142345522-c3048-pnj-cal-b-0002-b-conveyor-11-cv-01

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 Descriptions Date Prepared By Checked

By Approved

By

B Issued for Client Review 14/03/12

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

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

CONVEYOR CV-01 SHEET : REV : B CALCULATION BY : RBO DATE : March 14, 2012

CHKD : AJA DATE : March 14, 2012

TABLE OF CONTENT

1 GENERAL ..................................................................................................................................... 2

2 REFERENCE DOCUMENT ........................................................................................................... 2

3 HELIX OUTPUT RESULT ............................................................................................................. 2

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

CONVEYOR CV-01 SHEET : REV : B CALCULATION BY : RBO DATE : March 14, 2012

CHKD : AJA 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 Circuit Process Flow Diagram

3 HELIX OUTPUT RESULT

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

J ResourcesPT Resindo Resources Indonesia

ProjectProject No.Conveyor No.

ClientPrepared ByDesign Date

Penjom Gold ExpansionC304811-CV-01

RBO07 Maret 2012

Material Description Gold OreConveyed Material

High Bulk Density 16001600Low Bulk Density kg/m3

kg/m3Angle of Repose 30

20Surcharge Angle degdeg

Material Lump size 30 mmConveyor Data

Nett Lift / Lower (-) -0,057,70Conveying Distance m

mDesign Capacity 120 tonnes/hrBelt Speed 1 m/s

Belt Details

Belt Class & Run Safety Factor 250/3800Belt Width Selected mm Calculated Belt % Full 29,7 %

Top Cover Thickness 8 mm

Belt Total Length 25,525Belt Rated Tension kN/m

mBottom Cover Thickness 2 mmBelt Mass 12,16 kg/m

Belt Tensions and Power Calculations ISO

Maximum Tension Tmax 5,221,34Effective Tens. Fully Loaded kN Belt Power - Empty Belt 1,14 kW

Belt Power - Inclines Loaded 1,34 kW

Sag Tension 3,353,92Minimum Tension Tmin kN

kNBelt Power - Declines Loaded 1,27 kWBelt Power - Fully Loaded 1,34 kW2 %

kN

Takeup Type Screw Take-UpTakeup 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

3 m3 x 127Carry Idler No Rolls x Dia mm 1 x 127 mm

Return Idler SpacingReturn Idler Trough Angle

Return Idler No Rolls x Diam

Dynamics and Miscellaneous Data

Startup Factor - Empty 140140Startup Factor - Fully Loaded 1,00

0,00 kNm0,40Starting Time - Fully Loaded sec 1,05 sec

Total Braking Torque LSSCEMA Temperature Factor Kt

Stop Time - Loaded, Braking0,31Starting Time - Empty sec 1,05 secStop Time - Loaded, Coasting

%%

Takeup Pulley Belt Tension 4,90 kN

38,33

Designers Comments

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

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





RBO07 Maret 2012

Friction Factor InputDescription

No. of Scrapers

Skirt Length

m

Idler Spacing

m

Cap-acity tph

Y co-ord m

X co-ord mStation

Section Lift m

Section Length

m

Station / Section

Z co-ord m

Ten Adj. kN

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





RBO07 Maret 2012

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

140 %%140 Takeup Mass 1000 kg

Running

Drive Number

Fully Loaded

Empty Belt

Starting Braking

Fully Loaded

Empty Belt

Fully Loaded

Empty Belt

1Drive No. Drive

Wrap Angle 185Co-efficient of Friction 0,25Drive Factor CwCalculated Belt Tension T1 kNCalculated Belt Tension T2Minimum Required T2Surplus T2 Tension (T1-T2)

