36.M111 Potasium Sulphate BW 750,1.67 M S

17 Oct 2014 11:16
Project
Project No.
Conveyor No.
Conveyor Design Summary
Helix Technologies Pty Ltd

Sistem Reaktor 36.R-101
Client
Prepared By
36.M111, 1.67 m/s
Design Date
1/27
Page
PT.PETROKIMIA GRESIK
JSA
Conveyed Material
Material Description
Low Bulk Density
High Bulk Density
POTASSIUM SULPHATE
Surcharge Angle
1040 kg/m3
Angle of Repose
1040 kg/m3
Material Lump size
Conveyor Data
Conveying Distance
21.83 m
Design Capacity
Nett Lift / Lower (-)
0.00 m
Belt Speed
Belt Details
Belt Width Selected
750 mm
Calculated Belt % Full
Belt Class & Run Safety Factor
PN800/4
14.42 Top Cover Thickness
Belt Rated Tension
90 kN/m
Bottom Cover Thickness
Belt Total Length
52.7 m
Belt Mass
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded
3.64 kN
Belt Power - Empty Belt
Maximum Tension Tmax
41.60 kN
Belt Power - Inclines Loaded
Minimum Tension Tmin
38.18 kN
Belt Power - Declines Loaded
Sag Tension
1.5 %
1.4 kN
Belt Power - Fully Loaded
Takeup Type
Fixed Centres
Drive Efficiency
Takeup Mass
8100 kg
Absorbed Power Fully Loaded
Takeup Pulley Belt Tension
39.72 kN
Installed Motor Power
Carry and Return Idlers
Carry Idler Trough Angle
30
Return Idler Trough Angle
Carry Idler Spacing
1 m
Return Idler Spacing
Carry Idler No Rolls x Dia
3 x 152 mm
Return Idler No Rolls x Dia
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded
140 %
CEMA Temperature Factor Kt
Startup Factor - Empty
140 %
Total Braking Torque LSS
Starting Time - Fully Loaded
0.74 sec
Stop Time - Loaded, Braking
Starting Time - Empty
0.74 sec
Stop Time - Loaded, Coasting
30 deg
46 deg
3 mm
1.4 tonnes/hr
1.67 m/s
0.3
8
6
16.96
6.07
6.07
6.07
6.07
95.0
6.40
11
%
mm
mm
kg/m
kW
kW
kW
kW
%
kW
kW
0
3 m
1 x 152 mm
1.00
22.00 kNm
0.06 sec
1.08 sec
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Ver 6.0.15
Licenced to PT Krakatau Engineering
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Station / Sectio
Station
Page
Conveyor Sections - Input Data
Section Section
Length
Lift
Description
m
m
JSA
X coord m
Y coord m
Z coord m
Capacity
tph
Ten
Idler
Skirt
Friction
Adj. Spacing Length No. of
Factor
Scrapers Input
kN
m
m
1 Takeup
3.60
0.00
0.00
0.00
0.00
2 Hopper
1.40
0.00
3.60
0.00
0.25
1.4
3 Int. Pt
7.00
0.00
5.00
0.00
0.25
1.4
4 Hopper
2.00
0.00
12.00
0.00
0.25
1.4
5 Int. Pt
11.43
0.00
14.00
0.00
0.25
1.4
2.00
6 Drive
25.43
0.13
25.43
0.00
-0.07
2.00
50.85
0.13
Totals:
2/27
0.50
1.00
0.35
0.0000
2.00
0.0000
1.50
1.00
2.00
1.50
0.0000
2.00
0.0000
0.0000
3
4.00
0.0000
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive Torque Start-up Factor Loaded
140 %
Drive Torque Start-up Factor Empty
140 %
Drive
Number
Drive No.
Pulley No. 6
Wrap Angle
Fully
Loaded
JSA
Takeup Pulley Belt Tension

Takeup Mass
Running
Starting
Empty
Belt
3/27
Page
Takeup & Drive Traction Calculation
Fully
Loaded
39.72 kN
8100 kg
Braking
Empty
Belt
Fully
Loaded
Empty
Belt
1 Drive
Lagging Type
Co-efficient of Friction
Drive Factor Cw
180
Rubber
180
180
Rubber
180
180
Rubber
180
0.35
0.499
0.35
0.499
0.45
0.321
0.45
0.321
0.45
0.321
0.45
0.321
Calculated Belt Tension T1
kN
41.6
41.6
43.45
43.44
16.93
17
Calculated Belt Tension T2

