.4640.46 40.46Int. Pt 39.99 39.9932.20 32.1641.08 41.08

4 40.51 40.5140.51 40.51Hopper 39.73 39.7326.20 26.1941.59 41.59

5 41.53 41.5341.53 41.53Int. Pt 40.67 40.6725.69 25.7042.72 42.716 41.60 41.6041.60 41.60Drive 40.28 40.2916.93 17.0043.45 43.44

Minimum Ten 39.16

Maximum Ten

Effective Ten

39.16 39.16 39.16 38.7438.74 17.0016.93 39.0939.09

41.60 41.60 41.60 41.60 43.45 43.44 44.81 44.79 40.67 40.67

39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72

3.64 3.63 3.64 3.64

Ave. Belt Ten

Belt Elong. m

T/up Travel m

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Designers Comments



5/27

Belt Details Report17 Oct 2014 11:16 5/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Low BD = 1040kg/m3 High BD = 1040kg/m3

kNBelt Rated Tension for width 67.5

Belt Reinforcement Fibre Fabric

PN800/4

Apex PN 200 StandardBelt Description

Apex PN Fabric - SplicedBelt Category

Belt Make & Class

Belt Dimensions

Belt Speed & CapacityConveyed Material

Carry Idler Trough Angle 30

kNMinimum Tension Tmin 38.18

kNAllowable Belt Tension, Starting 94.5

kg/m17Belt Mass Wb (per linear m)

mm6Bottom Cover Thickness

m

kN/mBelt Rated Tension / m width 90

52.7Belt Total Belt Length (L)

mm8Top Cover Thickness

mmBelt Width Selected 750

4Belt Class / Plies

m/s1.67Belt Speed

tonnes/hr1.4Belt Design Capacity Input

mm3Material Lump size

deg

degSurcharge Angle 30

46Angle of Repose

kg/m3

kg/m3Low Bulk Density 1040

1040High Bulk Density

POTASSIUM SULPHATEMaterial Description

Belt Tensions

kN/mCalculated Tension / m width 55.5

Calculated Max Run Tension 41.60 kN

mm5.3Belt Carcass Thickness

mm19.3Belt Total Thickness

sec31.6Time for 1 Revolution

Actual Belt Tension, Starting 59.96

Allowable Tension Rise, Starting 140 %

kN

Belt Modulus 9200 kN/m

Belt and Material Mass

kg/m6.8Belt Top Cover Mass

kg/m5.1Belt Bottom Cover Mass

kg/m5.1Belt Carcass Mass

kg/m0.2Material Mass Wm

kg/m17.2Total Mass (Wb + Wm)

Flooded Belt Material Mass 103.4 kg/m

tonnes/hr621Flooded Belt Capacity

kg894Total Belt Mass (Wb x L)

Belt Load Area and Capacity at 1040kg/m3

m20.0664Belt Load Area at MinimumRecommended Edge Distance

m20.0994Flooded Belt Load Area at ZeroEdge Distance

mm64Minimum Rec. Edge Distance

mm267Actual Edge Distance Low BD

mm35Load Burden Depthmm227Load Burden Width

Belt Actual % Full at Low BD %0.3

Belt Load Area Utilised at LowBulk Density 0.0002 m2

Belt Load Area Utilised at HighBulk Density 0.0002 m2

mm267Actual Edge Distance High BD

Belt Load Area and Capacity at 1040kg/m3

Minimum Rec. Edge Distance 64 mm

Belt Actual % Full at High BD 0.3 %

Flooded Belt Capacity at 1040kg/m3

tonnes/hr1.4Section Loading Max Capacity

Designers Comments



6/27

Tension Calculations - Summary Belt Sag17 Oct 2014 11:16 6/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Allowable Belt Sag % Running

