c3048-pnj-cal-b-0002_b conveyor 11-cv-01

7/30/2019 C3048-PNJ-CAL-B-0002_B Conveyor 11-CV-01

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J Resources Gold UK Limited

Penjom Gold Expansion Project

Penjom Kuala Lipis,

Pahang, Malaysia

Project No.: 3048

CALCULATION OF CONVEYOR CV-01

SUBJECT: CALCULATION

Doc. No.: PNJ-CAL-B-0002

Project Reference: C3048

Reference Drawings and/or Data: As Attached

Issue Descriptio ns DatePrepared

ByChecked

By Approved

By

B Issued for Client Review 14/03/12

A Issued for Internal Review 12/03/12 RBO AJA AJA



PROJ ECT No. : C3048

DOC No. : C3048-PNJ-CAL-B-0002

CONVEYOR CV-01 SHEET : REV : B

CALCULATION BY : RBO DATE : March 14, 2012

CHKD : AJ A DATE : March 14, 2012

TABLE OF CONTENT

1 GENERAL ..................................................................................................................................... 2 2 REFERENCE DOCUMENT ........................................................................................................... 2 3 HELIX OUTPUT RESULT ............................................................................................................. 2



PROJ ECT No. : C3048

DOC No. : C3048-PNJ-CAL-B-0002

CONVEYOR CV-01 SHEET : REV : B

CALCULATION BY : RBO DATE : March 14, 2012

CHKD : AJ A DATE : March 14, 2012

1 GENERAL

This document is the mechanical calculation of conveyor CV-01 for Penjom Gold Expansion Project.

2 REFERENCE DOCUMENT

PNJ -DOC-G-0001 Project Design Basis and Scope of Work.

PNJ -DWG-F-0001 Process Plant Up Grade – Schematic Diagram

PNJ -DWG-F-0002 Proposed Nordberg Ball Mill Line – Crushing & Grinding –Process Flow Diagram

PNJ -DWG-F-0004 Proposed Kobe SAG Mill Line – Crushing & Grinding CircuitProcess Flow Diagram

3 HELIX OUTPUT RESULT



Conveyor Design Summary15 Mar 2012 08:41 1/27Page

J Resources

PT Resindo Resources Indonesia

Project

Project No.

Conveyor No.

Client

Prepared By

Design Date

Penjom Gold Expansion

C3048

11-CV-01

RBO

07 Maret 2012

Material Description Gold Ore

Conveyed Material

High Bulk Density 1600

1600Low Bulk Density kg/m3

kg/m3

Angle of Repose 30

20Surcharge Angle deg

deg

Material Lump size 30 mm

Conveyor Data

Nett Lift / Lower (-) -0,05

7,70Conveying Distance m

m

Design Capacity 120 tonnes/hr

Belt Speed 1 m/s

Belt Details

Belt Class & Run Safety Factor 250/3

800Belt Width Selected mm Calculated Belt % Full 29,7 %

Top Cover Thickness 8 mm

Belt Total Length 25,525

Belt Rated Tension kN/m

m

Bottom Cover Thickness2

mm

Belt Mass 12,16 kg/m

Belt Tensions and Power Calculations ISO

Maximum Tension Tmax 5,22

1,34Effective Tens. Fully Loaded kN Belt Power - Empty Belt 1,14 kW

Belt Power - Inclines Loaded 1,34 kW

Sag Tension 3,35

3,92Minimum Tension Tmin kN

kN

Belt Power - Declines Loaded 1,27 kW

Belt Power - Fully Loaded 1,34 kW2 %

kN

Takeup Type Screw Take-Up

Takeup Mass 1000 kg Absorbed Power Fully Loaded 1,63 kW

Installed Motor Power 4 kW

Drive Efficiency 82,0 %

Carry and Return Idlers

Carry Idler Spacing 1,235Carry Idler Trough Angle 0 º

3 m

3 x 127Carry Idler No Rolls x Dia mm 1 x 127 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

0,00 kNm

0,40Starting Time - Fully Loaded sec 1,05 sec

Total Braking Torque LSS

CEMA Temperature Factor Kt

Stop Time - Loaded, Braking

0,31Starting Time - Empty sec 1,05 secStop Time - Loaded, Coasting

º

%

%

Takeup Pulley Belt Tension 4,90 kN

38,33

Designers Comments

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Helix TechnologiesVer 6.0.13 Licenced to PT Resindo Resources



Conveyor Sections - Input Data15 Mar 2012 08:41 2/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

FrictionFactor InputDescription

No. of Scrapers

SkirtLength

m

Idler Spacing

m

Cap-acitytph

Y co-ord m

X co-ord mStation

SectionLiftm

SectionLength

m

Station / Section

Z co-ord m

Ten Adj .

