CF-EPF-R-03 & CF-EPF-R-04 (Crushed Revert)

30 Dec 2022 Conveyor Design Summary Page: 1/33
Macawber Beekay Private Limited

Project 0.5 MTPA Copper Refinery Project Client Kutch Copper Limited (KCL)
Project No. C-1647 Prepared By Harish Kumar
Conveyor No. CF-EPF-R-03 & Design Date 28 Oct 2022
CF-EPF-R-04 (Crushed
Revert)
Conveyor Material
Material Crushed Revert / Ladle Scull Surcharge Angle 10 °
Low Bulk Density 2100 kg/m3 Angle of Repose 30 °
High Bulk Density 2500 kg/m3 Material Lump size 35 mm
Conveyor Data
Conveying Distance 25.27 m Design Capacity 220 tonnes/hr
Nett Lift / Lower(-) 5.23 m Belt Speed 1 m/s
Belt Details
Belt Width 800 mm Calculated Belt % Full 45.08 %
Belt Class & Run Safety Factor 315/3 14.81 Top Cover Thickness 6 mm
Belt Rated Tension 31 kN/m Bottom Cover Thickness 3 mm
Belt Total Length 58.2 m Belt Mass 11.01 kg
Belt Tensions and Power Calculations ISO
Effective Tens. Fully Loaded 5.35 kN Belt Power - Empty Belt 1.52 kW
Maximum Tension Tmax 17.02 kN Belt Power - Inclines Loaded 5.35 kW
Minimum Tension Tmin 11.75 kN Belt Power - Declines Loaded 1.76 kW
Sag Tension 2% 4.42 kN Belt Power - Fully Loaded 5.35 kW
Takeup Type Fixed Centres Drive Efficiency 95.00 %
Takeup Mass 2650 kg Absorbed Power Fully Loaded 5.63 kW
Takeup Pulley Belt Tension 12.99 kN Installed Motor Power 7.5 kW
Carry and Return Idlers
Carry Idler Trough Angle 45 ° Return Idler Trough Angle 0°
Carry Idler Spacing 1m Return Idler Spacing 3m
Carry Idler No Rolls x Dia 3 x 127 mm Return Idler No Rolls x Dia 1 x 127 mm
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded 240.00 % CEMA Temperature Factor Kt 1
Startup Factor - Empty 240.00 % Total Braking Torque LSS 0.00 kNm
Starting Time - Fully Loaded 0.38 sec Stop Time - Loaded, Braking 0.84 sec
Starting Time - Empty 0.19 sec Stop Time - Loaded, Coasting 0.84 sec
Designers Comments
Updated with actual belt weight, finalized profiles, idlers weight and drive units
Helix DeltaT Conveyor Design program version: 1.1.16

www.helixconveyor.com
30 Dec 2022 Conveyor Sections - Input Data Page: 2/33
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Station / Section
Section Section Cap- Ten Idler Skirt Friction
Length Lift X co- Y co- Z co- acity Adj. Spacing Length No. of Factor
Station Description m m ord m ord m ord m tph kN m m Scrapers Input
1 Takeup Tail 3.07 0.65 0.00 0.00 0.00 0 1 1 0.03000

2 Hopper Incoming Chute 25.27 5.23 2.96 0.00 0.84 220 1 5.00 0.03000
3 Drive Head Pulley 0.87 -0.06 27.73 0.00 5.83 0 1 2 0.03000
4 Snub Snub 27.38 -5.71 26.85 0.00 5.36 0 3 0.03000
Totals: 56.59 0.11 0.00 5.00 3.00

30 Dec 2022 Takeup & Drive Traction Calculation Page: 3/33
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Drive Torque Start-up Factor Loaded 240.00 % Takeup Pulley Belt Tension 12.99 kN
Drive Torque Start-up Factor Empty 240.00 % Takeup Mass 2650 kg
Running Starting Braking
Drive / Brake Fully Empty Fully Empty Fully Empty
Number Loaded Belt Loaded Belt Loaded Belt
Drive No. 1 Type: Drive Head Pulley
Pulley No. 3 Lagging Type: Ceramic Ceramic Ceramic
Wrap Angle ° 203 203 203 203 203 203
Co-efficient of Friction 0.25 0.25 0.35 0.35 0.35 0.35
Drive Factor Cw 1.002 1.002 0.707 0.707 0.707 0.707
Calculated Belt Tension T1 kN 17.02 14.03 22.01 17.71 14.72 13.66
Calculated Belt Tension T2 kN 11.75 12.58 9.17 9.14 12.99 12.95
Minimum Required T2 kN 5.28 1.45 9.08 6.06 1.22 0.50
Surplus T2 Tension (T1-T2) kN 6.47 11.13 0.09 3.08 11.77 12.45