Minimum Required T2
kN
kN
38.18
1.71
38.18
1.71
36.53
2.22
36.53
2.22
59.93
13.8
59.96
13.79
Surplus T2 Tension (T1-T2)
kN
36.47
36.47
34.31
34.31
3.13
3.21
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive Torque Start-up Factor Loaded
140 %
Drive Torque Start-up Factor Empty
140 %
Fully
Loaded
Tension
kN
Starting
Empty
Tension
kN
Inclines
Loaded
Tension
kN
Declines
Loaded
Tension
kN
4/27
JSA
Takeup Mass
Running
Station
No
Page
Tension Calculations - Summary Run / Start
8100 kg
Braking
Fully
Loaded
Tension
kN
Empty
Tension
kN
Fully
Loaded
Tension
kN
Coasting
Empty
Tension
kN
Fully
Loaded
Tension
kN
Empty
Tension
kN
1 Takeup
39.16
39.16
39.16
39.16
38.74
38.74
44.81
44.79
39.40
39.40
2 Hopper
39.43
39.43
39.43
39.43
39.85
39.85
33.84
33.80
39.09
39.09
3 Int. Pt
40.46
40.46
40.46
40.46
41.08
41.08
32.20
32.16
39.99
39.99
4 Hopper
40.51
40.51
40.51
40.51
41.59
41.59
26.20
26.19
39.73
39.73
5 Int. Pt
41.53
41.53
41.53
41.53
42.72
42.71
25.69
25.70
40.67
40.67
6 Drive
41.60
41.60
41.60
41.60
43.45
43.44
16.93
17.00
40.28
40.29
Minimum Ten
39.16
39.16
39.16
39.16
38.74
38.74
16.93
17.00
39.09
39.09
Maximum Ten
41.60
41.60
41.60
41.60
43.45
43.44
44.81
44.79
40.67
40.67
Effective Ten
3.64
3.63
3.64
3.64
Ave. Belt Ten
39.72
39.72
39.72
39.72
39.72
39.72
39.72
39.72
39.72
39.72
Belt Elong. m
T/up Travel m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
JSA
Low BD = 1040kg/m3
High BD = 1040kg/m3
Conveyed Material
Belt Speed & Capacity
Material Description
POTASSIUM SULPHATE
Belt Speed
Low Bulk Density
1040 kg/m3
Belt Design Capacity Input
High Bulk Density
1040 kg/m3
Section Loading Max Capacity
Surcharge Angle
30 deg
Carry Idler Trough Angle
Angle of Repose
46 deg
Belt Dimensions
Material Lump size
3 mm
Belt Make & Class

Belt Category
Apex PN Fabric - Spliced
Belt Description
Apex PN 200 Standard
Belt Class / Plies
PN800/4
4
Belt Reinforcement Fibre
Fabric
Belt Width Selected
750 mm
Belt Modulus
9200 kN/m
Belt Tensions
Belt Rated Tension / m width
Calculated Tension / m width
Belt Rated Tension for width
Calculated Max Run Tension
Minimum Tension Tmin
Allowable Tension Rise, Starting
Allowable Belt Tension, Starting
Actual Belt Tension, Starting
Belt and Material Mass
Belt Top Cover Mass
Belt Bottom Cover Mass
Belt Carcass Mass
Belt Mass Wb (per linear m)
Material Mass Wm
Total Mass (Wb + Wm)
Total Belt Mass (Wb x L)
90
55.5
67.5
41.60
38.18
140
94.5
59.96
kN/m
kN/m
kN
kN
kN
%
kN
kN
Top Cover Thickness

Bottom Cover Thickness
Belt Carcass Thickness
Belt Total Thickness
Belt Total Belt Length (L)
Time for 1 Revolution
kg/m
kg/m
kg/m
kg/m
kg/m
kg/m
kg
1.67
1.4
1.4
30
m/s
tonnes/hr
tonnes/hr
8 mm
6 mm
5.3
19.3
52.7
31.6
mm
mm
m
sec
Belt Load Area and Capacity at 1040kg/m3

Minimum Rec. Edge Distance
64 mm
Actual Edge Distance Low BD
267 mm
Load Burden Depth
35 mm
Load Burden Width
227 mm
Belt Load Area at Minimum
0.0664 m2
Recommended Edge Distance
Belt Load Area Utilised at Low
Bulk Density
Belt Actual % Full at Low BD
0.0002 m2
0.3 %
Belt Load Area and Capacity at 1040kg/m3

Minimum Rec. Edge Distance
64 mm
Actual Edge Distance High BD
267 mm
Belt Load Area Utilised at High
0.0002 m2
Bulk Density
Belt Actual % Full at High BD
6.8
5.1
5.1
17
0.2
17.2
894
5/27
Page
Belt Details Report
0.3 %
Flooded Belt Capacity at 1040kg/m3