kN

1 0,00 0,004,30 0,00 0 1,20 Takeup 0,00000,00

2 4,30 0,004,40 0,00 120 0,30Hopper 7,50 0,00000,20

3 8,70 0,002,50 0,00 120 1,20Int. Pt 0,00000,20

4 11,20 0,000,80 -0,05 120 1,20Int. Pt 0,00000,20

5 12,00 0,001,19 0,15 0 3,00Drive 2 0,0000-0,10

6 10,80 0,008,80 0,00 0 3,00Int. Pt 0,0000-0,20

7 2,00 0,002,00 0,00 0 3,00Int. Pt 1 0,0000-0,20

Totals: 23,99 0,00 7,50 30,10

Designers Comments




Takeup & Drive Traction Calculation15 Mar 2012 08:41 3/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

%140 Takeup Mass 1000 kg

Running

DriveNumber

FullyLoaded

EmptyBelt

Starting Braking

FullyLoaded

EmptyBelt

FullyLoaded

EmptyBelt

1Drive No. Drive

Wrap Angle º 185

Co-efficient of Friction 0,25

Drive Factor Cw

Calculated Belt Tension T1 kN

Calculated Belt Tension T2Minimum Required T2

Surplus T2 Tension (T1-T2)

0,805

kNkN

kN

1,04

5,21

3,92

2,88

Lagging Type

185

0,25

0,805

0,88

5,01

3,92

3,04

Rubber

185

0,35

0,477

1,65

7,14

3,69

2,04

185

0,35

0,477

1,5

6,67

3,52

2,02

Rubber

185

0,35

0,477

0,15

4,47

4,15

4

Rubber

185

0,35

0,477

0,16

4,5

4,16

4

Pulley No. 5

Designers Comments




Tension Calculations - Summary Run / Start15 Mar 2012 08:41 4/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

140 % Takeup Mass 1000 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 4,90 4,904,90 4,90 Takeup 4,90 4,904,90 4,904,90 4,90

2 4,97 4,974,97 4,97Hopper 4,75 4,744,75 4,745,56 5,73

3 5,19 5,155,19 5,00Int. Pt 4,62 4,564,62 4,566,67 6,43

4 5,22 5,165,22 5,01Int. Pt 4,52 4,524,52 4,527,03 6,61

5 5,22 5,155,21 5,01Drive 4,47 4,504,47 4,507,14 6,676 4,57 4,574,57 4,57Int. Pt 4,77 4,784,77 4,784,40 4,25

7 4,59 4,594,59 4,59Int. Pt 4,67 4,674,67 4,674,75 4,69

Minimum Ten 4,57

Maximum Ten

Effective Ten

4,57 4,57 4,57 4,254,40 4,504,47 4,504,47

5,22 5,01 5,22 5,16 7,14 6,67 4,90 4,90 4,90 4,90

4,80 4,76 4,80 4,79 5,28 5,20 4,68 4,68 4,68 4,68

1,34 1,14 1,34 1,27

Ave. Belt Ten

Belt Elong. m

T/up Travel m

-0,002

-0,001

-0,003

-0,002

-0,002

-0,001

-0,002

-0,001

0,007

0,004

0,006

0,003

-0,004

-0,002

-0,004

-0,002

-0,004

-0,002

-0,004

-0,002

Designers Comments




Belt Details Report15 Mar 2012 08:41 5/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Low BD = 1600kg/m3 High BD = 1600kg/m3

kNBelt Rated Tension for width 20

Belt Reinforcement Fibre Fabric

250/3

GOODYEAR PLYLON-HIBelt Description

Goodyear FabricBelt Category

Belt Make & Class

Belt Dimensions

Belt Speed & CapacityConveyed Material

ºCarry Idler Trough Angle 35

kNMinimum Tension Tmin 3,92

kNAllowable Belt Tension, Starting 28

kg/m12,2Belt Mass Wb (per linear m)

mm2Bottom Cover Thickness

m

kN/mBelt Rated Tension / m width 25

25,5Belt Total Belt Length (L)

mm8 Top Cover Thickness

mmBelt Width Selected 800

3Belt Class / P lies

m/s1Belt Speed

tonnes/hr120Belt Design Capacity Input

mm30Material Lump size

deg

degSurcharge Angle 20

30Angle of Repose

kg/m3

kg/m3Low Bulk Density 1600

1600High Bulk Density

Gold OreMaterial Description

Belt Tensions

kN/mCalculated Tension / m width 6,5

Calculated Max Run Tension 5,22 kN

mm3,6Belt Carcass Thickness

mm13,6Belt Total Thickness

sec25,5 Time for 1 Revolution

Actual Belt Tension, Starting 7,14

Allowable Tension Rise, Starting 140 %

kN

Belt Modulus 1660 kN/m

Belt and Material Mass

kg/m7,2Belt Top Cover Mass

kg/m1,8Belt Bottom Cover Mass

kg/m3,1Belt Carcass Mass

kg/m33,3Material Mass Wm

kg/m45,5 Total Mass (Wb + Wm)

