13.m501 potasium sulphate bw 750,0.5 m s

8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s

1/27

Conveyor Design Summary17 Oct 2014 13:37 1/27Page

PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd

ProjectProject No.Conveyor No.

ClientPrepared ByDesign Date

Sistem Reaktor 36.R-101

13.M501,0,5 m/sJSA

Material Description POTASSIUM SULPHATE Conveyed Material

High Bulk Density 1040 1040 Low Bulk Density kg/m3

kg/m3 Angle of Repose 46

30 Surcharge Angle degdeg

Material Lump size 3 mmConveyor Data

Nett Lift / Lower (-) 0.074.60Conveying Distance m

mDesign Capacity 2.2 tonnes/hr Belt Speed 0.5 m/s

Belt Details

Belt Class & Run Safety Factor PN800/4750 Belt Width Selected mm Calculated Belt % Full 1.8 %

Top Cover Thickness 8 mm

Belt Total Length 13.190 Belt Rated Tension kN/m

mBottom Cover Thickness 6 mmBelt Mass 16.96 kg/m

Belt Tensions and Power Calculations CEMA

Maximum Tension Tmax 44.222.47Effective Tens. Fully Loaded kN Belt Power - Empty Belt 1.23 kW

Belt Power - Inclines Loaded 1.24 kW

Sag Tension 1.4941.98Minimum Tension Tmin kN

kNBelt Power - Declines Loaded 1.23 kWBelt Power - Fully Loaded 1.24 kW1.5 %

kN

Takeup Type Fixed CentresTakeup Mass 8800 kg Absorbed Power Fully Loaded 1.31 kW

Installed Motor Power 2.2 kW

Drive Efficiency 95.0 %

Carry and Return Idlers

Carry Idler Spacing 130 Carry Idler Trough Angle 0

3 m3 x 152 Carry Idler No Rolls x Dia mm 1 x 152 mm

Return Idler SpacingReturn Idler Trough Angle

Return Idler No Rolls x Diam

Dynamics and Miscellaneous Data

Startup Factor - Empty 140 140 Startup Factor - Fully Loaded 1.00

22.00 kNm0.13Starting Time - Fully Loaded sec 0.01 sec

Total Braking Torque LSSCEMA Temperature Factor Kt

Stop Time - Loaded, Braking0.13Starting Time - Empty sec 0.19 secStop Time - Loaded, Coasting

%%

Takeup Pulley Belt Tension 43.15 kN

13.57

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering


2/27

Conveyor Sections - Input Data17 Oct 2014 13:37 2/27Page





13.M501,0,5 m/sJSA

FrictionFactor InputDescription

No. of Scrapers

SkirtLengthm

Idler Spacingm

Cap-acitytph

Y co-ord m

X co-ord mStation

Section Lift m

SectionLength m

Station / Sectio

Z co-ord m

TenAdj.kN

1 0.00 0.001.00 -0.05 0 1.00Takeup 0.03000.00

2 1.00 0.000.50 0.00 2.2 0.35Hopper 2.00 0.03000.20 1.00

3 1.50 0.004.10 0.07 2.2 1.50Int. Pt 0.03000.20

4 5.60 0.005.60 0.12 0 2.00Drive 3 0.0300-0.05

Totals: 11.20 1.00 2.00 30.13

Designers Comments



3/27

Takeup & Drive Traction Calculation17 Oct 2014 13:37 3/27Page





13.M501,0,5 m/sJSA

Drive Torque Start-up Factor LoadedDrive Torque Start-up Factor Empty

140 %%140 Takeup Mass 8800 kg

Takeup Pulley Belt Tension 43.15 kN

Running

DriveNumber

FullyLoaded

EmptyBelt

Starting Braking

FullyLoaded

EmptyBelt

FullyLoaded

EmptyBelt

1Drive No. Drive

Wrap Angle 180Co-efficient of Friction 0.25Drive Factor Cw

Calculated Belt Tension T1 kN Calculated Belt Tension T2Minimum Required T2Surplus T2 Tension (T1-T2)

