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 Joint 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 contact 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
Support 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 contact heavy contact 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 Joint 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 Joint
0.9
DUNLOPLAST
Finger Splice Joint
0.9
Steel Cord Belts
Splice 1 and 2 step
1
Various
3 step
0.95
4 step
0.9
Mechanical Joints: 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
