Conveyor Calculation Sheet Draft.xls 1n17n

PETROVIETNAM ENGINEERING - PVE CALCULATION SHEET No. I. 1

2

3

4

II. 1

PARAMETERS INPUT DATA INSTALLATION Troughing Type Capacity Design Conveying Length Lift Belt Width Belt Speed Length of middle carrying roll Troughing Angle Incline Angle MATERIAL Material Density Lump Size Temperature Surcharge Angle CONVEYOR BELT Friction Coefficient of Pulleys Friction Coefficient of Pulleys at Start-Up

3

VALUVE BMCR

Unit

3 roll Q L H B v I λ δ

Idler length if 3 or 5 roll

Name ρ

1,000 258.0 17.9 1,200 1.68 465 35 4.8

t/h m m mm m/s mm Degree Degree

1.50

t/m3 mm o C Degree

MEDIUM

35 15

μ μA

0.30 0.35

-

Angle of Wrap 1 at Pulley Drive 1

α1

210

Degree

Angle of Wrap at Snub Pulley 1

α12

0

Degree

Angle of Wrap 2 at Pulley Drive 2

α2

210

Degree

Angle of Wrap at Snub Pulley 2

α21

0

Degree

Drive factor

c1

0.50

-

Drive factor at Start-Up

c1A

0.38

-

Drive factor at Pulley Drive 2

c2

0.50

Drive factor at Pulley Drive 2 at Start-Up FACTORS Gravitational Acceleration

c2A

0.38

Effective Degree of Filling

φ

g φ = φ1 * φ2

9.81

m/s2

0.70

-

1

-

- Degree of Filling

φ1

- Gradient of the installation

φ2

0.70

-

Width Factor

CB

277

kg/m

Length Factor

CL

52

m-1

Working Conditions Factor Efficiency of the drive

kf

1 0.90

DESIGN CAPACITY Loading width of outer rolls Load stream width Cross-Sectional Area of load Stream

η

Normal working conditions

For drives with fluid couplings

I1

282.50 1,030.00 0.1705

b A A5

NA 0

Qm

-

mm mm m2 m2 Degree

1,546.86

t/h

1,082.80

t/h

P1

28.18

kW

P2

48.77

kW

Power for trippers, skirtboard friction, ploughs

P3

0.00

kW

Power at Drive Pulley

PT

76.95

kW

Required Motor power

PM

85.50

kW

Slected Motor BELT TYPE Friction Value Factor

PN

110

kW

- Effective value POWER REQUIREMENTS Power for empty & load over the Horizontal

Qm'

Power for Lift or Fall

Breaking Strength Loss at t Factor Belt breaking strength Material (carcase) Nominal Breaking Strength

4

FORMULAR

β

Cross-Sectional Area of load Stream for 5 roll - Troughing Angle 2 Conveying Capacity - Theoretical value 2

SYMBOL

Number of Plies Carrying side Cover thickness Pulley side Cover thickness Cover Quality - Belt weight - Carcase thickness PULLEY DIAMETER Drive Pulley Calculation - Type of Belt Material Contruction - Belt Material Factor

Qm' = Qm*φ

PT = P1+P2+P3

CR

μ = 0.3

CV

Number of plies

k kN

Belt Class Cv

d D'Tr CTr

D'Tr=d*CTr

15 0.75 916.12 EP 1,000 4 8 4 X 25.40 5.80 626.40 SUPERFORT (Multiply Belt EP) 108

N/mm N/mm ply mm mm kg/m mm mm

5

Drive Pulley selected Tail Pulley, Tension Pulley Snub Pulleys, Bend Pulleys etc. Pulley revolutions IDLER Values for Idler Spacing - Belt sag ratio

hrel = h/Io

0.01 1.2

- Return side

Iu

Application 1.2m Iu = (2-3)*Io

DR nR

Not be greater than 650 rpm

m m

133.0

mm

241

r.p.m

LR

465

mm

Mass of one set of carrying idler rollers

mRo

22.3

kg

Mass of one set of return idler rollers

mRu

19.3

kg

CALCULATION Peripheral Force at Steady state working Length Factor Friction Factor Mass of the rotating carrying and return idlers