30 Dec 2022 Tension Summary Run / Start Page: 4/33
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Drive Torque Start-up Factor Loaded 240.00 % Takeup Pulley Belt Tension 12.99 kN
Drive Torque Start-up Factor Empty 240.00 % Takeup Mass 2650 kg
Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
1 Takeup 11.97 12.80 11.97 12.74 10.79 12.19 12.48 12.85 12.48 12.85
2 Hopper 12.46 13.29 12.46 13.23 11.80 13.74 12.73 13.24 12.73 13.24
3 Drive 17.02 14.03 17.02 14.21 22.01 17.71 14.72 13.66 14.72 13.66
4 Snub 12.38 13.21 12.38 13.15 9.89 9.94 13.58 13.56 13.58 13.56
Minimum Tension 11.97 12.80 11.97 12.74 9.89 9.94 12.48 12.85 12.48 12.85
Maximum Tension 17.02 14.03 17.02 14.21 22.01 17.71 14.72 13.66 14.72 13.66
Effective Tension 5.35 1.52 5.35 1.76
Ave.Belt Tension 13.30 13.30 13.30 13.30 13.30 13.30 13.30 13.30 13.30 13.30
Belt Elong. m 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
T/up Travel m 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

30 Dec 2022 Belt Details Report Page: 5/33
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Conveyed Material Belt Speed & Capacity

Material Description Crushed Revert / Ladle Scull Belt Speed 1 m/s
Low Bulk Density 2100 kg/m3 Belt Design Capacity Input 220 tonnes/hr
High Bulk Density 2500 kg/m3 Section Loading Max Capacity 220 tonnes/hr
Surcharge Angle 10 ° Carry Idler Trough Angle 45 °
Angle of Repose 30 ° Belt Dimensions
Material Lump Size 35 mm Top Cover Thickness 6 mm
Belt Make & Class Bottom Cover Thickness 3 mm
Belt Category Phoenix NN Belts Belt Carcass Thickness 2.7 mm
Belt Description NN 315/3 - M24 Cover Belt Total Thickness 11.7 mm
Belt Class / Plies 315/3 3 ply Total Belt (Tape) Length 58.2 m
Belt Reinforcement Fibre Fabric Time for 1 Revolution 58.2 sec
Belt Width 800 mm Belt Load Area & Capacity at 2100kg/m3
Belt Modulus 2362 kN/m Minimum Rec. Edge Distance 67 mm
Cord Diameter Actual Edge Distance 155 mm
Cord Pitch Load Burden Depth 81 mm
Number of Cords Load Burden Width 439 mm
Belt Tensions Belt Load Area at Minimum
Belt Rated Tension / m width 31 kN/m Recommended Edge Distance 0.0646 m2
Calculated Tension / m width 21.3 kN/m Belt Load Area utilised at Low
Belt Rated Tension for width 24.8 kN Bulk Density 0.0291 m2
Calculated Max Run Tension 17.0 kN Belt Actual % Full at Low BD 45.1 %
Minimum Tension Tmin 11.8 kN Belt Load Area & Capacity at 2500 kg/m3
Allowable Tension Rise, Starting 150 % Minimum Recommended Edge Distance 67 mm
Allowable Belt Tension, Starting 37.2 kN Actual Edge Distance High BD 169 mm
Actual Belt Tension, Starting 22.0 kN Belt Load Area Utilised at High
Bulk Density 0.0244 m2
Belt and Material Mass Belt Actual % Full at High BD 37.9 %
Belt Top Cover Mass 5.3 kg/m Flooded Belt Capacity at 2500 kg/m3
Belt Bottom Cover Mass 2.7 kg/m Flooded Belt Load Area at Zero
Belt Carcass Mass 3.0 kg/m Edge Distance 0.0961 m2
Belt Mass Wb (per linear m) 11.0 kg/m Flooded Belt Capacity 865 tonnes/hr
Material Mass Wm (per linear m) 61.1 kg/m Flooded Belt Material Mass 240.2 kg/m
Total Mass (Wb + Wm) 72.1 kg/m
Total Belt Mass (Wb x L) 641 kg