Flooded Belt Material Mass 165 kg/m

tonnes/hr594Flooded Belt Capacity

kg310 Total Belt Mass (Wb x L)

Belt Load Area and Capacity at 1600kg/m3

m20,0702Belt Load Area at MinimumRecommended Edge Distance

m20,1031Flooded Belt Load Area at ZeroEdge Distance

mm67Minimum Rec. Edge Distance

mm194Actual Edge Distance Low BD

mm76Load Burden Depthmm389Load Burden Width

Belt Actual % Full at Low BD %29,7

Belt Load Area Utilised at LowBulk Density 0,0208 m2

Belt Load Area Utilised at HighBulk Density 0,0208 m2

mm194Actual Edge Distance High BD

Belt Load Area and Capacity at 1600kg/m3

Minimum Rec. Edge Distance 67 mm

Belt Actual % Full at High BD 29,7 %

Flooded Belt Capacity at 1600kg/m3

tonnes/hr120Section Loading Max Capacity

Designers Comments




Tension Calculations - Summary Belt Sag15 Mar 2012 08:41 6/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Allowable Belt Sag % Running

Allowable Belt Sag % Start / Stop

2 %

%5 Takeup Mass 1000 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 4,90 4,904,90 4,90 Takeup 4,90 4,904,90 4,904,90 4,90

Belt Sag % 0,36

Idler Spacing m 1,20

0,36 0,36 0,36 0,36 0,36 0,36 0,36 0,36 0,36

2 4,97 4,974,97 4,97Hopper 4,75 4,744,75 4,745,56 5,73

Belt Sag % 0,34


0,09 0,34 0,34 0,3 0,08 0,35 0,09 0,35 0,09

3 5,19 5,155,19 5,00Int. Pt 4,62 4,564,62 4,566,67 6,43

Belt Sag % 1,29


0,36 1,29 1,3 1 0,28 1,45 0,39 1,45 0,39

4 5,22 5,165,22 5,01Int. Pt 4,52 4,524,52 4,527,03 6,61

Belt Sag % 1,28


0,36 0,34 1,3 0,95 0,27 1,48 0,4 1,48 0,4

5 5,22 5,155,21 5,01Drive 4,47 4,504,47 4,507,14 6,67

Belt Sag % 0,86


0,89 0,86 0,87 0,63 0,67 1 0,99 1 0,99

6 4,57 4,574,57 4,57Int. Pt 4,77 4,784,77 4,784,40 4,25

Belt Sag % 0,98


0,98 0,98 0,98 1,02 1,05 0,94 0,93 0,94 0,93

7 4,59 4,594,59 4,59Int. Pt 4,67 4,674,67 4,674,75 4,69

Belt Sag % 0,97


0,97 0,97 0,97 0,94 0,95 0,96 0,96 0,96 0,96

Minimum Ten 4,57

Maximum Sag

4,57 4,57 4,57 4,254,40 4,504,47 4,504,47

1,29 0,98 1,29 1,3 1,02 1,05 1,48 0,99 1,48 0,99

Designers Comments




Tension Calculations - Run Fully Loaded15 Mar 2012 08:41 7/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Takeup Mass 1000 kg

FrictionFactor

SectionEffectiveTension

Scraper Friction

kN

SkirtFriction

kN

TensionsMaterial Accel .

kN

DriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / PulleyTp

Pulley

Ten Adj .

kN

ISO

1 4,90 4,954,30 0,00 Takeup 0,02 0,01980,05

2 4,97 4,974,40 0,00 0,03Hopper 0,11 0,07 0,0194

3 5,19 5,192,50 0,00Int. Pt 0,03 0,0233

4 5,22 5,220,80 -0,05Int. Pt -0,01 0,0233

5 5,21 3,921,19 0,15 1,28Drive 0,63 0,02 0,0160,05

6 4,57 4,578,80 0,00Int. Pt 0,02 0,016

7 4,59 4,592,00 0,00Int. Pt 0,31 0,00 0,016

Totals: 0,10 1,3 0,00 0,03 0,11 0,94 0,15

Maximum Tension

Minimum Tension

5,22

3,92

kN

kN

Average Tension Fully Loaded 4,80 kN

Average Tension Belt Stationary 4,90 kN

Average Tension Difference -0,1 kN

Total Effective Tension

Total Belt Power (Te x V)

