PETROVIETNAM ENGINEERING - PVE

CALCULATION SHEET
No.
I.
1

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

VALUVE
BMCR

Unit

3 roll
Q
L
H
B
v
I

Idler length if 3 or 5 roll

Name

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

0.30
0.35

Angle of Wrap 1 at Pulley Drive 1

210

Degree

Angle of Wrap at Snub Pulley 1

12

Degree

Angle of Wrap 2 at Pulley Drive 2

210

Degree

Angle of Wrap at Snub Pulley 2

21

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

g
= 1 * 2

9.81

m/s2

0.70

- Degree of Filling

- Gradient of the installation

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

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

FORMULAR

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*

PT = P1+P2+P3

CR

= 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

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

Secondary Resistance

FN

4,562.81

Slope Resistance

FSt

29,034.23

Special Resistance

FS

0.00

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

Acceleration Distance
Peripheral Force on Braking state
Braking time

sA

3.83

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

nT

Io

- Resistance caused by forward tilt of idler rollers

630
500
400
51

hrel

- Idler Rotation

A
B
C

- Carrying side
Idler Diameter

III.
1

DTr

Selected Motor Power

Hydraulic Coupling

tB

N
N

mred

m/s2
m
kg

Non-braked elements force

FT

#DIV/0!

Peripheral Force

FB

#DIV/0!

Individual Resistances
Main Resistance

FH

12,331.91

Secondary Resistance
Friction Resistance
- Carrying side

FN

4,562.81

Fo

10,596.06

- Return side
Slope Resistance
- Carrying side

Fu

1,774.22

Fsto

33,494.44

- Return side
Inertial Resistance
- Carrying side

Fstu

4,460.21

Fao

19,724.02

- Return side
Belt Tension
Drive System
Runing - Steady state working
- Distribution for Head and Tail Drive

Fau

3240.45

NA

- Distribution for Dual Pulley Head Drive

Total Peripheral Force

Single Pulley Head Drive

x1

x1 = Fo/Fu

x2

NA

FU

45,928.94

- 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

T3

20278.47

Tension

T4

20278.47

Tension

T1

68931.78

Control
Start Up - Non Steady state working
- Distribution for Head and Tail Drive

T1

68893.41

NA

x1A

x1 = Fo/Fu

x2A

NA

FUA

68893.41

- Peripheral Force Pulley 1

FU1A

68893.41

- 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

26455.07

TA3

27009.52

Tension

TA4

27009.52

Tension

TA1

95386.85

Control
Braking state

TA1

95348.48

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

T2

33816.41

T3

31130.41

T4

31130.41

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

4134.24

kg

6731.05

75662.83

T2

29695.52

T3

27009.52

T4

27009.52
Satisfied

28067.97

27009.52
1058.44

N
N

TAi = Ti

Check conditional
C

22964.47

- Distribution for Dual Pulley Head Drive

T2 = FU*c

Tmin
Moveable Take-up
T
T1

T = Tmin - Ti

76721.27

T2

30753.96

T3

28067.97

T4

28067.97

TA1

96445.29

TA2

27513.51

TA3

28067.97

TA4

28067.97
Satisfied

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

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

Cotton

(Natural fibre)

2.2

Polyamide

(Synthetic fibre)

Plyester

(Synthetic fibre)

EP

Plyester - Polyamide

(Synthetic fibre)

5.5

Aramid

(Synthetic fibre)

7.5

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

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

COVER GRADE

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)

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

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

Gradient

BELT WIDTH

LIGHT

MEDIUM

HEAVY

UP TO CA. 1.0

1.0 TO 2.0

OVER 2.0

0.99

300

31

36

0.98

400

54

59

65

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

667 Favourable, good alignment, slow speed

625 Normal (Standard conditions)

5
6

555 Unfavourable, dusty, low temperature, overloading,

526 hight speed

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

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 1.2
Angle = 30o - 45o

TABLE 25
Friction Value Factor CR
P (kw)
0.8*v
1.5*v
2.3*v

Drive Pulley Surface

Friction value

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

62

46

37

28

23

18

15

13

12

10

57

43

34

26

21

17

14

12

11

53

40

32

25

20

16

13

11

10

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

0.5

0.67

0.75

0.8

0.83

FERROFLEX

Zig-Zag Splice Joint

0.9

DUNLOPLAST

Finger Splice Joint

0.9

Steel Cord Belts

Splice 1 and 2 step

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)

Material of Carcase in Warp or Belt Type

CTr

Polyamide (P)

90

DUNLOFLEX (2 ply Belt)

80

7.6

TRIOFLEX (3 ply Belt)

95

6.6

SUPERFORT (Multiply Belt EP)

108

5.9

FERROFLEX (Steel Weave Type)

138

5.1

SILVERCORD (Steel Cord Belt)

145

10

4.5

DUNLOPLAST (Monoply Belt)

100

13

16

3.6

20

25

2.9

32

2.6

40

2.4

50

2.2

63

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

0.8

0.85

0.9

1.1

b) With other temperatures the following applies:

f = c * f20C

With T < 20C

T (C)

Factor c

+20

1.07

-10

1.17

-20

1.28

-30

1.47

e Page 12.3

TABLE 30
Degree of Efficiency

Types of Drive

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
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