Conveyor Design Summary Report

22/09/2005 12:06:14 PM Project New Nickel Mine Project No P902399 Conveyor No.
CV 01
Conveyor Design Summary

Helix Technologies Pty Ltd
Client Prepared By Design Date
Page 1
ABC Mining Peter Burrow 18/09/2004
Conveyor Design Summary Report
Conveyed Material LIMESTONE, CRUSHED High Bulk Density 1,360 kg/m3 1,450 Surcharge Angle 38 deg 25 mm Uniform / Mixed Material 10 Mixed Material Conveyer Data Conveying Distance Design Capacity 69.44 m 777 Nett Lift / Lower (-) 11.2 m Belt Speed 3 Belt Details Belt Width Selected Belt Percentage Full 750 mm 80 Belt Class / Plies Top Cover Thickness 315/2 6 Belt Rated Tension Bottom Cover Thickness 31.5 kN/m 2 Belt Plies 2 Belt Mass 9.41 Belt Tensions and Power Calculations ISO Effective Tension-Fully Loaded Belt Power - Empty Belt 11.71 kN 5.79 Maximum Tension Tmax Belt Power - Inclines Loaded 22.07 kN 35.13 Minimum Tension Tmin Belt Power - Declines Loaded 10.26 kN 8.16 Sag Tension Belt Power - Fully Loaded 1.5 % 7.98 kN 35.13 Takeup Type Drive Efficiency (Ave) Vertical Gravity 94 Takeup Mass Absorbed Power (Fully Loaded) 2,108 kg 37.34 Installed Power 45 Carry and Return Idlers Carry Idler Trough Angle Return Idler Trough Angle 35 deg 10 Carry Idler Spacing Return Idler Spacing 1.2 m 3 Carry Idler No Rolls x Dia Return Idler No Rolls x Dia 3 x 152 mm 2 x 127 Material Description Low Bulk Density Angle of Repose Material Lumpsize Start-up Factor - Fully Loaded Start-up Factor - Empty Starting Time - Fully Loaded Starting Time - Empty
Designers Comments:
kg/m3 deg
tonnes/h m/s % mm mm kg/m kW kW kW kW % kW kW deg m mm
Dynamics and Miscellaneous Data CEMA Temperature Factor Kt 140 % % Total Braking Torque LSS 140 Stopping Time - Loaded, Braking 3.77 sec Stopping Time - Loaded, Coasting 1 sec
1 1 kNm 2.11 sec 2.8 sec
Note Belt lift during starting due to light belt and tight geometry of conveyor. Refer to Vertical curves report. Starting torque should be reduced if possible. Suggest using a VVVF drive to reduce starting torque and removing the Fluid Coupling. This would also result in a better match with the Shaft mounted gearbox.
C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES
Ver 5.0.42.3
Helix
22/09/2005 12:06:15 PM Project New Nickel Mine Project No P902399 Conveyor No. CV 01
Conveyor Sections - Input Data

Page 1
Conveyor Sections - Input Data
Station 1 2 3 4 5 6 7 8 9 10 11 Tail Hopper Int. Pt Int. Pt Drive Snub Bend Takeup Bend Int. Pt Int. Pt
Description Tail Second Third Third
X coord m 0 2 5 34.75 69.7 69 59.3 58.9 58.5 35
Y coord m 0 0 0 0 0 0 0 0 0 0 0
Z coord m 0.25 0.5 0.5 0.55 11.7 11.3 7.7 2.3 7.4 -0.2 0
Section Length m 2.02 3 29.75 36.69 0.81 10.35 5.41 5.12 24.7 34 1.03 152.88
Section Lift m 0.25 0 0.05 11.15 -0.4 -3.6 -5.4 5.1 -7.6 0.2 0.25 0
Section Capacity tonnes/hr 0 777 777 777 0 0 0 0 0 0 0
Idler Spacing m 1 0.5 1.5 1.5 3 3 3 3 3 3 1
Friction Factor Input 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Skirt Length m
Tension No. AdjustScra- ment pers kN
Dummy
Totals: Designers Comments:
Helix
Conveyor Belt Details

Page 1
Belt Details
Belt Make & Class Belt Category Belt Description Belt Class Belt Fibre Belt Rated Tension Number of Plies Belt Modulus Cable Diameter Cable Pitch Number of Cables
Goodyear Fabric GOODYEAR PLYLON-HI 315/2 FABRIC 31.5 2 2,070 0 0 0 kN/m kN/m mm mm
Input Data Belt Speed Belt Design Capacity Input Section Loading Max Capacity Material Low Bulk Density Material High Bulk Density Material Lump Size Carry Idler Trough Angle Belt Tensions Belt Rated Operating Tension Actual Maximum Run Tension Actual Maximum Start Tension Allowable Belt Tension, Starting Actual Belt Tension, Starting Belt Load Area & Capacity Belt Load Area Available Flooded Belt Load Area Belt Min. Rec. Edge Distance Belt Actual Edge Distance Burden Depth Allowable Percentage Full Belt Actual Percentage Full Max Capacity @ 100% Full
3 777 777 1,360 1,450 10 35 31.5 29.43 37.65 150 119.53
m/s tonnes/hr tonnes/hr kg/m3 kg/m3 mm deg kN/m kN/m kN/m % %
Belt Dimensions Belt Width Belt Top Cover Thickness Belt Carcass Thickness Belt Bottom Cover Thickness Belt Total Thickness Belt Total Length (L) Time for 1 Belt Revolution Belt & Material Mass Belt Top Cover Mass Belt Carcass Mass Belt Bottom Cover Mass Belt Mass Wb (per unit length) Material Mass Wm Total Mass Wb + Wm Flooded Belt Material Mass Flooded Belt Capacity Belt Total Mass (Wb x L)
Designers Comments:
750 6.00 3.10 2.00 11.10 155.87 46.29
mm mm mm mm mm m sec
5.08 2.63 1.70 9.41 71.94 81.35 142.27 1,537 1,466
kg/m kg/m kg/m kg/m kg/m kg/m kg/m tonnes/hr kg
0.0664 0.0981 64.3 93.0 135 80.00 80.00 975
m2 m2 mm mm mm % % tonnes/hr
Ver 5.0.42.3
Helix
22/09/2005 12:06:16 PM
Tension Summary
Page 1
Project New Nickel Mine Project No P902399 Conveyor No. CV 01
Conveyor Tension Summary Report
Drive Torque Start-up Factor Loaded Drive Torque Start-up Factor Empty
140 % 140 %
Takeup Mass 1.5 % Sag Tension 5% Sag Tension

Starting Fully Loaded Tension kN 11.58
0.10
2108 kg 7.98 kN 2.39 kN

Coasting Fully Loaded Tension kN 9.56
0.12
Running Fully Inclines Declines Loaded Empty Loaded Loaded Tension Tension Tension Tension kN 10.72
0.11
Braking Fully Loaded Tension kN 9.18

