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PETROVIETNAM ENGINEERING - PVE

CALCULATION SHEET
VALUVE
No. PARAMETERS SYMBOL FORMULAR Unit REMARKS
BMCR
I. INPUT DATA
1 INSTALLATION
Troughing Type 3 roll
Capacity Design Q 1,000 t/h Use for analysis
Conveying Length L 258.0 m
Lift H 17.9 m
Belt Width B 1,200 mm Select in Table 1
Belt Speed v 1.68 m/s
Length of middle carrying roll I Idler length if 3 or 5 roll 465 mm Select in Table 3
Troughing Angle λ 35 Degree
Incline Angle δ 4.8 Degree
2 MATERIAL
Material Name MEDIUM
Density ρ 1.50 t/m3
Lump Size mm
Temperature 35 o
C
Surcharge Angle β 15 Degree
3 CONVEYOR BELT
Friction Coefficient of Pulleys μ 0.30 - Select in Table 31
Friction Coefficient of Pulleys at Start-Up μA 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 c2A 0.38
4 FACTORS
Gravitational Acceleration g 9.81 m/s2
Effective Degree of Filling φ φ = φ1 * φ2 0.70 -
- Degree of Filling φ1 Normal working conditions 1 -
- Gradient of the installation φ2 0.70 - Select in Table 20
Width Factor CB 277 kg/m Select in Table 21
Length Factor CL 52 m-1 Select in Table 22
Working Conditions Factor kf 1 - Select in Table 23
Efficiency of the drive η For drives with fluid couplings 0.90 - Select in Table 30

II. DESIGN
1 CAPACITY
Loading width of outer rolls I1 282.50 mm
Load stream width b 1,030.00 mm
Cross-Sectional Area of load Stream A 0.1705 m2
Cross-Sectional Area of load Stream for 5 roll A5 NA m2
- Troughing Angle 2 0 Degree
Conveying Capacity
- Theoretical value Qm 1,546.86 t/h
- Effective value Qm' Qm' = Qm*φ 1,082.80 t/h
2 POWER REQUIREMENTS
Power for empty & load over the Horizontal P1 28.18 kW
Power for Lift or Fall P2 48.77 kW
Power for trippers, skirtboard friction, ploughs P3 0.00 kW Select in Table 24
Power at Drive Pulley PT PT = P1+P2+P3 76.95 kW
Required Motor power PM 85.50 kW
Slected Motor PN 110 kW Select in Table 4
3 BELT TYPE
Friction Value Factor CR μ = 0.3 15 Select in Table 25
Breaking Strength Loss at Joint Factor CV Number of plies 0.75 Select in Table 26
Belt breaking strength k 916.12 N/mm
Material (carcase) EP Select in Table 5
Nominal Breaking Strength kN Belt Class 1,000 N/mm Select in Table 6
Number of Plies Cv 4 ply
Carrying side Cover thickness 8 mm Select in Table 7
Pulley side Cover thickness 4 mm Select in Table 7
Cover Quality X Select in Table 8
- Belt weight 25.40 kg/m chua hieu
- Carcase thickness d 5.80 mm Appendix C
4 PULLEY DIAMETER
Drive Pulley Calculation D'Tr D'Tr=d*CTr 626.40 mm
- Type of Belt Material Contruction SUPERFORT (Multiply Belt EP)
- Belt Material Factor CTr 108 Select in Table 27
Drive Pulley selected DTr A 630 mm Select in Table 9
Tail Pulley, Tension Pulley B 500 mm Select in Table 10
Snub Pulleys, Bend Pulleys etc. C 400 mm Select in Table 10
Pulley revolutions nT 51 R/min
5 IDLER
Values for Idler Spacing
- Belt sag ratio hrel hrel = h/Io 0.01 1%
- Carrying side Io Application 1.2m 1.2 m Normal installation
- Return side Iu Iu = (2-3)*Io 2.0 m
Idler Diameter DR 133.0 mm Appendix B
- Idler Rotation nR Not be greater than 650 rpm 241 r.p.m
Idler Length LR 465 mm Select in Table 3
Mass of one set of carrying idler rollers mRo 22.3 kg Appendix B
Mass of one set of return idler rollers mRu 19.3 kg Appendix B