0,805

kNkNkN

1,04

5,213,92

2,88

Lagging Type185

0,250,805

0,88

5,013,92

3,04

Rubber1850,35

0,477

1,65

7,143,69

2,04

1850,35

0,477

1,5

6,673,52

2,02

Rubber1850,35

0,477

0,15

4,474,15

4

Rubber185

0,350,477

0,16

4,54,16

4

Pulley No. 5

Designers Comments


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





RBO07 Maret 2012

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

140 %

140 % Takeup Mass 1000 kg

Running

Station No

Fully Loaded Tension

kN

Empty Tension

kN

Inclines Loaded Tension

kN

Declines Loaded Tension

kN

Starting


kN

Empty Tension

kN

Braking

Empty Tension

kN


kN

Coasting


kN

Empty Tension

kN

1 4,90 4,904,90 4,90Takeup 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 6,67

6 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 4,57Maximum Ten

Effective Ten

4,57 4,57 4,57 4,254,40 4,504,47 4,504,475,22 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

0,0070,004

0,0060,003

-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





RBO07 Maret 2012

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

kNBelt Rated Tension for width 20

Belt Reinforcement Fibre Fabric250/3

GOODYEAR PLYLON-HIBelt DescriptionGoodyear FabricBelt Category

Belt Make & Class

Belt Dimensions

Belt Speed & CapacityConveyed Material

Carry 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)

mm8Top Cover Thickness

mmBelt Width Selected 800

3Belt Class / Plies

m/s1Belt Speedtonnes/hr120Belt Design Capacity Input

mm30Material Lump sizedegdegSurcharge Angle 20

30Angle of Repose

kg/m3kg/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 Thicknessmm13,6Belt Total Thickness

sec25,5Time for 1 Revolution

Actual Belt Tension, Starting 7,14

Allowable Tension Rise, Starting 140 %

kN

Belt Modulus 1660 kN/m

Belt and Material Masskg/m7,2Belt Top Cover Masskg/m1,8Belt Bottom Cover Masskg/m3,1Belt Carcass Mass

kg/m33,3Material Mass Wmkg/m45,5Total Mass (Wb + Wm)

Flooded Belt Material Mass 165 kg/mtonnes/hr594Flooded Belt Capacity

kg310Total Belt Mass (Wb x L)

Belt Load Area and Capacity at 1600kg/m3

m20,0702Belt Load Area at Minimum Recommended Edge Distance

m20,1031Flooded Belt Load Area at Zero Edge Distance

mm67Minimum Rec. Edge Distancemm194Actual Edge Distance Low BDmm76Load Burden Depthmm389Load Burden Width

Belt Actual % Full at Low BD %29,7

Belt Load Area Utilised at Low Bulk Density 0,0208 m2

Belt Load Area Utilised at High Bulk Density 0,0208 m2

mm194Actual Edge Distance High BD

Belt Load Area and Capacity at 1600kg/m3Minimum 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





RBO07 Maret 2012

Allowable Belt Sag % Running

Allowable Belt Sag % Start / Stop

2 %

%5 Takeup Mass 1000 kg

Running

Station No


kN

Empty Tension

kN

Inclines Loaded Tension

kN

Declines Loaded Tension

kN

Starting


kN

Empty Tension

kN

Braking

Empty Tension

kN


kN

Coasting


kN

Empty Tension

kN1 4,90 4,904,90 4,90Takeup 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 0,362 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 0,093 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 0,394 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 0,45 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 0,996 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 0,937 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 4,57Maximum Sag

4,57 4,57 4,57 4,254,40 4,504,47 4,504,471,29 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





RBO07 Maret 2012

Takeup Mass 1000 kg

Friction Factor

Section Effective Tension

Scraper Friction

kN

Skirt Friction

kN

Tensions Material Accel.

kNDrive Te kN

T2 Run kN

T1 Run kNStation

Section Lift m

Section Length

m

Station / Pulley Tp Pulley

Ten Adj. kN

ISO

1 4,90 4,954,30 0,00Takeup 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 0,15Maximum Tension

Minimum Tension

5,22

3,92

kN

kNAverage Tension Fully Loaded 4,80 kNAverage Tension Belt Stationary 4,90 kNAverage Tension Difference -0,1 kN

