By Pass System RCD-1 to SP-3 RCD-2 to SP2 Pelabuhan Batubara Tarahan
CALCULATION OF BY PASS CONVEYOR C - 12A
1 Belt Capacity Required
Q2 t/h
825
2 Belt Width
B
mm
1200
3 Be Belt Speed Required
v
m/ s
1.13
4 Angle Angle of Inclination Inclination
φ
o
12.8
5 Be Belt Center Distance L Vertical height to elevate= Lsinφ H Skirt board length each side
m m m t/m3
6 Material Material / Bulk density density 7 Capacity Factor
k
8 Troug Trough h Angl Angle e
λ
9 Total Moisture Material Temperature Temperature Lump Size
o
% C mm o
G kg/m s1 m s2 m 11 Additional l m if center distance >100 m. L m 12 Coefficient of friction of rolling rolling parts parts f
1
=
6
=
0.28
1.4 0.89 H/L
10 We Weight of Moving Part Conv. if s1 and s2 and density < 1.5
Check Theoritical Capacity
154.4 18 3 sbl
35
β
o
10
28 35 100 45 1 3 100 154.4
see table 7 see table 7 see table 7 see table 8 see table 8
0.023
see table 9
Qt Qt'
=
{Q2/(v x x k)}
=
584.22 584.22 m3/h m3/h
See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't
=
B λ
mm
2
Qt
=
3
Q
=
with ; Belt Width Trough Angle
Q > Q2
PT. Protech Asia Engineering. Engineering.
o
614 m3/h 1200 35
β
Q't x v x k Qt x
o
15 = =
619.32 m3/h 867.05 t/h
By Pass System RCD-1 to SP-3 RCD-2 to SP2 Pelabuhan Batubara Tarahan
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW) N1 = {G(L+l)fxv}/102
=
2.93 kW
2 Power Required to convey material on the level N2 (kW) N2 = {Q(L+l)f}/367
=
13.82 kW
3 Power Required to elevated material N3 (kW ) N3 = (QxH)/367
=
42.53 kW
=
0.54 kW
4 Additional Power Requirement N4 (kW), see table 10 0.08x v x length of N4 = skirt board * Theoritical Necessary Motor Capacity Nn (kW) Nn
=
N1 + N2 + N3 + N4
=
59.82 kW
Nm
=
Nn / ŋ
=
70.38 Kw
* Motor Capacity (Nm)
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = 500 mm D1 = 733 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION
Service Factor * Nominal Power Rating *
Gear Reducer output speed
*
Gear Reducer Ratio
*
Thermal Rating
sf= PN
2 =
Pm x sf
=
140.75 kW
n2
=
(v x 60)/(3.14 x D1)
=
29.54 rpm
i
=
1500 / n2
=
50.77
PG PG1
= PG1 x 0.87 x 1.2 = 143
=
149.29 kW
PN < PG the Gear Reducer no need extra cooling. According above mention , choice gear reducer type and size ; FLENDER type : HANSEN P4 type:
PT. Protech Asia Engineering.
B3HH11 QHRF3
i i
= =
50 50
or
By Pass System RCD-1 to SP3 RCD-2 to SP2 Pelabuhan Batubara Tarahan.
CALCULATION OF BY PASS CONVEYOR C - 12A
1 Belt Capacity Required
Q2 t/h
1650
2 Belt Width
B
mm
1200
3 Belt Speed Required
v
m/s
4.5
4 Angle of Inclination
φ
o
16
5 Belt Center Distance L m Vertical height to elevate= Lsinφ H m Skirt board length each side m 6 Material / Bulk density t/m3
15.5 4.06 3 sbl 0.9
7 Capacity Factor
k
0.89 H/L
8 Trough Angle
λ
9 Total Moisture Material Temperature Lump Size
o
% C mm o
10 Weight of Moving Part Conv. if s1 and s2 and density < 1.5
G kg/m s1 m s2 m 11 Additional l m if center distance < 30 m. L m 12 Coefficient of friction of rolling parts parts f
Check Theoritical Capacity
1
35
β
=
6
=
0.28
o
10
28 35 100 45 1.5 3 50 15.5
see table 7 see table 7 see table 7 see table 8 see table 8
0.023
see table 9
Qt Qt'
=
{Q2/(v x x k)}
=
457.76 m3/h
See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't
=
B λ
mm
2
Qt
=
3
Q
=
with ; Belt Width Trough Angle
Q > Q2
PT. Protech Asia Engineering.
o
493 m3/h 1200 20
β
Q't x v x k Qt x
o
15 = =
1974.47 m3/h 1777.02 t/h
By Pass System RCD-1 to SP3 RCD-2 to SP2 Pelabuhan Batubara Tarahan.