30 Dec 2022 Tension Calculations - Summary Belt Sag Page: 6/33
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Allowable Belt Sag % Running 2% Takeup Pulley Belt Tension 12.99 kN

Allowable Belt Sag % Start / Stop 5 % 1.77 kN Takeup Mass 2650 kg
Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
1 Takeup 11.97 12.80 11.97 12.74 10.79 12.19 12.48 12.85 12.48 12.85
Idler Spacing m 1.00
Belt Sag % 0.11 0.11 0.11 0.11 0.13 0.11 0.11 0.10 0.11 0.10
2 Hopper 12.46 13.29 12.46 13.23 11.80 13.74 12.73 13.24 12.73 13.24
Belt Sag % 0.71 0.10 0.71 0.10 0.75 0.10 0.69 0.10 0.69 0.10
3 Drive 17.02 14.03 17.02 14.21 22.01 17.71 14.72 13.66 14.72 13.66
Belt Sag % 0.08 0.10 0.08 0.09 0.06 0.08 0.09 0.10 0.09 0.10
4 Snub 12.38 13.21 12.38 13.15 9.89 9.94 13.58 13.56 13.58 13.56
Belt Sag % 0.33 0.31 0.33 0.31 0.41 0.41 0.30 0.30 0.30 0.30
Minimum Tension 11.97 12.80 11.97 12.74 9.89 9.94 12.48 12.85 12.48 12.85
Maximum Sag % 0.71 0.31 0.71 0.31 0.75 0.41 0.69 0.30 0.69 0.30

30 Dec 2022 Tension Calculations - Run Fully Loaded Page: 7/33
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Run Fully Loaded

Takeup Mass 2650 kg Takeup Pulley Belt Tension 12.99 kN
Tensions ISO 5048(1) Section ISO

Section Section Tp Drive Tension Material Skirt Scraper Effective Friction
Station Length Lift T1 Run T2 Run Pulley Te Adj. Accel. Friction Friction Tension Factor
m m kN kN kN kN kN kN kN kN kN
1 Takeup 3.07 0.65 11.97 12.06 0.09 0.31 0.09 0.0300
2 Hopper 25.27 5.23 12.46 12.46 0.06 0.18 4.32 0.0300
3 Drive 0.87 -0.06 17.02 11.75 0.08 5.27 0.63 0.00 0.0300
4 Snub 27.38 -5.71 12.38 12.46 0.08 -0.49 0.0300
Totals 0.25 5.27 0.00 0.06 0.18 0.94 3.92

Maximum Tension 17.02 kN Total Effective Tension 5.35 kN
Minimum Tension 11.75 kN Total Belt Power 5.35 kW
Average Tension Fully Loaded 13.30 kN Belt Modulus 2362 kN/m
Average Tension Belt Stationary 13.30 kN Total Belt Length 58.20 m
Average Tension Difference 0.00 kN Belt Elastic Elongation 0.000 m
Takeup Movement 0.000 m

30 Dec 2022 Tension Calculations - Run Empty Page: 8/33
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Run Empty

1 Takeup 3.07 0.65 12.80 12.89 0.09 0.31 0.09 0.0300
2 Hopper 25.27 5.23 13.29 13.29 0.74 0.0300
3 Drive 0.87 -0.06 14.03 12.58 0.07 1.45 0.63 0.00 0.0300
4 Snub 27.38 -5.71 13.21 13.29 0.08 -0.49 0.0300
Totals 0.24 1.45 0.00 0.94 0.34

Average Tension Empty 13.30 kN Belt Modulus 2362 kN/m

30 Dec 2022 Tension Calculations - Run Inclines Loaded Page: 9/33
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Run Inclines Loaded


1 Takeup 3.07 0.65 11.97 12.06 0.09 0.31 0.09 0.0300
2 Hopper 25.27 5.23 12.46 12.46 0.06 0.18 4.32 0.0300
3 Drive 0.87 -0.06 17.02 11.75 0.08 5.27 0.63 0.00 0.0300
4 Snub 27.38 -5.71 12.38 12.46 0.08 -0.49 0.0300
Totals 0.25 5.27 0.00 0.06 0.18 0.94 3.92

