PETROVIETNAM ENGINEERING - PVE

CALCULATION SHEET
No. PARAMETERS SYMBOL FORMULAR VALUVE
BMCR
I. INPUT DATA
1 INSTALLATION
Troughing Type 3 roll
Capacity Design Q 1,000
Conveying Length L 258.0
Lift H 17.9
Belt Width B 1,200
Belt Speed v 1.68
Length of middle carrying roll I Idler length if 3 or 5 roll 465
Troughing Angle λ 35
Incline Angle δ 4.8
2 MATERIAL
Material Name MEDIUM
Density ρ 1.50
Lump Size
Temperature 35
Surcharge Angle β 15
3 CONVEYOR BELT
Friction Coefficient of Pulleys μ 0.30
Friction Coefficient of Pulleys at Start-Up μ A
0.35
Angle of Wrap 1 at Pulley Drive 1 α 1
210
Angle of Wrap at Snub Pulley 1 α
12 0
Angle of Wrap 2 at Pulley Drive 2 α 2
210
Angle of Wrap at Snub Pulley 2 α
21 0
Drive factor c 1
0.50
Drive factor at Start-Up c
1A 0.38
Drive factor at Pulley Drive 2 c 2
0.50
Drive factor at Pulley Drive 2 at Start-Up c
2A 0.38
4 FACTORS
Gravitational Acceleration g 9.81
Effective Degree of Filling φ φ=φ*φ 1 2
0.70
- Degree of Filling φ 1
Normal working conditions 1
- Gradient of the installation φ 2
0.70
Width Factor C B
277
Length Factor C L
52
Working Conditions Factor k f
1
Efficiency of the drive η For drives with fluid couplings 0.90

II. DESIGN
1 CAPACITY
Loading width of outer rolls I 1
282.50
Load stream width b 1,030.00
Cross-Sectional Area of load Stream A 0.1705
Cross-Sectional Area of load Stream for 5 roll A 5
NA
- Troughing Angle 2 0
Conveying Capacity
- Theoretical value Q m
1,546.86
- Effective value Q
m' Q = Q *φ
m' m
1,082.80
2 POWER REQUIREMENTS
Power for empty & load over the Horizontal P 1
28.18
Power for Lift or Fall P 2
48.77
Power for trippers, skirtboard friction, ploughs P 3
0.00
Power at Drive Pulley P T
P = P +P +P
T 1 2 3
76.95
Required Motor power P M
85.50
Slected Motor P N
110
3 BELT TYPE
Friction Value Factor C R
μ = 0.3 15
Breaking Strength Loss at Joint Factor C V
Number of plies 0.75
Belt breaking strength k 916.12
Material (carcase) EP
Nominal Breaking Strength k N
Belt Class 1,000
Number of Plies C
v
4
Carrying side Cover thickness 8
 Pulley side Cover thickness 4
Cover Quality X
- Belt weight 25.40
- Carcase thickness d 5.80
4 PULLEY DIAMETER
Drive Pulley Calculation D' Tr
D' =d*C
Tr Tr
626.40
- Type of Belt Material Contruction SUPERFORT (Multiply Belt EP)
- Belt Material Factor C
Tr 108
Drive Pulley selected D
Tr A 630
Tail Pulley, Tension Pulley B 500
Snub Pulleys, Bend Pulleys etc. C 400
Pulley revolutions n T
51
5 IDLER
Values for Idler Spacing
- Belt sag ratio h
rel h = h/I
rel o
0.01
- Carrying side I o
Application 1.2m 1.2
- Return side I u
I = (2-3)*I
u o
2.0
Idler Diameter D R
133.0
- Idler Rotation n R
Not be greater than 650 rpm 241
Idler Length L R
465
Mass of one set of carrying idler rollers m
Ro 22.3
Mass of one set of return idler rollers m
Ru 19.3

III. CALCULATION
1 Peripheral Force at Steady state working F U

Length Factor C 1.37

Friction Factor f 0.02
Mass of the rotating carrying and return idlers m' R
28.23
Mass of the belt m' G
25.40
Mass of the load m' L
165.34
Main Resistance F H
12,331.91
Secondary Resistance F N
4,562.81
Slope Resistance F
St 29,034.23
Special Resistance F S
0.00
- Resistance caused by forward tilt of idler rollers F S
0.00
+ Carrying side F
SO