0.13
Point No 1 2 3 4 5 6 7 8 9 10 11 Tail
Sag %
Empty Tension kN 13.97

0.08

0.12

0.11
kN 10.72
0.11
kN 10.72
0.11
kN 10.72
0.11
Hopper
Sag %
10.81
0.46
10.81
0.05
10.81
0.46
10.81
0.46
11.81
0.42
14.6
0.34
9.01
0.55
9.59
0.52
9.46
0.53
10.4
0.48
Int. Pt
Sag %
11.8
1.27
11.1
0.16
11.8
1.27
11.8
1.27
13.07
1.14
14.99
1.00
9.52
1.57
9.49
1.58
10.08
1.48
10.38
1.44
Int. Pt
Sag %
12.47
1.20
11.2
0.15
12.47
1.20
11.94
1.25
15.93
0.94
16.91
0.88
6.29
2.38
9.01
1.66
7.81
1.91
10.28
1.45
Drive
Sag %
22.1
0.16
12.34
0.28
22.1
0.16
13.13
0.26
28.24
0.12
20.25
0.17
11.13
0.31
9.44
0.37
13.83
0.25
11.19
0.31
Snub
Sag %
11.02
0.31
11.02
0.31
11.02
0.31
11.04
0.31
11.4
0.30
9.64
0.36
11.55
0.30
11.06
0.31
11.59
0.30
10.93
0.32
Bend
Sag %
10.77
0.32
10.77
0.32
10.77
0.32
10.79
0.32
11.29
0.31
9.94
0.35
11.04
0.31
10.63
0.33
11.14
0.31
10.62
0.33
Takeup
Sag %
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
10.34
0.33
Bend
Sag %
10.87
0.32
10.87
0.32
10.87
0.32
10.87
0.32
11.02
0.31
11.44
0.30
10.59
0.33
10.68
0.32
10.66
0.32
10.8
0.32
Int. Pt
Sag %
10.29
0.34
10.29
0.34
10.29
0.34
10.29
0.34
10.78
0.32
12.16
0.28
9.4
0.37
9.69
0.36
9.62
0.36
10.08
0.34
Int. Pt
Sag %
10.39
0.11
10.39
0.11
10.39
0.11
10.39
0.11
11.22
0.10
13.52
0.09
8.9
0.13
9.38
0.12
9.27
0.12
10.05
0.11
Minimum T Maximum T Max Sag% Effective T Ave.Belt Ten Belt Elong.(m) T/up Travel
10.29 22.1 1.27 11.71 12.45 0.204 0.102
10.29 12.34 0.34 1.93 10.96 0.054 0.027
10.29 22.1 1.27 11.71 12.45 0.204 0.102 6.29 kN
10.29 13.13 1.27 2.72 11.28 0.087 0.043
10.34 28.24 1.14
9.64 20.25 1.00
6.29 11.55 2.38
9.01 11.06 1.66
7.81 13.83 1.91
10.05 11.19 1.45
14.33 0.393 0.196
14.33 0.393 0.196
9.2 -0.122 -0.061
9.68 -0.074 -0.037
Average Belt Tension Stationary = 10.42 kN 344 kg
Minimum Operating Tension : Designers Comments:
Takeup Mass Deficiency due to Belt Sag:
Note Belt lift during starting due to light belt and tight geometry of conveyor. Refer to Vertical curves report. Starting torque should be reduced if possible. Suggest using a VVVF drive to reduce starting torque and removing the Fluid Coupling. This would also result in a better match
C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES Ver 5.0.42.3
Helix
22/09/2005 12:06:16 PM
Running
Tension Summary
Starting Fully Loaded Tension kN Empty Tension kN Braking Fully Loaded Tension kN Empty Tension kN Coasting Fully Loaded Tension kN
Page 2
Point No
Fully Inclines Declines Loaded Empty Loaded Loaded Tension Tension Tension Tension kN kN kN kN
Empty Tension kN
with the Shaft mounted gearbox.
Ver 5.0.42.3
Helix
Takeup & Drive Traction

Page 1
Takeup & Drive Traction Calculation
Drive Torque Start-up Factor Loaded Drive Torque Start-up Factor Empty
Drive No Fully Loaded
140 % 140 %
Running Empty Belt
Takeup Mass
Starting Fully Loaded
2108 kg
Braking Fully Loaded
Empty Belt
Empty Belt
Drive Number: 1 Wrap Angle Co-efficient of Friction Drive Factor Tight Side Tension, T1 Slack Side Tension, T2 Minimum Required T2 Surplus T2 Tension
deg
kN kN kN kN
210 0.35 0.384 22.1 10.47 4.47 6.00 0 kg
210 0.35 0.384 12.34 10.47 0.72 9.75
210 0.45 0.238 28.24 10.84 4.14 6.70
210 0.45 0.238 20.25 9.07 2.66 6.41
210 0.45 0.238 11.01 11.13 0.03 10.98
210 0.45 0.238 10.52 9.44 0.26 9.19
Additional Takeup Mass Required

Designers Comments:
Helix
Conveyor Starting & Stopping

Page 1
Conveyor Dynamics, Starting, Stopping Times
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 Tensions and Accelerating Forces Total Braking Force Effective Tension - Loaded Effective Tension - Empty Accelerating Tension - Loaded Accelerating Tension - Empty Starting Times & Acceleration Rates Starting Time - Fully Loaded Starting Time - Empty Acceleration Rate - Fully Loaded Acceleration Rate - Empty
1,466 4,996 872 239 741 2,651 10,937
kg kg kg kg kg kg kg
Input Data Belt Speed Belt Rated Tension Allowable Belt Start Tension Rise Drive Inertia Total Braking Torque Start-up Factor - Fully Loaded Start-up Factor - Empty Installed Power Drive Efficiency (Ave)
3 31.5 150 1 1 140 140 45 94
m/s kN/m % kg-m2 kNm % % kW %
3.82 11.71 1.93 9.99 19.19
kN kN kN kN kN
Stopping Times & Deceleration Rates Stopping Time - Loaded, Braking 2.11 sec Stopping Time - Loaded, Coasting 2.8 sec Stopping Time - Empty, Braking 3.11 sec Stopping Time - Empty, Coasting 9.28 sec Deceleration - Loaded, Braking Deceleration - Loaded, Coasting Deceleration - Empty, Braking Deceleration - Empty, Coasting -1.42 -1.07 -0.96 -0.32 m/s2 m/s2 m/s2 m/s2
3.77 1 0.8 3
sec sec m/s2 m/s2
Belt Tension Rise Starting / Braking Max Belt Tension, Start/Brake 28.24 Belt Width 750 Maximum Belt Tension /width 37.65 Belt Rated Tension /width 31.5 Actual Max Tension, Start/Brake 119.53
kN mm kN/m kN/m %
Stopping Distances & Discharge Volumes Stopping Distance - Loaded, Braking 3.17 Stopping Distance - Loaded, Coasting 4.2 Stopping Distance - Empty, Braking 4.67 Stopping Distance - Empty, Coasting 13.92 Discharge Mass, Braking Discharge Mass, Coasting Discharge Volume, Braking Discharge Volume, Coasting 228 302 0.17 0.22
m m m m kg kg m3 m3
Designers Comments: Note Belt lift during starting due to light belt and tight geometry of conveyor. Refer to Vertical curves report. Starting torque should be reduced if possible. Suggest using a VVVF drive to reduce starting torque and removing the Fluid Coupling. This would also result in a better match with the Shaft mounted gearbox.
Ver 5.0.42.3
Helix
Conveyor Drive Details

Page 1
Conveyor Drive Details
Drive Number Drive Type Load Share % Number of Motors on Drive Starting Torque % Fully Loaded Starting Torque % Empty Belt Total Drive Inertia Drive Equivalent Mass Tight Side Tension T1 Slack Side Tension T2 Effective Tension Te Pulley Lagging Thickness Pulley Shell Diameter Pulley Outside Diameter Pulley Shaft Diameter Pulley Bearing Diameter Backstop Required Backstop Torque (3 x FLT) Backstop Torque (for runback)
Designers Comments:
1 Tripper 100 1 140 140 1 2,651 22.1 10.47 11.7 12 500 524 120 110 YES 11791 1571
% % % kg-m2 kg kN kN kN mm mm mm mm mm Nm Nm
Pulley Condition Belt Wrap Angle Co-Eff of Friction - Running Drive Factor Cw - Running Co-Eff of Friction - Starting Drive Factor Cw - Starting Pulley Lagging Type Pulley Lagging Thickness Pulley Input Power (Te x V) Drive Efficiency Motor Selection Safety Factor Motor Power Rating Motor Voltage Motor FL Speed Pulley Speed Reducer Ratio Required Low Speed Brake Torque High Speed Brake Torque
Dry 210 0.35 0.384 0.45 0.238 Rubber 12 35.1 94 1.1 45 415 1,475 109.34 13.49 1 79
deg
mm kW % kW Volts rpm rpm kNm Nm
Figures in Italics are Design Input Values
Helix
Conveyor Motor Details