Allowable Belt Sag % Start / Stop

1.5 %

%5 Takeup Mass 8100 kg

Running

StationNo

FullyLoadedTension

kN

EmptyTension

kN

InclinesLoadedTension

kN

DeclinesLoadedTension

kN

Starting

FullyLoadedTension

kN

EmptyTension

kN

Braking

EmptyTension

kN

FullyLoadedTension

kN

Coasting

FullyLoadedTension

kN

EmptyTension

kN

1 39.16 39.1639.16 39.16Takeup 39.40 39.4044.81 44.7938.74 38.74

Belt Sag % 0.03

Idler Spacing m 0.50

0.03 0.03 0.03 0.03 0.03 0.02 0.02 0.03 0.03

2 39.43 39.4339.43 39.43Hopper 39.09 39.0933.84 33.8039.85 39.85

Belt Sag % 0.02


0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02

3 40.46 40.4640.46 40.46Int. Pt 39.99 39.9932.20 32.1641.08 41.08

Belt Sag % 0.08


0.08 0.08 0.08 0.08 0.08 0.1 0.1 0.08 0.08

4 40.51 40.5140.51 40.51Hopper 39.73 39.7326.20 26.1941.59 41.59

Belt Sag % 0.08


0.08 0.08 0.08 0.08 0.07 0.12 0.12 0.08 0.08

5 41.53 41.5341.53 41.53Int. Pt 40.67 40.6725.69 25.7042.72 42.71

Belt Sag % 0.1


0.1 0.1 0.1 0.1 0.1 0.16 0.16 0.1 0.1

6 41.60 41.6041.60 41.60Drive 40.28 40.2916.93 17.0043.45 43.44

Belt Sag % 0.1


0.1 0.1 0.1 0.1 0.1 0.25 0.24 0.1 0.1

Minimum Ten 39.16

Maximum Sag

39.16 39.16 39.16 38.7438.74 17.0016.93 39.0939.09

0.1 0.1 0.1 0.1 0.1 0.1 0.25 0.24 0.1 0.1

Designers Comments



7/27

Tension Calculations - Run Fully Loaded17 Oct 2014 11:16 7/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Takeup Mass 8100 kg

FrictionFactor

SectionEffectiveTension

ScraperFriction

kN

SkirtFriction

kN

TensionsMaterialAccel.

kNDriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / PulleyTp

Pulley

TenAdj.kN

CEMA

1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22

2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00

3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161

4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00

5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016

6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22

Totals: 0.43 3.4 2.00 0.00 0.00 0.89 0.31

Maximum Tension

Minimum Tension

41.6

38.18

kN

kN

Average Tension Fully Loaded 39.72 kN

Average Tension Belt Stationary 39.72 kN

Average Tension Difference 0 kN

Total Effective Tension

Total Belt Power (Te x V)

Belt Modulus

Total Belt Length

Belt Elastic Elongation

3.64

6.07

9200

52.70

0 m

m

kN/m

kW

kN

Takeup Movement 0 m

Designers Comments



8/27

Tension Calculations - Run Empty17 Oct 2014 11:16 8/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

FrictionFactor


ScraperFriction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22

2 39.43 39.431.40 0.00Hopper 0.03 0.0161.00

3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161

4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00

5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016

6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22

Totals: 0.44 3.42 2.00 0.89 0.31

Maximum TensionMinimum Tension

41.638.18

kNkN

Average Tension Fully Loaded 39.72 kN



Total Effective TensionTotal Belt Power (Te x V)

Belt Modulus

Total Belt Length


3.636.07

9200

52.70

0 m

m

kN/m

kWkN

Takeup Movement 0 m

Designers Comments



9/27

Tension Calculations - Run Inclines Loaded17 Oct 2014 11:16 9/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

FrictionFactor


ScraperFriction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22

2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00

3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161

4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00

5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016

6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22

Totals: 0.43 3.42 2.00 0.00 0.00 0.89 0.31


41.638.18

kNkN

Average Tension Inclines Loaded 39.72 kN




Belt Modulus

Total Belt Length


3.646.07

9200

52.70

0 m

m

kN/m

kWkN

Takeup Movement 0 m

Designers Comments



10/27

Tension Calculations - Run Declines Loaded17 Oct 2014 11:16 10/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

FrictionFactor


ScraperFriction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22

2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00

3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161

4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00

5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016

6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22

Totals: 0.43 3.4 2.00 0.00 0.00 0.89 0.31


41.638.18

kNkN

Average Tension Declines Loaded 39.72 kN




Belt Modulus

Total Belt Length


3.646.07

9200

52.70

0 m

m

kN/m

kWkN

Takeup Movement 0 m

Designers Comments



11/27

Conveyor Starting and Stopping17 Oct 2014 11:16 11/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Mass of BeltSystem Masses