Flooded Belt Load Area at Zero
0.0994 m2
Edge Distance
Flooded Belt Capacity
Flooded Belt Material Mass
621 tonnes/hr
103.4 kg/m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Allowable Belt Sag % Running
5 %
Starting
Fully
Loaded
Tension
kN
Empty
Tension
kN
Inclines
Loaded
Tension
kN
39.16
39.16
39.16
0.03
39.43
Empty
Tension
kN
Fully
Loaded
Tension
kN
Empty
Tension
kN
39.16
38.74
38.74
44.81
44.79
39.40
39.40
0.03
39.43
0.03
39.43
0.03
39.85
0.03
39.85
0.02
33.84
0.02
33.80
0.03
39.09
0.03
39.09
0.02
40.46
0.02
40.46
0.02
40.46
0.02
41.08
0.02
41.08
0.02
32.20
0.02
32.16
0.02
39.99
0.02
39.99
0.08
40.51
0.08
40.51
0.08
40.51
0.08
41.59
0.08
41.59
0.1
26.20
0.1
26.19
0.08
39.73
0.08
39.73
0.08
41.53
0.08
41.53
0.08
41.53
0.08
42.72
0.07
42.71
0.12
25.69
0.12
25.70
0.08
40.67
0.08
40.67
0.1
41.60
0.1
41.60
0.1
41.60
0.1
43.45
0.1
43.44
0.16
16.93
0.16
17.00
0.1
40.28
0.1
40.29
0.1
0.1
0.1
0.1
0.1
0.1
0.25
0.24
0.1
0.1
39.16
39.16
39.16
39.16
38.74
38.74
16.93
17.00
39.09
39.09
0.1
0.1
0.1
0.1
0.1
0.1
0.25
0.24
0.1
0.1
0.03
39.43
Idler Spacing m
0.35
0.02
40.46
Idler Spacing m
1.50
Belt Sag %
4 Hopper
0.08
40.51
Idler Spacing m
1.50
Idler Spacing m
Belt Sag %
6 Drive
Idler Spacing m
Belt Sag %
Minimum Ten
Maximum Sag
Coasting
Fully
Loaded
Tension
kN
Belt Sag %
2 Hopper
Belt Sag %
5 Int. Pt
Braking
Empty
Tension
kN
0.50
0.08
41.53
Declines
Loaded
Tension
kN
8100 kg
Fully
Loaded
Tension
kN
Idler Spacing m
Belt Sag %
3 Int. Pt
JSA
Takeup Mass
Running
1 Takeup
6/27
1.5 %
Allowable Belt Sag % Start / Stop
Station
No
Page
Tension Calculations - Summary Belt Sag
2.00
0.1
41.60
2.00
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Page
Tension Calculations - Run Fully Loaded

Client
Prepared By
36.M111, 1.67 m/s
Design Date
JSA
Takeup Mass
Station / Pulley
Station
Section Section
Length
Lift
m
m
Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley
1 Takeup
3.60
0.00
39.16
39.37
2 Hopper
1.40
0.00
39.43
39.43
3 Int. Pt
7.00
0.00
40.46
40.46
4 Hopper
2.00
0.00
40.51
40.51
5 Int. Pt
11.43
0.00
41.53
41.53
6 Drive
25.43
0.13
41.60
38.18
Totals:
Drive
Te kN
8100 kg
Ten Material Skirt Scraper Section CEMA

Adj. Accel. Friction Friction Effective Friction
kN
kN
kN
kN
Tension Factor
0.22
1.00
0.00
1.00
0.22
3.42
0.43
3.4
7/27
0.89
2.00
0.00
0.00
0.89
0.06
0.016
0.03
0.016
0.05
0.0161
0.01
0.016
0.07
0.016
0.09
0.015
0.31
Maximum Tension
41.6 kN
Minimum Tension
38.18 kN
Total Belt Power (Te x V)
6.07 kW
Average Tension Fully Loaded
39.72 kN
Belt Modulus
9200 kN/m
Average Tension Belt Stationary
39.72 kN
Total Belt Length
52.70 m
Average Tension Difference
0 kN
Total Effective Tension
3.64 kN
Belt Elastic Elongation
0 m
Takeup Movement
0 m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Station / Pulley
Station
Page
Tension Calculations - Run Empty

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Section Section
Length
Lift
m
m
Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley
1 Takeup
3.60
0.00
39.16
39.37
2 Hopper
1.40
0.00
39.43
39.43
3 Int. Pt
7.00
0.00
40.46
40.46
4 Hopper
2.00
0.00
40.51
40.51
5 Int. Pt
11.43
0.00
41.53
41.53
6 Drive
25.43
0.13
41.60
38.18
Totals:
Drive
Te kN
JSA

kN
kN
kN
kN
Tension Factor
0.22
1.00
1.00
0.22
3.42
0.44
3.42
8/27
0.89
2.00
0.89
0.06
0.016
0.03
0.016
0.05
0.0161
0.01
0.016
0.07
0.016
0.09
0.015
0.31
Maximum Tension
41.6 kN
3.63 kN
Minimum Tension
38.18 kN
6.07 kW
Average Tension Fully Loaded
39.72 kN
Belt Modulus
9200 kN/m
39.72 kN
Total Belt Length
52.70 m
0 kN
0 m
Takeup Movement
0 m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Station / Pulley
Station
Page
Tension Calculations - Run Inclines Loaded

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Section Section
Length
Lift
m
m
Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley
1 Takeup
3.60
0.00
39.16
39.37
2 Hopper
1.40
0.00
39.43
39.43
3 Int. Pt
7.00
0.00
40.46
40.46
4 Hopper
2.00
0.00
40.51
40.51
5 Int. Pt
11.43
0.00
41.53
41.53
6 Drive
25.43
0.13
41.60
38.18
Totals:
Drive
Te kN
JSA

kN
kN
kN
kN
Tension Factor
0.22
1.00
0.00
1.00
0.22
3.42
0.43
3.42
9/27
0.89
2.00
0.00
0.00
0.89
0.06
0.016
0.03
0.016
0.05
0.0161
0.01
0.016
0.07
0.016
0.09
0.015
0.31
Maximum Tension
41.6 kN
3.64 kN
Minimum Tension
38.18 kN
6.07 kW
Average Tension Inclines Loaded
39.72 kN
Belt Modulus
9200 kN/m
39.72 kN
Total Belt Length
52.70 m
0 kN
0 m
Takeup Movement
0 m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Station / Pulley
Station
Page
Tension Calculations - Run Declines Loaded