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW) N1 = {G(L+l)fxv}/102
=
2.99 kW
2 Power Required to convey material on the level N2 (kW) N2 = {Q(L+l)f}/367
=
7.29 kW
3 Power Required to elevated material N3 (kW ) N3 = (QxH)/367
=
19.66 kW
=
2.16 kW
4 Additional Power Requirement N4 (kW), see table 10 0.08x v x length of N4 = skirt board * Theoritical Necessary Motor Capacity Nn (kW) Nn
=
N1 + N2 + N3 + N4
=
32.10 kW
Nm
=
Nn / ŋ
=
37.77 Kw
* Motor Capacity (Nm)
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = 500 mm D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION
Service Factor * Nominal Power Rating *
Gear Reducer output speed
*
Gear Reducer Ratio
*
Thermal Power Rating
sf= PN
2 =
Pm x sf
=
75.54 kW
n2
=
(v x 60)/(3.14 x D1)
=
136.49 rpm
i
=
1500 / n2
=
10.99
=
53.24 kW
PG PG1
= PG1 x 0.87 x 1.2 = 51
PN < PG the Gear Reducer no need extra cooling. According above mention , choice gear reducer type and size ; FLENDER type : B2HH4 HANSEN P4 type: QHRA2
PT. Protech Asia Engineering.
i i
= =
11.2 11.2
or
CALCULATION OF BY PASS CONVEYOR C - 12A 1 Belt Capacity Required
Q2 t/h
1650
2 Belt Width
B
mm
1200
3 Belt Speed Required
v
m/s
4.5
4 Angle of Inclination
φ
o
5 Belt Center Distance Vertical height to elevate= Lsinφ Skirt board length each side
L H
m m m t/m3
6 Material / Bulk density 7 Capacity Factor
k
8 Trough Angle
λ
9 Total Moisture Material Temperature Lump Size 10 Weight of Moving Part Conv. if s1 and s2 and density < 1.5 11 Additional if center distance < 30 m. 12 Coefficient of friction of rolling parts, on dusty running periodic overloaded. Check Theoritical Capacity
1
16 17 4.06 3 sbl
o
35
% C mm
28 35 100
G kg/m s1 m s2 m l m L m f
6
=
0.28
o
10
1.1 0.89 H/L
o
=
β
67 1.5 3 50 17
see table 7 see table 7 see table 7 see table 8 see table 8
0.03
see table 9
Qt Qt'
=
{Q2/(v x x k)}
=
374.53 m3/h
See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;
with ; Belt Width Trough Angle 2
Q't
=
B
mm
λ
o
Qt
=
396 m3/h 1000 30
β
Q't x v x k
o
15 =
1585.98 m3/h
3
=
1744.58 t/h
1 Power Required to drive empty Conveyor N1 (kW) {G(L+l)fxv}/102 N1 =
=
5.94 kW
2 Power Required to convey material on the level N2 (kW) {Q(L+l)f}/367 N2 =
=
9.55 kW
3 Power Required to elevated material N3 (kW ) N3 =
=
19.30 kW
=
2.16 kW
Q
=
Qt x
Q > Q2 ed to modify the speed , belt size , trough angle
Power Requirement
(QxH)/367
4 Additional Power Requirement N4 (kW), see table 10 0.08x v x length of N4 = skirt board * Theoritical Necessary Motor Capacity Nn (kW) Nn
=
N1 + N2 + N3 + N4
=
36.96 kW
Nm
=
Nn / ŋ
=
43.48 Kw
* Motor Capacity (Nm)
Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = 500 mm D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION
* Prime Mover Electric motor Motor speed Max. starting torque
P1 n1 TA
= = =
55 kW 1500 rpm 525 Nm
* Driven machine Belt Conveyor
P2
=
45 kW
* Output rotation need * Gear Reducer Ratio
n2
=
i
=
( v x 60 )/( 3.14 x D1 ) n1 / n2
= =
136.49 rpm 10.99
* Service factor for Gear Units with 24 hours operation. Factor for driven machine Belt onveyor. Factor for prime mover use electric motor Peak torque factor with load peaks per hour 6 - 30 Thermal factor Thermal factor with cooling Factor for altitude Factor for altitude with cooling Oil supply factor for horz. Thermal capacity Thermal capacity factor with fan * Determination of Nominal Power rating
PN
= = = = = = = = = =
f1 f2 f3 f4 f5 f6 f7 f8 f9 f 10
1.30 1.00 0.95 0.71 1.19 1.00 1.00 0.95 1.20 1.49
P2 x f1 x f2
≥
table 1, page 12 table 2, page 12 table 3, page 12 table 4, page 12 table 5, page 12 table 6, page 12 table 7, page 12 table 8, page 13 table 9, page 13 table 10, page 13 =
* Selected from power rating table: type B2 gear unit size 4 , with P N = 81 kW
* Checking the starting torque
PN
58.50 kW page :22
=
3.33 x P2 ≥ PN 149.85 kW > PN = 82 kW
=
149.85 kW
≥
(T A x n1) / 9550 x f 3
=
78.34 kW
PN = 81 kW > 78.34 kW * Thermal Power Rating without auxiliary cooling * Thermal capacity for gear units without auxiliary cooling
PG1
=
PG
=
51
page:23 PG1 x f4 x f6 x f8 x f9
=
41.28 kW
PG = 41.28 kW < P2 = 45 kW Gear unit need auxiliary fan cooling
Check thermal power rating with auxiliary fan cooling * Thermal Power Rating with
PG2
=
67
page:23