0.838

kN kN kN

1.88

44.2241.98

40.1

Lagging Type180

0.250.838

1.87

44.2141.98

40.11

Rubber 180

0.350.499

2.07

45.2641.11

39.04

1800.35

0.499

2.07

45.2441.1

39.03

Rubber 180

0.350.499

17.54

23.6758.82

6.13

Rubber 180

0.350.499

17.45

23.8858.85

6.43

Pulley No. 4

Designers Comments



4/27

Tension Calculations - Summary Run / Start17 Oct 2014 13:37 4/27Page





13.M501,0,5 m/sJSA

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

140 % Takeup Mass 8800 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 42.93 42.9342.93 42.93Takeup 43.20 43.2051.29 51.2742.52 42.52

2 43.16 43.1643.16 43.16Hopper 42.80 42.8033.88 33.7443.64 43.64

3 44.17 44.1744.17 44.17Int. Pt 43.75 43.7532.97 32.8744.74 44.75

4 44.22 44.2144.22 44.21Drive 43.47 43.4723.67 23.8845.26 45.24

Minimum Ten 42.93Maximum Ten

Effective Ten

42.93 42.93 42.93 42.5242.52 23.8823.67 42.8042.8044.22 44.21 44.22 44.21 45.26 45.24 51.29 51.27 43.75 43.75

42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99

2.47 2.46 2.47 2.46

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 13:37 5/27Page





13.M501,0,5 m/sJSA

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

kNBelt Rated Tension for width 67.5

Belt Reinforcement Fibre Fabric PN800/4

Apex PN 200 Standard Belt Description Apex PN Fabric - Spliced Belt Category

Belt Make & Class

Belt Dimensions

Belt Speed & Capacity Conveyed Material

Carry Idler Trough Angle 30

kNMinimum Tension Tmin 41.98

kN Allowable Belt Tension, Starting 94.5

kg/m17Belt Mass Wb (per linear m)

mm6 Bottom Cover Thickness

m

kN/mBelt Rated Tension / m width 90

13.1Belt Total Belt Length (L)

mm8 Top Cover Thickness

mmBelt Width Selected 750

4Belt Class / Plies

m/s0.5 Belt Speedtonnes/hr 2.2 Belt Design Capacity Input

mm3Material Lump sizedegdegSurcharge Angle 30

46 Angle of Repose

kg/m3kg/m3Low Bulk Density 1040

1040 High Bulk Density

POTASSIUM SULPHATE Material Description

Belt Tensions

kN/mCalculated Tension / m width 59

Calculated Max Run Tension 44.22 kN

mm5.3Belt Carcass Thicknessmm19.3Belt Total Thickness

sec26.2Time for 1 Revolution

Actual Belt Tension, Starting 58.85

Allowable Tension Rise, Starting 140 %

kN

Belt Modulus 9200 kN/m

Belt and Material Masskg/m6.8Belt Top Cover Masskg/m5.1Belt Bottom Cover Masskg/m5.1Belt Carcass Mass

kg/m1.2Material Mass Wmkg/m18.2Total Mass (Wb + Wm)

Flooded Belt Material Mass 103.4 kg/mtonnes/hr 186Flooded Belt Capacity

kg222Total 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 Distancemm262 Actual Edge Distance Low BD

mm37Load Burden Depthmm237Load Burden Width

Belt Actual % Full at Low BD %1.8

Belt Load Area Utilised at LowBulk Density 0.0012 m2

Belt Load Area Utilised at HighBulk Density 0.0012 m2

mm262 Actual Edge Distance High BD

Belt Load Area and Capacity at 1040kg/m3Minimum Rec. Edge Distance 64 mm

Belt Actual % Full at High BD 1.8 % Flooded Belt Capacity at 1040kg/m3

tonnes/hr 2.2 Section Loading Max Capacity

Designers Comments



6/27

Tension Calculations - Summary Belt Sag17 Oct 2014 13:37 6/27Page





13.M501,0,5 m/sJSA

Allowable Belt Sag % Running

Allowable Belt Sag % Start / Stop

1.5 %

%5 Takeup Mass 8800 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 42.93 42.9342.93 42.93Takeup 43.20 43.2051.29 51.2742.52 42.52

Belt Sag % 0.05

Idler Spacing m 1.00

0.05 0.05 0.05 0.05 0.05 0.04 0.04 0.05 0.052 43.16 43.1643.16 43.16Hopper 42.80 42.8033.88 33.7443.64 43.64