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Section Section
Length
Lift
m
m
Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley
1 Takeup
3.60
0.00
39.16
39.37
2 Hopper
1.40
0.00
39.43
39.43
3 Int. Pt
7.00
0.00
40.46
40.46
4 Hopper
2.00
0.00
40.51
40.51
5 Int. Pt
11.43
0.00
41.53
41.53
6 Drive
25.43
0.13
41.60
38.18
Totals:
Drive
Te kN
JSA

kN
kN
kN
kN
Tension Factor
0.22
1.00
0.00
1.00
0.22
3.42
0.43
3.4
10/27
0.89
2.00
0.00
0.00
0.89
0.06
0.016
0.03
0.016
0.05
0.0161
0.01
0.016
0.07
0.016
0.09
0.015
0.31
Maximum Tension
41.6 kN
Minimum Tension
38.18 kN
6.07 kW
Average Tension Declines Loaded
39.72 kN
Belt Modulus
9200 kN/m
39.72 kN
Total Belt Length
52.70 m
0 kN
3.64 kN
0 m
Takeup Movement
0 m
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Conveyor Starting and Stopping

Client
Prepared By
36.M111, 1.67 m/s
Design Date
System Masses
Mass of Belt
Mass of Material
Carry Idler Equivalent Mass
Return Idler Equivalent Mass
Pulley Equivalent Mass
Drive Equivalent Mass
Total System Equivalent Mass
894
5
373
179
524
383
2,358
kg
kg
kg
kg
kg
kg
kg
Tensions and Accelerating Forces

Effective Tens. Fully Loaded
3.64 kN
Effective Tension Empty
3.63 kN
Total Braking Force
67.28 kN
Tension Available to Accelerate Conveyor
Accelerating Tension - Loaded
5.31 kN
Accelerating Tension - Empty
5.31 kN
Starting Times & Acceleration Rates
Starting Time - Fully Loaded
0.74 sec
Starting Time - Empty
0.74 sec
Acceleration Rate - Loaded
2.25 m/s2
Accelerating Rate - Empty
2.26 m/s2
Belt Tension Rise Starting / Braking
Max Belt Tension, Start/Brake
59.96 kN
Belt Width
750 mm
Maximum Belt Tension / width
79.95 kN/m
Belt Rated Tension / width
90 kN/m
Actual Max Tension, Start/Brake
88.8 %
Page
11/27
JSA
Input Data
Belt Speed
Belt Rated Tension
Allow. Belt Start Tension Rise
Drive Inertia
Total Braking Torque
Start-up Factor - Loaded
Start-up Factor - Empty
Installed Power
Drive Efficiency (Average)
1.67
90
140
0.0467
22
140
140
11
95
m/s
kN/m
%
kg-m2
kNm
%
%
kW
%
Stopping Times & Deceleration Rates

Stopping Time Loaded Braking
0.06 sec
Stopping Time Loaded Coasting
1.08 sec
Stopping Time Empty Braking
0.06 sec
Stopping Time Empty Coasting
1.08 sec
Deceleration - Loaded Braking
Deceleration - Loaded Coasting
Deceleration - Empty Braking
Deceleration - Empty Coasting
-30.07 m/s2
-1.54 m/s2
-30.14 m/s2
-1.54 m/s2
Stopping Distances & Discharge Volumes

Stopping Distance Loaded Braking
0.05 m
Stopping Distance Loaded Coasting
0.9 m
Stopping Distance Empty Braking
0.05 m
Stopping Distance Empty Coasting
0.9 m
Discharge Mass, Braking
Discharge Mass, Coasting
Discharge Volume, Braking
Discharge Volume, Coasting
0
0
0
0
kg
kg
m3
m3
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Conveyor Idler Details Report

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Idler Category
Idler Description
Idler Design Belt Width
Idler Series
Drawing Number
Nominal Idler Spacing
Total Number of Idlers
Idler Price
Carry Side Idlers

Sandvik Carry
Series 20 3 Roll Carry 152 Plain
Inline
750 mm
20
1
23
0
Troughing Angle
Idler Shaft Diameter
Idler Bearing Diameter
Number of Idler Rolls
Idler Roll Diameter
Idler Rotation Speed
Roll Face Width
Roll Bearing Centres
Shaft Support Centres
Idler Support Fixing Width
Idlerset Rotating Mass
Idlerset Total Mass
Idler Vertical Misalignment Allowance
Dynamic Load Factor
Belt Deviation Load
Total Load on Centre Roll
30.0
27.0
25.0
3
152
210
deg
mm
mm
283
226.8
307
1000
16.2
31.7
Ball
6205
14,000
4,525,995
8.00
1.04
JSA
Return Side Idlers

Sandvik Flat Carry
Series 30 1 Roll Flat Carry
152 Dia
750 mm
30
3
13
0
deg
mm
mm
mm
rpm
0.0
30.0
25.0
1
152
210
mm
mm
mm
mm
kg
kg
849
785.4
873
1000
13.8
23.1
mm
mm
mm
mm
kg
kg
3.0 mm
1.04
500 N
728 N
Type of Bearing
Bearing Designation
Bearing Dynamic Load Rating C
Bearing L10h Life
Allowable Shaft Deflection at Bearing
Actual Shaft Deflection at Bearing
12/27
Page
N
hrs
min
min
mm
rpm
56.3 mm
1.40
1,501 N
2,446 N
Ball
6305
22,500
494,760
10.00
8.66
N
hrs
min
min
Designers Comments