Belt Modulus

Total Belt Length

Belt Elastic Elongation

1,34

1,34

1660

25,50

-0,002 m

m

kN/m

kW

kN

Takeup Movement -0,001 m

Designers Comments




Tension Calculations - Run Empty15 Mar 2012 08:41 8/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

FrictionFactor


Scraper FrictionkN

SkirtFrictionkN

Tensions

Material Accel.kN

DriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLengthm

Station / Pulley

TpPulley

Ten Adj .kN

ISO

1 4,90 4,954,30 0,00 Takeup 0,02 0,01980,05

2 4,97 4,974,40 0,00Hopper 0,03 0,0194

3 5,00 5,002,50 0,00Int. Pt 0,01 0,0233

4 5,01 5,010,80 -0,05Int. Pt 0,00 0,0233

5 5,01 3,921,19 0,15 1,09Drive 0,63 0,02 0,0160,05

6 4,57 4,578,80 0,00Int. Pt 0,02 0,016

7 4,59 4,592,00 0,00Int. Pt 0,31 0,00 0,016

Totals: 0,10 1,09 0,00 0,94 0,10

Maximum Tension

Minimum Tension

5,01

3,92

kN

kN

Average Tension Fully Loaded 4,76 kN





Belt Modulus

Total Belt Length


1,14

1,14

1660

25,50

-0,003 m

m

kN/m

kW

kN


Designers Comments




Tension Calculations - Run Inclines Loaded15 Mar 2012 08:41 9/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

FrictionFactor


Scraper Friction

kN

SkirtFriction

kN

TensionsMaterial Accel.

kN

DriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / Pulley

TpPulley

Ten Adj .

kN

ISO

1 4,90 4,954,30 0,00 Takeup 0,02 0,01970,05

2 4,97 4,974,40 0,00 0,03Hopper 0,11 0,07 0,0194

3 5,19 5,192,50 0,00Int. Pt 0,03 0,0233

4 5,22 5,220,80 -0,05Int. Pt 0,00 0,0196

5 5,22 3,921,19 0,15 1,29Drive 0,63 0,02 0,0160,05

6 4,57 4,578,80 0,00Int. Pt 0,02 0,016

7 4,59 4,592,00 0,00Int. Pt 0,31 0,00 0,016

Totals: 0,10 1,28 0,00 0,03 0,11 0,94 0,15

Maximum Tension

Minimum Tension

5,22

3,92

kN

kN

Average Tension Inclines Loaded 4,80 kN





Belt Modulus

Total Belt Length


1,34

1,34

1660

25,50

-0,002 m

m

kN/m

kW

kN


Designers Comments




Tension Calculations - Run Declines Loaded15 Mar 2012 08:41 10/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

FrictionFactor


Scraper Friction

kN

SkirtFriction

kN

TensionsMaterial Accel.

kN

DriveTe kN

T2 RunkN

T1 RunkNStation

SectionLiftm

SectionLength

m

Station / Pulley

TpPulley

Ten Adj .

kN

ISO

1 4,90 4,954,30 0,00 Takeup 0,02 0,01980,05

2 4,97 4,974,40 0,00 0,03Hopper 0,11 0,03 0,0194

3 5,15 5,152,50 0,00Int. Pt 0,01 0,0233

4 5,16 5,160,80 -0,05Int. Pt -0,01 0,0233

5 5,15 3,921,19 0,15 1,22Drive 0,63 0,02 0,0160,05

6 4,57 4,578,80 0,00Int. Pt 0,02 0,016

7 4,59 4,592,00 0,00Int. Pt 0,31 0,00 0,016

Totals: 0,10 1,3 0,00 0,03 0,11 0,94 0,15

Maximum Tension

Minimum Tension

5,16

3,92

kN

kN

Average Tension Declines Loaded 4,79 kN





Belt Modulus

Total Belt Length


1,27

1,27

1660

25,50

-0,002 m

m

kN/m

kW

kN


Designers Comments




Conveyor Starting and Stopping15 Mar 2012 08:41 11/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Mass of BeltSystem Masses

Carry Idler Equivalent Mass 231

257Mass of Material kg

kg

Input Data

Pulley Equivalent Mass 326

36Return Idler Equivalent Mass kg

kg

Belt Rated Tension

Belt Speed 1 m/s

Total Braking Force 0,00

1,14Effective Tension Empty kN

3,5

Tension Available to Accelerate Conveyor

kN

kN

310 kg

Total System Equivalent Mass 1.404

244Drive Equivalent Mass kg

kg

25 kN/m

Drive Inertia

Allow. Belt Start Tension Rise 140 %

0,0109 kg-m2

Start-up Factor - Loaded

Total Braking Torque 0 kNm

140

Start-up Factor - Empty 140

Drive Efficiency (Average)