+ Return side F
SU

- Resistance from skirt places beyond F

Sch

- Resistance due to sideways discharge F L

- Resistance due to trippers F B

- Resistance from skirting material beyond F

Mf

- Resistance to motion of bunker drag-out belts F

Ba

Peripheral Force at Steady state working F U

45,928.94
Drive Motor at Pulley P T
77.16
Required Motor Power P M
85.73
Motor Power on Braked Installation P M
NA
Installed Motor Power P N
Selected Motor Power 110
Min. Belt Tension for Control T
min 28,068
2 Peripheral Force at Non-Steady state working F A

Type of Coupling Hydraulic Coupling

Start-up Factor k A
1.50
Pre Non-steady state F' A
68,893.41
Peripheral Force at Start-Up (Non-steady state) F A
68,893.41
Acceleration a A
0.368
- Reduced mass of idlers m'
Red 25.41
- Reduced mass of drive elements m'
Ared 0.00
- Reduced mass of non-driven (bend pulleys etc.) m'
red 0.00
Acceleration Time t A
4.56
Acceleration Distance s A
3.83
3 Peripheral Force on Braking state
Braking time t B

Acceleration a B
#DIV/0!
Over-run distance s B
0.00
Reduced mass of the non-braked elements or pulleys m
red

Non-braked elements force F T

#DIV/0!
Peripheral Force F B
#DIV/0!

4 Individual Resistances
Main Resistance F H
12,331.91
Secondary Resistance F N
4,562.81
Friction Resistance
 - Carrying side F o
10,596.06
- Return side F u
1,774.22
Slope Resistance
- Carrying side F
sto 33,494.44
- Return side F
stu 4,460.21
Inertial Resistance
- Carrying side F
ao 19,724.02
- Return side F
au 3240.45
5 Belt Tension
A Drive System Single Pulley Head Drive
Runing - Steady state working
- Distribution for Head and Tail Drive x1
x = F /F
1 o u
NA
- Distribution for Dual Pulley Head Drive x2
NA
Total Peripheral Force F U
45,928.94
RING - PVE

Unit

t/h
m
m
mm
m/s
mm
Degree
Degree

t/m 3

mm
o
C

Degree

-
-
Degree
Degree
Degree
Degree
-
-

m/s 2

-
-
-
kg/m
-1
m

-
-

mm
mm
2
m

2
m

Degree

t/h
t/h

kW
kW
kW
kW
kW
kW

N/mm

N/mm
ply
mm
mm

kg/m
mm

mm

mm
mm
mm
R/min

m
m
mm
r.p.m
mm
kg
kg

kg/m
kg/m
kg/m
N
N
N
N

N
kW
kW
kW
kW
N

N
N
m/s 2

kg/m
kg/m
kg/m
s
m

s
m/s 2

m
kg
N
N

N
N
N
N

N
N

N
N

-
-
N
 - Peripheral Force Pulley 1 F
U1 45,928.94
- Peripheral Force Pulley 2 F
U2 NA
Total Power P T
77.16
- Motor 1 P 1
77.16
- Motor 2 P 2
NA
Tension T 2
T = F *c
2 U
22964.47
Tension T 3
20278.47
Tension T 4
20278.47
Tension T 1
68931.78
Control T 1
68893.41
Start Up - Non Steady state working
- Distribution for Head and Tail Drive x
1A x = F /F
1 o u
NA
- Distribution for Dual Pulley Head Drive x
2A NA
Total Peripheral Force F
UA 68893.41
- Peripheral Force Pulley 1 F
U1A 68893.41
- Peripheral Force Pulley 2 F
U2A NA
Total Power P
TA 115.74
- Motor 1 P
1A 115.74
- Motor 2 P
2A NA
Tension T
A2 T = F *c
2 U
26455.07
Tension T
A3 27009.52
Tension T
A4 27009.52
Tension T
A1 95386.85
Control T
A1 95348.48
Braking state

B Belt Tension Correction (1st Adjustment)

