CALCULATIONS

SUMMARY SHEET Engineer's Stamp

Project: Terrace Bay Neenah Paper Project #: Y5424-01 Rev.#: A

Item: M-2054 Conv. Modifications at 350 fpm Calculations by: cdk Date: Aug 23/05
Checked by: Date:

BELT CONVEYOR AND BELT FEEDER DRIVE SIZING CALCULATIONS

The reference material for this spreadsheet consists of CEMA's 4th Edition of Belt Conveyors for Bulk Materials from
which all of the lookup values are obtained.
CEMA 4th Edition
Table or Figure or
Page

BELT CAPACITY
Required Conveying Rate: 250.00 tph << input
Material Conveyed: wood chips << input Table 3-3
Material Density: 30.0 lb/ft3 << input Table 3-3
Angle of Repose: 45.0 deg << input Table 3-3
Angle of Surcharge: 30.0 deg << input Table 3-1
Belt Width: 36.0 in << input Figure 4-1
Trough Angle (0 for flat belt): 35.0 deg << input
Maximum Load Cross Sectional Area: 1.1420 ft2 << input Tables 4-2 to 4-5
Maximum Belt Capacity: 6,857.00 ft3/hr/100fpm << input Tables 4-2 to 4-5
Maximum Lump Size: 1.0 in << input
Belt Speed:
Design: 350.0 fpm << input Table 4-1
Minimum to Handle Design Capacity: 243.1 fpm Should be less than design
Maximum Capacity at Design Speed: 359.993 TPH

IDLER DESIGN (Only Belt Weight Wb req'd for Pan Belt Conveyors)
Troughing Idler Info:
Diameter 5.0 in << input
Class (A-E) C << input Tables 5-8 to 5-12
Load Rating 837.0 lb << input Tables 5-8 to 5-12
Si, Load Idler Spacing: 4.000 ft << input Table 5-2
Return Idler Spacing: 10.0 ft << input Table 5-2
K1, Lump Adjustment Factor: 1.00 << input Table 5-4
K2, Environmental & Maintenance Factor: 1.15 << input Table 5-5
K3, Service Factor: 1.20 << input Table 5-6
K4, Belt Speed Factor: 0.85 << input Table 5-7
Wb, Belt Unit Weight: ** 9.0 lb/ft << input Table 6-1
Wm, Material Unit Weight:
Max Material Weight 34.26 lb/ft
Actual Material Weight 23.81 lb/ft
Idler Load (Max material weight): 173.04 lb
Adjusted Idler Load (Max material weight): 202.98 lb
Suitability of Idler Selection: Selection is OK

COOK ENGINEERING 1
Te, EFFECTIVE TENSION
Conveyor is Pan Type (Y or N): N << input
Coefficient of Dynamic Friction: 0.45 << input Pan Conveyor Only
# of Plows: 0.0 << input
# of Belt Cleaners (Scraper Type): 1.0 << input
L, Length of Conveyor (3000 ft maximum): 39.3 ft << input
H, Lift of Conveyor (Negative for Declining): 9.5 ft << input
# of Tight Side Non-Driving Pulleys: 0.0 << input
# of Slack Side Non-Driving Pulleys: 0.0 << input
Belt Material (Fabric or Steel): Fabric << input
Approximate Tight Side Tension (Iterate): 2,074.3 lbs << input from below
Approximate Slack Side Tension (Iterate): 1,131.4 lbs << input from below
Number of drive pulleys: 1.0 << input
Lb, Length of Skirtboards (1 Side): 8.0 ft << input
Kt, Temperature Factor: 1.0 << input Fig 6-1
Ai: 1.8 << input Page 76
Kx: 0.47 lb/ft
Ky: 0.028 << input Tables 6-2, 6-3
Material velocity component in direction of
belt travel as it is fed onto conveyor: 300.0 fpm << input Calculate
Cs, Skirtboard Friction Factor: 0.0095 << input Table 6-7
Hopper used to regulate flow of material (Y or N)? N << input
w, Width of Hopper Outlet: 0.0 in << input
l, Length of Hopper Outlet: 0.0 in << input
Tp, Tension From Non-Driving Pulleys: 0.0 lb
Tam, Tension from Acceleration: 3.6 lb
Tsb, Skirtboard Tension: 49.0 lb
Ttr, Tripper Tension: 0.0 lb << input Page 84
Tpl, Plow Tension: 0.0 lb
Tbc, Belt Cleaner Tension: 180.0 lb
Tension required to extract material from
hopper (normal operation): 0.0 lb
Tension from belt on slide (Pan Conveyor Only): 0.0 lb **** Manual entry for this conveyor ***
Te, Effective Tension (Required for Operation): 518.5 lb

BELT SELECTION
Angle of Wrap, Drive Pulley: 180.0 deg << input
Wrap Factor Cw: (Lagged) 1.20 << input Table 6-8
T2, Slack-Side Tension Required to Prevent Slip
with Dry Belt (higher for wet conditions): 622.2 lb
Allowable percent sag of belt: 2.00 % << input Table 6-10
T0, Required Belt Tension to Reduce Sag: 826.8 lb
T1, Operating Maximum Belt Tension: 1,140.7 lb << input Calc's p. 102-110
Maximum Belt Tension per inch (operating): 31.7 lb/in
Maximum Allowable Starting Tension: 330.0 lb/in << input Manufacturer

COOK ENGINEERING 2
MOTOR SELECTION
Operating Shaft Power Required from Te: 5.5 hp
Drive pulley friction loss horsepower: 0.28 hp
Speed Reduction Efficiency: 98.5 % << input Manufacturer
Motor and Power Supply Efficiency: 99.0 % << input
Operating Motor Power Required: 5.9 hp

