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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 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
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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
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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
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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
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Conveyor Sections - Input Data15 Mar 2012 08:41 2/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Takeup & Drive Traction Calculation15 Mar 2012 08:41 3/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Tension Calculations - Summary Run / Start15 Mar 2012 08:41 4/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
Fully Loaded Tension
kN
Empty Tension
kN
Braking
Empty Tension
kN
Fully Loaded Tension
kN
Coasting
Fully Loaded Tension
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Belt Details Report15 Mar 2012 08:41 5/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Tension Calculations - Summary Belt Sag15 Mar 2012 08:41 6/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
Allowable Belt Sag % Running
Allowable Belt Sag % Start / Stop
2 %
%5 Takeup Mass 1000 kg
Running
Station No
Fully Loaded Tension
kN
Empty Tension
kN
Inclines Loaded Tension
kN
Declines Loaded Tension
kN
Starting
Fully Loaded Tension
kN
Empty Tension
kN
Braking
Empty Tension
kN
Fully Loaded Tension
kN
Coasting
Fully Loaded Tension
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
Idler Spacing m 0,30
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
Idler Spacing m 1,20
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
Idler Spacing m 1,20
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
Idler Spacing m 3,00
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
Idler Spacing m 3,00
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
Idler Spacing m 3,00
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Tension Calculations - Run Fully Loaded15 Mar 2012 08:41 7/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
-
Tension Calculations - Run Empty15 Mar 2012 08:41 8/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
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 / 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
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt LengthBelt Elastic Elongation
1,141,14
166025,50
-0,003 mm
kN/m
kW
kN
Takeup Movement -0,002 m
Designers Comments
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Tension Calculations - Run Inclines Loaded15 Mar 2012 08:41 9/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
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 / 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
Totals: 0,10 1,28 0,00 0,03 0,11 0,94 0,15Maximum Tension
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
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Tension Calculations - Run Declines Loaded15 Mar 2012 08:41 10/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
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 / 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
Totals: 0,10 1,3 0,00 0,03 0,11 0,94 0,15Maximum Tension
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
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt LengthBelt Elastic Elongation
1,271,27
166025,50
-0,002 mm
kN/m
kW
kN
Takeup Movement -0,001 m
Designers Comments
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Conveyor Starting and Stopping15 Mar 2012 08:41 11/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
-
Conveyor Idler Details Report15 Mar 2012 08:41 12/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
-
Vertical Curve Radius Calculations15 Mar 2012 08:41 13/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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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
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Viscoelastic Friction Factor Report15 Mar 2012 08:41 15/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Conveyor Belt Resonance Report15 Mar 2012 08:41 16/27Page
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ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Takeup Travel Report15 Mar 2012 08:41 17/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources
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Drive Details Report15 Mar 2012 08:41 18/27Page
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ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Drive Motor Details Report15 Mar 2012 08:41 19/27Page
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ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
1Drive No. Drive Pulley No. 5
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
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Drive Fluid Coupling Details Report15 Mar 2012 08:41 20/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
170 % FLTPeak Torque %
5
1
kW
HeadDrive Description
FENNER TRANSFLUID REDUCED FILL
Coupling Power Rating
Coupling Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 5
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
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Drive Gearbox Details Report15 Mar 2012 08:41 21/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
996Motor Torque at Pulley Speed
Helical Bevel Gear
1HeadDrive Description
Flender Helical Bevel GearTypeGearbox Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 5
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
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Brake Details Report15 Mar 2012 08:41 22/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Shaft Coupling Report15 Mar 2012 08:41 23/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
Number of Motors on Drive Pulley
Load Share on Drive Pulley
1Drive No. Drive Pulley No. 5
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
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Conveyor Pulley Shafts15 Mar 2012 08:41 24/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Conveyor Pulleys15 Mar 2012 08:41 25/27Page
J ResourcesPT Resindo Resources Indonesia
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
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
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Conveyor Pulley Dimensions15 Mar 2012 08:41 26/27Page
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ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
Mom of Inertia kgm2Description
Pulley & Shaft
Mass kg
Shaft Dia mm
Shaft Length
mm
Face Width mmStation
Lagging mm
Shell Dia mm
Station / SectionBrg Ctrs 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
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Conveyor Pulleys Data Sheet15 Mar 2012 08:41 27/27Page
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ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Penjom Gold ExpansionC304811-CV-01
RBO07 Maret 2012
Description
Pulley Speed rpm
Wrap Angle deg
Drive Power
kW
Face Width mmStation
Lagging mm
Shell Dia mm
Station / SectionBrg Ctrs 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
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml HelixTechnologiesVer 6.0.13 Licenced to PT Resindo Resources