III. CALCULATION
1 Peripheral Force at Steady state working FU
Length Factor C 1.37 Select in Table 28
Friction Factor f 0.02 Select in Table 29
Mass of the rotating carrying and return idlers m'R 28.23 kg/m
Mass of the belt m'G 25.40 kg/m chua hieu
Mass of the load m'L 165.34 kg/m
Main Resistance FH 12,331.91 N
Secondary Resistance FN 4,562.81 N Appendix E
Slope Resistance FSt 29,034.23 N
Special Resistance FS 0.00 N
- Resistance caused by forward tilt of idler roller FS 0.00
+ Carrying side FSO
+ Return side FSU
- Resistance from skirt places beyond 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 FBa
Peripheral Force at Steady state working FU 45,928.94 N
Drive Motor at Pulley PT 77.16 kW
Required Motor Power PM 85.73 kW
Motor Power on Braked Installation PM NA kW
Installed Motor Power PN Selected Motor Power 110 kW
Min. Belt Tension for Control Tmin 28,068 N
2 Peripheral Force at Non-Steady state working FA
Type of Coupling Hydraulic Coupling
Start-up Factor kA 1.50
Pre Non-steady state F'A 68,893.41 N FA ≤ 2.5*FU
Peripheral Force at Start-Up (Non-steady state) FA 68,893.41 N
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 sA 3.83 m
3 Peripheral Force on Braking state
Braking time tB s
Acceleration aB #DIV/0! m/s2
Over-run distance sB 0.00 m
Reduced mass of the non-braked elements or pulley mred kg
Non-braked elements force FT #DIV/0! N
Peripheral Force FB #DIV/0! N

4 Individual Resistances
Main Resistance FH 12,331.91 N
Secondary Resistance FN 4,562.81 N
Friction Resistance
- Carrying side Fo 10,596.06 N
- Return side Fu 1,774.22 N
Slope Resistance
- Carrying side Fsto 33,494.44 N
- Return side Fstu 4,460.21 N
Inertial Resistance
- Carrying side Fao 19,724.02 N
- Return side Fau 3240.45 N
5 Belt Tension
A Drive System Single Pulley Head Drive Select in Table 11
Runing - Steady state working
- Distribution for Head and Tail Drive x1 x1 = Fo/Fu NA -
- Distribution for Dual Pulley Head Drive x2 NA -
Total Peripheral Force FU 45,928.94 N
- Peripheral Force Pulley 1 FU1 45,928.94 N
- Peripheral Force Pulley 2 FU2 NA N
Total Power PT 77.16 kW
- Motor 1 P1 77.16 kW
- Motor 2 P2 NA kW
Tension T2 T2 = FU*c 22964.47 N
Tension T3 20278.47 N
Tension T4 20278.47 N
Tension T1 68931.78 N
Control T1 68893.41 N 38.37
Start Up - Non Steady state working
- Distribution for Head and Tail Drive x1A x1 = Fo/Fu NA -
- Distribution for Dual Pulley Head Drive x2A NA -
Total Peripheral Force FUA 68893.41 N
- Peripheral Force Pulley 1 FU1A 68893.41 N
- Peripheral Force Pulley 2 FU2A NA N
Total Power PTA 115.74 kW
- Motor 1 P1A 115.74 kW
- Motor 2 P2A NA kW
Tension TA2 T2 = FU*c 26455.07 N 26455.068370192
Tension TA3 27009.52 N 27009.522999464
Tension TA4 27009.52 N 27009.522999464
Tension TA1 95386.85 N 95386.84762691
Control TA1 95348.48 N 95348.475584232
Braking state 38.37

B Belt Tension Correction (1st Adjustment)