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17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Vertical Curve Radius Calculations

36.M111, 1.67 m/s
17 Oct 2014 11:16
Belt Width
Belt Mass - New Belt
Top Cover Mass - New Belt
Bottom Cover Mass
Worn Belt Mass
Reduction of Top Cover Mass
Conveyed Material Mass
Station / Sectio
Station
Curve
Type
750
16.96
6.78
5.08
12.72
62.5
0.23
mm
kg/m
kg/m
kg/m
kg/m
%
kg/m
Design
Running
Vertical
Load
Fully Loaded
Empty
Curve
Capacity Radius Tension Radius
Tension Radius
tonnes/hr
m
kN
m
kN
m
1 Takeup
Page
% Belt Mass for Lift-off Calculation

Curve Tension Safety Factor
Average Drive Torque Start-up Factor - Loaded
Average Drive Torque Start-up Factor - Empty
Belt Modulus
Belt Rated Tension
90 kN/m
Allowable Edge Tension - Running:
115 % Starting
Starting
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
39.16
39.16
38.74
38.74
44.81
44.79
39.43
39.43
39.85
39.85
33.84
33.8
3 Int. Pt
40.46
40.46
41.08
41.08
32.2
32.16
75
1
140
140
9200
67.5
140
Braking
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
2 Hopper
Ver 6.0.15
13/27
Page

Client
Prepared By JSA
Design Date
13/27
%
%
%
kN/m
kN
%
Largest
Reqd.
Radius
m
Helix
Technologies
17 Oct 2014 11:16
Belt Width
Belt Mass - New Belt
Top Cover Mass - New Belt
Bottom Cover Mass
Worn Belt Mass
Reduction of Top Cover Mass
Conveyed Material Mass
Station / Sectio
Station
Curve
Type
750
16.96
6.78
5.08
12.72
62.5
0.23
mm
kg/m
kg/m
kg/m
kg/m
%
kg/m
Design
Running
Vertical
Load
Fully
Loaded
Empty
Curve
Capacity Radius Tension Radius
Tension Radius
tonnes/hr
m
kN
m
kN
m
Page
% Belt Mass for Lift-off Calculation

Curve Tension Safety Factor
Average Drive Torque Start-up Factor - Loaded
Average Drive Torque Start-up Factor - Empty
Belt Modulus
Belt Rated Tension
90 kN/m
Allowable Edge Tension - Running:
115 % Starting
Starting
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
Braking
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
4 Hopper
40.51
40.51
41.59
41.59
26.2
26.19
5 Int. Pt
41.53
41.53
42.72
42.71
25.69
25.7
41.6
41.6
43.45
43.44
16.93
17.0
6 Drive
75
1
140
140
9200
67.5
140
14/27
%
%
%
kN/m
kN
%
Largest
Reqd.
Radius
m
Designers Comments

Ver 6.0.15
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Technologies
17 Oct 2014 11:16

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Project
Project No.
Conveyor No.
Page
Viscoelastic Friction Factor Report
15/27
JSA
Viscoelastic Calculations Input Data

Belt Rubber Description
Rubber description ...
6 N/mm2
Top Cover Dynamic Modulus E'
Top Cover Dynamic Loss Factor Tan(delta)
0.13
Belt Top Cover Temperature
30 deg C
Rolling Resistance Factor RRF Top
0.072 RRF Bot.
0.072
Bottom Cover Dynamic Modulus E'
6 N/mm2
Bot Cover Dynamic Loss Factor Tan(delta)
0.13
Belt Bottom Cover Temperature
30 deg C
Belt & Material Flexure Adjustment factor
1
Belt has Turnover on Return Run
Station / Section
No
Total
Loaded
Section
Idler Friction
Length Spacing factor f
Carry Idler Centre Roll Dia

Carry Idler Centre Roll Drag
Carry Idler Wing Roll Dia
Carry Idler Wing Roll Drag
Return Idler Centre Roll Dia
Return Idler Centre Roll Drag
Return Idler Wing Roll Dia
Return Idler Wing Roll Drag
Idlerset Skew Angle
Idlerset Forward Tilt angle
friction factor f (loaded)

Indentation
Matl.& Belt
Idler Drag
Indent Indent
Freq Flexure Flexure Drag
Drag
factor factor uency friction friction factor factor
fi
%
rad/s
fm
%
fr
%
152
2
152
2
152
2
152
2
0.1
0.1
mm
N
mm
N
mm
N
mm
N
deg
deg
Empty
Idler Skew & Tilt

Tilt
Tilt
friction friction
ft
%
Empty
Friction
factor f
3.60
0.50
0.0160 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0160
1.40
0.35
0.0160 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0160
7.00
1.50
0.0161 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0161
2.00
1.50
0.0160 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0160
11.43
2.00
0.0160 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0160
25.43
2.00
0.0150 0.00000
0.0
0.00000
0.0
0.00000
0.0
0.00000
0.0
0.0150
Totals:
50.85
0.13
2.00
4.00
Designers Comments

Ver 6.0.15
Helix
Technologies
Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Carry Roll Diameter