Carry Idler Equivalent Mass 373

5Mass of Material kg

kg

Input Data

Pulley Equivalent Mass 524

179Return Idler Equivalent Mass kg

kg

Belt Rated Tension

Belt Speed 1.67 m/s

Total Braking Force 67.28

3.63Effective Tension Empty kN

5.31

Tension Available to Accelerate Conveyor

kN

kN

894 kg

Total System Equivalent Mass 2,358

383Drive Equivalent Mass kg

kg

90 kN/m

Drive Inertia

Allow. Belt Start Tension Rise 140 %

0.0467 kg-m2

Start-up Factor - Loaded

Total Braking Torque 22 kNm

140

Start-up Factor - Empty 140

Drive Efficiency (Average)

Installed Power 11 kW

95

%

%

%Tensions and Accelerating Forces

Stopping Times & Deceleration Rates

Effective Tens. Fully Loaded 3.64 kN

5.31Accelerating Tension - Empty kN

Starting Times & Acceleration Rates

Acceleration Rate - Loaded 2.25

0.74Starting Time - Empty sec

2.26Accelerating Rate - Empty m/s2

m/s2

Starting Time - Fully Loaded 0.74 sec

Belt Tension Rise Starting / Braking

Maximum Belt Tension / width 79.95750Belt Width mm

90Belt Rated Tension / width kN/m

kN/m

Max Belt Tension, Start/Brake 59.96 kN

88.8Actual Max Tension, Start/Brake %

1.08Stopping Time Loaded Coasting secStopping Time Loaded Braking 0.06 sec

1.08Stopping Time Empty Coasting sec

Stopping Time Empty Braking 0.06 sec

-1.54Deceleration - Loaded Coasting m/s2

Deceleration - Loaded Braking -30.07 m/s2

-1.54Deceleration - Empty Coasting m/s2

Deceleration - Empty Braking -30.14 m/s2

Stopping Distances & Discharge Volumes

Stopping Distance Loaded Coasting m

Stopping Distance Loaded Braking m

Stopping Distance Empty Coasting mStopping Distance Empty Braking m

Discharge Mass, Coasting kg

Discharge Mass, Braking kg

Discharge Volume, Coasting m3

Discharge Volume, Braking m3

0.05

0.9

0.050.9

0

0

0

0

Accelerating Tension - Loaded

Designers Comments



12/27

Conveyor Idler Details Report17 Oct 2014 11:16 12/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Idler Category Sandvik Carry