Average Tension Incl. Loaded 13.30 kN Belt Modulus 2362 kN/m

30 Dec 2022 Tension Calculations - Run Declines Loaded Page: 10/33
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Run Declines Loaded


1 Takeup 3.07 0.65 12.74 12.83 0.09 0.31 0.09 0.0300
2 Hopper 25.27 5.23 13.23 13.23 0.06 0.18 0.74 0.0300
3 Drive 0.87 -0.06 14.21 12.52 0.07 1.69 0.63 0.00 0.0300
4 Snub 27.38 -5.71 13.15 13.23 0.08 -0.49 0.0300
Totals 0.24 1.69 0.00 0.06 0.18 0.94 0.34

Average Tension Decl Loaded 13.30 kN Belt Modulus 2362 kN/m

30 Dec 2022 Starting and Stopping Report Page: 11/33
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System Masses Input Data

Mass of Belt 640 kg Belt Speed 1 m/s
Mass of Material 1,544 kg Belt Rated Tension 31 kN/m
Carry Idler Equivalent Mass 386 kg Allowable Belt Start Tension Rise 150 %
Return Idler Equivalent Mass 120 kg Drive Inertia 0.06 kg-m2
Pulley Equivalent Mass 399 kg Total Braking Torque 0.00 kNm
Drive Equivalent Mass 1,398 kg Start Up Factor - Full 240 %
Total System Equivalent Mass 4,487 kg Start Up Factor - Empty 240 %
Conveyor load inertia at HSS 0.19 kgm2
Tensions and Accelerating Forces Installed Power 7.5 kW
Effective Tension Fully Loaded 5.35 kN Drive Efficiency (Average) 95.00 %
Effective Tension Empty 1.52 kN Stopping Times & Deceleration Rates
Total Braking Force 0.00 kN Stopping Time Loaded Braking 0.84 s
Tension Available to Accelerate conveyor Stopping Time Loaded Coasting 0.84 s
Accelerating Tension - Loaded 11.75 kN Stopping Time Empty Braking 1.94 s
Accelerating Tension - Empty 15.58 kN Stopping Time Empty Coasting 1.94 s
Starting Times & Acceleration Rates
Starting Time - Fully Loaded 0.38 s Deceleration - Loaded Braking -1.19 m/s2
Starting Time - Empty 0.19 s Deceleration - Loaded Coasting -1.19 m/s2
Acceleration Rate - Loaded 2.62 m/s2 Deceleration - Empty Braking -0.52 m/s2
Acceleration Rate - Empty 5.29 m/s2 Deceleration - Empty Coasting -0.52 m/s2
Belt Tension Rise Starting / Braking Stopping distances & Discharge Volumes
Max Belt Tension Start / Brake 22.01 kN Stopping Distance Loaded Braking 0.42 m
Belt Width 800 mm Stopping Distance Loaded Coasting 0.42 m
Max Belt Tension / Width 27.51 kN/m Stopping Distance Empty Braking 0.97 m
Belt Rated Tension / Width 31 kN/m Stopping Distance Empty Coasting 0.97 m
Actual Max Tension Start/Brake 88.8 %
Allowable Tension Rise Start/Brake 150 % Discharge Mass Braking 26 kg
Discharge Mass Coasting 26 kg
Discharge Volume Braking 0.01 m3
Discharge Volume Coasting 0.01 m3

30 Dec 2022 Conveyor Idler Details Report Page: 12/33
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Carry Side Idlers Return Side Idlers

Idler Category MBL 45 Deg Carry Idlers MBL Flat Return Idlers
Idler Description 800mm BW 3 Roll Inline Carry 127 Dia 800mm BW Single Roll Flat
Return 127 Dia
Idler Design Belt Width 800 mm 800 mm