C f m'R

1.37 0.02 28.23

kg/m

Mass of the belt

m'G

25.40

kg/m

Mass of the load

m'L

165.34

kg/m

Main Resistance

FH

12,331.91

N

Secondary Resistance

FN

4,562.81

N

Slope Resistance

FSt

29,034.23

N

Special Resistance

FS

0.00

N

FS

0.00

+ Return side - Resistance from skirt places beyond

FU

FSO FSU FSch

- Resistance due to sideways discharge

FL

- Resistance due to trippers

FB

- Resistance from skirting material beyond

FMf

- Resistance to motion of bunker drag-out belts Peripheral Force at Steady state working Drive Motor at Pulley

FBa FU PT

45,928.94 77.16

N kW

Required Motor Power

PM

85.73

kW

Motor Power on Braked Installation Installed Motor Power Min. Belt Tension for Control

PM PN Tmin

NA 110 28,068

kW kW N

Peripheral Force at Non-Steady state working Type of Coupling Start-up Factor

FA kA

1.50

Pre Non-steady state

F'A

68,893.41

Peripheral Force at Start-Up (Non-steady state)

FA

68,893.41

Acceleration

aA

0.368

m/s2

- Reduced mass of idlers

m'Red

25.41

kg/m

- Reduced mass of drive elements

m'Ared

0.00

kg/m

- Reduced mass of non-driven (bend pulleys etc.)

m'red

0.00

kg/m

Acceleration Time

tA

4.56

s

Acceleration Distance Peripheral Force on Braking state Braking time

sA

3.83

m

Acceleration

aB

#DIV/0!

sB

0.00

Over-run distance Reduced mass of the non-braked elements or pulleys

5 A

2.0

mm mm mm R/min

Idler Length

+ Carrying side

4

nT

Io

- Resistance caused by forward tilt of idler rollers

3

630 500 400 51

hrel

- Idler Rotation

2

A B C

- Carrying side Idler Diameter

III. 1

DTr

Selected Motor Power

Hydraulic Coupling

tB

N N

s

mred

m/s2 m kg

Non-braked elements force

FT

#DIV/0!

N

Peripheral Force

FB

#DIV/0!

N

Individual Resistances Main Resistance

FH

12,331.91

N

Secondary Resistance Friction Resistance - Carrying side

FN

4,562.81

N

Fo

10,596.06

N

- Return side Slope Resistance - Carrying side

Fu

1,774.22

N

Fsto

33,494.44

N

- Return side Inertial Resistance - Carrying side

Fstu

4,460.21

N

Fao

19,724.02

N

- Return side Belt Tension Drive System Runing - Steady state working - Distribution for Head and Tail Drive

Fau

3240.45

N

NA

-

- Distribution for Dual Pulley Head Drive Total Peripheral Force

Single Pulley Head Drive x1

x1 = Fo/Fu

x2

NA

-

FU

45,928.94

N

- Peripheral Force Pulley 1

FU1

45,928.94

- Peripheral Force Pulley 2

FU2

NA

Total Power

PT

77.16

kW

- Motor 1

P1

77.16

kW

- Motor 2

P2

NA

kW

Tension

T2

Tension

N

T3

20278.47

N

Tension

T4

20278.47

N

Tension

T1

68931.78

N

Control Start Up - Non Steady state working - Distribution for Head and Tail Drive

T1

68893.41

N

NA

-

x1A

x1 = Fo/Fu

x2A

NA

-

FUA

68893.41

N

- Peripheral Force Pulley 1

FU1A

68893.41

N

- Peripheral Force Pulley 2

FU2A

NA

Total Power

PTA

115.74

kW

- Motor 1

P1A

115.74

kW

- Motor 2

P2A

NA

kW

Total Peripheral Force

Tension

TA2

Tension

T2 = FU*c

N

26455.07

N

TA3

27009.52

N

Tension

TA4

27009.52

N

Tension

TA1

95386.85

N

Control Braking state

TA1

95348.48

N

TM

33113.30 43965.24 10851.94

N N N

Belt Tension Correction (1st Adjustment) Correction with Fixed Take-up Belt tension at rest Average belt tension at start-up Correction value for Fixed Take-up Belt Tension Correction

T ∆T T1

∆T = T - TM

79783.72

N

T2

33816.41

N

T3

31130.41

N

T4

31130.41

N

∑T = ∑TA

Check conditional Correction with Moveable Take-up Location of Take-up Take-up Tension