Total Effective Tension

Total Belt Power (Te x V)

Belt Modulus

Total Belt LengthBelt Elastic Elongation

1,341,34

166025,50

-0,002 mm

kN/m

kW

kN

Takeup Movement -0,001 m

Designers Comments


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





RBO07 Maret 2012

Friction Factor


Scraper Friction

kN

Skirt Friction

kN


kNDrive Te kN

T2 Run kN

T1 Run kNStation

Section Lift m

Section Length

m

Station / PulleyTp

Pulley

Ten Adj. kN

ISO

1 4,90 4,954,30 0,00Takeup 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 0,10Maximum Tension

Minimum Tension

5,01

3,92

kN

kNAverage Tension Fully Loaded 4,76 kNAverage Tension Belt Stationary 4,90 kNAverage Tension Difference -0,14 kN



Belt Modulus


1,141,14

166025,50

-0,003 mm

kN/m

kW

kN


Designers Comments


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





RBO07 Maret 2012

Friction Factor


Scraper Friction

kN

Skirt Friction

kN


kNDrive Te kN

T2 Run kN

T1 Run kNStation

Section Lift m

Section Length

m

Station / PulleyTp

Pulley

Ten Adj. kN

ISO

1 4,90 4,954,30 0,00Takeup 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


Minimum Tension

5,22

3,92

kN

kNAverage Tension Inclines Loaded 4,80 kNAverage Tension Belt Stationary 4,90 kNAverage Tension Difference -0,1 kN



Belt Modulus


1,341,34

166025,50

-0,002 mm

kN/m

kW

kN


Designers Comments


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





RBO07 Maret 2012

Friction Factor


Scraper Friction

kN

Skirt Friction

kN


kNDrive Te kN

T2 Run kN

T1 Run kNStation

Section Lift m

Section Length

m

Station / PulleyTp

Pulley

Ten Adj. kN

ISO

1 4,90 4,954,30 0,00Takeup 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


Minimum Tension

5,16

3,92

kN

kNAverage Tension Declines Loaded 4,79 kNAverage Tension Belt Stationary 4,90 kNAverage Tension Difference -0,11 kN



Belt Modulus


1,271,27

166025,50

-0,002 mm

kN/m

kW

kN


Designers Comments


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





RBO07 Maret 2012

Mass of BeltSystem Masses

Carry Idler Equivalent Mass 231257Mass of Material kg

kg

Input Data

Pulley Equivalent Mass 32636Return Idler Equivalent Mass kg

kg

Belt Rated TensionBelt Speed 1 m/s

Total Braking Force 0,001,14Effective Tension Empty kN

3,5Tension Available to Accelerate Conveyor

kN

kN

310 kg

Total System Equivalent Mass 1.404244Drive Equivalent Mass kg

kg

25 kN/m

Drive InertiaAllow. Belt Start Tension Rise 140 %

0,0109 kg-m2

Start-up Factor - LoadedTotal Braking Torque 0 kNm

140Start-up Factor - Empty 140

Drive Efficiency (Average)Installed Power 4 kW

82

%%

%Tensions and Accelerating Forces

Stopping Times & Deceleration RatesEffective Tens. Fully Loaded 1,34 kN

3,66Accelerating Tension - Empty kN

Starting Times & Acceleration Rates

Acceleration Rate - Loaded 2,490,31Starting Time - Empty sec

3,19Accelerating Rate - Empty m/s2m/s2

Starting Time - Fully Loaded 0,40 sec

Belt Tension Rise Starting / Braking

Maximum Belt Tension / width 8,93800Belt Width mm

25Belt Rated Tension / width kN/mkN/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 secStopping Time Empty Braking 1,00 sec

-0,95Deceleration - Loaded Coasting m/s2Deceleration - Loaded Braking -0,95 m/s2

-1,00Deceleration - Empty Coasting m/s2Deceleration - Empty Braking -1,00 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