Installed Power 4 kW

82

%

%

%Tensions and Accelerating Forces

Stopping Times & Deceleration Rates

Effective Tens. Fully Loaded 1,34 kN

3,66Accelerating Tension - Empty kN

Starting Times & Acceleration Rates

Acceleration Rate - Loaded 2,49

0,31Starting Time - Empty sec

3,19Accelerating Rate - Empty m/s2

m/s2

Starting Time - Fully Loaded 0,40 sec

Belt Tension Rise Starting / Braking

Maximum Belt Tension / width 8,93

800Belt Width mm

25Belt Rated Tension / width kN/m

kN/m

Max Belt Tension, Start/Brake 7,14 kN

35,7Actual Max Tension, Start/Brake %

1,05Stopping Time Loaded Coasting secStopping Time Loaded Braking 1,05 sec

1,00Stopping Time Empty Coasting sec

Stopping Time Empty Braking 1,00 sec

-0,95Deceleration - Loaded Coasting m/s2

Deceleration - Loaded Braking -0,95 m/s2

-1,00Deceleration - Empty Coasting m/s2

Deceleration - Empty Braking -1,00 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

0,53

0,53

0,50,5

18

18

0,01

0,01

Accelerating Tension - Loaded

Designers Comments




Conveyor Idler Details Report15 Mar 2012 08:41 12/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Idler Category Sandvik Carry