Idler Design Belt Width 750

Series 20 3 Roll Carry 152 PlainInline

Idler Description

mm

Drawing Number

20Idler Series

Total Number of Idlers 23

1Nominal Idler Spacing m

Troughing Angle 30.0

0Idler Price

deg

Idler Bearing Diameter 25.0

27.0Idler Shaft Diameter mm

Idler Roll Diameter 152

3Number of Idler Rolls

mm

mm

Idler Rotation Speed 210

Roll Face Width 283 mm

307Shaft Support Centres

1000Idler Support Fixing Width mm

Idlerset Total Mass 31.7

16.2Idlerset Rotating Mass

3.0Idler Vertical Misalignment Allowance mm1.04Dynamic Load Factor

mm

kg

kg

Roll Bearing Centres 226.8 mm

Carry Side Idlers Return Side Idlers

500Belt Deviation Load N

728Total Load on Centre Roll N

BallType of Bearing

6205Bearing Designation

14,000Bearing Dynamic Load Rating C N

4,525,995Bearing L10h Life hrs

8.00Allowable Shaft Deflection at Bearing min

1.04Actual Shaft Deflection at Bearing min

rpm

Sandvik Flat Carry

750

Series 30 1 Roll Flat Carry152 Dia

mm

30

13

3 m

0.0

0

deg

25.0

30.0 mm

152

1

mm

mm

210

849 mm

873

1000 mm

23.1

13.8

56.3 mm1.40

mm

kg

kg

785.4 mm

1,501 N

2,446 N

Ball

6305

22,500 N

494,760 hrs

10.00 min

8.66 min

rpm

Designers Comments



13/27

Vertical Curve Radius Calculations17 Oct 2014 11:16 13/27Page

PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd

Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

17 Oct 2014 11:16 Vertical Curve Radius Calculations Page 13/27

Belt Mass - New Belt 16.96 kg/m

Top Cover Mass - New Belt 6.78 kg/m

Bottom Cover Mass 5.08 kg/m

Worn Belt Mass 12.72 kg/m

Reduction of Top Cover Mass 62.5 %

Conveyed Material Mass 0.23 kg/m

% Belt Mass for Lift-off Calculation 75 %

Curve Tension Safety Factor 1

Average Drive Torque Start-up Factor - Loaded 140 %

Average Drive Torque Start-up Factor - Empty 140 %

Allowable Edge Tension - Running: 140 %


Belt Rated Tension 67.5 kN

Belt Width 750 mm

90 kN/m

115% Starting

CurveType

Fully Loaded

Running

Station

DesignVertical

CurveRadius

LoadCapacity

Station / Sectio

Empty

tonnes/hr m

Tension Radius

kN m

Radius

m

Tension

kN

Starting

Fully LoadedRadius

mkN

TensionEmpty

Tension Radius

mkN

Braking

Fully LoadedRadius

mkN

TensionEmpty

Tension Radius

mkN

Largest

Reqd.Radius

m

1 39.16Takeup 39.16 38.74 38.74 44.81 44.79

2 39.431Hopper 39.43 39.85 39.85 33.84 33.8

3 40.461Int. Pt 40.46 41.08 41.08 32.2 32.16



14/27

17 Oct 2014 11:16 Vertical Curve Radius Calculations Page 14/27

Belt Mass - New Belt 16.96 kg/m

Top Cover Mass - New Belt 6.78 kg/m

Bottom Cover Mass 5.08 kg/m

Worn Belt Mass 12.72 kg/m

Reduction of Top Cover Mass 62.5 %

Conveyed Material Mass 0.23 kg/m

% Belt Mass for Lift-off Calculation 75 %

Curve Tension Safety Factor 1

Average Drive Torque Start-up Factor - Loaded 140 %

Average Drive Torque Start-up Factor - Empty 140 %

Allowable Edge Tension - Running: 140 %


Belt Rated Tension 67.5 kN

Belt Width 750 mm

90 kN/m

115% Starting

CurveType

Fully Loaded

Running

Station

DesignVerticalCurveRadius

LoadCapacity

Station / Sectio

Empty

tonnes/hr m

Tension Radius

kN m

Radius

m

Tension

kN

Starting

Fully Loaded

Radius

mkN

Tension

Empty

Tension Radius

mkN

Braking

Fully Loaded

Radius

mkN

Tension

Empty

Tension Radius

mkN

LargestReqd.Radius

m

4 40.511Hopper 40.51 41.59 41.59 26.2 26.19

5 41.531Int. Pt 41.53 42.72 42.71 25.69 25.7

6 41.6Drive 41.6 43.45 43.44 16.93 17.0

Designers Comments



15/27

Viscoelastic Friction Factor Report17 Oct 2014 11:16 15/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

deg0.1Idlerset Forward Tilt angle

N/mm2

deg C

Belt has Turnover on Return Run

deg

N

mm

N

mm

N

mm

N

mm

0.1

2

152

2

152

2

152

152

2

Idlerset Skew Angle

Return Idler Wing Roll Drag

Return Idler Wing Roll Dia

Return Idler Centre Roll Drag

Return Idler Centre Roll Dia

Carry Idler Wing Roll Drag

Carry Idler Wing Roll Dia

Carry Idler Centre Roll Drag

Carry Idler Centre Roll Dia

1

30

0.13

6

deg C30

0.13

N/mm2

Rubber description ...