FV

Take-up Weight

GV

GV = FV/g

Correction value for Moveable Take-up

∆T T1

∆T = TAi - Ti

Belt Tension Correction

Control of Minimum Belt Tension (2st Adjustment) Take-up Type Belt Tension at Carrying side minimum Correction value Belt Tension Correction

Check conditional Belt Safety Factor Steady state

Satisfied Installed at the Tail 40556.94

N

4134.24

kg

6731.05

N

75662.83

N

T2

29695.52

N

T3

27009.52

N

T4

27009.52 Satisfied

N

28067.97

N

27009.52 1058.44

N N

TAi = Ti

Check conditional C

N

22964.47

- Distribution for Dual Pulley Head Drive

B

T2 = FU*c

N

Tmin Moveable Take-up ∆T T1

∆T = Tmin - Ti

76721.27

N

T2

30753.96

N

T3

28067.97

N

T4

28067.97

N

TA1

96445.29

N

TA2

27513.51

N

TA3

28067.97

N

TA4

28067.97 Satisfied

N

Tmin ≤ Ti SB

11.73

-

Non-Steady state Take-up Travel Elongation value of the belt

SA sp

9.33

-

kD

10.50

Rest state

sp

1149.45

mm

Steady state

sp

1675.07

mm

Non-Steady state

sp

1843.83

mm

Troughing Trainsition - Factor for carcase - Portion of belt in w/ side idler rollers - Lift of Pulley Reduced transition length Convex Vertical Curve - Factor for carcase - Convex Radius - Curve Length - Deviation per idler - Number of Idlers in Curve - Idler Picth Concave Vertical Curve - Length from loading to curve - Belt tension at start of curve - Concave Radius

LM

1686.31 8.00 367.50 64.55 1169.88

mm mm mm mm

L α z Io

125.00 26.35 71519.14 2.00 3.00 23839.71

m m Degree Pieces m

Lx Tx Ra

40.00 29710.77 145.56

m N m

x s h Lred

Textile belt x=8 ST. belt x=16

x Re

Textile belt x=125 steel cord belt x=400

-

REMARKS

Use for analysis

Select in Table 1 Select in Table 3

Select in Table 31

Select in Table 20 Select in Table 21 Select in Table 22 Select in Table 23 Select in Table 30

Select in Table 24

Select in Table 4 Select in Table 25 Select in Table 26 Select in Table 5 Select in Table 6 Select in Table 7 Select in Table 7 Select in Table 8 chua hieu Appendix C

Select in Table 27

Select in Table 9 Select in Table 10 Select in Table 10

1% Normal installation

Appendix B Select in Table 3 Appendix B Appendix B

Select in Table 28 Select in Table 29 chua hieu

Appendix E

FA ≤ 2.5*FU

Select in Table 11

38.37

26455.0683701915 27009.5229994644 27009.5229994644 95386.8476269095 95348.4755842319 38.37

30752 13213.24 Increased for Running 82145.02 36177.71 33491.71

Inc. for Running

Inc. for all State

TABLE 1 STANDARD WIDTH (mm)

TABLE 2 STANDARD IDLER DIA. (mm) Carrying Idlers

Impact Idlers

Return Idlers

Idlers

300

51

400

63.5

120

500

88.9

138

650

108

156

150

800

133

180

180

1000

159

215

215

1200

193.7

250

250

1400

219.1

290

290

1600 1800 2000 2200

CALCULATION FOR START-UP kA Motor/coupling type Rigid Couplings Flexible Coupling Hydraulic Coupling Location of Take-up Installed at the Head Installed at the Tail Take-up Type Fixed Take-up Moveable Take-up

Belt Width B (mm)

TABLE 3 STANDARD IDLER LENGTH (mm) Troughing Type Flat

2 roll

3 roll

Deeptrough

5 roll

300

380

200

-

-

-

400

500

250

160

-

-

500

600

315

200

-

-

600

700

340

250

-

-

650

750

380

250

-

-

800

950

465

315

200

165

1000

1150

600

380

250

205

1200

1400

700

465

315

250

1400

1600

800

530

380

290

1600

1800

900

600

465

340

1800

2000

1000

670

530

380

2000

2200

1100

750

600

420

2200

2500

1250

800

640

460

Garland (5 roll)