auxiliary fan cooling * Thermal capacity for gear units with auxiliary fan cooling
PG
=
PG2 x f4 x f6 x f8 x f10
=
67.34 kW
PG = 67.88 kW > P2 = 45 kW
According above mention , choice gear reducer type and size ; FLENDER type : B2DH4 i = 11.2 Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan
`
63.2238
54.3467
59.1293 63.9373 power yang diminta
75
150 97.5
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
CALCULATION OF BY PASS CONVEYOR C - 12A 1 Belt Capacity Required
Q2 t/h
1650
2 Belt Width
B
mm
1200
3 Belt Speed Required
v
m/s
4.5
4 Angle of Inclination
φ
o
16
5 Belt Center Distance Vertical height to elevate= Lsinφ Skirt board length each side
L H
m m m t/m3
6 Material / Bulk density 7 Capacity Factor
k
8 Trough Angle
λ
9 Total Moisture Material Temperature Lump Size 10 Weight of Moving Part Conv. if s1 and s2 and density < 1.5 11 Additional if center distance < 30 m. 12 Coefficient of friction of rolling parts, on dusty running periodic overloaded. Check Theoritical Capacity
1
15.5 4.06 3 sbl
% C mm o
6
=
0.28
o
10
1.1 0.89 H/L
o
=
35
β
28 35 100
G kg/m s1 m s2 m l m L m
67 1.5 3 50 15.5
see table 7 see table 7 see table 7 see table 8 see table 8
f
0.03
see table 9
Qt Qt'
=
{Q2/(v x x k)}
=
374.53 m3/h
See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't
=
with ; Belt Width
B
mm
Trough Angle
λ
o
2
Qt
=
3
Q
=
396 m3/h 1000 30
Q't x v x k Qt x
Q > Q2 No need to modify the speed , belt size , trough angle
PT. Protech Asia Engineering.
β
o
15 = =
1585.98 m3/h 1744.58 t/h
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW) N1 = {G(L+l)fxv}/102
=
5.81 kW
2 Power Required to convey material on the level N2 (kW) N2 = {Q(L+l)f}/367
=
9.34 kW
3 Power Required to elevated material N3 (kW ) N3 =
=
19.30 kW
=
2.16 kW
(QxH)/367
4 Additional Power Requirement N4 (kW), see table 10 0.08x v x length of N4 = skirt board * Theoritical Necessary Motor Capacity Nn (kW) Nn
=
N1 + N2 + N3 + N4
=
36.61 kW
Nm
=
Nn / ŋ
=
43.07 Kw
* Motor Capacity (Nm)
Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = 500 mm D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION
* Prime Mover Electric motor Motor speed Max. starting torque
P1 = n1 = TA =
* Driven machine Belt Conveyor
P2
=
* Output rotation need
n2
=
* Gear Reducer Ratio
i
=
55 kW 1500 rpm 525 Nm 45 kW ( v x 60 )/( 3.14 x D1 ) n1 / n2
* Service factor for Gear Units with 24 hours operation. PT. Protech Asia Engineering.
= =
136.49 rpm 10.99
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
Factor for driven machine Belt onveyor. Factor for prime mover use electric motor Peak torque factor with load peaks per hour 6 - 30 Thermal factor Thermal factor with cooling Factor for altitude Factor for altitude with cooling Oil supply factor for horz. Thermal capacity Thermal capacity factor with fan * Determination of Nominal Power rating
PN
= = = = = = = = = =
f1 f2 f3 f4 f5 f6 f7 f8 f9 f10
1.30 1.00 0.95 0.71 1.19 1.00 1.00 0.95 1.20 1.49
P2 x f1 x f2
≥
table 1, page 12 table 2, page 12 table 3, page 12 table 4, page 12 table 5, page 12 table 6, page 12 table 7, page 12 table 8, page 13 table 9, page 13 table 10, page 13 =
58.50 kW
* Selected from power rating table: type B2 gear unit size 4 , with PN = 81 kW
* Checking the starting torque
PN
page :22
=
3.33 x P2 ≥ PN 149.85 kW > PN = 82 kW
=
149.85 kW
≥
(T A x n1) / 9550 x f3
=
78.34 kW
PN = 81 kW > 78.34 kW * Thermal Power Rating without auxiliary cooling * Thermal capacity for gear units without auxiliary cooling
PG1
=
PG
=
51
page:23 PG1 x f4 x f6 x f8 x f9
=
41.28 kW
PG = 41.28 kW < P 2 = 45 kW Gear unit need auxiliary fan cooling
Check thermal power rating with auxiliary fan cooling * Thermal Power Rating with auxiliary fan cooling * Thermal capacity for gear units with auxiliary fan cooling
PG2
=
PG
=
67 PG2 x f4 x f6 x f8 x f10
page:23 =
67.34 kW
PG = 67.88 kW > P 2 = 45 kW
According above mention , choice gear reducer type and size ; FLENDER type : B2HH4 i = 11.2 Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan
`
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
63.2238
53.8366
58.5742 63.3371 power yang diminta
75
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan
150 97.5
PT. Protech Asia Engineering.
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