Effective Tension Required for Starts: 810.8 lbs

Percentage Full Load Torque req'd for Starts: 156.4 %
Breakaway Torque Required for Starting: 27.8 ft-lbs

Selected Motor Horsepower: 10.0 hp << input

Selected Motor RPM: 1,750.0 rpm << input
Motor Locked Rotor Torque (percentage of
rated full load torque. Use 140% max for VFD
applications, check with manufacturer): 250.0 % << input Table 13-1
Motor Pull Up Torque (percentage of rated
full load torque, check with manufacturer): 175.0 % << input Table 13-5
Motor Rated Full Load Torque: 30.0 ft-lbs
Breakaway Torque Available for Starting: 75.0 ft-lbs
Minimum Pull Up Torque Available: 52.5 ft-lbs

Breakaway Torque Sufficient for Starting: YES

Pull Up Torque Sufficient for Acceleration: YES
Selected Motor and Drive O.K.: YES
Reduced Torque Starting Required: NO

Notes and Comments:

1. This design method does not cover conveyors of over 3000 feet length, horizontally curved conveyors, head and tail
driven conveyors, high lift conveyors, large decline with braking requirements or conveyors with undulating Page 16
geometrics.

2. This design method uses actual expected belt loading. It is worthwhile checking the horsepower requirements for a
fully loaded belt in case of future higher capacity requirements.

3. Motor starting torque characteristics and conveyor acceleration should be checked in depth to ensure compatibility
between motor and conveyor. Page 119

PULLEY SELECTION (Based on Dodge PT-Components Engineering Catalog:)

Selected Motor Horsepower: 10.0 hp
Pulley Face Width: 38 Inches
Design Bearing Center to Center: 51.00 Inches << input
BCMF: 13.00
Te (Effective Tension): 942.9 lbs
Drive Factor: (1.2 for bare manual, 0.8 for lagged) 1.2 << input Table 2 pg.13-52
T2 (Slack Side Tension): 1,131.4 lbs
T1 (Tight Side Tension): 2,074.3 lbs
Design PIW (Drive Side): 57.6 lbs per inch
Design PIW (Slack Side): 31.4 lbs per inch
Arc of Contact: 180.0 degrees
Tail Pulley Diameter: (Ext'g., Bare) 20.0 Inches << input Table 1 pg.13-12
Drive Pulley Diameter: (Lagged, 1/4") 24.5 Inches << input Table 1 pg.13-12
Check on Tail Pulley to Belt Tension 275 lbs per inch << input Manufacturer
Check on Drive Pulley to Belt Tension 345 lbs per inch << input Manufacturer
Selected Tail Pulley Size O.K.: YES
Selected Drive Pulley Size O.K.: YES

SHAFT SELECTION (Based on Dodge PT-Components Engineering Catalog:)

COOK ENGINEERING 3
Resultant Pulley Load (Tail): 2,023.0 lbs
Resultant Pulley Load (Drive): 2,865.9 lbs
Design Drive Pulley Shaft Size: 2.9375 Inches << input Manufacturer
Design Tail Pulley Shaft Size: 2.1875 Inches << input Manufacturer
Check on Drive Shaft Load Rating: 3200 lbs << input Table 3 PT13-13
Check on Tail Shaft Load Rating: 1100 lbs << input Table 3 PT13-13
Design Steel Shafting Grade: (1045) 8,000 psi << input Manufacturer
Valve N 6.5 Inches
Adrive (use Table 4 to choose correct A calc.) 8.25 Inches << input
KB-drive (KB = 1.5 or KB = 2.5 for Overhung load) 2.50 << input
Check on Drive Pulley Shaft from Torque: 2.7235 Inches
Atail (use Table 4 to choose correct A calc.) 8.13 << input
KB-tail (KB = 1.5 or KB = 2.5 for Overhung load) 1.50 << input
Check on Tail Pulley Shaft from Torque: 1.9873 Inches
Selected Drive Pulley Shaft O.K. for Load: YES
Selected Drive Pulley Shaft O.K. for Torque: YES
Selected Tail Pulley Shaft O.K. for Load: YES
Selected Tail Pulley Shaft O.K. for Torque: YES

BELT SELECTION
Select a belt with a MOR 1/4" X 1/8", Grooved Pattern
SELECTION: SCANDURA ROLYALON 3-330 BELT

SPEED REDUCER SELECTION (Based on Dodge Gearing Catalogue:)

Dodge TDT Series
Convert FPM to RPM: 54.6 RPM < Note: Manual add in lagging thickness
Determine Service Factor: 1 << input Table 2 pg.2-7
Calculate Equivalent HP 10 HP
Application Class II << input
Select Unit Size & Ratio TDT425 << input pg G1-21
Unit ratio 24.38 Ratio << input
Therefore reuse existing 10 hp motor, new TDT425 reducer required

BELT DRIVE SELECTION (Based on Dodge PT-Components Engineering Catalog:)

Determine Service Factor: 1.5 << input table 2 pg PT7-43
Design HP: 15.0
Determine Overall Ratio Required: 32.07 Motor rpm/belt rpm
Determine Belt Drive Ratio: 1.32 Overall Ratio/reducer ratio
Selected nearest ratio 1.31 << input Page B-168
Driver Sheave OD 5.70 Inches << input Page B-168
Driven Sheave OD 7.50 Inches << input Page B-168
HP Per Belt 3VX series 15.64 << input Page B-168
Minimum Number of belts required: 1.0
Belt Selection 5VX-500 << input
Belt Center to Center Distance 16.4 << input Page B-168
Note: Designer can also use Dodge PT-Components Engineering Catalog pg. PT7-1

COOK ENGINEERING 4
COOK ENGINEERING 5