6

Belt Bottom Cover Temperature

Belt & Material Flexure Adjustment factor

Bottom Cover Dynamic Modulus E'

Bot Cover Dynamic Loss Factor Tan(delta)

Top Cover Dynamic Loss Factor Tan(delta)

Belt Top Cover Temperature

Top Cover Dynamic Modulus E'

Belt Rubber Description

Rolling Resistance Factor 0.072 0.072 RRF Bot.RRF Top

Viscoelastic Calculations Input Data

EmptyFrictionfactor f

SectionLength

Tiltfriction

%

Tiltfriction

ft

Dragfactor

%

Flexurefriction

%

Frequencyrad/s

Indentfactor

%No

Indentfactor

fi

TotalLoadedFrictionfactor f

Station / Section

Flexurefriction

fm

Dragfactor

fr

IdlerSpacing

Indentation Matl.& Belt Idler Drag Idler Skew & Tilt

Emptyfriction factor f (loaded)

1 0.00.0160 0.000003.60 0.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600

2 0.00.0160 0.000001.40 0.35 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600

3 0.00.0161 0.000007.00 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01610

4 0.00.0160 0.000002.00 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600

5 0.00.0160 0.0000011.43 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600

6 0.00.0150 0.0000025.43 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01500

Totals: 50.85 2.00 4.00 30.13

Designers Comments



16/27

Conveyor Belt Resonance Report17 Oct 2014 11:16 16/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Description

SectionIdler

Spacing

Idler RollExcitationFrequency

Belt TransverseWave Frequency

RangeStation

EndBelt

Tension

Station / Sectio

Hz

Running Fully Loaded Belt Resonance

to Hz

CriticalIdler

SpacingStart

CriticalIdler

SpacingEnd

IdlerSpacingwithin

+/- 10%

m m mmkNkN

StartBelt

Tension

Hz Mode

Belt Speed 1.67 m/sCarry Roll Diameter 152 mm

Return Roll Diameter 152 mm Takeup Mass 8100 kgBelt Resonance +/- Tolerance 10 %

1 48.12 48.7939.37 40.46 3.5 0.5Takeup 6.97 OK6.88

2 68.33 69.2639.43 40.51 3.5 0.35Hopper 6.93 OK6.84

3 16.15 16.3640.46 41.53 3.5 1.5Int. Pt 7.02 OK6.93

4 16.16 16.3840.51 41.6 3.5 1.5Hopper 7.02 OK6.93

5 12.27 11.9241.53 39.16 3.5 2Int. Pt 6.81 OK7.02

6 11.85 1238.18 39.16 3.5 2Drive 6.86 OK6.78

Designers Comments



17/27

Takeup Travel Report17 Oct 2014 11:16 17/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Takeup Travel

m0Safety Margin Top +

kg

kgTakeup Mass kg (ManualInput)

8100

8100Takeup Mass Calculated

kgTakeup Mass step increment 200

100Max no. of Calc Increments

Fixed CentresTakeup Type

Auto Calc Takeup Mass

Takeup Travel Estimate

m0.5Belt Splice Allowance +

m0Dynamic Travel Up +

m0Dynamic Travel Down +

m0Safety Margin Bottom +

deg0Minimum Site Temperature

Thermal Expansion Distance

deg30Maximum Site Temperature

1.17E-05Belt Expansion co-efficientm/m per degree C

m52.70Total Belt Length

m0.009Thermal Expansion Distance +

%0.15Permanent Stretch co-efficient % of Belt Length

Permanent Belt Stretch

m0.04Permanent Belt StretchDistance +

m0.55Total Takeup Travel Distance



18/27

Drive Details Report17 Oct 2014 11:16 18/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

%95Drive Efficiency

:1

:1

m/s1.57Calculated Belt Speed

m/s1.67Required Belt Speed

rpm45.87Calculated Pulley Speed for Reducer

rpm48.77Required Pulley Speed

31.5Selected Gearbox Ratio

29.63Required Gearbox Ratio

Flender Helical Bevel GearGearbox Description

380 VoltsMotor Voltage

kg383

rpm1445Motor Full Load Speed

0.0467

kg-m20.0467Total Drive Inertia

kg-m20Gearbox Inertia (HSS)