Belt Sag % 0.02


0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.023 44.17 44.1744.17 44.17Int. Pt 43.75 43.7532.97 32.8744.74 44.75

Belt Sag % 0.08


0.07 0.08 0.07 0.07 0.07 0.1 0.09 0.08 0.074 44.22 44.2144.22 44.21Drive 43.47 43.4723.67 23.8845.26 45.24

Belt Sag % 0.09


0.09 0.09 0.09 0.09 0.09 0.18 0.17 0.1 0.1

Minimum Ten 42.93

Maximum Sag

42.93 42.93 42.93 42.5242.52 23.8823.67 42.8042.80

0.09 0.09 0.09 0.09 0.09 0.09 0.18 0.17 0.1 0.1

Designers Comments



7/27

Tension Calculations - Run Fully Loaded17 Oct 2014 13:37 7/27Page





13.M501,0,5 m/sJSA

Takeup Mass 8800 kg

FrictionFactor

SectionEffectiveTension

Scraper Friction

kN

SkirtFriction

kN

Tensions MaterialAccel.

kNDriveTe kN

T2 RunkN

T1 RunkNStation

Section Lift m

SectionLength

m

Station / Pulley TpPulley

TenAdj.kN

CEMA

1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23

2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00

3 44.17 44.174.10 0.07Int. Pt 0.05 0.03

4 44.22 41.985.60 0.12 2.24Drive 0.89 0.06 0.030.23

Totals: 0.46 2.2 1.00 0.00 0.00 0.89 0.12

Maximum Tension

Minimum Tension

44.22

41.98

kN

kN Average Tension Fully Loaded 42.99 kN

Average Tension Belt Stationary 42.99 kN

Average Tension Difference 0 kN

Total Effective Tension

Total Belt Power (Te x V)

Belt Modulus

Total Belt Length

Belt Elastic Elongation

2.47

1.24

9200

13.10

0 m

m

kN/m

kW

kN

Takeup Movement 0 m

Designers Comments



8/27

Tension Calculations - Run Empty17 Oct 2014 13:37 8/27Page





13.M501,0,5 m/sJSA

FrictionFactor


Scraper Friction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

Section Lift m

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23

2 43.16 43.160.50 0.00Hopper 0.01 0.031.00

3 44.17 44.174.10 0.07Int. Pt 0.04 0.03

4 44.21 41.985.60 0.12 2.23Drive 0.89 0.06 0.030.23

Totals: 0.46 2.23 1.00 0.89 0.11

Maximum Tension

Minimum Tension

44.21

41.98

kN

kN

Average Tension Fully Loaded 42.99 kN





Belt Modulus

Total Belt Length


2.46

1.23

9200

13.10

0 mm

kN/m

kW

kN

Takeup Movement 0 m

Designers Comments



9/27

Tension Calculations - Run Inclines Loaded17 Oct 2014 13:37 9/27Page





13.M501,0,5 m/sJSA

FrictionFactor


Scraper Friction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

Section Lift m

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23

2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00

3 44.17 44.174.10 0.07Int. Pt 0.05 0.03

4 44.22 41.985.60 0.12 2.24Drive 0.89 0.06 0.030.23

Totals: 0.46 2.24 1.00 0.00 0.00 0.89 0.12

Maximum Tension

Minimum Tension

44.22

41.98

kN

kN

Average Tension Inclines Loaded 42.99 kN





Belt Modulus

Total Belt Length


2.47

1.24

9200

13.10

0 mm

kN/m

kW

kN

Takeup Movement 0 m

Designers Comments



10/27

Tension Calculations - Run Declines Loaded17 Oct 2014 13:37 10/27Page





13.M501,0,5 m/sJSA

FrictionFactor


Scraper Friction

kN

SkirtFriction

kN


kNDriveTe kN

T2 RunkN

T1 RunkNStation

Section Lift m

SectionLength

m

Station / Pulley

TpPulley

TenAdj.kN

CEMA

1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23

2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00

3 44.17 44.174.10 0.07Int. Pt 0.04 0.03

4 44.21 41.985.60 0.12 2.23Drive 0.89 0.06 0.030.23

Totals: 0.46 2.2 1.00 0.00 0.00 0.89 0.12

Maximum Tension

Minimum Tension

44.21

41.98

kN

kN

Average Tension Declines Loaded 42.99 kN Average Tension Belt Stationary 42.99 kN