Idler Design Belt Width 800

Series 15 3 Roll Carry 127 PlainInline

Idler Description

mm

Drawing Number

15Idler Series

Total Number of Idlers 22

1,2Nominal Idler Spacing m

Troughing Angle 35,0

0Idler Price

deg

Idler Bearing Diameter 25,0

25,0Idler Shaft Diameter mm

Idler Roll Diameter 127

3Number of Idler Rolls

mm

mm

Idler Rotation Speed 150

Roll Face Width 296 mm

320Shaft Support Centres

1050Idler Support Fixing Width mm

Idlerset Total Mass 27,2

10,5Idlerset Rotating Mass

3,0Idler Vertical Misalignment Allowance mm1,01Dynamic Load Factor

mm

kg

kg

Roll Bearing Centres 239,8 mm

Carry Side Idlers Return Side Idlers

500Belt Deviation Load N

926 Total Load on Centre Roll N

Ball Type of Bearing

6205Bearing Designation

14.000Bearing Dynamic Load Rating C N

3.064.374Bearing L10h Life hrs

8,00Allowable Shaft Deflection at Bearing min

1,90Actual Shaft Deflection at Bearing min

rpm

Sandvik Flat Return

800

Series 15 1 Roll Flat Carry127 Dia

mm

15

4

3 m

0,0

0

deg

25,0

27,0 mm

127

1

mm

mm

150

896 mm

920

1050 mm

16,2

9

5,0 mm1,40

mm

kg

kg

839,8 mm

500 N

1.162 N

Ball

6205

14.000 N

1.551.716 hrs

10,00 min

6,14 min

rpm

Designers Comments




Vertical Curve Radius Calculations15 Mar 2012 08:41

J ResourcesPT Resindo Resources Indonesia

Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

15 Mar 2012 08:41 Vertical Curve Radius Calculations

Belt Mass - New Belt 12,16 kg/m

Top Cover Mass - New Belt 7,23 kg/m

Bottom Cover Mass 1,81 kg/m

Worn Belt Mass 9,12 kg/m

Reduction of Top Cover Mass 42 %

Conveyed Material Mass 33,33 kg/m

% Belt Mass for Lift-off Calculation

Curve Tension Safety Factor

Average Drive Torque Start-up Fa


Allowable Edge Tension - Running

Belt Modulus

Belt Rated Tension

Belt Width 800 mm

2

Curve

Type

Fully Loaded

Running

Station

DesignVerticalCurveRadius

LoadCapacity

Station / Section

Empty

tonnes/hr m

Tension Radius

kN m

Radius

m

Tension

kN

Starting

Fully Loaded

Radius

mkN

Tension

Empty

Tension Rad ius

mkN

F

k

Ten

1 4,9 Takeup 4,9 4,9 4,9

2 4,97120Hopper 4,97 5,56 5,73

3 5,19120Int. Pt 5,0 6,67 6,43

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml

Ver 6.0.13 Licenced to PT Resindo Resources



15 Mar 2012 08:41 Vertical Curve Radius Calculations

Belt Mass - New Belt 12,16 kg/m

Top Cover Mass - New Belt 7,23 kg/m

Bottom Cover Mass 1,81 kg/m

Worn Belt Mass 9,12 kg/m

Reduction of Top Cover Mass 42 %

Conveyed Material Mass 33,33 kg/m

% Belt Mass for Lift-off Calculation

Curve Tension Safety Factor



Allowable Edge Tension - Running

Belt Modulus

Belt Rated Tension

Belt Width 800 mm

2

CurveType

Fully Loaded

Running

Station

DesignVerticalCurveRadius

LoadCapacity

Station / Section

Empty

tonnes/hr m

Tension Radius

kN m

Radius

m

Tension

kN

Starting

Fully Loaded

Radius

mkN

Tension

Empty

Tension Rad ius

mkN

F

k

Ten

4 5,22120Int. Pt Convex 5,01 7,03 6,61

Min. Edge Tension Radius

Max. Buckling Radius

8

30

8

34

8

17

8

19

Belt Edge Tension Rise at Curve kN 0

Total Edge Tension at Curve kN and % 5,22 5,01 7,03 6,61

0 0 0

26% 25% 35% 33%

Centre Tension at Curve kN 5,22 5,01 7,03 6,61

Belt Tension at Curve kN 5,22 5,01 7,03 6,61

5 5,21Drive 5,01 7,14 6,67

6 4,57Int. Pt Convex 4,57 4,4 4,25

Min. Edge Tension Radius

Max. Buckling Radius

Belt Edge Tension Rise at Curve kN Flat Belt

Total Edge Tension at Curve kN and %

Centre Tension at Curve kN

Belt Tension at Curve kN 4,57 4,57 4,4 4,25

7 4,59Int. Pt 4,59 4,75 4,69

Designers Comments

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml

Ver 6.0.13 Licenced to PT Resindo Resources



Viscoelastic Friction Factor Report15 Mar 2012 08:41 15/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

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

127

2

127

2

127

127

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 0,072RRF 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

Idler Spacing

Indentation Matl.& Belt Idler Drag Idler Skew & Tilt

Emptyfriction factor f (loaded)

1 0,00,0198 0,000004,30 1,20 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01970

2 0,00,0194 0,000004,40 0,30 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01600

3 0,00,0233 0,000002,50 1,20 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01960

4 0,00,0233 0,000000,80 1,20 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01960

5 0,00,0160 0,000001,19 3,00 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01600

6 0,00,0160 0,000008,80 3,00 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01600

7 0,00,0160 0,000002,00 3,00 0,00000 0,0 0,00000 0,0 0,00000 0,0 0,01600

Totals: 23,99 0,00 7,50 30,10

Designers Comments




Conveyor Belt Resonance Report15 Mar 2012 08:41 16/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Description

SectionIdler

Spacing

Idler RollExcitationFrequency

Belt TransverseWave Frequency

RangeStation

EndBelt

Tension

Station / Section

Hz

Running Fully Loaded Belt Resonance

to Hz

CriticalIdler

SpacingStart

CriticalIdler

SpacingEnd

Idler Spacingwithin

+/- 10%

m m mmkNkN

StartBelt

Tension

HzM

o d e

Belt Speed 1 m/sCarry Roll Diameter 127 mm

Return Roll Diameter 127 mm Takeup Mass 1000 kg

1 8,39 8,594,95 5,19 2,51 1,2 Takeup 4,11 OK 4,02

2 17,27 17,74,97 5,22 2,51 0,3Hopper 2,12 OK 2,07

3 4,41 4,425,19 5,21 2,51 1,2Int. Pt 2,12 OK 2,11

4 4,42 4,135,22 4,57 2,51 1,2Int. Pt 1,98 OK 2,12

5 2,98 3,233,92 4,59 2,51 3Drive 3,87 OK 3,57

6 3,22 3,344,57 4,9 2,51 3Int. Pt 3,99 OK 3,86

7 3,23 3,344,59 4,9 2,51 3Int. Pt 3,99 OK 3,87

Designers Comments




Takeup Travel Report15 Mar 2012 08:41 17/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Takeup Travel

m0Safety Margin Top +

kg

kg Takeup Mass kg (ManualInput)

2000

1000 Takeup Mass Calculated

kg Takeup Mass step increment 500

100Max no. of Calc Increments

Screw Take-Up Takeup Type

Auto Calc Takeup Mass

Takeup Travel Estimate

m0Belt Splice Allowance +

m0Dynamic Travel Up +

m0Dynamic Travel Down +

m0Safety Margin Bottom +

deg0Minimum Site Temperature

Thermal Expansion Distance

deg45Maximum Site Temperature

1,17E-05Belt Expansion co-efficientm/m per degree C

m25,50 Total Belt Length

m0,007 Thermal Expansion Distance +

%1,5Permanent Stretch co-efficient % of Belt Length

Permanent Belt Stretch

m0,191Permanent Belt StretchDistance +

m0,2 Total Takeup Travel Distance




Drive Details Report15 Mar 2012 08:41 18/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