kg-m20Flywheel Inertia

kg-m20High Speed Brake Disc Inertia

%140Starting Torque Factor, Empty

%140Starting Torque Factor, Fully Loaded

kg-m20High Speed Coupling Inertia

kg-m2Motor Inertia

11

1

125Pulley Shaft Diameter at Brg mm

150Pulley Shaft Diameter at Hub mm

mm

654Pulley Outside Diameter

630Pulley Shell Diameter

mm

kW

%

0.32Drive Factor Cw, Starting

0.5Drive Factor Cw, Running

0.45Coefficient of Friction, Starting

12Pulley Lagging Thickness

0.35Coefficient of Friction, Running

MoistPulley ConditionHeadDrive Description

Rubber

Electric Motor

100 Pulley Lagging Type

Total Drive Equivalent Mass

Motor Power Rating

Motor Description

Number of Motors on Drive Pulley

mm

Load Share on Drive Pulley

180 Belt Wrap Angle

1Drive No. Drive Pulley No. 6

Drive Inertia

Pulley and Belt Speed

Pulley and Shaft Dimensions

Holdback

Brake

Brake Location High Speed

Low Speed Brake Torque Input 22

Static Analysis Runback Force Fv 0 N

Static Analysis Horizontal Force Fh 3640 N

Holdback Required (Yes / No) No

Nm

Equiv HS Brake Torque 782

Holdback Torque 3 x Motor FLT

Calculated Holdback Torque N/A

Nm6462

Fv>Fh/2

kNm

Nm

High Speed Coupling

Low Speed Coupling

HS Coupling Make

HS Coupling Model 1040T

Falk

LS Coupling Make

LS Coupling Model RFK140

Ringspann

Holdback Make Not Installed

Holdback Model

Designers Comments



19/27

Drive Motor Details Report17 Oct 2014 11:16 19/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

380 VoltsMotor Voltage

0.0467 kg-m2Motor Inertia

11

1

kW

HeadDrive Description

Electric Motor

Motor Power Rating

Motor Description



Motor Category Metric Motor

DX160MMotor Frame Size

4Number of poles

160 mmMotor Shaft Height

42 mmMotor Shaft Diameter

1445 rpmMotor Full Load Speed

6.08 kWAbsorbed Power at Pulley

11 kWTotal Motor Power on Drive

6.4 kWAbsorbed Power at Motor

95 %Drive Efficiency

134 kgMass of Motor

22.3 AmpsMotor Full Load Current

72.7 NmMotor Full Load Torque

0.76Motor Power Factor @ Duty Pt

86.44 %Motor Efficiency @ Duty Point

Designers Comments



20/27

Drive Fluid Coupling Details Report17 Oct 2014 11:16 20/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

0 % FLTPeak Torque %

0

1

kW


No Selection - Direct Drive

Coupling Power Rating

Coupling Description



Coupling Category Flender

0Max Starting Time

Min. Required Ramping Time

sec

0 %Coupling Rated Slip

11 kWMotor Power Rating

Coupling Size


0 kg

1445 rpmCoupling Output Speed

0Run-up Torque % (2 sec)

Mass of Coupling

sec

% FLT

Selection Mode Auto

Designers Comments



21/27

Drive Gearbox Details Report17 Oct 2014 11:16 21/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

2154Motor Torque at Pulley Speed

Helical Bevel Gear

1


Flender Helical Bevel Gear

Type

Gearbox Description



Gearbox Category Flender

B3SH4Code

4Size

73Motor Torque @ FL Speed

11 kWMotor Power Rating


210 kgkg-m2Gearbox Inertia

6400Gearbox Rated Torque

Mass of Gearbox

Selection Mode Manual

Number of Stages

31.5

B3SH4

Service Factor Required

Ratio

1.5

Gearbox Actual Efficiency

95Design Efficiency (Input)

93rpm

mm

rpm

Maximum Input Shaft Speed 1500

Minimum Input Shaft Speed 700

Output Shaft Diameter 80

Input Shaft Diameter 30

Service Factor Calculated 2.97

5 %Plus Speed Selection Tolerance

5Minus Speed Selection Tolerance %

Fluid Coupling Slip 0

Nm

Nm

Nm

:1

:1

m/s1.57Calculated Belt Speed

m/s1.67Required Belt Speed

rpm45.87Calculated Pulley Speed for Reducer

rpm48.77Required Pulley Speed31.5Selected Gearbox Ratio

29.63Required Gearbox Ratio

%

mm

%

%

Designers Comments



22/27

Brake Details Report17 Oct 2014 11:16 22/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