Page 1
Conveyor Motor Details
Motor Details for Drive Number: 1 Motor Category Metric Motor Decription Electric Motor Number of Motors on Drive 1 Motor Power Rating 45 Motor Voltage 415 Number of poles 4 Motor Frame Size F225M04 Motor Shaft Diameter 60 Motor Shaft Height 225 Moment of Inertia 0.775
Designers Comments:
Auto Selection
kW Volts
mm mm kg-m2
Total Motor Power on Drive Absorbed Power at Pulley Drive Efficiency Absorbed Power at Motor Motor FL Speed Motor FL Torque Motor Full Load Current Motor Efficiency @ Duty Point Motor Power Factor @ Duty Pt Mass of Motor
45.00 35.1 94 37.34 1,475 291 75.7 92.43 0.87 400
kW kW % kW rpm Nm Amps % kg
Helix
Fluid Coupling Details

Page 1
Fluid Coupling Details
Fluid Coupling / Soft Starter Details for Drive Number: 1 Coupling Category Coupling Size Voith Decription Motor Power Rating VOITH TSS Number of Motors on Drive Motor FL Speed 1 Coupling Power Rating kW Coupling Rated Slip 75 Peak Torque % Run-up Torques % (2 sec) 140 % Min. Required Ramping Time Coupling Output Speed 0.29 sec Max Starting Time Mass of Coupling 30 sec
Designers Comments:
Auto Selection
422 45 1,475 3 75 1431 66
kW rpm % % kg
Helix
Conveyor Gearbox Details

Page 1
Conveyor Gearbox Details
Gearbox Details for Drive Number: 1 Gearbox Category Fenner Shaft Mounted Decription Fenner Shaft Mounted Type 250x630-4 SPB Size J5 Code 5.047 Ratio 12.718 Number of Stages 1 Service Factor 1.5 Design Efficiency 94 % Actual Efficiency 92 % Maximum Input Shaft Speed 1,500 rpm Minimum Input Shaft Speed 1,300 rpm Input Shaft Diameter 55 mm Output Shaft Diameter 100 mm
Designers Comments:
Auto Selection
Number of Motors on Drive Motor Power Rating Maximum LS Shaft Torque Rating LS Shaft Torque @ Motor FL Motor FL Speed Plus Speed Selection Tolerance Minus Speed Selection Tolerance Fluid Coupling Slip Max Output Shaft speed Min Output Shaft speed Design Pulley Speed Actual Pulley Speed
1 45 kW 5,940 Nm 3,930 Nm 1,475 5 5 3 rpm % % % rpm rpm rpm rpm
117.94 102.22 109.34 112.50 Shaft Mount
Helix
Brake Details
Page 1
Brake Details
Brake Details for Drive Number: Brake Category Svendborg BSFH 200 Description Svendborg - Simon Hydraulics Number of Motors on Drive 1 Caliper BSFH 202 Brake Location Low Speed Side Low Speed Braking Torque @Pulley 1 kNm High Speed Braking Torque @Pulley 79 Nm
Brake Selection Input Data
Manual Selection
Disc Material Disc Diameter Disc Thickness Co-eff of Friction (Pad-Disc) Caliper Clamping Force Pad offset Width W Maximum Air Gap
Recommended working airgap is 1mm
Mild Steel 700 20 0.4 2,000 60 3
mm mm u N mm mm
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
Designers Comments:
800 461 10 3 3 30 44
Nm Nm sec sec / hr deg C deg C
Disc Initial Speed Disc Moment of Inertia Gearbox Ratio Required Drive Efficiency Mass of Caliper Brake Caliper Price
1,450 rpm 3.701 kg-m2 13.49 94 % 26 kg $0
Helix
Conveyor Idlers
Page 1
Conveyor Idlers
Idler Category Idler Description Idler Design Belt Width Idler Series Drawing Number Nominal Idler Spacing Total Number of Idlers Idler Price 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 Type of Bearing Bearing Designation Bearing Dynamic Load Rating C Bearing L10h Life Allowable Shaft Deflection at Bearing Actual Shaft Deflection at Bearing
Carry Side Idlers Prok Carry Series 20 3 Roll Carry 152 Plain Inline 750 mm 20 1.2 m 53 $0.00 35 27 25 3 152 377 283 226.8 307 1,000 16.2 31.7 deg mm mm mm rpm mm mm mm mm kg kg
Return Side Idlers Prok Vee Return Vee Return Series 15 2 Roll 127 Dia 750 mm 15 3 m 26 $0.00 10 27 25 2 127 451 419 367.2 447.4 1,000 9.2 24.2 deg mm mm mm rpm mm mm mm mm kg kg
9 mm 1.13 600 N 1,442 N Ball 6205 14,000 323,526 8 2.06
36 mm 1.4 480 N 797 N Ball 6205 14,000 1,602,098 10 1.84
N hrs min min
N hrs min min
Designers Comments: Note Belt lift during starting due to light belt and tight geometry of conveyor. Refer to Vertical curves report. Starting torque should be reduced
Helix
22/09/2005 12:06:19 PM
Conveyor Idlers
Page 2
if possible. Suggest using a VVVF drive to reduce starting torque and removing the Fluid Coupling. This would also result in a better match with the Shaft mounted gearbox.
Helix
Conveyor Pulleys
Page 1
Conveyor Pulleys
Pulley Pulley Position Desc Tail Drive Snub Bend Takeup Bend
Shell Dia D mm 400 500 273 400 400 400
Lagging t mm 12 12 12 12 12 12
Face Width mm 850 850 850 850 850 850
Shaft Length mm 1,590 1,640 1,490 1,550 1,590 1,550
Shaft Dia S mm 100 120 60 90 100 90
Brg Crs mm 1,270 1,270 1,270 1,270 1,270 1,270
Brg Dia mm 90 110 60 80 90 80
Wrap Angle deg 180 210 20 90 180 90
Pulley Speed rpm 135 109 193 135 135 135
Pulley Mass kg 175 257 78 176 175 176
Mom of Inertia kg-m2 5.67 12.35 1.29 5.62 5.67 5.62
Braking Torque Force kNm kN
3.82
Designers Comments:
Note: * indicates manual pulley dimension override was used
Helix
Pulley Design Data

Page 1
Conveyor Pulleys
Belt Speed Belt Width Pulley Pulley Position Desc Tail Drive Snub Bend Takeup Bend Designers Comments: Tail Shell Dia D mm 400 500 273 400 400 400 Lagging t mm 12 12 12 12 12 12
3 m/s 750 mm Face Width mm 850 850 850 850 850 850 Brg Crs mm 1,270 1,270 1,270 1,270 1,270 1,270 Drive Extension mm 0 0 0 0 0 0 45.00 Drive Power kW
Total Installed Power
45 kW
Pulley Speed rpm 135.1 109.3 192.9 135.1 135.1 135.1
Wrap Angle deg 180 210 20 90 180 90
T1 Start kN 13.97 28.24 11.59 11.29 10.34 11.44
T2 Start kN 14.41 10.84 11.59 11.45 10.77 11.88
T1 Run kN 10.72 22.1 11.02 10.77 10.34 10.87
T2 Run kN 10.78 10.47 11.08 10.83 10.39 10.93
Starting Empty
Running Full
Starting Full
Running Full
Coasting Full
Running Full
Starting Full
Running Full
Starting Empty
Running Full
Starting Empty
Running Full
Helix
Conveyor Pulleys
Page 1
Conveyor Pulleys
Pulley Type
Overall Dia mm
Shell Dia D mm
Face Width F mm
Belt Width B mm
Shaft Length L mm
Shaft Dia S mm
Bearing Crs C mm
Bearing Dia d mm
Shaft Ext E mm
Lagging t mm
Tail Drive Snub Bend Takeup Bend
424 524 297 424 424 424
400 500 273 400 400 400
850 850 850 850 850 850
750 750 750 750 750 750
1,590 1,640 1,490 1,550 1,590 1,550
100 120 60 90 100 90
1,270 1,270 1,270 1,270 1,270 1,270
90 110 60 80 90 80
0 0 0 0 0 0
12 12 12 12 12 12
Helix
Conveyor Pulley Shafts