Belt Modulus

Total Belt Length


2.46

1.23

9200

13.100 m

m

kN/m

kW

kN

Takeup Movement 0 m

Designers Comments



11/27

Conveyor Starting and Stopping17 Oct 2014 13:37 11/27Page





13.M501,0,5 m/sJSA

Mass of BeltSystem Masses

Carry Idler Equivalent Mass 816Mass of Material kg

kg

Input Data

Pulley Equivalent Mass 52441Return Idler Equivalent Mass kg

kg

Belt Rated TensionBelt Speed 0.5 m/s

Total Braking Force 67.28

2.46Effective Tension Empty kN

3.5Tension Available to Accelerate Conveyor

kN

kN

221 kg

Total System Equivalent Mass 91946Drive Equivalent Mass kg

kg

90 kN/m

Drive Inertia Allow. Belt Start Tension Rise 140 %

0.0012 kg-m2

Start-up Factor - LoadedTotal Braking Torque 22 kNm

140 Start-up Factor - Empty 140

Drive Efficiency (Average)Installed Power 2.2 kW

95

%%

%Tensions and Accelerating Forces

Stopping Times & Deceleration RatesEffective Tens. Fully Loaded 2.47 kN

3.51 Accelerating Tension - Empty kN

Starting Times & Acceleration Rates

Acceleration Rate - Loaded 3.810.13Starting Time - Empty sec

3.85 Accelerating Rate - Empty m/s2m/s2

Starting Time - Fully Loaded 0.13 sec

Belt Tension Rise Starting / Braking

Maximum Belt Tension / width 78.47750Belt Width mm

90Belt Rated Tension / width kN/mkN/m

Max Belt Tension, Start/Brake 58.85 kN

87.2 Actual Max Tension, Start/Brake %

0.19Stopping Time Loaded Coasting secStopping Time Loaded Braking 0.01 sec

0.19Stopping Time Empty Coasting secStopping Time Empty Braking 0.01 sec

-2.69Deceleration - Loaded Coasting m/s2Deceleration - Loaded Braking -75.90 m/s2