TABLE 4

TABLE 5 MATERIAL CARCASE

STANDARD ELECTRIC MOTOR (KW)

SYMBOL

1.5

B

Cotton

(Natural fibre)

2.2

P

Polyamide

(Synthetic fibre)

3

E

Plyester

(Synthetic fibre)

4

EP

Plyester - Polyamide

(Synthetic fibre)

5.5

D

Aramid

(Synthetic fibre)

7.5

F

Steel Weave

(Ferroflex)

11

ST

Steel Cord

(ST belt)

15 18.5 22 30 37 45 55 75 90 110 132 160 200 250 315 400 500 630

PLY MATERIALS

TABLE 6

TABLE 7 COVER THICKNESS GAUGES (mm)

NOMINAL BREAKING STRENGTH (N/mm)

COVEYOR LOAD/DUTY

CARRYING SIDE

125

Light packayge conveying

2

160

Gravel, Earth, Potash etc.

2-4

200

Ore, Ballast, Coal

4-8

250

Slag

4-8

315

Coarse ballast, coarse Ore

8 - 12

400

Large lump Coal

8 - 12

500 630 800 1000 1250 1600 2000 2500

TABLE 8 COVER GRADE - DIN 22102 (April 1991)

GES (mm) PULLEY SIDE

2

COVER GRADE

W

X

Y

Z

Tensile strength

N/mm2 min.

18

25

20

15

2-3

Breaking elongation

%

400

450

400

350

2-3

Abrasion loss

90

120

150

250

2-3 3-5 3-5

mm3 max.

TABLE 9

TABLE 10

Standard Pulley Diameter

Pulley Diameter DTr (mm)

A

B

C

100

100

100

-

-

125

125

125

100

-

160

160

160

125

100

200

200

200

160

125

250

250

250

200

160

315

315

315

250

200

400

400

400

315

250

500

500

500

400

315

630

630

630

500

400

800

800

800

630

500

1000

1000

1000

800

630

1250

1250

1250

1000

800

1400

1400

1400

1250

1000

1600

1600

1600

1250

1000

1800

1800

1800

1400

1250

2000

2000

2000

1600

1250

Diameter Of Pulley Groups (mm)

100

c

3 -

TABLE 11 Drive location Single Pulley Head Drive Tail Drive Head and Tail Drive Dual Pulley Head Drive

Tail Drive (Braking)

TABLE 20

TABLE 21

For Smooth Belt

WIDTH FACTOR CB

φ2

Gradient

BELT WIDTH

LIGHT

MEDIUM

HEAVY

UP TO CA. 1.0

1.0 TO 2.0

OVER 2.0

2

1

4

0.99

300

31

36

6

0.98

400

54

59

65

8

0.97

500

67

76

86

10

0.95

650

81

92

103

12

0.93

800

108

126

144

14

0.91

1000

133

187

241

16

0.89

1200

194

277

360

18

0.85

1400

227

320

414

20

0.81

1600

291

468

644

22

0.76

1800

-

554

727

2000

-

691

957

2200

-

745

1033

-

TABLE 22

TABLE 23

LENGTH FACTOR CL

WORKING CONDITIONS FACTOR fk

CL

L (m)

WORKING CONDITIONS

3

667 Favourable, good alignment, slow speed

4

625 Normal (Standard conditions)

5 6

555 Unfavourable, dusty, low temperature, overloading, 526 hight speed

8

454 Extremely low temperature

10

417

12.5

370

16

323

20

286

25

250

32

222

40

192

50

167

63

145

80

119

90

109

100

103

150

77

200

63

250

53

300

47

350

14

400

37

450

33

500

31

550

28

600

26

700

23

800

20

900

18

1000

17

1500

12

2000

9

TABLE 24

NS FACTOR fk

ADDITIONAL POWER VALUES fk 1.17 1

BELT WIDTH B TRPPERS (throw-off carraiges)

<=1000 >1000

0.87 - 0.74 0.57

<=500

Scraper type SCRAPERS (For installations L<=80m)

simple, normal heavy multifunctional fac scraper

Material - Skirtboard Discharge plough * If : Length of material between skirtboard

beyond loading point Bulk density ρ ≤ 1.2 Angle α = 30o - 45o

TABLE 25 Friction Value Factor CR P (kw) 0.8*v 1.5*v 2.3*v

Drive Pulley Surface

Friction value μ

bare, wet

0.15

rubber lagged, wet and dirty

0.25 0.3

0.3*B*v

bare, dry, lagged, wet

0.35

1.5*B*v

rubber lagged, dry

0.4

1.8*B*v 0.16*B*If 1.5*B*v

TABLE 25 Friction Value Factor CR Belt Width B (mm) 300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200 98