%82Drive Efficiency

:1

:1

m/s1,05Calculated Belt Speed

m/s1Required Belt Speed

rpm38,27Calculated Pulley Speed for Reducer

rpm38,37Required Pulley Speed

35,5Selected Gearbox Ratio

37,273Required Gearbox Ratio

Flender Helical Bevel Gear Gearbox Description

380 VoltsMotor Voltage

kg244

rpm1430Motor Full Load Speed

0,0109

kg-m20,0109 Total 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

4

1

70Pulley Shaft Diameter at Brg mm

75Pulley Shaft Diameter at Hub mm

mm

524Pulley Outside Diameter

500Pulley Shell Diameter

mm

kW

%

0,48Drive Factor Cw, Starting

0,81Drive Factor Cw, Running

0,35Coefficient of Friction, Starting

12Pulley Lagging Thickness

0,25Coefficient 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

185 ºBelt Wrap Angle

1Drive No. Drive Pulley No. 5

Drive Inertia

Pulley and Belt Speed

Pulley and Shaft Dimensions

Holdback

Brake

Brake Location High Speed

Low Speed Brake Torque Input 0

Static Analysis Runback Force Fv -16 N

Static Analysis Horizontal Force Fh 1356 N

Holdback Required (Yes / No) No

Nm

Equiv HS Brake Torque 0

Holdback Torque 3 x Motor FLT

Calculated Holdback Torque N/A

Nm3144

Fv>Fh/2

Fluid Coupling FENNER TRANSFLUIDREDUCED FILL

Fluid Coupling Size 8K

kNm

Nm

High Speed Coupling

Low Speed Coupling

Fluid Coupling

LS Coupling Make

LS Coupling Model

No Selection

Holdback Make No Selection

Holdback Model

Designers Comments




Drive Motor Details Report15 Mar 2012 08:41 19/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

380 VoltsMotor Voltage

0,0109 kg-m2Motor Inertia

4

1

kW

HeadDrive Description

Electric Motor

Motor Power Rating

Motor Description



Motor Category Metric Motor

DX112MMotor Frame Size

4Number of poles

112 mmMotor Shaft Height

28 mmMotor Shaft Diameter

1430 rpmMotor Full Load Speed

1,34 kWAbsorbed Power at Pulley

4 kW Total Motor Power on Drive

1,63 kWAbsorbed Power at Motor

82 %Drive Efficiency

48 kgMass of Motor

9 AmpsMotor Full Load Current

26,7 NmMotor Full Load Torque

0,57Motor Power Factor @ Duty Pt

78,77 %Motor Efficiency @ Duty Point

Designers Comments




Drive Fluid Coupling Details Report15 Mar 2012 08:41 20/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

170 % FLTPeak Torque %

5

1

kW


FENNER TRANSFLUIDREDUCED FILL

Coupling Power Rating

Coupling Description



Coupling Category Transfluid

30Max Starting Time

Min. Required Ramping Time

sec

5 %Coupling Rated Slip

4 kWMotor Power Rating

8KCoupling Size


6 kg

1358 rpmCoupling Output Speed

160Run-up Torque % (2 sec)

Mass of Coupling

sec

% FLT

Selection Mode Manual

Designers Comments




Drive Gearbox Details Report15 Mar 2012 08:41 21/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

996Motor Torque at Pulley Speed

Helical Bevel Gear

1


Flender Helical Bevel Gear

Type

Gearbox Description



Gearbox Category Flender

B3SH3Code

3Size

27Motor Torque @ FL Speed



130 kgkg-m2Gearbox Inertia

3400Gearbox Rated Torque

Mass of Gearbox

Selection Mode Auto

Number of Stages

35,5

B3SH3

Service Factor Required

Ratio

1,5

Gearbox Actual Efficiency

82Design Efficiency (Input)

93rpm

mm

rpm

Maximum Input Shaft Speed 1500

Minimum Input Shaft Speed 700

Output Shaft Diameter 65

Input Shaft Diameter 28

Service Factor Calculated 3,41

5 %Plus Speed Selection Tolerance

5Minus Speed Selection Tolerance %

Fluid Coupling Slip 5

Nm

Nm

Nm

:1

:1

m/s1,05Calculated Belt Speed

m/s1Required Belt Speed

rpm38,27Calculated Pulley Speed for Reducer

rpm38,37Required Pulley Speed35,5Selected Gearbox Ratio

37,273Required Gearbox Ratio

%

mm

%

%

Designers Comments




Brake Details Report15 Mar 2012 08:41 22/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