0,530,530,50,5

1818

0,010,01

Accelerating Tension - Loaded

Designers Comments


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





RBO07 Maret 2012

Idler Category Sandvik Carry

Idler Design Belt Width 800

Series 15 3 Roll Carry 127 Plain Inline

Idler Description

mm

Drawing Number15Idler Series

Total Number of Idlers 221,2Nominal Idler Spacing m

Troughing Angle 35,0

0Idler Price

deg

Idler Bearing Diameter 25,025,0Idler Shaft Diameter mm

Idler Roll Diameter 1273Number of Idler Rolls

mm

mm

Idler Rotation Speed 150

Roll Face Width 296 mm

320Shaft Support Centres1050Idler Support Fixing Width mm

Idlerset Total Mass 27,210,5Idlerset Rotating Mass

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

mm

kgkg

Roll Bearing Centres 239,8 mm

Carry Side Idlers Return Side Idlers

500Belt Deviation Load N926Total Load on Centre Roll N

BallType of Bearing6205Bearing Designation

14.000Bearing Dynamic Load Rating C N3.064.374Bearing L10h Life hrs

8,00Allowable Shaft Deflection at Bearing min1,90Actual Shaft Deflection at Bearing min

rpm

Sandvik Flat Return

800

Series 15 1 Roll Flat Carry 127 Dia

mm15

43 m

0,0

0

deg

25,027,0 mm

1271

mm

mm

150

896 mm

9201050 mm

16,29

5,0 mm1,40

mm

kgkg

839,8 mm

500 N1.162 N

Ball6205

14.000 N1.551.716 hrs

10,00 min6,14 min

rpm

Designers Comments


Vertical Curve Radius Calculations15 Mar 2012 08:41 13/27Page





RBO07 Maret 2012

15 Mar 2012 08:41 Vertical Curve Radius Calculations Page 13/27

Belt Mass - New Belt 12,16 kg/mTop Cover Mass - New Belt 7,23 kg/mBottom Cover Mass 1,81 kg/mWorn Belt Mass 9,12 kg/mReduction of Top Cover Mass 42 %Conveyed Material Mass 33,33 kg/m

% Belt Mass for Lift-off Calculation 75 %Curve Tension Safety Factor 1Average Drive Torque Start-up Factor - Loaded 140 %Average Drive Torque Start-up Factor - Empty 140 %

Allowable Edge Tension - Running: 140 %

Belt Modulus 1660 kN/mBelt Rated Tension 20 kN

Belt Width 800 mm

25 kN/m115 % Starting

Curve Type

Fully LoadedRunning

Station

Design Vertical Curve Radius

Load Capacity

Station / Section

Empty

tonnes/hr mTension Radius

kN mRadius

mTension

kN

StartingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

BrakingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

Largest Reqd. Radius

m

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

2 4,97120Hopper 4,97 5,56 5,73 4,75 4,74

3 5,19120Int. Pt 5,0 6,67 6,43 4,62 4,56


15 Mar 2012 08:41 Vertical Curve Radius Calculations Page 14/27

Belt Mass - New Belt 12,16 kg/mTop Cover Mass - New Belt 7,23 kg/mBottom Cover Mass 1,81 kg/mWorn Belt Mass 9,12 kg/mReduction of Top Cover Mass 42 %Conveyed Material Mass 33,33 kg/m

% Belt Mass for Lift-off Calculation 75 %Curve Tension Safety Factor 1Average Drive Torque Start-up Factor - Loaded 140 %Average Drive Torque Start-up Factor - Empty 140 %

Allowable Edge Tension - Running: 140 %

Belt Modulus 1660 kN/mBelt Rated Tension 20 kN

Belt Width 800 mm

25 kN/m115 % Starting

Curve Type

Fully LoadedRunning

Station

Design Vertical Curve Radius

Load Capacity

Station / Section

Empty

tonnes/hr mTension Radius

kN mRadius

mTension

kN

StartingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

BrakingFully Loaded

RadiusmkN

TensionEmpty

Tension RadiusmkN

Largest Reqd. Radius

m

4 5,22120Int. Pt Convex 5,01 7,03 6,61 4,52 4,52

Min. Edge Tension RadiusMax. Buckling Radius

830

834

817

819

744

745

Belt Edge Tension Rise at Curve kN 0Total Edge Tension at Curve kN and % 5,22 5,01 7,03 6,61 4,52 4,52