Page 1
Conveyor Pulley Shafts
Pulley Position Tail Drive Snub Bend Takeup Bend
Shaft Desc
Shaft Length mm 1,590 1,640
Wrap Angle deg 180 210 20 90 180 90 5
T1 Run kN 10.72 22.1 11.02 10.77 10.34 10.87 min
T2 Run kN 10.78 10.47 11.08 10.83 10.39 10.93
Resultant Force kN 21.44 31.56 3.83 15.25 20.67 15.37
T1 Start kN 11.58 28.24 11.4 11.29 10.34 11.02
Calculated Defl. Dt. Dia Dia mm 91.4 100.7 59.4 83.9 90.5 84.1 mm 88.5 106.7 49.8 79 87.4 79.2
Selected Shaft Brg Dia S Dia mm 100 120 60 90 100 90 41 mm 90 110 60 80 90 80 N/mm2
Brg Crs mm 1,270 1,270 1,270 1,270 1,270 1,270
Shaft Mass kg 98 146 33 77 98 77
Drive BBK
1,490 1,550 1,590
BBK
1,550
Allowable Shaft Deflection at Hub: Designers Comments:
Allowable Shaft Stress
Helix
Conveyor Belt Tensions

Page 1
Conveyor Tension Graphs
Running Tensions - Fully Loaded Tail 26 24 22 20 18 Tension 16 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 11 10.72 10.81 11.8 12.47 11.02 10.77 10.34 10.87 10.29 10.39 Hopper Int. Pt Int. Pt Drive 22.1 Snub Bend Takeup Bend Int. Pt Int. Pt
Running Tensions - Empty Belt Tail 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Hopper Int. Pt Int. Pt Drive 12.34 10.72 10.81 11.1 11.2 11.02 10.77 10.34 10.87 10.29 10.39 Snub Bend Takeup Bend Int. Pt Int. Pt
Tension
10
11
Helix
22/09/2005 12:06:20 PM

Running Tensions - Inclines & Level Sections Loaded Int. Pt Int. Pt Drive 22.1 Snub Bend Takeup Bend Int. Pt
Page 2
Tail 26 24 22 20 18 Tension 16 14 12 10 8 6 4 2 0 1 10.72
Hopper
Int. Pt
10.81
11.8
12.47 11.02 10.77 10.34 10.87 10.29 10.39
10
11
Running Tensions - Declines & Level Sections Loaded Tail Hopper Int. Pt Int. Pt Drive 13.13 14 10.72 12 10 Tension 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 11 10.81 11.8 11.94 11.04 10.79 10.34 10.87 10.29 10.39 Snub Bend Takeup Bend Int. Pt Int. Pt
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Starting Fully Loaded Int. Pt Int. Pt Drive 28.24 Snub Bend Takeup Bend Int. Pt
Page 3
Tail
Hopper
Int. Pt
30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 11.58 11.81 13.07 11.4 11.29 10.34 11.02 10.78 11.22 15.93
Tension
Belt Tensions - Starting Empty Tail 24 22 20 18 16 Tension 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 11 9.64 9.94 10.34 13.97 14.6 14.99 13.52 11.44 12.16 16.91 Hopper Int. Pt Int. Pt Drive 20.25 Snub Bend Takeup Bend Int. Pt Int. Pt
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Braking Fully Loaded Int. Pt Int. Pt Drive 11.13 Snub 11.55 Bend 11.04 10.34 Takeup Bend Int. Pt
Page 4
Tail 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Hopper
Int. Pt
10.59 9.4 8.9
9.18
9.01
9.52
Tension
6.29
10
11
Belt Tensions - Braking Empty Tail 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 Hopper Int. Pt Int. Pt Drive Snub 11.06 9.67 9.59 9.49 9.01 9.44 Bend 10.63 Takeup Bend 10.68 9.69 9.38 Int. Pt Int. Pt
10.34
Tension
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Coasting Fully Loaded Int. Pt Int. Pt Drive 13.83 11.59 11.14 10.34 7.81 Snub Bend Takeup Bend Int. Pt
Page 5
Tail 16 14 12 Tension 10 8 6 4 2 0 1 9.56
Hopper
Int. Pt
9.46
10.08
10.66 9.62 9.27
10
11
Belt Tensions - Coasting Empty Tail 13 12 11 10 9 Tension 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 10.37 10.4 10.38 10.28 Hopper Int. Pt Int. Pt Drive 11.19 Snub 10.93 Bend 10.62 Takeup Bend 10.8 10.08 10.05 Int. Pt Int. Pt
10.34
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Conveyor Stationary Int. Pt Int. Pt Drive 11.2 Snub 11.16 Bend 10.83 Takeup Bend 10.81 10.11 10.13 Int. Pt
Page 6
Tail 13 12 11 10 9 Tension 8 7 6 5 4 3 2 1 0 1
Designers Comments:
Hopper
Int. Pt
10.15
10.17
10.17
10.17
10.34
10
11
Helix

Page 1
Conveyor Tension Graphs
Running Tensions - Fully Loaded 22 21 20 19 18 Tension 17 16 15 14 13 12 11 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Station X Co-ordinate
Running Tensions - Empty Belt
12.2 12 11.8 11.6 Tension 11.4 11.2 11 10.8 10.6 10.4 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Helix
22/09/2005 12:06:21 PM

Running Tensions - Inclines Loaded
Page 2
22 21 20 19 18 Tension 17 16 15 14 13 12 11 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Running Tensions - Declines Loaded 13 12.8 12.6 12.4 12.2 12 11.8 11.6 11.4 11.2 11 10.8 10.6 10.4 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Tension
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Starting Fully Loaded
Page 3
28 26 24 22 Tension 20 18 16 14 12 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Belt Tensions - Starting Empty 20 19 18 17 16 Tension 15 14 13 12 11 10 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Braking Fully Loaded
Page 4
11.5 11 10.5 10 9.5 Tension 9 8.5 8 7.5 7 6.5 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Belt Tensions - Braking Empty 11 10.8 10.6 10.4 Tension 10.2 10 9.8 9.6 9.4 9.2 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Coasting Fully Loaded
Page 5
13.5 13 12.5 12 11.5 Tension 11 10.5 10 9.5 9 8.5 8 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Belt Tensions - Coasting Empty
11.1 11 10.9 10.8 Tension 10.7 10.6 10.5 10.4 10.3 10.2 10.1 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Helix
22/09/2005 12:06:21 PM

Belt Tensions - Conveyor Stationary
Page 6
11.1 11 10.9 10.8 Tension 10.7 10.6 10.5 10.4 10.3 10.2 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Helix
22/09/2005 12:06:21 PM
Conveyor Tensions Declines Loaded

Page 1
Declines & Level Sections Loaded Tensions
Station / Pulley Tensions T1 Run kN 1 2 3 4 5 6 7 8 9 10 11 Tail Hopper Int. Pt Int. Pt Drive Snub Bend Takeup Bend Int. Pt Int. Pt 10.72 10.81 11.8 11.94 13.13 11.04 10.79 10.34 10.87 10.29 10.39 T2 Run kN 10.78 10.81 11.8 11.94 10.49 11.1 10.85 10.39 10.93 10.29 10.39 0.35 2.69 22.1 kN 10.29 kN 11.28 kN 10.42 kN 0.86 kN 0.06 0.06 0.06 0.05 0.06 2.69 Pulley Tp kN 0.06 Drive Te kN Section Section Length Lift m 2.02 3 29.75 36.69 0.81 10.35 5.41 5.12 24.7 34 1.03 152.88 m 0.25 0 0.05 11.15 -0.4 -3.6 -5.4 5.1 -7.6 0.2 0.25 0 0.65 0.65
Conveyor Section Matl. Skirt Accel. Friction Tension Tension kN kN Scraper Friction Tension kN Section Effective Friction Factor Tension kN 0.03 0.27 0.07 0.14 1.19 0.59 -0.04 -0.31 -0.49 0.48 -0.64 0.1 0.3 0.27 0.89 0.03 0.56 2.74 kN 8.22 kW 2,070 kN/m 155.87 m 0.087 m 0.043 m 0.0160 0.0206 0.0160 0.0160 0.0188 0.0192 0.0192 0.0194 0.0193 0.0193 0.0160
Station
Totals: Maximum Tension Minimum Tension Average Tension Fully Loaded Average Tension Belt Stationary Average Tension Difference
Total Effective Tension Total Belt Power (Te x V) Belt Modulus Total Belt Length Belt Elastic Elongation Takeup Movement
Helix
Conveyor Tensions-Empty Belt