Return Roll Diameter
Station / Sectio
Station
Description
152 mm
152 mm
JSA
Belt Speed
Takeup Mass
Belt Resonance +/- Tolerance
Running Fully Loaded Belt Resonance

Start
End
Belt
Belt
Tension Tension
kN
kN
16/27
Page
Conveyor Belt Resonance Report
Belt Transverse
Idler Roll Section
Wave Frequency Excitation
Idler
Range
Frequency Spacing
Hz
to Hz
Hz
m
1.67 m/s
8100 kg
10 %
Critical Critical
Idler
Idler
Spacing Spacing
Start
End
m
Idler
Spacing
within
+/- 10%
m
1 Takeup
39.37
40.46
48.12
48.79
3.5
0.5
6.88
6.97
OK
2 Hopper
39.43
40.51
68.33
69.26
3.5
0.35
6.84
6.93
OK
3 Int. Pt
40.46
41.53
16.15
16.36
3.5
1.5
6.93
7.02
OK
4 Hopper
40.51
41.6
16.16
16.38
3.5
1.5
6.93
7.02
OK
5 Int. Pt
41.53
39.16
12.27
11.92
3.5
7.02
6.81
OK
6 Drive
38.18
39.16
11.85
12
3.5
6.78
6.86
OK
Mode
17 Oct 2014 11:16
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Takeup Travel Report

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Takeup Travel
Takeup Type
Page
17/27
JSA
Fixed Centres
Auto Calc Takeup Mass

Takeup Mass step increment
200 kg
Max no. of Calc Increments
100
Takeup Mass kg (Manual
Input)
Takeup Mass Calculated
Takeup Travel Estimate
Safety Margin Top
+
Belt Splice Allowance +
Dynamic Travel Up
+
Dynamic Travel Down +
Safety Margin Bottom +
Thermal Expansion Distance
Minimum Site Temperature
Maximum Site Temperature
Belt Expansion co-efficient
m/m per degree C
Total Belt Length
Thermal Expansion Distance +
Permanent Belt Stretch
Permanent Stretch coefficient % of Belt Length
Permanent Belt Stretch
Distance
+
Total Takeup Travel Distance
8100 kg
8100 kg
0
0.5
0
0
0
m
m
m
m
m
0 deg
30 deg
1.17E-05
52.70 m
0.009 m
0.15 %
0.04 m
0.55 m

Ver 6.0.15
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17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive No.
1 Drive
Pulley No.
Drive Description
Load Share on Drive Pulley
Head
100 %
Starting Torque Factor, Fully Loaded

Starting Torque Factor, Empty
140 %
140 %
Number of Motors on Drive Pulley

Motor Description
Motor Power Rating
Motor Voltage
Gearbox Description
380 Volts
Flender Helical Bevel Gear
Drive Efficiency
95 %
High Speed Coupling

HS Coupling Make
Falk
HS Coupling Model
Low Speed Coupling
LS Coupling Make
1040T
Ringspann
LS Coupling Model
Brake
Brake Location
RFK140
High Speed
Low Speed Brake Torque Input

Equiv HS Brake Torque
Holdback
Static Analysis Runback Force Fv
Static Analysis Horizontal Force Fh
Calculated Holdback Torque
Holdback Required (Yes / No)
Holdback Torque 3 x Motor FLT
Holdback Make
Holdback Model
JSA
Pulley Condition
Pulley Lagging Type
Belt Wrap Angle
Coefficient of Friction, Running
Drive Factor Cw, Running
Electric Motor
11 kW
0 N
3640 N
N/A Nm
No Fv>Fh/2
6462 Nm
Moist
Rubber
180
0.35
0.5
Coefficient of Friction, Starting

Drive Factor Cw, Starting
0.45
0.32
Pulley and Shaft Dimensions

Pulley Shell Diameter
630 mm
Pulley Lagging Thickness
12 mm
Pulley Outside Diameter

Pulley Shaft Diameter at Hub
654 mm
150 mm
Pulley Shaft Diameter at Brg
125 mm
Pulley and Belt Speed

Motor Full Load Speed
1445 rpm
Required Gearbox Ratio
29.63 :1
Selected Gearbox Ratio

Required Pulley Speed
31.5 :1
48.77 rpm
Calculated Pulley Speed for Reducer

Required Belt Speed
45.87 rpm
1.67 m/s
Calculated Belt Speed
22 kNm
782 Nm
18/27
Page
Drive Details Report
Drive Inertia
Motor Inertia
1.57 m/s
0.0467 kg-m2
High Speed Coupling Inertia

High Speed Brake Disc Inertia
0 kg-m2
0 kg-m2
Flywheel Inertia
0 kg-m2
Gearbox Inertia (HSS)

Total Drive Inertia
Total Drive Equivalent Mass
0 kg-m2
0.0467 kg-m2
383 kg
Not Installed
Designers Comments

Ver 6.0.15
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Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive No.
Page
Drive Motor Details Report
1 Drive
Pulley No.
Drive Description
Head
1
Motor Category
Metric Motor
Motor Description
Electric Motor
Motor Power Rating
11 kW
Motor Voltage
380 Volts
Number of poles
4
Motor Frame Size
DX160M
Motor Shaft Diameter
42 mm
Motor Shaft Height
160 mm
Motor Inertia
0.0467 kg-m2
19/27
JSA
Total Motor Power on Drive