Correction with Fixed Take-up
Belt tension at rest T M
33113.30
Average belt tension at start-up T 43965.24
Correction value for Fixed Take-up ∆T ∆T = T - T M
10851.94
Belt Tension Correction T 1
79783.72
T 2
33816.41
T 3
31130.41
T 4
31130.41
Check conditional ∑T = ∑T A
Satisfied
Correction with Moveable Take-up
Location of Take-up Installed at the Tail
Take-up Tension F V
40556.94
Take-up Weight G V
G = F /g
V V
4134.24
Correction value for Moveable Take-up ∆T ∆T = T - T Ai i
6731.05
Belt Tension Correction T 1
75662.83
T 2
29695.52
T 3
27009.52
T 4
27009.52
Check conditional T =T Ai i
Satisfied
C Control of Minimum Belt Tension (2st Adjustment) T
min 28067.97
Take-up Type Moveable Take-up
Belt Tension at Carrying side minimum 27009.52
Correction value ∆T ∆T = T - T min i
1058.44
Belt Tension Correction T 1
76721.27
T 2
30753.96
T 3
28067.97
T 4
28067.97
T
A1 96445.29
T
A2 27513.51
T
A3 28067.97
T
A4 28067.97
Check conditional T
min
≤T
i Satisfied
Belt Safety Factor
Steady state S B
11.73
Non-Steady state S A
9.33
Take-up Travel s p

Elongation value of the belt k D

10.50
Rest state s p
1149.45
Steady state s p
1675.07
Non-Steady state s p
1843.83
Troughing Trainsition L M
1686.31
- 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
- Lift of Pulley h 64.55
Reduced transition length L
red 1169.88
Convex Vertical Curve
- Factor for carcase x Textile belt x=125 125.00
- Convex Radius R e
steel cord belt x=400 26.35
- Curve Length L 71519.14
 - Deviation per idler α 2.00
- Number of Idlers in Curve z 3.00
- Idler Picth Io 23839.71
Concave Vertical Curve
- Length from loading to curve Lx 40.00
- Belt tension at start of curve Tx 29710.77
- Concave Radius Ra 145.56

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

F ≤ 2.5*F
A U
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

N
N
kW
kW
kW
N
N
N
N
N

-
-
N
N
N
kW
kW
kW
N
N
N
N
N

N
N
N
N
N
N
N

N
kg
N
N
N
N
N

N
N
N
N
N
N
N
N
N
N

-
-

-
mm
mm
mm
mm
-
mm
mm
mm

-
m
m
Degree
Pieces
m

m
N
m
 TABLE 1 TABLE 2
STANDARD STANDARD IDLER DIA. (mm)
WIDTH (mm)
Carrying Idlers Impact Idlers Return Idlers

300 51
400 63.5
500 88.9
650 108 156
800 133 180
1000 159 215
1200 193.7 250
1400 219.1 290
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
(mm)
Support Idlers

120
138
150
180
215
250
290
 TABLE 3
STANDARD IDLER LENGTH (mm)
Belt Width B Troughing Type
(mm)
Flat 2 roll 3 roll Deeptrough
300 380 200 - -
400 500 250 160 -
500 600 315 200 -
600 700 340 250 -
650 750 380 250 -
800 950 465 315 200
1000 1150 600 380 250
1200 1400 700 465 315
1400 1600 800 530 380
1600 1800 900 600 465
1800 2000 1000 670 530
2000 2200 1100 750 600
2200 2500 1250 800 640
Garland (5 roll)
5 roll
-
-
-
-
-
165
205
250
290
340
380
420
460
 TABLE 4 TABLE 5
STANDARD MATERIAL CARCASE
ELECTRIC MOTOR
(KW) SYMBOL PLY MATERIALS
1.5 B Cotton
2.2 P Polyamide
3 E Plyester
4 EP Plyester - Polyamide
5.5 D Aramid
7.5 F Steel Weave
11 ST Steel Cord
15
18.5
22
30
37
45
55
75
90
110
132
160
200
250
315
400
500
630
 TABLE 5
TERIAL CARCASE
PLY MATERIALS
(Natural fibre)
(Synthetic fibre)
(Synthetic fibre)
(Synthetic fibre)
(Synthetic fibre)
(Ferroflex)
(ST belt)
 TABLE 6 TABLE
NOMINAL BREAKING 7
COVER THICKNESS GAUGES
STRENGTH (N/mm) (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)
PULLEY SIDE COVER GRADE W X
2 Tensile strength N/mm2 min. 18 25
2-3 Breaking elongation % 400 450
2-3 Abrasion loss mm3 max. 90 120
2-3
3-5
3-5
991)
Y Z
20 15
400 350
150 250
 TABLE 9 TABLE 10
Pulley Diameter Of Pulley Groups (mm)
Standard Pulley Diameter
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