Correction with Fixed Take-up
Belt tension at rest TM 33113.30 N 30752
Average belt tension at start-up T 43965.24 N 13213.24
Correction value for Fixed Take-up ∆T ∆T = T - TM 10851.94 N Increased for Running
Belt Tension Correction T1 79783.72 N 82145.02
T2 33816.41 N 36177.71
T3 31130.41 N 33491.71
T4 31130.41 N
Check conditional ∑T = ∑TA Satisfied
Correction with Moveable Take-up
Location of Take-up Installed at the Tail
Take-up Tension FV 40556.94 N
Take-up Weight GV GV = FV/g 4134.24 kg
Correction value for Moveable Take-up ∆T ∆T = TAi - Ti 6731.05 N Inc. for Running
Belt Tension Correction T1 75662.83 N
T2 29695.52 N
T3 27009.52 N
T4 27009.52 N
Check conditional TAi = Ti Satisfied
C Control of Minimum Belt Tension (2st Adjustmen Tmin 28067.97 N
Take-up Type Moveable Take-up
Belt Tension at Carrying side minimum 27009.52 N
Correction value ∆T ∆T = Tmin - Ti 1058.44 N Inc. for all State
Belt Tension Correction T1 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 N
Check conditional Tmin ≤ Ti Satisfied
Belt Safety Factor
Steady state SB 11.73 -
Non-Steady state SA 9.33 -
Take-up Travel sp
Elongation value of the belt kD 10.50 -
Rest state sp 1149.45 mm
Steady state sp 1675.07 mm
Non-Steady state sp 1843.83 mm
Troughing Trainsition LM 1686.31 mm
- Factor for carcase x Textile belt x=8 8.00 -
- Portion of belt in contact w/ side idler rollers s ST. belt x=16 367.50 mm
- Lift of Pulley h 64.55 mm
Reduced transition length Lred 1169.88 mm
Convex Vertical Curve
- Factor for carcase x Textile belt x=125 125.00 -
- Convex Radius Re steel cord belt x=400 26.35 m
- Curve Length L 71519.14 m
- Deviation per idler α 2.00 Degree
- Number of Idlers in Curve z 3.00 Pieces
- Idler Picth Io 23839.71 m
Concave Vertical Curve
- Length from loading to curve Lx 40.00 m
- Belt tension at start of curve Tx 29710.77 N
- Concave Radius Ra 145.56 m
TABLE 1 TABLE 2 TABLE 3
STANDARD STANDARD IDLER DIA. (mm) STANDARD IDLER LE
WIDTH
(mm) Carrying Idlers Impact Idlers Return Idlers Support Idlers Belt Width Trough
B (mm)
300 51 Flat
400 63.5 120 300 380
500 88.9 138 400 500
650 108 156 150 500 600
800 133 180 180 600 700
1000 159 215 215 650 750
1200 193.7 250 250 800 950
1400 219.1 290 290 1000 1150
1600 1200 1400
1800 1400 1600
2000 1600 1800
2200 1800 2000
2000 2200
2200 2500

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
TABLE 3 TABLE 4 TABLE 5
STANDARD IDLER LENGTH (mm) STANDARD MATERIAL CARCASE
ELECTRIC
Troughing Type MOTOR (KW) SYMBOL
2 roll 3 roll Deeptrough 5 roll 1.5 B
200 - - - 2.2 P
250 160 - - 3 E
315 200 - - 4 EP
340 250 - - 5.5 D
380 250 - - 7.5 F
465 315 200 165 11 ST
600 380 250 205 15
700 465 315 250 18.5
800 530 380 290 22
900 600 465 340 30
1000 670 530 380 37
1100 750 600 420 45
1250 800 640 460 55
75
90
110
Garland (5 roll) 132
160
200
250
315
400
500
630
TABLE 5 TABLE 6 TABLE 7
NOMINAL
MATERIAL CARCASE BREAKING COVER THICKNESS GAUGE
PLY MATERIALS STRENGTH COVEYOR LOAD/DUTY
(N/mm)
Cotton (Natural fibre) 125 Light packayge conveying
Polyamide (Synthetic fibre) 160 Gravel, Earth, Potash etc.
Plyester (Synthetic fibre) 200 Ore, Ballast, Coal
Plyester - Polyamide (Synthetic fibre) 250 Slag
Aramid (Synthetic fibre) 315 Coarse ballast, coarse Ore
Steel Weave (Ferroflex) 400 Large lump Coal
Steel Cord (ST belt) 500
630
800
1000
1250
1600
2000
2500
TABLE 7 TABLE 8
R THICKNESS GAUGES (mm) COVER GRADE - DIN 22102 (April 1991)
CARRYING SIDE PULLEY SIDE COVER GRADE W X Y Z
2 2 Tensile strength N/mm2 min. 18 25 20 15
2-4 2-3 Breaking elongation % 400 450 400 350
4-8 2-3 Abrasion loss mm3 max. 90 120 150 250
4-8 2-3
8 - 12 3-5
8 - 12 3-5
TABLE 9 TABLE 10 TABLE 11
Pulley Diameter Of Pulley Groups (mm) Drive location
Standard Pulley Diameter
Diameter DTr (mm) A B C

100 100 100 - - Single Pulley Head Drive


125 125 125 100 - Tail Drive
160 160 160 125 100 Head and Tail Drive
200 200 200 160 125 Dual Pulley Head Drive
250 250 250 200 160

315 315 315 250 200

400 400 400 315 250 Tail Drive (Braking)


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

100 3
c -
TABLE 20 TABLE 21 TABLE 22

For Smooth Belt WIDTH FACTOR CB LENGTH FACTOR CL

Gradient φ2 LIGHT MEDIUM HEAVY L (m)