Absorbed Power at Pulley
Drive Efficiency
Absorbed Power at Motor
Motor Full Load Torque
Motor Full Load Current
Motor Efficiency @ Duty Point
Motor Power Factor @ Duty Pt
Mass of Motor
11
6.08
95
6.4
1445
72.7
22.3
86.44
0.76
134
kW
kW
%
kW
rpm
Nm
Amps
%
kg
Designers Comments

Ver 6.0.15
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17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Drive Fluid Coupling Details Report

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive No.
1 Drive
Pulley No.
Drive Description
Head
1
Selection Mode
Auto
Coupling Category
Flender
Coupling Description
No Selection - Direct Drive
Coupling Power Rating
0 kW
Min. Required Ramping Time
sec
Max Starting Time
0 sec
Page
20/27
JSA
Coupling Size
Motor Power Rating
Coupling Rated Slip
Peak Torque %
Run-up Torque % (2 sec)
Coupling Output Speed
Mass of Coupling
11
1445
0
0
0
1445
0
kW
rpm
%
% FLT
% FLT
rpm
kg
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Drive Gearbox Details Report

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive No.
1 Drive
Pulley No.
Drive Description
Head
1
Selection Mode
Manual
Gearbox Category
Flender
Gearbox Description
Flender Helical Bevel Gear
Type
Helical Bevel Gear
Size
4
Code
B3SH4
Ratio
31.5
Number of Stages
B3SH4
Design Efficiency (Input)
Gearbox Actual Efficiency
Maximum Input Shaft Speed
Minimum Input Shaft Speed
Input Shaft Diameter
Output Shaft Diameter
Gearbox Inertia
95
93
1500
700
30
80
%
%
rpm
rpm
mm
mm
kg-m2
Page
21/27
JSA
Motor Power Rating

Motor Torque @ FL Speed
Motor Torque at Pulley Speed
Gearbox Rated Torque
Service Factor Required
Service Factor Calculated
11
1445
73
2154
6400
1.5
2.97
kW
rpm
Nm
Nm
Nm
Plus Speed Selection Tolerance

Minus Speed Selection Tolerance
Fluid Coupling Slip
Selected Gearbox Ratio
Required Pulley Speed
Calculated Pulley Speed for Reducer
Required Belt Speed
Calculated Belt Speed
Mass of Gearbox
5
5
0
29.63
31.5
48.77
45.87
1.67
1.57
210
%
%
%
:1
:1
rpm
rpm
m/s
m/s
kg
Designers Comments

Ver 6.0.15
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Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Page
Brake Details Report

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive / Brake No.
1 Drive
Brake Selection Input Data

Low Speed Brake Torque Input
Equiv HS Brake Torque
Design Braking Torque Input
Selected Brake's Torque Rating
Design Stopping Time
Consecutive No of Stops
Average No of Stops
Ambient Temperature
Disc Temperature after stops
JSA
Pulley No.
Description
Head
100 %
Brake Category
Svendborg BSFH 200
Brake Description
Svendborg
Caliper
BSFH 202
1
22
782
782
-43
10.0
3
6
40
NaN
kNm
Nm
Nm
Nm
sec
deg C
deg C
22/27
Brake Location
Disc Material
Disc Diameter
Disc Thickness
Co-eff of Friction (Pad-Disc)
Caliper Clamping Force Minimum
Caliper Clamping Force Maximum
Pad offset Width W
Maximum Air Gap
High Speed
Mild Steel
0 mm
0 mm
0.4
2000
3500
60
3
N
N
mm
mm
Recommended working airgap is 1mm
Disc Initial Speed

Disc Moment of Inertia
Drive Efficiency
Mass of Caliper
Brake Caliper Price
0
0.0
29.63
95
26
$0.00
rpm
kg-m2
:1
%
kg
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Drive No.
1 Drive
Drive Description
Starting Torque Factor, Fully Loaded
Starting Torque Factor, Empty
Drive Efficiency
Pulley No.
Head
100
140
140
1
95
%
%
%
23/27
Page
Shaft Coupling Report
JSA
Motor Power Rating

Motor Torque @ FL Speed
Motor Torque at Pulley Speed
Pulley Shaft Diameter at Brg
11
1445
73
2154
125
kW
rpm
Nm
Nm
mm
High Speed Coupling

HS Coupling Category
Falk SteelFlex Grid
HS Coupling Make
Falk
HS Coupling Model
1040T
Coupling Type
Grid
Coupling Torque Rating
249 Nm
1.5
3.43
Maximum Shaft Bore
43 mm
Minimum Shaft Bore
0 mm
Maximum Rotation Speed
4500 rpm
High Speed Coupling Inertia
0.0033 kg-m2
Drawing Number
High Speed Coupling Mass
3.36 kg
High Speed Coupling Price
0
Fluid Coupling
Direct Drive
Fluid Coupling
No Selection - Direct Drive
Fluid Coupling Size
Low Speed Coupling

LS Coupling Category
LS Coupling Make
LS Coupling Model
Coupling Type
Coupling Torque Rating
Maximum Shaft Bore
Minimum Shaft Bore
Maximum Rotation Speed
Low Speed Coupling Inertia
Drawing Number
Low Speed Coupling Mass
Low Speed Coupling Price
Falk SteelFlex Grid

Ringspann
RFK140
Rigid Flanged
56000
1.5
26
140
115
3800
2.9
Nm
mm
mm
rpm
kg-m2
800 kg
0
Designers Comments

Ver 6.0.15
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.