100 3
c -
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 C B

Gradient φ 2
LIGHT MEDIUM
BELT WIDTH
2 1 UP TO CA. 1.0 1.0 TO 2.0
4 0.99 300 31 36
6 0.98 400 54 59
8 0.97 500 67 76
10 0.95 650 81 92
12 0.93 800 108 126
14 0.91 1000 133 187
16 0.89 1200 194 277
18 0.85 1400 227 320
20 0.81 1600 291 468
22 0.76 1800 - 554
2000 - 691
2200 - 745
B

HEAVY
OVER 2.0
-
65
86
103
144
241
360
414
644
727
957
1033
 TABLE 22 TABLE
23
LENGTH FACTOR C L
WORKING CONDITIONS
FACTO
L (m) C L
WORKING CONDITIONS
3 667 Favourable, good alignment, slow speed
4 625 Normal (Standard conditions)
5 555 Unfavourable, dusty, low temperature, overloading, hight
speed
6 526
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
Rf k
ADDITIONAL POWER VALUES

f k
TRPPERS
(throw-off carraiges)
1.17
1

0.87 - 0.74
SCRAPERS
0.57
(For installations
L<=80m)

Material - Skirtboard

Discharge plough

* I : Length of material between skirtboard

f
 TABLE 24
ADDITIONAL POWER VALUES

BELT WIDTH B
<=500
<=1000
>1000
Scraper type
simple, normal contact
heavy contact
multifunctional fac scraper
beyond loading point
Bulk density ρ ≤ 1.2 Angle
α = 30o - 45o

ween skirtboard
 P (kw) Friction value μ
Drive Pulley Surface
0.8*v
1.5*v bare, wet 0.15
2.3*v 0.25
rubber lagged, wet and dirty
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*I f

1.5*B*v
 TABLE 25
Friction Value Factor C R

Belt Width B (mm)

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

Polyamide (P) 90 3
DUNLOFLEX (2 ply Belt) 80 4
TRIOFLEX (3 ply Belt) 95 5
SUPERFORT (Multiply Belt EP) 108 6
FERROFLEX (Steel Weave Type) 138 8
SILVERCORD (Steel Cord Belt) 145 10
DUNLOPLAST (Monoply Belt) 100 13
16
20
25
32
40
50
63
80
90
100
120
140
160
180
200
250
300
350
400
450
500
550
600
 TABLE 28
LENGTH FACTOR C

C
9
7.6
6.6
5.9
5.1
4.5
4
3.6
3
2.9
2.6
2.4
2.2
2
1.92
1.86
1.78
1.7
1.63
1.56
1.5
1.45
1.38
1.31
1.27
1.25
1.2
1.19
1.18
1.17
 700 1.14
800 1.12
900 1.1
1000 1.09
1500 1.06
2000 1
* More Detail pls. see Page 1
* More Detail pls. see Page 12.3
 TABLE 29
Horizontal, inclined or slightly declined installations - Motor driven k (for v = 5m/s and +20 C)
o

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: With v
<> 5 m/s
f=c*f 5m/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*f 20°C

T (°C) Factor c
+20° 1
0° 1.07
-10° 1.17
-20° 1.28
-30° 1.47
for v = 5m/s and +20 C)
o

=c*f 20°C
 TABLE 30
Degree of Efficiency

Types of Drive η
Wormgear drive 0.7 - 0.8
Toothed chain drive 0.9 - 0.95
V-Rope drive 0.95
Pulley motor 0.96
Normal coupled drive 0.94
Geared and hydraulic coupling 0.9
Hydraulic motor 0.86
Braked installations 0.95 - 1.0
Operating Condition

Dry
Wet (Clean)
Wet (dirty mud, clay)
 TABLE 31
Friction Coefficient μ

Pulley Surface
Plain Steel Polyurethane lagging Rubber lagging
(smooth) (grooved) (grooved)

0.35 to 0.4 0.35 to 0.4 0.4 to 0.45

0.1 0.35 0.35
0.05 to 0.1 0.2 0.25 - 0.3
Conveyor Belt Thicknesses and Weights
SUPERFORT Belts
SECONDARY RESISTANCES
Ceramic lagging
(porous)

0.4 to 0.45
0.35 to 0.4
0.35