-2.70Deceleration - Empty Coasting m/s2Deceleration - Empty Braking -76.38 m/s2

Stopping Distances & Discharge Volumes

Stopping Distance Loaded Coasting mStopping Distance Loaded Braking m

Stopping Distance Empty Coasting mStopping Distance Empty Braking m

Discharge Mass, Coasting kgDischarge Mass, Braking kg

Discharge Volume, Coasting m3Discharge Volume, Braking m3

00.05

00.05

0000

Accelerating Tension - Loaded

Designers Comments



12/27

Conveyor Idler Details Report17 Oct 2014 13:37 12/27Page





13.M501,0,5 m/sJSA

Idler Category Sandvik Carry

Idler Design Belt Width 750

Series 20 3 Roll Carry 152 PlainInline

Idler Description

mm

Drawing Number 20 Idler Series

Total Number of Idlers 51Nominal Idler Spacing m

Troughing Angle 30.0

0 Idler Price

deg

Idler Bearing Diameter 25.0 27.0 Idler Shaft Diameter mm

Idler Roll Diameter 152 3Number of Idler Rolls

mm

mm

Idler Rotation Speed 63

Roll Face Width 283 mm

307 Shaft Support Centres1000 Idler Support Fixing Width mm

Idlerset Total Mass 31.7 16.2 Idlerset Rotating Mass

3.0 Idler Vertical Misalignment Allowance mm1.00Dynamic Load Factor

mm

kgkg

Roll Bearing Centres 226.8 mm

Carry Side Idlers Return Side Idlers

500 Belt Deviation Load N734Total Load on Centre Roll N

Ball Type of Bearing6205 Bearing Designation

14,000 Bearing Dynamic Load Rating C N14,720,410Bearing L10h Life hrs

8.00 Allowable Shaft Deflection at Bearing min1.05 Actual Shaft Deflection at Bearing min

rpm

Sandvik Flat Return

750

Series 30 1 Roll Flat Carry 152 Dia

mm30

33 m

0.0

0

deg

25.0 30.0 mm

152 1

mm

mm

63

849 mm

8731000 mm

23.113.8

56.3 mm1.40

mm

kgkg

785.4 mm

1,501 N2,446 N

Ball 6305

22,500 N1,652,498 hrs

10.00 min8.66 min

rpm

Designers Comments



13/27

Vertical Curve Radius Calculations17 Oct 2014 13:37 13/27Page





13.M501,0,5 m/s

JSA

17 Oct 2014 13:37 Vertical Curve Radius Calculations Page 13/27

Belt Mass - New Belt 16.96 kg/mTop Cover Mass - New Belt 6.78 kg/mBottom Cover Mass 5.08 kg/mWorn Belt Mass 12.72 kg/mReduction of Top Cover Mass 62.5 %Conveyed Material Mass 1.22 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 Modulus 9200 kN/mBelt Rated Tension 67.5 kN

Belt Width 750 mm

90 kN/m115 % Starting

CurveType

Fully Loaded

Running

Station

DesignVerticalCurve

RadiusLoad

Capacity

Station / Sectio

Empty

tonnes/hr mTension Radius

kN mRadius

mTension

kN

Starting

Fully LoadedRadius

mkNTension

EmptyTension Radius

mkN

Braking

Fully LoadedRadius

mkNTension

EmptyTension Radius

mkN

Largest

Reqd.Radius

m

1 42.93Takeup 42.93 42.52 42.52 51.29 51.27

2 43.162Hopper 43.16 43.64 43.64 33.88 33.74

3 44.172Int. Pt Concave 44.17 44.74 44.75 32.97 32.87



14/27

17 Oct 2014 13:37 Vertical Curve Radius Calculations Page 14/27

Belt Mass - New Belt 16.96 kg/mTop Cover Mass - New Belt 6.78 kg/mBottom Cover Mass 5.08 kg/mWorn Belt Mass 12.72 kg/mReduction of Top Cover Mass 62.5 %Conveyed Material Mass 1.22 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 Modulus 9200 kN/mBelt Rated Tension 67.5 kN

Belt Width 750 mm

90 kN/m115 % Starting

CurveType

Fully LoadedRunning

Station

DesignVerticalCurve

RadiusLoad

Capacity

Station / Sectio

Empty

tonnes/hr mTension Radius

kN mRadius

mTension

kN

StartingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

BrakingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

LargestReqd.

Radius

m

32.8732.9744.7544.7444.1744.17Belt Tension at Curve kN

364198199364364356356Min. Concave Lift Off Radius

523

523

913

913

991313

Max. Centre Tension RadiusMin. Edge Tension Radius

4 44.22Drive 44.21 45.26 45.24 23.67 23.88

Designers Comments



15/27

Viscoelastic Friction Factor Report17 Oct 2014 13:37 15/27Page





13.M501,0,5 m/sJSA

deg0.1Idlerset Forward Tilt angle

N/mm2

deg C

Belt has Turnover on Return Run

degNmmNmmNmmNmm

0.12

152 2

152 2

152

152 2

Idlerset Skew AngleReturn Idler Wing Roll DragReturn Idler Wing Roll DiaReturn Idler Centre Roll DragReturn Idler Centre Roll DiaCarry Idler Wing Roll DragCarry Idler Wing Roll DiaCarry Idler Centre Roll DragCarry Idler Centre Roll Dia

130

0.136

deg C30 0.13

N/mm2Rubber description ...

6

Belt Bottom Cover TemperatureBelt & 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 Idler

Spacing

Indentation Matl.& Belt Idler Drag Idler Skew & TiltEmptyfriction factor f (loaded)

1 0.00.0300 0.000001.00 1.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000

2 0.00.0300 0.000000.50 0.35 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000

3 0.00.0300 0.000004.10 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000

4 0.00.0300 0.000005.60 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000

Totals: 11.20 1.00 2.00 30.13

Designers Comments



16/27

Conveyor Belt Resonance Report17 Oct 2014 13:37 16/27Page





13.M501,0,5 m/sJSA

DescriptionSection

Idler Spacing

Idler RollExcitationFrequency

Belt TransverseWave Frequency

RangeStation

EndBelt

Tension

Station / Sectio

Hz

Running Fully Loaded Belt Resonance

to Hz

CriticalIdler

SpacingStart

CriticalIdler

SpacingEnd

Idler Spacing

within+/- 10%

m m mmkNkN

StartBelt

TensionHz

M o d e

Belt Speed 0.5 m/sCarry Roll Diameter 152 mmReturn Roll Diameter 152 mm Takeup Mass 8800 kg