Page 1
Empty Belt Running Tensions
Station / Pulley Tensions T1 Run kN 1 2 3 4 5 6 7 8 9 10 11 Tail Hopper Int. Pt Int. Pt Drive Snub Bend Takeup Bend Int. Pt Int. Pt 10.72 10.81 11.1 11.2 12.34 11.02 10.77 10.34 10.87 10.29 10.39 T2 Run kN 10.78 10.81 11.1 11.2 10.47 11.08 10.83 10.39 10.93 10.29 10.39 0.35 1.89 12.34 kN 10.29 kN 10.96 kN 10.42 kN 0.54 kN 0.06 0.06 0.06 0.05 0.06 1.89 Pulley Tp kN 0.06 Drive Te kN Section Section Length Lift m 2.02 3 29.75 36.69 0.81 10.35 5.41 5.12 24.7 34 1.03 152.88 m 0.25 0 0.05 11.15 -0.4 -3.6 -5.4 5.1 -7.6 0.2 0.25 0
Station
Helix
22/09/2005 12:06:22 PM
Conveyor Tensions Fully Loaded

Page 1
Fully Loaded Tensions
Station
Helix
22/09/2005 12:06:23 PM
Conveyor Tensions Inclines Loaded

Page 1
Inclines & Level Sections Loaded Tensions
Station
Helix
22/09/2005 12:06:23 PM
Vertical Curves
Page 1
Project Project No Conveyor No.
New Nickel Mine P902399 CV 01 9.41 5.08 1.7 7.05 46 71.94 kg/m kg/m kg/m kg/m % kg/m
ABC Mining Peter Burrow 18/09/2004 75 1 140 140 2070 31.5 15 % % % kN/m kN/m %
Vertical Curve Radius Calculations

Belt Mass - New Belt Top Cover Mass - New Belt Bottom Cover Mass Worn Belt Mass Reduction of Top Cover Mass Conveyed Material Mass % 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 Allowable Edge Tension Rise
Running Fully Loaded Tension kN 10.72 777 Concave 777 10.81 11.8 171 13 5 777 150 12.47 180 12 5 22.1 11.02 10.77 10.34 10.87 12.34 11.02 10.77 10.34 10.87 11.2 Radius m Empty Tension kN 10.72 10.81 11.1 160 13 5 162 13 5 28.24 11.4 11.29 10.34 11.02 15.93 Radius m Tension kN 11.58 11.81 13.07 189 11 5 230 9 7 20.25 9.64 9.94 10.34 11.44 16.91 Starting Fully Loaded Radius m Empty Tension kN 13.97 14.6 14.99 217 10 6 244 9 7 11.13 11.55 11.04 10.34 10.59 6.29 Radius m Tension kN 9.18 9.01 9.52 138 16 4 91 24 4 9.44 11.06 10.63 10.34 10.68 9.01
Point No 1 2 3 Tail Hopper Int. Pt
Curve Type
Load Capacity tonnes/hr
Design Vertical Curve Radius m
Braking Fully Loaded Radius m Empty Tension kN 9.67 9.59 9.49 137 16 4 130 16 4 244 217 Radius m Max. Radius m
Min. Edge Tension Radius Max. Centre Tension Radius 4 Int. Pt Concave
Min. Edge Tension Radius Max. Centre Tension Radius 5 6 7 8 9 Drive Snub Bend Takeup Bend
Helix
22/09/2005 12:06:23 PM
Design Vertical Curve Radius m 150 Running Fully Loaded Tension kN 10.29 Radius m 149 14 1 10.39 150 14 1
Vertical Curves
Starting Empty Tension kN 10.29 Radius m 149 14 1 10.39 150 14 1 11.22 Fully Loaded Tension kN 10.78 Radius m 156 14 1 162 13 1 13.52 Empty Tension kN 12.16 Radius m 176 12 2 196 11 2 8.9 Tension kN 9.4 Braking Fully Loaded Radius m 136 16 1 129 17 1 9.38 Empty Tension kN 9.69 Radius m 140 15 1 136 16 1 Load Capacity tonnes/hr
Page 2
Point No 10 Int. Pt
Curve Type Concave
Max. Radius m 176
Min. Edge Tension Radius Max. Centre Tension Radius 11 Int. Pt Concave
196
Min. Edge Tension Radius Max. Centre Tension Radius Designers Comments:
Helix
22/09/2005 12:06:23 PM
Tension Summary
Page 1
Idler and Belt Resonance Report
Belt Speed Carry Idler Roll Diameter Return Idler Roll Diameter
3 m/s 152 mm 127 mm
Takeup Mass 1.5 % Sag Tension 5% Sag Tension

Critical Idler Spacing Start m 2.62 0.85 0.86 0.90 2.40 2.20 2.26 2.24 2.19 2.25 2.61
2108 kg 7.98 1.99 kN

Critical Idler Spacing End m 2.67 0.86 0.90 0.93 3.21 2.26 2.23 2.19 2.24 2.18 2.62
Running Fully Loaded Belt Resonance Start Belt Tension kN 10.39 10.78 10.81 11.80 12.47 10.47 11.08 10.83 10.39 10.93 10.29 End Belt Tension kN 10.72 10.81 11.80 12.47 22.10 11.02 10.77 10.34 10.87 10.29 10.39 Belt Transverse Wave Frequency Range Hz 16.48 10.73 3.58 3.76 6.03 5.51 5.68 5.61 5.49 5.64 16.40 to Hz 16.74 10.74 3.76 3.88 8.05 5.66 5.59 5.48 5.62 5.47 16.48 Idler Roll Excitation Frequency Hz 6.28 6.28 6.28 6.28 7.52 7.52 7.52 7.52 7.52 7.52 6.28 Section Idler Spacing m 1.00 0.50 1.50 1.50 3.00 3.00 3.00 3.00 3.00 3.00 1.00
Point No 1 2 3 4 5 6 7 8 9 10 11 Tail Hopper Int. Pt Int. Pt Drive Snub Bend Takeup Bend Int. Pt Int. Pt
Idler Spacing within +/- 10% OK OK OK OK Warning OK OK OK OK OK OK

1
Ver 5.0.42.3
Helix
22/09/2005 12:06:24 PM
Discharge Trajectory
Page 1
ABC Mining Peter Burrow 18/09/2004 20 18 deg 1.5 sec
Conveyor Discharge Trajectory Report

Belt Speed Discharge Radius at Belt Line Discharge Radius at Load Line 4 m/s 0.5 m 0.6 m Number of Calc Increments Belt Incline Angle (-Decline) Time after Discharge
Co-ordinates Measured from Pulley Centre Line Calc No 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Time, t sec 0.000 0.075 0.150 0.225 0.300 0.375 0.450 0.525 0.600 0.675 0.750 0.825 0.900 0.975 1.050 1.125 1.200 1.275 1.350 1.425 1.500 Fall, H m 0.476 0.541 0.551 0.505 0.405 0.250 0.039 -0.227 -0.548 -0.924 -1.356 -1.842 -2.384 -2.981 -3.633 -4.340 -5.102 -5.919 -6.792 -7.720 -8.703 Distance X m -0.155 0.131 0.416 0.701 0.987 1.272 1.557 1.843 2.128 2.413 2.699 2.984 3.269 3.555 3.840 4.125 4.411 4.696 4.981 5.267 5.552
Helix
22/09/2005 12:07:24 PM
Discharge Trajectory
Page 1
ABC Mining Peter Burrow 18/09/2004 20 18 deg 0.8 sec
Conveyor Discharge Trajectory Report