Client
Prepared By
36.M111, 1.67 m/s
Design Date
Station / Sectio
T1
Run
T2
Run
kN
kN
180.0
39.2
39.4
180.0
41.6
38.2
Shaft
Length
mm
Wrap
Angle
deg
1 Takeup
1610
6 Drive
1610
Station
Description
Resultant
Force
kN
JSA
kN
Calculated
Defl.
Dt.
Dia
Dia
mm
mm
78.5
38.7
120.8
123.7
150
125
1270
223
79.8
43.4
121.3
124.7
150
125
1270
223
T1
Start
Selected
Shaft
Brg
Dia
Dia
mm
mm
Brg
Ctrs
mm
Shaft
Mass
kg
* Denotes manual pulley shaft dimensions entered
Designers Comments

Ver 6.0.15
24/27
Page
Conveyor Pulley Shafts
Helix
Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Page
Conveyor Pulleys

Client
Prepared By
36.M111, 1.67 m/s
Design Date
25/27
JSA
Station / Sectio
Station
Shell Lagging
Description Dia mm
mm
Face
Width
mm
Shaft
Length
mm
Brg
Ctrs
mm
Shaft
Dia
mm
Brg
Dia
mm
Wrap
Angle
deg
Pulley Pulley & Mom of

Speed
Shaft
Inertia
rpm Mass kg kgm2
1 Takeup
500
12
850
1610
1270
150
125
180.0
60.9
475
12.7
6 Drive
630
12
850
1610
1270
150
125
180.0
48.8
718
36.2
* Denotes manual pulley dimensions entered
Designers Comments

Ver 6.0.15
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Technologies
17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Page
Conveyor Pulley Dimensions

Client
Prepared By
36.M111, 1.67 m/s
Design Date
26/27
JSA
Station / Sectio
Station
Shell Lagging
Description Dia mm
mm
OD
mm
Face
Width
mm
Shaft
Length
mm
Brg
Ctrs
mm
Shaft
Dia
mm
Brg
Dia
mm
Belt
Width
mm
Pulley & Mom of

Shaft Inertia
Mass kg kgm2
1 Takeup
500
12
524
850
1610
1270
150
125
750
475
12.7
6 Drive
630
12
654
850
1610
1270
150
125
750
718
36.2
Designers Comments

Ver 6.0.15
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17 Oct 2014 11:16

Project
Project No.
Conveyor No.
Page
Conveyor Pulleys Data Sheet

Client
Prepared By
36.M111, 1.67 m/s
Design Date
27/27
JSA
Station / Sectio
Station
Shell Lagging
Description Dia mm
mm
Face
Width
mm
Brg
Ctrs
mm
1 Takeup
500
12
850
1270
6 Drive
630
12
850
1270
Drive
Power
kW
11
Wrap Pulley
Angle Speed
deg
rpm
T1
Run
kN
T2
Run
kN
T1
Start
kN
T2
Start
kN
180.0
60.9
39.16
39.37
Running Full
44.81
39.45
Braking Full
180.0
48.8
41.6
38.18
Running Full
43.45
36.53
Starting Full
Designers Comments

Ver 6.0.15
Helix
Technologies

36.M111 Potasium Sulphate BW 750,1.67 M S

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Conveyor Design Summary

Helix Technologies Pty Ltd

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

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Conveyor Sections - Input Data

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

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Helix Technologies Pty Ltd

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

Takeup Pulley Belt Tension

Takeup & Drive Traction Calculation

Calculated Belt Tension T1

Calculated Belt Tension T2

Surplus T2 Tension (T1-T2)

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Licenced to PT Krakatau Engineering

17 Oct 2014 11:16

Helix Technologies Pty Ltd

Drive Torque Start-up Factor Loaded

Drive Torque Start-up Factor Empty

Tension Calculations - Summary Run / Start

Ave. Belt Ten

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Licenced to PT Krakatau Engineering

17 Oct 2014 11:16

Helix Technologies Pty Ltd

Belt Make & Class

Top Cover Thickness

Belt Load Area and Capacity at 1040kg/m3

Belt Load Area and Capacity at 1040kg/m3

Belt Details Report

Flooded Belt Capacity at 1040kg/m3

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Licenced to PT Krakatau Engineering

17 Oct 2014 11:16

Helix Technologies Pty Ltd

Allowable Belt Sag % Running

Allowable Belt Sag % Start / Stop

Tension Calculations - Summary Belt Sag

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Licenced to PT Krakatau Engineering

17 Oct 2014 11:16

Tension Calculations - Run Fully Loaded

Helix Technologies Pty Ltd

Ten Material Skirt Scraper Section CEMA

Total Belt Power (Te x V)

Average Tension Fully Loaded

Average Tension Belt Stationary

Total Belt Length

Average Tension Difference

Total Effective Tension

Belt Elastic Elongation

E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml

Licenced to PT Krakatau Engineering

17 Oct 2014 11:16

Tension Calculations - Run Empty

Helix Technologies Pty Ltd

Ten Material Skirt Scraper Section CEMA