Belt Resonance +/- Tolerance 10 %

1 25.22 25.5143.16 44.17 1.05 1Takeup 24.37 OK24.09

2 69.59 70.4443.16 44.22 1.05 0.35Hopper 23.55 OK23.26

3 16.43 16.244.17 42.93 1.05 1.5Int. Pt 23.2 OK23.53

4 12.44 12.5841.98 42.93 1.05 2Drive 24.02 OK23.75

Designers Comments



17/27

Takeup Travel Report17 Oct 2014 13:37 17/27Page





13.M501,0,5 m/sJSA

Takeup Travel

m0 Safety Margin Top +

kg

kgTakeup Mass kg (ManualInput)

8800

8800Takeup Mass Calculated

kgTakeup Mass step increment 200 100 Max no. of Calc Increments

Fixed CentresTakeup Type

Auto Calc Takeup Mass

Takeup Travel Estimate

m0.5 Belt Splice Allowance +m0 Dynamic Travel Up +m0 Dynamic Travel Down +m0 Safety Margin Bottom +

deg0 Minimum Site Temperature Thermal Expansion Distance

deg30 Maximum Site Temperature

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

m13.10Total Belt Lengthm0.002Thermal Expansion Distance +

%0.15 Permanent Stretch co-efficient % of Belt Length

Permanent Belt Stretch

m0.009Permanent Belt StretchDistance +

m0.51Total Takeup Travel Distance



18/27

Drive Details Report17 Oct 2014 13:37 18/27Page





13.M501,0,5 m/sJSA

%95Drive Efficiency

:1:1

m/s1.02Calculated Belt Speedm/s0.5Required Belt Speedrpm29.68Calculated Pulley Speed for Reducer rpm14.6Required Pulley Speed

31.5Selected Gearbox Ratio64.035Required Gearbox Ratio

Flender Helical Bevel Gear Gearbox Description380 VoltsMotor Voltage

kg46

rpm935Motor Full Load Speed

0.0012

kg-m20.0012Total Drive Inertiakg-m20Gearbox Inertia (HSS)kg-m20Flywheel Inertiakg-m20High Speed Brake Disc Inertia