0 0 0 0 026% 25% 35% 33% 23% 23%

Centre Tension at Curve kN 5,22 5,01 7,03 6,61 4,52 4,52

45Belt Tension at Curve kN 5,22 5,01 7,03 6,61 4,52 4,52

5 5,21Drive 5,01 7,14 6,67 4,47 4,5

6 4,57Int. Pt Convex 4,57 4,4 4,25 4,77 4,78

Min. Edge Tension RadiusMax. Buckling RadiusBelt Edge Tension Rise at Curve kN Flat BeltTotal Edge Tension at Curve kN and %Centre Tension at Curve kN

0Belt Tension at Curve kN 4,57 4,57 4,4 4,25 4,77 4,78

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

Designers Comments


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





RBO07 Maret 2012

deg0,1Idlerset Forward Tilt angle

N/mm2

deg C

Belt has Turnover on Return RundegNmmNmmNmmNmm

0,12

1272

1272

127

1272

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 C300,13

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 0,072RRF Bot.RRF Top

Viscoelastic Calculations Input Data

Empty Friction factor f

Section Length

Tilt friction

%

Tilt friction

ft

Drag factor

%

Flexure friction

%

Freq uency rad/s

Indent factor

%No

Indent factor

fi

Total Loaded Friction factor f

Station / Section

Flexure friction

fm

Drag factor

frIdler

Spacing

Indentation Matl.& Belt Idler Drag Idler Skew & TiltEmptyfriction 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





RBO07 Maret 2012

DescriptionSection

Idler Spacing

Idler Roll Excitation Frequency

Belt Transverse Wave Frequency

RangeStation

End Belt

Tension

Station / Section

Hz

Running Fully Loaded Belt Resonance

to Hz

Critical Idler

Spacing Start

Critical Idler

Spacing End

Idler Spacing within

+/- 10%m m mmkNkN

Start Belt

TensionHz M

ode

Belt Speed 1 m/sCarry Roll Diameter 127 mmReturn Roll Diameter 127 mm Takeup Mass 1000 kg

1 8,39 8,594,95 5,19 2,51 1,2Takeup 4,11 OK4,02

2 17,27 17,74,97 5,22 2,51 0,3Hopper 2,12 OK2,07

3 4,41 4,425,19 5,21 2,51 1,2Int. Pt 2,12 OK2,11

4 4,42 4,135,22 4,57 2,51 1,2Int. Pt 1,98 OK2,12

5 2,98 3,233,92 4,59 2,51 3Drive 3,87 OK3,57

6 3,22 3,344,57 4,9 2,51 3Int. Pt 3,99 OK3,86

7 3,23 3,344,59 4,9 2,51 3Int. Pt 3,99 OK3,87

Designers Comments


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





RBO07 Maret 2012

Takeup Travel

m0Safety Margin Top +

kg

kgTakeup Mass kg (Manual Input)

2000

1000Takeup Mass Calculated

kgTakeup Mass step increment 500100Max no. of Calc Increments

Screw Take-UpTakeup TypeAuto Calc Takeup Mass

Takeup Travel Estimate

m0Belt Splice Allowance +m0Dynamic Travel Up +m0Dynamic Travel Down +m0Safety Margin Bottom +

deg0Minimum Site TemperatureThermal Expansion Distance

deg45Maximum Site Temperature

1,17E-05Belt Expansion co-efficient m/m per degree Cm25,50Total Belt Lengthm0,007Thermal Expansion Distance +