%95Drive Efficiency

SvendborgBrake Description

Brake Location

mm3

Mild Steel

mm60Pad offset Width W

N3500Caliper Clamping Force Maximum

0.4Co-eff of Friction (Pad-Disc)

mm0Disc Thickness

mm0Disc Diameter

Disc Material

BSFH 202

%

HeadDescription

Svendborg BSFH 200

100

Maximum Air Gap

Caliper

Brake Category

Load Share on Drive Pulley

1Drive / Brake No. Drive Pulley No. 6

High Speed

Low Speed Brake Torque Input 22

Equiv HS Brake Torque 782

kNm

Nm

Brake Selection Input Data

Design Braking Torque Input

Selected Brake's Torque Rating -43

782

Number of Motors on Drive Pulley 1

Nm

Nm

Design Stopping TimeConsecutive No of Stops 3

10.0 sec

Average No of Stops

Ambient Temperature 40

6

deg C

Disc Temperature after stops NaN deg C

Recommended working airgap is 1mm

kg-m20.0

rpm0Disc Initial Speed

Disc Moment of InertiaRequired Gearbox Ratio 29.63 : 1

Mass of Caliper 26 kg

Brake Caliper Price $0.00

Caliper Clamping Force Minimum 2000 N

Designers Comments



23/27


24/27

Conveyor Pulley Shafts17 Oct 2014 11:16 24/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Description

ShaftMass

kg

WrapAngledeg

Defl.Diamm

T1Run

Station

ShaftLength

mm

Station / Sectio Resul-tant

ForceDt.DiammkN kN

T2Run

kN

T1Start

kN

Calculated

ShaftDiamm

Selected

BrgDiamm

BrgCtrsmm

1 39.2 39.41610 125120.8180.0Takeup 150 22378.5 123.738.7 1270

6 41.6 38.21610 125121.3180.0Drive 150 22379.8 124.743.4 1270

Designers Comments * Denotes manual pulley shaft dimensions entered



25/27

Conveyor Pulleys17 Oct 2014 11:16 25/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Mom ofInertiakgm2Description

Pulley &Shaft

Mass kg

PulleySpeedrpm

WrapAngledeg

ShaftDiamm

ShaftLength

mm

FaceWidthmmStation

Laggingmm

ShellDia mm

Station / Sectio

BrgCtrsmm

BrgDiamm

1 850 1610500 12 150 180.0Takeup 60.9 475 12.71270 125

6 850 1610630 12 150 180.0Drive 48.8 718 36.21270 125

Designers Comments * Denotes manual pulley dimensions entered



26/27

Conveyor Pulley Dimensions17 Oct 2014 11:16 26/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Mom ofInertiakgm2Description

Pulley &Shaft

Mass kg

ShaftDiamm

ShaftLength

mm

FaceWidthmmStation

Laggingmm

ShellDia mm

Station / Sectio

BrgCtrsmm

BrgDiamm

ODmm

BeltWidthmm

1 850 1610500 12 150Takeup 475 12.71270 125524 750

6 850 1610630 12 150Drive 718 36.21270 125654 750

Designers Comments



27/27

Conveyor Pulleys Data Sheet17 Oct 2014 11:16 27/27Page



Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


36.M111, 1.67 m/s

JSA

Description

PulleySpeed

rpm

WrapAngledeg

DrivePower

kW

FaceWidthmmStation

Laggingmm

ShellDia mm

Station / Sectio

BrgCtrsmm

T1RunkN

T2RunkN

T1StartkN

T2StartkN

1 850500 12 44.81180.0Takeup 60.91270 39.4539.16 39.37

Braking FullRunning Full

6 850630 12 43.45180.0Drive 48.8111270 36.5341.6 38.18

Starting FullRunning Full

Designers Comments

Documents

36.M111 Potasium Sulphate BW 750,1.67 m s