%140Starting Torque Factor, Empty%140Starting Torque Factor, Fully Loaded

kg-m20High Speed Coupling Inertiakg-m2Motor Inertia

2.2

1

125Pulley Shaft Diameter at Brg mm150Pulley Shaft Diameter at Hub mm

mm

654Pulley Outside Diameter

630Pulley Shell Diameter

mm

kW

%

0.5Drive Factor Cw, Starting

0.84Drive Factor Cw, Running0.35Coefficient of Friction, Starting

12Pulley Lagging Thickness

0.25Coefficient of Friction, Running

MoistPulley ConditionHeadDrive DescriptionRubber

Electric Motor

100 Pulley Lagging Type

Total Drive Equivalent Mass

Motor Power RatingMotor DescriptionNumber of Motors on Drive Pulley

mm

Load Share on Drive Pulley180 Belt Wrap Angle

1Drive No. Drive Pulley No. 4

Drive Inertia

Pulley and Belt Speed

Pulley and Shaft Dimensions

Holdback

BrakeBrake Location High SpeedLow Speed Brake Torque Input 22

Static Analysis Runback Force Fv 1 NStatic Analysis Horizontal Force Fh 2469 N

Holdback Required (Yes / No) NoNm

Equiv HS Brake Torque 362

Holdback Torque 3 x Motor FLT

Calculated Holdback Torque N/A

Nm4317

Fv>Fh/2

kNmNm

High Speed Coupling

Low Speed Coupling

HS Coupling MakeHS Coupling Model 1020T

Falk

LS Coupling MakeLS Coupling Model RFK140

Ringspann

Holdback Make Not InstalledHoldback Model

Designers Comments



19/27

Drive Motor Details Report17 Oct 2014 13:37 19/27Page





13.M501,0,5 m/sJSA

380 VoltsMotor Voltage

0.0012 kg-m2Motor Inertia

2.2

1

kW

HeadDrive Description

Electric Motor Motor Power RatingMotor Description

Number of Motors on Drive Pulley


Motor Category Metric Motor

DX112MMotor Frame Size6Number of poles

112 mmMotor Shaft Height28 mmMotor Shaft Diameter

935 rpmMotor Full Load Speed

1.24 kW Absorbed Power at Pulley2 kWTotal Motor Power on Drive

1.31 kW Absorbed Power at Motor 95 %Drive Efficiency

48 kgMass of Motor

5.9 AmpsMotor Full Load Current22.5 NmMotor Full Load Torque

0.62Motor Power Factor @ Duty Pt76.49 %Motor Efficiency @ Duty Point

Designers Comments



20/27

Drive Fluid Coupling Details Report17 Oct 2014 13:37 20/27Page





13.M501,0,5 m/sJSA

0 % FLTPeak Torque %0

1

kW

HeadDrive Description

No Selection - Direct DriveCoupling Power RatingCoupling Description



Coupling Category Flender

0Max Starting TimeMin. Required Ramping Time

sec

0 %Coupling Rated Slip

2.2 kWMotor Power RatingCoupling Size

935 rpmMotor Full Load Speed

0 kg935 rpmCoupling Output Speed

0Run-up Torque % (2 sec)

Mass of Couplingsec

% FLT

Selection Mode Auto

Designers Comments



21/27

Drive Gearbox Details Report17 Oct 2014 13:37 21/27Page





13.M501,0,5 m/sJSA

1439Motor Torque at Pulley Speed

Helical Bevel Gear

1HeadDrive Description

Flender Helical Bevel Gear TypeGearbox Description



Gearbox Category Flender

B3SH4Code4Size

22Motor Torque @ FL Speed

2.2 kWMotor Power Rating935 rpmMotor Full Load Speed

210 kgkg-m2Gearbox Inertia

6400Gearbox Rated Torque

Mass of Gearbox

Selection Mode Manual

Number of Stages31.5

B3SH4

Service Factor Required

Ratio

1.5

Gearbox Actual Efficiency

95Design Efficiency (Input)

93 rpm

mmrpm

Maximum Input Shaft Speed 1500Minimum Input Shaft Speed 700

Output Shaft Diameter 80Input Shaft Diameter 30

Service Factor Calculated 4.45

5 %Plus Speed Selection Tolerance5Minus Speed Selection Tolerance %

Fluid Coupling Slip 0

NmNmNm

:1

:1

m/s1.02Calculated Belt Speedm/s0.5Required Belt Speedrpm29.68Calculated Pulley Speed for Reducer rpm14.6Required Pulley Speed 31.5Selected Gearbox Ratio