Belt Speed Discharge Radius at Belt Line Discharge Radius at Load Line 3 m/s 0.5 m 0.6 m Number of Calc Increments Belt Incline Angle (-Decline) Time after Discharge
Co-ordinates Measured from Pulley Centre Line Calc No 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Time, t sec 0.000 0.040 0.080 0.120 0.160 0.200 0.240 0.280 0.320 0.360 0.400 0.440 0.480 0.520 0.560 0.600 0.640 0.680 0.720 0.760 0.800 Fall, H m 0.476 0.505 0.518 0.516 0.498 0.465 0.416 0.351 0.270 0.174 0.062 -0.066 -0.209 -0.368 -0.543 -0.733 -0.940 -1.161 -1.399 -1.652 -1.921 Distance X m -0.155 -0.040 0.074 0.188 0.302 0.416 0.530 0.644 0.759 0.873 0.987 1.101 1.215 1.329 1.443 1.557 1.672 1.786 1.900 2.014 2.128
Helix
CV 01 Discharge Trajectory 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 -0.1 -0.2 -0.3 -0.4 -0.5 -0.6 -0.7 -0.8 -0.9 -1 -1.1 -1.2 -1.3 -1.4 -1.5 -1.6 -1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 Distance 0.8 1 1.2 1.4 1.6 1.8 2
Fall
Feeder / Hopper Pull-out Force

Page 1
Feeder / Hopper Pull-out Force

Input Data Width of Hopper Bottom Length of Hopper Bottom Effective Height of Material Bulk Density of Material b c h D 0.5 10 2 1,300 m m m kg/m3 Bruff's Method
Co-efficient of Friction u Material "Flow" Factor - Starting n s Material "Flow" Factor - Running n s Feeder Belt Speed V
0.4 4 1 0.0946 m/s
Calculation Results Pull-out Resistance from Hopper - Starting Pull-out Resistance from Hopper - Running Pull-out Power Required - Starting Pull-out Power Required - Running Fs Fr Ps Pr 97.13 24.28 9.19 2.3 kN kN kW kW
Helix
Trough Transition Calculation

Page 1
Trough Transition Distance
Applies to 3 equal roll idlers Refer to ISO 5293:2004 Input Data Description Description or location of transition lambda b M h Tr T1 T1s F Fs 35 750 2,070 110 31.5 22 28 15 67 deg mm kN/m mm kN/m 315/2 kN kN % (default = 15% i.e f=1.15) % (default = 167% i.e f=1.67)
Idler Trough Angle Belt Width Belt Modulus Transition Depth h (h = H - offset) Belt Rated Operating Tension Belt Tension at Pulley (running) Belt Tension at Pulley (starting) Allowable Edge Tension Rise running % Allowable Edge Tension Rise starting %
Calculation Results
Minimum Transition Distance for Edge Tension, running Minimum Transition Distance for Edge Tension, starting Minimum Transition Distance for Centre Tension > 0 Required Transition Distance
L1e L1s L1c L1
1,154 775 382 1,154
mm mm mm mm
Helix
Pulley Inertia Calculation

Page 1
Pulley Inertia J
Input Data Description Description or location of pulley F D t Lt Dt L1 L S d 1,400 1,000 20 12 50 1,100 1,800 200 160 mm mm mm mm mm mm mm mm mm
Pulley Face Width Pulley Diameter over steel Steel Shell thicknes Rubber Lagging thickness End Disc thickness Shaft Dimension length L1 Overall Shaft length Shaft Dia at Hub Shaft Dia at Bearing
Calculation Results Shaft Mass Pulley Shell mass (including lagging) Total Assembly Inertia J J 382 kg 1,305 kg 245.04 kg-m2
Helix
Calculate Bearing Life

Page 1
Calculate Bearing Life

Input Data Pulley Number Pulley Description Radial Load on Bearing Bearing Dynamic Load Rating Bearing Rotating Speed 99 Pulley Drive Factor check P 1,080.5 N C 14,000 N N 565 rpm
(half pulley load)
Calculation Results Bearing Life L10h 64,167 hrs
Helix
Conveyor Cost Report

Page 1
Category
Accessories Accessories
Description
Dyna Sraper "T" Weightometer - ACC Type 2
Unit
ea ea Accessories
Quantity
1 1 SubTotal
Rate
2,200.00 8,200.00
Total Cost
2,200 8,200 $10,400.00
Margin
943 3,514
Selling Price
3,143 11,714 $14,857.14
Accessories Accessories
Belt Belt Belt
Belt Belt Splicing GOODYEAR PLYLON-HI 2 Plies 1200 mm ea m Belt 1 70.33 SubTotal 900.00 152.00 900 10,690 $11,590.16 386 4,581 1,286 15,272 $16,557.37
Civils Civils Civils Civils Civils
Civil Work Clearing & Grubbing Cut to Fill Cut to Spoil Concrete for Footings ha m3 m3 m3 Civils 4.68 4500 500 8 SubTotal 1,250.00 4.75 3.80 1,500.00 5,850 21,375 1,900 12,000 $41,125.00 2,507 9,161 814 5,143 8,357 30,536 2,714 17,143 $58,750.00
Drives Drives Drives Drives Drives Drives Drives Drives Drives Drives Drives Drives
Conveyor Drive Components Gearbox size B@SH13 Ratio 16:1 Fluid Coupling Voith 266 Size 56 Disc Brake size USB2.1 c/w thrustor Low speed couling Flanged type 451 Electric Motor 37kW 415 Volt 4 Pole Electric Motor 30kW 415 Volt 4 Pole VOITH TSS Size 422 75kW 140 % FLT BTR POWERTECH Size 50 37kW 200 % FLT Fenner Shaft Mounted Size H5 8.075:1 ratio Greaves HR 225 Size 160 8.4:1 ratio Base plates ea ea ea ea ea ea ea ea ea ea ea Drives 1 55,000.00 1 18,500.00 1 1 1 1 7,800.00 2,780.00 2,564.00 2,023.00 55,000 18,500 7,800 2,780 2,564 2,023 13,750 7,800 3,600 12,400 2,800 $129,017.00 13,750 4,625 1,950 695 641 506 3,438 1,950 900 3,100 700 68,750 23,125 9,750 3,475 3,205 2,529 17,188 9,750 4,500 15,500 3,500 $161,271.25
1 13,750.00 1 1 7,800.00 3,600.00
1 12,400.00 2 SubTotal 1,400.00
Electrical Electrical
Electrical Transformer 3.3 kV 150 kVa ea 1 15,000.00 15,000 3,750 18,750
Helix
22/09/2005 12:11:10 PM