74

59

45

37

30

25

21

18

16

15

14

69

52

41

32

26

21

17

15

13

12

10

9

62

46

37

28

23

18

15

13

12

10

9

8

57

43

34

26

21

17

14

12

11

9

8

8

53

40

32

25

20

16

13

11

10

9

8

7

TABLE 26 Breaking Strength Loss at t Factor Cv DUNLOP Belt Type DUNLOFLEX

Splice Type Ply Rating 2 ply overlap 100% 1 ply overlap 50%

TRIOFLEX

SUPERFORT

3 ply overlap 100%

Factor cv 1 0.5 1

2 ply overlap 67%

0.67

Number of plies 1

0.7

2

0.5

3

0.67

4

0.75

5

0.8

6

0.83

FERROFLEX

Zig-Zag Splice t

0.9

DUNLOPLAST

Finger Splice t

0.9

Steel Cord Belts

Splice 1 and 2 step

1

Various

3 step

0.95

4 step

0.9

Mechanical ts: Refer to Manufacturer

TABLE 27

TABLE 28

VALUE CTR

LENGTH FACTOR C

L(m)

C

Material of Carcase in Warp or Belt Type

CTr

Polyamide (P)

90

3

9

DUNLOFLEX (2 ply Belt)

80

4

7.6

TRIOFLEX (3 ply Belt)

95

5

6.6

SUPERFORT (Multiply Belt EP)

108

6

5.9

FERROFLEX (Steel Weave Type)

138

8

5.1

SILVERCORD (Steel Cord Belt)

145

10

4.5

DUNLOPLAST (Monoply Belt)

100

13

4

16

3.6

20

3

25

2.9

32

2.6

40

2.4

50

2.2

63

2

80

1.92

90

1.86

100

1.78

120

1.7

140

1.63

160

1.56

180

1.5

200

1.45

250

1.38

300

1.31

350

1.27

400

1.25

450

1.2

500

1.19

550

1.18

600

1.17

700

1.14

800

1.12

900

1.1

1000

1.09

1500

1.06

2000 1 * More Detail pls. see Page 12.3

TABLE 29 Horizontal, inclined or slightly declined installations - Motor driven k (for v = 5m/s and +20oC) Favourable working conditions, easily rotating idlers, material with low internal friction and good tracking, good maintenance

0.017

Normal installation, normal material

0.02

Unfavourable conditions, low temperature, material with high internal friction, subject to overload, poor maintenance

0.023 - 0.027

Installations with steep declines creating regenerative conditions

0.012 - 0.016

Note: a) With other speeds the following applies: f = c * f5m/s

With v <> 5 m/s v (m/s)

Factor c

2

0.8

3

0.85

4

0.9

5

1

6

1.1

b) With other temperatures the following applies: f = c * f20°C

With T < 20°C T (°C)

Factor c

+20°

1

0°

1.07

-10°

1.17

-20°

1.28

-30°

1.47

e Page 12.3

TABLE 30 Degree of Efficiency

F

Types of Drive

η

Wormgear drive

0.7 - 0.8

Toothed chain drive

0.9 - 0.95

Operating Condition

V-Rope drive

0.95

Dry

Pulley motor

0.96

Wet (Clean)

Normal coupled drive

0.94

Wet (dirty mud, clay)

Geared and hydraulic coupling

0.9

Hydraulic motor

0.86

Braked installations

0.95 - 1.0

TABLE 31 Friction Coefficient μ Pulley Surface Plain Steel (smooth)

Polyurethane lagging (grooved)

Rubber lagging (grooved)

Ceramic lagging (porous)

0.35 to 0.4

0.35 to 0.4

0.4 to 0.45

0.4 to 0.45

0.1

0.35

0.35

0.35 to 0.4

0.05 to 0.1

0.2

0.25 - 0.3

0.35

Conveyor Belt Thicknesses and Weights SUPERFORT Belts

SECONDARY RESISTANCES