BELT WIDTH
2 1 UP TO CA. 1.0 1.0 TO 2.0 OVER 2.0 3
4 0.99 300 31 36 - 4
6 0.98 400 54 59 65 5
8 0.97 500 67 76 86 6
10 0.95 650 81 92 103 8
12 0.93 800 108 126 144 10
14 0.91 1000 133 187 241 12.5
16 0.89 1200 194 277 360 16
18 0.85 1400 227 320 414 20
20 0.81 1600 291 468 644 25
22 0.76 1800 - 554 727 32
2000 - 691 957 40
2200 - 745 1033 50
63
80
90
100
150
200
250
300
350
400
450
500
550
600
700
800
900
1000
1500
2000
TABLE 22 TABLE 23
LENGTH FACTOR CL WORKING CONDITIONS FACTOR fk

CL WORKING CONDITIONS fk
667 Favourable, good alignment, slow speed 1.17
625 Normal (Standard conditions) 1
555 Unfavourable, dusty, low temperature,
0.87 - 0.74
526 overloading, hight speed
454 Extremely low temperature 0.57
417
370
323
286
250
222
192
167
145
119
109
103
77
63
53
47
14
37
33
31
28
26
23
20
18
17
12
9
TABLE 24

ADDITIONAL POWER VALUES

BELT WIDTH B P (kw)


Drive Pulley Surface
TRPPERS <=500 0.8*v
(throw-off carraiges) <=1000 1.5*v bare, wet
>1000 2.3*v rubber lagged, wet and
Scraper type dirty

SCRAPERS simple, normal contact 0.3*B*v bare, dry, lagged, wet


(For installations L<=80m) heavy contact 1.5*B*v rubber lagged, dry
multifunctional fac scraper 1.8*B*v
Material - Skirtboard beyond loading point 0.16*B*If

Bulk density ρ ≤ 1.2


Discharge plough 1.5*B*v
Angle α = 30o - 45o
* If : Length of material between skirtboard
TABLE 25
Friction Value Factor CR

Friction Belt Width B (mm)


value μ 300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200
0.15 98 74 59 45 37 30 25 21 18 16 15 14
0.25 69 52 41 32 26 21 17 15 13 12 10 9
0.3 62 46 37 28 23 18 15 13 12 10 9 8
0.35 57 43 34 26 21 17 14 12 11 9 8 8
0.4 53 40 32 25 20 16 13 11 10 9 8 7
TABLE 26

Breaking Strength Loss at Joint Factor Cv


DUNLOP Belt Type Splice Type Ply Rating Factor cv
DUNLOFLEX 2 ply overlap 100% 1

1 ply overlap 50% 0.5

TRIOFLEX 3 ply overlap 100% 1

2 ply overlap 67% 0.67

SUPERFORT 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 Joint 0.9

DUNLOPLAST Finger Splice Joint 0.9

Steel Cord Belts Splice 1 and 2 step 1

3 step 0.95

4 step 0.9

Various Mechanical Joints: Refer to Manufacturer


TABLE 27 TABLE 28

VALUE CTR LENGTH FACTOR C

Material of Carcase in Warp or Belt Type CTr L(m) C


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 TABLE 30
Horizontal, inclined or slightly declined installations -
Motor driven k (for v = 5m/s and +20oC)
Degree of Efficiency

Favourable working conditions, easily Types of Drive


rotating idlers, material with low internal
friction and good tracking, good
0.017 Wormgear drive
maintenance Toothed chain drive
Normal installation, normal material 0.02 V-Rope drive
Unfavourable conditions, low Pulley motor
temperature, material with high internal
friction, subject to overload, poor
0.023 - 0.027 Normal coupled drive
maintenance Geared and hydraulic coupling
Installations with steep declines Hydraulic motor
0.012 - 0.016
creating regenerative conditions
Braked installations
Note:
a) With other speeds the following applies:
With v <> 5 m/s f = c * f5m/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:


With T < 20°C f = c * f20°C
T (°C) Factor c
+20° 1
0° 1.07
-10° 1.17
-20° 1.28
-30° 1.47
pls. see Page 12.3
BLE 30 TABLE 31

f Efficiency Friction Coefficient μ

η Pulley Surface
Operating
0.7 - 0.8 Plain Steel Polyurethane Rubber lagging
Condition
0.9 - 0.95 (smooth) lagging (grooved) (grooved)
0.95 Dry 0.35 to 0.4 0.35 to 0.4 0.4 to 0.45
0.96 Wet (Clean) 0.1 0.35 0.35
0.94 Wet (dirty mud, clay) 0.05 to 0.1 0.2 0.25 - 0.3
0.9
0.86
0.95 - 1.0
ce
Ceramic lagging
(porous)
0.4 to 0.45
0.35 to 0.4
0.35
Conveyor Belt Thicknesses and Weights
SUPERFORT Belts
SECONDARY RESISTANCES