Unit
ea ea ea m m m ea Electrical
Page 2 Total Cost

8,000 6,500 900 250 629 1,938 200 $33,416.50
Category
Electrical Electrical Electrical Electrical Electrical Electrical Electrical
Description
MCC for Drive 1 - 75 kW MCC for Drive 2 -37 kW Pull Wire Switch (NHP) Pull Wire Cabling 4mm2 Cabling 16mm2 c/w trays Zero Speed Switch
Quantity
1 1 2 100 74 125 1 SubTotal
Rate
8,000.00 6,500.00 450.00 2.50 8.50 15.50 200.00
Margin
2,000 1,625 225 63 157 484 50
Selling Price
10,000 8,125 1,125 313 786 2,422 250 $41,770.62
EPCM EPCM EPCM EPCM EPCM EPCM EPCM
Engineering, Procurement etc Drawings Engineering Design Project Management Secretarial Procurement Costs Head office overheads hr hr hr hr hr LS EPCM 300 20 15 20 20 1 SubTotal 45.00 70.00 80.00 25.00 50.00 2,000.00 13,500 1,400 1,200 500 1,000 2,000 $19,600.00 3,375 350 300 125 250 500 16,875 1,750 1,500 625 1,250 2,500 $24,500.00
Freight Freight Freight Freight
Transport & Freight Packing Export Documnetation Transport to Dock LS set trips Freight 1 1 3 SubTotal 2,000.00 850.00 350.00 2,000 850 1,050 $3,900.00 857 364 450 2,857 1,214 1,500 $5,571.43
Idlers Idlers Idlers Idlers Idlers
Idlers Impact Idler - 3 Roll offset 1050 Trough Training 3 Roll 1050 Series 20, 3 Roll Carry, 152 Plain Inline Series 20 3 roll x 152 Series 15 1 Roll Flat Carry, 127 Dia Series 15 1 roll x 127 ea ea ea ea Idlers 5 4 27 15 SubTotal 261.00 465.00 120.00 104.00 1,305 1,860 3,240 1,560 $7,965.00 326 465 810 390 1,631 2,325 4,050 1,950 $9,956.25
Installation Installation Installation Installation
Installation & Commissioning Cranage 15t hire Assembly labour Commisioning Visit hr hr ea Installation 30 250 1 SubTotal 50.00 45.00 2,500.00 1,500 11,250 2,500 $15,250.00 643 4,821 1,071 2,143 16,071 3,571 $21,785.71
Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys
Pulleys & Shafts Tail Pulley No 1-505 dia x 1350 mm Shaft Tail Pulley No 1-150 dia x 1800 mm Bearing Tail Pulley No 1-125 dia SN3028 Drive Pulley No 4-600 dia x 1350 mm Shaft Drive Pulley No 4-150 dia x 1800 mm Bearing Drive Pulley No 4-125 dia SN3028 Bend Pulley No 5-505 dia x 1350 mm Shaft Bend Pulley No 5-150 dia x 1800 mm Bearing Bend Pulley No 5-125 dia SN3028 kg kg ea kg kg ea kg kg ea 330.78 296.86 2 684.17 296.86 2 330.78 296.86 2 6.00 4.92 .00 6.00 4.92 .00 6.00 4.92 .00 1,985 1,461 0 4,105 1,461 0 1,985 1,461 0 851 626 0 1,759 626 0 851 626 0 2,835 2,087 0 5,864 2,087 0 2,835 2,087 0
Helix
22/09/2005 12:11:10 PM

Unit
kg kg ea kg kg ea kg kg ea kg kg ea kg kg ea Pulleys
Page 3 Total Cost

4,105 1,461 0 1,788 522 936 1,985 1,447 0 1,985 1,461 0 1,985 1,447 0 $31,576.08
Category
Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys Pulleys
Description
Drive Pulley No 6-600 dia x 1350 mm Shaft Drive Pulley No 6-150 dia x 1800 mm Bearing Drive Pulley No 6-125 dia SN3028 Bend Pulley No 7-405 dia x 1350 mm Shaft Bend Pulley No 7-90 dia x 1800 mm Bearing Bend Pulley No 7-75 dia SNH517 Pulley Pulley No 8-505 dia x 1350 mm Shaft Pulley Pulley No 8-150 dia x 1800 mm Bearing Pulley Pulley No 8-115 dia SN3026 Takeup Pulley No 9-505 dia x 1350 mm Shaft Takeup Pulley No 9-150 dia x 1800 mm Bearing Takeup Pulley No 9-125 dia SN3028 Pulley Pulley No 10-505 dia x 1350 mm Shaft Pulley Pulley No 10-150 dia x 1800 mm Bearing Pulley Pulley No 10-115 dia SN3026
Quantity
684.17 296.86 2 248.32 102.38 2 330.78 294.09 2 330.78 296.86 2 330.78 294.09 2 SubTotal
Rate
6.00 4.92 .00 7.20 5.10 468.00 6.00 4.92 .00 6.00 4.92 .00 6.00 4.92 .00
Margin
1,759 626 0 766 224 401 851 620 0 851 626 0 851 620 0
Selling Price
5,864 2,087 0 2,554 746 1,337 2,835 2,067 0 2,835 2,087 0 2,835 2,067 0 $45,108.69
Steel Steel Steel Steel Steel Steel Steel Steel Steel Steel
Structural Steel Tail Frame Head Frame Trusses Trestles (8m high) Takeup Tower and Frames Conveyor Covers Walkways & Handrails Stringers & Idler supports Painting - Steelwork inc Sandblast & Primer t t ea ea ea m m t m2 Steel 8.2 2.7 2 2 1 33 33 3.5 180 SubTotal 1,250.00 1,250.00 4,800.00 3,500.00 5,800.00 236.00 450.00 1,250.00 22.50 10,250 3,375 9,600 7,000 5,800 7,788 14,850 4,375 4,050 $67,088.00 4,393 1,446 4,114 3,000 2,486 3,338 6,364 1,875 1,736 14,643 4,821 13,714 10,000 8,286 11,126 21,214 6,250 5,786 $95,840.00
Sub Sub
Subcontract None allowed for this conveyor ea Sub 1 SubTotal Total .00 0 $0.00 $370,927.74 25.21% 0 0 $0.00 $495,968.47
Helix
Conveyor Equipment Schedule

Helix Technologies Pty Ltd Client ABC Mining Prepared By Peter Burrow Design Date 18/09/2004
Page 1
Equipment Schedule - Conveyor Summary
Conveyor Number CV 01 FDR 03 CV O-Land 1 CV102 CV102
Conveying Distance m 69.44 5.81 1,204.75 2,037.44 18.08
Net Lift m 11.2 -0.4 -14.5 398.9 0.34
Capacity tonnes 777 77 777 2,000 777
Belt Speed m/s 3 0.3 4.5 5 4.5
Absorbed Power kW 37.34 4.46 70.23 2,710.05 21.69
Installed Power kW 45 7.5 90 3,000 29.5
Belt Width mm 750 1,000 900 1,200 900
Belt Class
Effective Tension kN
Max. Run Tension kN 22.07 48.45 80.07 712.79 10.83
Takeup Mass kg 2,108 7,227 9,018 41,122 1,612
Trough Angle deg 35 20 35 35 35
Carry Idler Spacing m 1.2 0.5 1.2 1.7 1.2
Return Idler Spacing m 3 3 3 3.4 3
315/2 500/2 XT 1000 ST 4000 ST1000
11.71 13.98 14.67 514.91 4.6
Helix

Page 1
Conveyor Equipment Schedule - Belts
Conveyor Number CV 01 FDR 03 CV O-Land 1 CV102 CV102
Belt Width mm 750 1,000 900 1,200 900
Belt Class
Belt Plies
Belt Length m
Top Cover Thick mm 6 13 6 6 6
Bottom Cover Thick mm 2 8 2 2 2
315/2 500/2 XT 1000 ST 4000 ST1000
2 2 3 0 0
155.89 17.85 2,421.12 4,092.3 52.52
Helix

Page 1
Conveyor Equipment Schedule - Idlers
Conveyor Number CV 01
Idler Description Series 20 3 Roll Carry 152 Plain Inline Vee Return Series 15 2 Roll 127 Dia Series 11 3 Roll Carry 114 Plain Offset Series 05 1 Roll Flat Carry 114 Dia Series 20 3 Roll Carry 152 Plain Inline Vee Return Series 15 2 Roll 127 Dia Series 35 3 Roll Carry 152 Plain Inline Vee Return Series 20 2 Roll 152 Dia Series 20 3 Roll Carry 152 Plain Inline Vee Return Series 15 2 Roll 127 Dia
Belt Width mm 750
Roll Dia mm 152
Shaft Dia mm 27
Trough Angle deg 35
No. of Rolls 3
No. of Idlers 53
C
CV 01
750
127
27
10
26
FDR 03
1,000
114
20
20
17
FDR 03
1,000
114
27
16
CV O-Land 1
900
152
27
35
946
CV O-Land 1
900
127
27
10
262
CV102
1,200
152
30
35
1,212
CV102
1,200
152
27
10
601
CV102
900
152
27
35
21
CV102
900
127
27
10
Helix