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

Permanent Belt Stretch

m0,191Permanent Belt Stretch Distance +

m0,2Total Takeup Travel Distance


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





RBO07 Maret 2012

%82Drive Efficiency

:1:1

m/s1,05Calculated Belt Speedm/s1Required Belt Speedrpm38,27Calculated Pulley Speed for Reducerrpm38,37Required Pulley Speed

35,5Selected Gearbox Ratio37,273Required Gearbox Ratio

Flender Helical Bevel GearGearbox Description380 VoltsMotor Voltage

kg244

rpm1430Motor Full Load Speed

0,0109

kg-m20,0109Total 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

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, 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 Pulley185 Belt Wrap Angle

1Drive No. Drive Pulley No. 5

Drive Inertia

Pulley and Belt Speed

Pulley and Shaft Dimensions

Holdback

BrakeBrake Location High SpeedLow Speed Brake Torque Input 0

Static Analysis Runback Force Fv -16 NStatic Analysis Horizontal Force Fh 1356 N

Holdback Required (Yes / No) NoNm

Equiv HS Brake Torque 0

Holdback Torque 3 x Motor FLT

Calculated Holdback Torque N/A

Nm3144Fv>Fh/2

Fluid Coupling FENNER TRANSFLUID REDUCED FILL

Fluid Coupling Size 8K

kNmNm

High Speed Coupling

Low Speed Coupling

Fluid Coupling

LS Coupling MakeLS Coupling Model

No Selection

Holdback Make No SelectionHoldback Model

Designers Comments


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





RBO07 Maret 2012

380 VoltsMotor Voltage

0,0109 kg-m2Motor Inertia

4

1

kW

HeadDrive Description

Electric MotorMotor Power RatingMotor Description

Number of Motors on Drive Pulley


Motor Category Metric Motor

DX112MMotor Frame Size4Number of poles

112 mmMotor Shaft Height28 mmMotor Shaft Diameter

1430 rpmMotor Full Load Speed

1,34 kWAbsorbed Power at Pulley4 kWTotal Motor Power on Drive

1,63 kWAbsorbed Power at Motor82 %Drive Efficiency

48 kgMass of Motor

9 AmpsMotor Full Load Current26,7 NmMotor Full Load Torque

0,57Motor Power Factor @ Duty Pt78,77 %Motor Efficiency @ Duty Point

Designers Comments


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





RBO07 Maret 2012

170 % FLTPeak Torque %

5

1

kW

HeadDrive Description

FENNER TRANSFLUID REDUCED FILL

Coupling Power Rating

Coupling Description



Coupling Category Transfluid

30Max Starting TimeMin. Required Ramping Time

sec

5 %Coupling Rated Slip

4 kWMotor Power Rating8KCoupling Size

1430 rpmMotor Full Load Speed

6 kg1358 rpmCoupling Output Speed160Run-up Torque % (2 sec)

Mass of Couplingsec

% FLT

Selection Mode Manual

Designers Comments


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





RBO07 Maret 2012

996Motor Torque at Pulley Speed

Helical Bevel Gear

1HeadDrive Description

Flender Helical Bevel GearTypeGearbox Description



Gearbox Category Flender

B3SH3Code3Size

27Motor Torque @ FL Speed

4 kWMotor Power Rating1430 rpmMotor Full Load Speed

130 kgkg-m2Gearbox Inertia

3400Gearbox Rated Torque

Mass of Gearbox

Selection Mode Auto

Number of Stages35,5

B3SH3

Service Factor Required

Ratio

1,5

Gearbox Actual Efficiency82Design Efficiency (Input)93

rpm

mmrpm

Maximum Input Shaft Speed 1500Minimum Input Shaft Speed 700

Output Shaft Diameter 65Input Shaft Diameter 28

Service Factor Calculated 3,41

5 %Plus Speed Selection Tolerance5Minus Speed Selection Tolerance %

Fluid Coupling Slip 5

NmNmNm

:1:1

m/s1,05Calculated Belt Speedm/s1Required Belt Speedrpm38,27Calculated Pulley Speed for Reducerrpm38,37Required Pulley Speed