%82Drive Efficiency

No SelectionBrake Description

Brake Location

mm

Mild Steel

mmPad offset Width W

NCaliper Clamping Force Maximum

0,4Co-eff of Friction (Pad-Disc)

mm30Disc Thickness

mm600Disc Diameter

Disc Material%

HeadDescription

100

Maximum Air Gap

Caliper

Brake Category


1Drive / Brake No. Drive Pulley No. 5

High Speed

Low Speed Brake Torque Input 0

Equiv HS Brake Torque 0

kNm

Nm

Brake Selection Input Data

Design Braking Torque Input

Selected Brake's Torque Rating

1000

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 0 deg C

Recommended working airgap is 1mm

kg-m20,1

rpm1480Disc Initial Speed

Disc Moment of InertiaRequired Gearbox Ratio 37,273 : 1

Mass of Caliper kg

Brake Caliper Price

Caliper Clamping Force Minimum N

Designers Comments




Shaft Coupling Report15 Mar 2012 08:41 23/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

%82Drive Efficiency

%140Starting Torque Factor, Empty

%140Starting Torque Factor, Fully Loaded

kg-m20High Speed Coupling Inertia

1 70Pulley Shaft Diameter at Brg mm

%


100




Fluid Coupling FENNER TRANSFLUIDREDUCED FILL

Fluid Coupling Size 8K

High Speed Coupling Low Speed Coupling

Fluid Coupling

HS Coupling Make

HS Coupling Model

No Selection LS Coupling Make

LS Coupling Model

No Selection

996Motor Torque at Pulley Speed

27Motor Torque @ FL Speed



Service Factor Required 3,5

Service Factor Calculated 0

Nm

Nm

Coupling Type

Nm

HS Coupling Category LS Coupling Category

Coupling Torque Rating 0

Maximum Shaft Bore 0 mm

Minimum Shaft Bore 0 mm

Maximum Rotation Speed 0 rpm

Drawing Number

High Speed Coupling Mass 0 kg

High Speed Coupling Price 0

kg-m20Low Speed Coupling Inertia

Service Factor Required 3,5

Service Factor Calculated 0

Coupling Type

NmCoupling Torque Rating 0

Maximum Shaft Bore 0 mm

Minimum Shaft Bore 0 mm

Maximum Rotation Speed 0 rpm

Drawing Number

Low Speed Coupling Mass 0 kg

Low Speed Coupling Price 0

Direct Drive

Designers Comments




Conveyor Pulley Shafts15 Mar 2012 08:41 24/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Description

ShaftMass

kg

Wrap Ang le

deg

Defl.Diamm

T1Run

Station

ShaftLength

mm

Station / Section Resul-tant

ForceDt.DiammkN kN

T2Run

kN

T1Start

kN

Calculated

ShaftDiamm

Selected

BrgDiamm

BrgCtrsmm

1 4,9 5,01620 7578,1180,0 Takeup 80 649,8 70,34,9 1370

5 5,2 3,91610 7076,6185,0Drive 75 569,1 71,611B 7,1 1370

Designers Comments * Denotes manual pulley shaft dimensions entered




Conveyor Pulleys15 Mar 2012 08:41 25/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Mom of Inertiakgm2

Description

Pulley &Shaft

Mass kg

PulleySpeed

rpm

Wrap Ang le

deg

ShaftDiamm

ShaftLength

mm

FaceWidthmm

StationLagging

mmShell

Dia mm

Station / Section

BrgCtrsmm

BrgDiamm

1 950 1620400 0 80 180,0 Takeup 47,7 252 5,41370 75

5 950 1610500 12 75 185,0Drive 36,4 332 13,11370 70

Designers Comments * Denotes manual pulley dimensions entered




Conveyor Pulley Dimensions15 Mar 2012 08:41 26/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Mom of Inertiakgm2

Description

Pulley &Shaft

Mass kg

ShaftDiamm

ShaftLength

mm

FaceWidthmm

StationLagging

mmShell

Dia mm

Station / Section

BrgCtrsmm

BrgDiamm

ODmm

BeltWidthmm

1 950 1620400 0 80 Takeup 252 5,41370 75400 800

5 950 1610500 12 75Drive 332 13,11370 70524 800

Designers Comments




Conveyor Pulleys Data Sheet15 Mar 2012 08:41 27/27Page

J Resources


Project

Project No.

Conveyor No.

Client

Prepared By

Design Date


C3048

11-CV-01

RBO

07 Maret 2012

Description

PulleySpeed

rpm

Wrap Ang le

deg

DrivePower

kW

FaceWidthmm

StationLagging

mmShell

Dia mm

Station / Section

BrgCtrsmm

T1RunkN

T2RunkN

T1StartkN

T2StartkN

1 950400 0 4,9180,0 Takeup 47,71370 5,394,9 4,95

Starting EmptyRunning Full

5 950500 12 7,14185,0Drive 36,441370 3,695,21 3,92

Starting FullRunning Full

Designers Comments

c3048-pnj-cal-b-0002_b conveyor 11-cv-01

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