Page 1
Conveyor Equipment Schedule - Pulleys
Conveyor Number CV 01 CV 01 CV 01 CV 01 CV 01 CV 01 FDR 03 FDR 03 CV O-Land 1 CV O-Land 1 CV O-Land 1 CV O-Land 1 CV O-Land 1 CV O-Land 1 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102 CV102
Pulley Dia Description Tail Drive Snub Bend Takeup Bend Takeup Drive Tail Drive Bend Pulley Takeup Pulley Tail Drive Bend Pulley Takeup Pulley Tail Drive Bend Drive Bend Pulley Takeup Pulley mm 400 500 273 400 400 400 400 500 600 800 273 600 600 600 1,458 1,458 800 1,458 1,458 1,458 382 505 382 500 382 382 382 382
Face Width mm 850 850 850 850 850 850 1,150 1,150 1,050 1,050 1,050 1,050 1,050 1,050 1,350 1,350 1,350 1,350 1,350 1,350 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050
Shaft Brg Length Centres mm 1,590 1,640 1,490 1,550 1,590 1,550 1,950 1,950 1,950 1,970 1,690 1,850 1,950 1,850 2,400 2,800 2,180 2,440 2,460 2,440 1,790 1,790 1,750 1,890 1,690 1,720 1,750 1,720 mm 1,270 1,270 1,270 1,270 1,270 1,270 1,570 1,570 1,470 1,470 1,470 1,470 1,470 1,470 1,800 1,800 1,800 1,800 1,800 1,800 1,470 1,470 1,470 1,570 1,470 1,470 1,470 1,470
Shaft Dia mm 100 120 60 90 100 90 160 160 170 180 60 160 170 160 240 500 160 260 300 260 100 100 90 100 60 90 90 90
Brg Dia mm 90 110 60 80 90 80 140 140 150 160 60 140 150 140 200 450 140 220 260 220 90 90 80 90 60 75 80 75
Lagging mm 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
Wrap Angle deg 180 210 20 90 180 90 180 180 180 180 20 90 180 90 180 180 20 90 180 90 180 175 160 180 20 90 180 90
T1 kN 10.72 22.1 11.02 10.77 10.34 10.87 33.3 46.45 50.49 57.52 43.66 44.37 44.22 44.69 84.37 713.38 202.12 202.08 201.63 202.49 8.96 10.87 8.04 9.16 8.12 8.13 7.9 8.35
T2 kN 10.78 10.47 11.08 10.83 10.39 10.93 33.57 32.81 50.69
R kN 21.44 31.56 3.83 15.25 20.67 15.37 66.88 79.27 101
43.07 100.41 43.84 44.55 44.4 44.87 15.16 62.75 88.44 63.2
84.92 168.11 202.45 914.65 203.31 70.21
203.27 285.79 202.82 403.27 203.69 286.38 9.05 8.21 8.13 7.42 8.21 8.22 7.99 8.44 17.93 19.01 15.9 16.58 2.84 11.58 15.81 11.82
Helix

Page 1
Conveyor Equipment Schedule - Motors
Conveyor Number CV 01 FDR 03 CV O-Land 1 CV102 CV102 CV102
Drive No 1 1 1 1 1 2
No. of Motors 1 1 1 1 1 1
Motor Power kW 45 7.5 90 3,000 18.5 11
Motor Speed rpm 1,475 1,450 1,480 1,488 1,460 1,455
Motor Voltage Volts 415 415 415 415 415 415
Frame F225M04 4AP132M-4 F280MK04 DUMMY F180M04 D160M
Helix

Page 1
Conveyor Equipment Schedule - Gearboxes
Conveyor Number CV 01 FDR 03 CV O-Land 1 CV102 CV102 CV102
Drive No 1 1 1 1 1 2
Gearbox Code 5.047
Motor Power Gearbox Description Fenner Shaft Mounted Rossi Bevel Helical No Selection No Selection kW 45 7.5 90 3,000 18.5 11
Motor Speed rpm 1,475 1,450 1,480 1,488 1,460 1,455 G5 Gearbox Size J5 200
Ratio 1: 12.72 127 1 1 8.45 1
Max Torque Nm 5,940 11,200 0 0 2,970 0
5.047
Fenner Shaft Mounted No Selection
Helix

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22/09/2005 12:06:14 PM Project New Nickel Mine Project No P902399 Conveyor No.

Conveyor Design Summary

ABC Mining Peter Burrow 18/09/2004

Conveyor Design Summary Report

tonnes/h m/s % mm mm kg/m kW kW kW kW % kW kW deg m mm

1 1 kNm 2.11 sec 2.8 sec

C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES

Conveyor Sections - Input Data

ABC Mining Peter Burrow 18/09/2004

Conveyor Sections - Input Data

Description Tail Second Third Third

X coord m 0 2 5 34.75 69.7 69 59.3 58.9 58.5 35

Section Capacity tonnes/hr 0 777 777 777 0 0 0 0 0 0 0

Idler Spacing m 1 0.5 1.5 1.5 3 3 3 3 3 3 1

Tension No. AdjustScra- ment pers kN

Totals: Designers Comments:

C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES

Conveyor Belt Details

ABC Mining Peter Burrow 18/09/2004

3 777 777 1,360 1,450 10 35 31.5 29.43 37.65 150 119.53

m/s tonnes/hr tonnes/hr kg/m3 kg/m3 mm deg kN/m kN/m kN/m % %

750 6.00 3.10 2.00 11.10 155.87 46.29

5.08 2.63 1.70 9.41 71.94 81.35 142.27 1,537 1,466

kg/m kg/m kg/m kg/m kg/m kg/m kg/m tonnes/hr kg

0.0664 0.0981 64.3 93.0 135 80.00 80.00 975

C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES

Project New Nickel Mine Project No P902399 Conveyor No. CV 01

ABC Mining Peter Burrow 18/09/2004

Conveyor Tension Summary Report

Takeup Mass 1.5 % Sag Tension 5% Sag Tension

2108 kg 7.98 kN 2.39 kN

Braking Fully Loaded Tension kN 9.18

Empty Tension kN 13.97

Empty Tension kN 9.67

Empty Tension kN 10.37

10.29 22.1 1.27 11.71 12.45 0.204 0.102

10.29 12.34 0.34 1.93 10.96 0.054 0.027

10.29 22.1 1.27 11.71 12.45 0.204 0.102 6.29 kN

10.29 13.13 1.27 2.72 11.28 0.087 0.043

10.34 28.24 1.14

9.64 20.25 1.00

6.29 11.55 2.38

9.01 11.06 1.66

7.81 13.83 1.91

10.05 11.19 1.45

14.33 0.393 0.196

14.33 0.393 0.196

9.2 -0.122 -0.061

9.68 -0.074 -0.037

Average Belt Tension Stationary = 10.42 kN 344 kg

Minimum Operating Tension : Designers Comments:

Takeup Mass Deficiency due to Belt Sag:

with the Shaft mounted gearbox.

C:\Program Files\Helix\Delta-T5 Dyn\Projects\Demo1 Sample Stockpile Conveyor.DES

Takeup & Drive Traction

ABC Mining Peter Burrow 18/09/2004

Takeup & Drive Traction Calculation

210 0.35 0.384 22.1 10.47 4.47 6.00 0 kg

210 0.35 0.384 12.34 10.47 0.72 9.75

210 0.45 0.238 28.24 10.84 4.14 6.70

210 0.45 0.238 20.25 9.07 2.66 6.41

210 0.45 0.238 11.01 11.13 0.03 10.98