35,5Selected Gearbox Ratio37,273Required Gearbox Ratio

%

mm

%%

Designers Comments


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





RBO07 Maret 2012

%82Drive Efficiency

No SelectionBrake Description

Brake Location

mm

Mild Steel

mmPad offset Width WNCaliper Clamping Force Maximum

0,4Co-eff of Friction (Pad-Disc)mm30Disc Thicknessmm600Disc Diameter

Disc Material%HeadDescription

100

Maximum Air Gap

Caliper

Brake CategoryLoad Share on Drive Pulley

1Drive / Brake No. Drive Pulley No. 5High Speed

Low Speed Brake Torque Input 0Equiv HS Brake Torque 0

kNmNm

Brake Selection Input Data

Design Braking Torque InputSelected Brake's Torque Rating

1000

Number of Motors on Drive Pulley 1

NmNm

Design Stopping TimeConsecutive No of Stops 3

10,0 sec

Average No of StopsAmbient Temperature 40

6deg C

Disc Temperature after stops 0 deg C

Recommended working airgap is 1mm

kg-m20,1rpm1480Disc Initial Speed

Disc Moment of InertiaRequired Gearbox Ratio 37,273 : 1

Mass of Caliper kgBrake Caliper Price

Caliper Clamping Force Minimum N

Designers Comments


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





RBO07 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

%HeadDrive Description

100


Load Share on Drive Pulley


Fluid Coupling FENNER TRANSFLUID REDUCED FILL

Fluid Coupling Size 8K

High Speed Coupling Low Speed Coupling

Fluid Coupling

HS Coupling MakeHS Coupling Model

No Selection LS Coupling MakeLS Coupling Model

No Selection

996Motor Torque at Pulley Speed27Motor Torque @ FL Speed

4 kWMotor Power Rating1430 rpmMotor Full Load Speed

Service Factor Required 3,5Service Factor Calculated 0

NmNm

Coupling TypeNm

HS Coupling Category LS Coupling Category

Coupling Torque Rating 0

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

Drawing NumberHigh Speed Coupling Mass 0 kgHigh Speed Coupling Price 0

kg-m20Low Speed Coupling Inertia

Service Factor Required 3,5Service Factor Calculated 0

Coupling TypeNmCoupling Torque Rating 0

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

Drawing NumberLow Speed Coupling Mass 0 kgLow Speed Coupling Price 0

Direct Drive

Designers Comments


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





RBO07 Maret 2012

Description

Shaft Mass

kg

Wrap Angle deg

Defl. Dia mm

T1 Run

Station

Shaft Length

mm

Station / Section Resul- tant

ForceDt. Dia mmkN kN

T2 Run

kN

T1 Start

kN

CalculatedShaft Dia mm

SelectedBrg Dia mm

Brg Ctrs mm

1 4,9 5,01620 7578,1180,0Takeup 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





RBO07 Maret 2012

Mom of Inertia kgm2Description

Pulley & Shaft

Mass kg

Pulley Speed

rpm

Wrap Angle deg

Shaft Dia mm

Shaft Length

mm

Face Width mmStation

Lagging mm

Shell Dia mm

Station / SectionBrg Ctrs mm

Brg Dia mm

1 950 1620400 0 80 180,0Takeup 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





RBO07 Maret 2012

Mom of Inertia kgm2Description

Pulley & Shaft

Mass kg

Shaft Dia mm

Shaft Length

mm


Lagging mm

Shell Dia mm


Brg Dia mm

OD mm

Belt Width mm

1 950 1620400 0 80Takeup 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





RBO07 Maret 2012

Description

Pulley Speed rpm

Wrap Angle deg

Drive Power

kW


Lagging mm

Shell Dia mm


T1 Run kN

T2 Run kN

T1 Start kN

T2 Start kN

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

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

Designers Comments


142345522-c3048-pnj-cal-b-0002-b-conveyor-11-cv-01

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