64.035Required Gearbox Ratio%

mm

%

%

Designers Comments



22/27

Brake Details Report17 Oct 2014 13:37 22/27Page





13.M501,0,5 m/sJSA

%95Drive Efficiency

SvendborgBrake Description

Brake Location

mm3

Mild Steel

mm60Pad offset Width WN3500Caliper Clamping Force Maximum

0.4Co-eff of Friction (Pad-Disc)mm0Disc Thicknessmm0Disc Diameter

Disc Material

BSFH 202

%HeadDescription

Svendborg BSFH 200100

Maximum Air Gap

Caliper

Brake CategoryLoad Share on Drive Pulley

1Drive / Brake No. Drive Pulley No. 4High Speed

Low Speed Brake Torque Input 22Equiv HS Brake Torque 362

kNmNm

Brake Selection Input Data

Design Braking Torque InputSelected Brake's Torque Rating -43

1210

Number of Motors on Drive Pulley 1

NmNm

Design Stopping TimeConsecutive No of Stops 310.0 sec

Average No of Stops Ambient Temperature 40

6deg 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 64.035 : 1

Mass of Caliper 26 kgBrake Caliper Price $0.00

Caliper Clamping Force Minimum 2000 N

Designers Comments



23/27

Shaft Coupling Report17 Oct 2014 13:37 23/27Page





13.M501,0,5 m/sJSA

%95Drive Efficiency

%140Starting Torque Factor, Empty%140Starting Torque Factor, Fully Loaded

kg-m20.0014High Speed Coupling Inertia

1 125Pulley Shaft Diameter at Brg mm

%HeadDrive Description

100


Load Share on Drive Pulley


Fluid Coupling No Selection - Direct DriveFluid Coupling Size

High Speed Coupling Low Speed Coupling

Fluid Coupling

HS Coupling MakeHS Coupling Model 1020T

Falk LS Coupling MakeLS Coupling Model RFK140

Ringspann

1439Motor Torque at Pulley Speed22Motor Torque @ FL Speed

2.2 kWMotor Power Rating935 rpmMotor Full Load Speed

Service Factor Required 1.5Service Factor Calculated 2.31

NmNm

Coupling Type Grid

Nm

HS Coupling Category Falk SteelFlex Grid LS Coupling Category Falk SteelFlex Grid

Coupling Torque Rating 52

Maximum Shaft Bore 28 mmMinimum Shaft Bore 0 mmMaximum Rotation Speed 4500 rpm

Drawing Number High Speed Coupling Mass 1.91 kgHigh Speed Coupling Price 0

kg-m22.9Low Speed Coupling Inertia

Service Factor Required 1.5Service Factor Calculated 38.92

Coupling Type Rigid Flanged

NmCoupling Torque Rating 56000

Maximum Shaft Bore 140 mmMinimum Shaft Bore 115 mmMaximum Rotation Speed 3800 rpm

Drawing Number Low Speed Coupling Mass 800 kgLow Speed Coupling Price 0

Direct Drive

Designers Comments



24/27

Conveyor Pulley Shafts17 Oct 2014 13:37 24/27Page





13.M501,0,5 m/sJSA

Description

ShaftMass

kg

WrapAngle

deg

Defl.Diamm

T1Run

Station

ShaftLength

mm

Station / Sectio Resul-tant

ForceDt.DiammkN kN

T2Run

kN

T1Start

kN

CalculatedShaftDiamm

SelectedBrgDiamm

BrgCtrsmm

1 42.9 43.21610 125123.6180.0Takeup 150 22386.1 127.542.5 1270

4 44.2 42.01610 125123.6180.0Drive 150 22386.2 127.745.3 1270

Designers Comments * Denotes manual pulley shaft dimensions entered



25/27

Conveyor Pulleys17 Oct 2014 13:37 25/27Page





13.M501,0,5 m/sJSA

Mom of Inertiakgm2Description

Pulley &Shaft

Mass kg

PulleySpeed

rpm

WrapAngle

deg

ShaftDiamm

ShaftLength

mm

FaceWidth

mmStationLagging

mmShell

Dia mm

Station / SectioBrgCtrsmm

BrgDiamm

1 850 1610500 12 150 180.0Takeup 18.2 475 12.71270 125

4 850 1610630 12 150 180.0Drive 14.6 718 36.21270 125

Designers Comments * Denotes manual pulley dimensions entered



26/27

Conveyor Pulley Dimensions17 Oct 2014 13:37 26/27Page





13.M501,0,5 m/sJSA

Mom of Inertiakgm2Description

Pulley &Shaft

Mass kg

ShaftDiamm

ShaftLength

mm

FaceWidth

mmStationLagging

mmShell

Dia mm

Station / SectioBrgCtrsmm

BrgDiamm

ODmm

BeltWidth

mm

1 850 1610500 12 150Takeup 475 12.71270 125524 750

4 850 1610630 12 150Drive 718 36.21270 125654 750

Designers Comments



27/27

Conveyor Pulleys Data Sheet17 Oct 2014 13:37 27/27Page





13.M501,0,5 m/sJSA

DescriptionPulleySpeed

rpm

WrapAngle

deg

DrivePower

kW

FaceWidth

mmStationLagging

mmShell

Dia mm

Station / Sectio

BrgCtrsmm

T1RunkN

T2RunkN

T1Start

kN

T2Start

kN

1 850500 12 51.29180.0Takeup 18.21270 37.4642.93 43.16Braking FullRunning Full

4 850630 12 45.26180.0Drive 14.62.21270 41.1144.22 41.98Starting FullRunning Full

Designers Comments

13.m501 potasium sulphate bw 750,0.5 m s

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