Idler Series 25 25
Drawing Number
Nominal Idler Spacing 1 m 3 m
Total Number of Idlers 29 9
Troughing Angle 45 deg 0 deg
Idler Shaft Diameter 25 mm 25 mm
Idler Bearing Diameter 25 mm 25 mm
Number of Idler Rolls 3 1
Idler Centre Roll Diameter 127 mm 127 mm
Idler Wing Roll Diameter 127 mm 127 mm
Idler Rotation Speed 150 rpm 150 rpm
Centre Roll Face Width 315 mm 950 mm
Wing Roll Face Width 315 mm 950 mm
Roll Bearing Centres 250 mm 885 mm
Shaft Support Centres 335 mm 967 mm
Idler Support Fixing Width 1090 mm 1090 mm
Idlerset Rotating Mass 13.3 kg 13.3 kg
Idlerset Total Mass 28.3 kg 25.5 kg
Idler Vertical Misalignment Allowance 10 mm 40 mm
Dynamic Load Factor 1.01 1.40
Belt Deviation Load 1601 N 534 N
Total Load on Centre Roll 2114 N 927 N
Type of Bearing Ball Ball
Bearing Designation 420205 420205
Bearing Dynamic Load Rating C 13,500 N 13,500 N
Bearing L10h Life 230,823 hrs 2,734,488 hrs
Allowable Shaft deflection At Bearing 8 min 8 min
Actual Shaft deflection At Bearing 4.79 min 7.18 min

30 Dec 2022 Vertical Curves report Page: 13/33
Conveyor No. CF-EPF-R-03 & CF-EPF-R-04 (Crushed Revert) Design Date 28 Oct 2022
Belt Width 800 mm % Belt Mass for Lift off Calculation 80 %

Belt Mass - New Belt 11.01 kg/m Curve Tension Safety Factor 1.2
Top Cover Mass - New Belt 5.33 kg/m Average Drive Torque safety Factor - Loaded 240 %
Bottom Cover Mass 2.66 kg/m Average Drive Torque safety Factor - Empty 240 %
Worn Belt Mass 8.81 kg/m Belt Modulus 2,362 kN/m
Reduction of Top Cover Mass 41.3 % Belt Rated Tension: 31 kN/m 24.8 kN
Conveyed Material Mass 61.11 kg/m Allowable Edge Tension Running: 100 % Starting: 150 %
Station / Section Information Running Starting Braking

Design Fully Loaded Empty Fully Loaded Empty Fully Loaded Empty Minimum
Curve Load Curve Required
Station Type Capacity Radius Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius Radius
tph m kN m kN m kN m kN m kN m kN m m
1 Takeup 11.97 12.80 10.79 12.19 12.48 12.85
2 Hopper 220 12.46 13.29 11.80 13.74 12.73 13.24
3 Drive 17.02 14.03 22.01 17.71 14.72 13.66

30 Dec 2022 Vertical Curve Radius Calculations Page: 14/33
Conveyor No. CF-EPF-R-03 & CF-EPF-R-04 (Crushed Revert) Design Date 28 Oct 2022
Station / Section Information Running Starting Braking
Design Fully Loaded Empty Fully Loaded Empty Fully Loaded Empty Minimum
Curve Load Curve Required
Station Type Capacity Radius Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius Radius
tph m kN m kN m kN m kN m kN m kN m m
4 Snub 12.38 13.21 9.89 9.94 13.58 13.56

30 Dec 2022 Viscoelastic Friction Factor Report Page: 15/33
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Viscoelastic Calculations Input Data

Belt Rubber Description Rubber description ... Carry Idler Centre Roll Dia 152 mm
Top Cover Dynamic Modulus E' 6 N/mm2 Carry Idler Centre Roll Drag 2 N
Top Cover Dynamic Loss Factor Tan(delta) 0.13 Carry Idler Wing Roller Dia 152 mm
Belt Top Cover Temperature 30 deg C Carry Idler Wing Roller Dia 2 N
Rolling Resistance Factor Top: 0.072 Bottom: 0.072 Return Idler Centre Roll Dia 152 mm
Bottom Cover Dynamic Modulus E 6 N/mm2 Return Idler Centre Roll Drag 2 N
Bottom Cover Dynamic Loss Factor Tan(delta) 0.13 Return Idler Wing Roll Dia 152 mm
Belt Bottom Cover Temperature 30 deg C Return Idler Wing Roll Drag 2 N
Belt & Material Flexure Adjustment Factor 1 Idlerset Skew Angle 0.1 deg
Belt has Turnover on return run No Idlerset Forward Tilt Angle 0.1 deg
Loaded Empty
Total Indentation Matl. & Belt Idler Drag Idler Skew & Tilt
Section Idler Loaded Indent Indent Freq- Flexure Flexure Drag Drag Tilt Tilt Empty
Station Length Spacing friction factor factor uency friction friction factor factor friction friction friction
m m factor f fi % rad/s fm % fr % ft % factor f
1 Takeup 3.07 1.00 0.0300 0.00493 16.4 2043 0.00043 1.4 0.02346 77.9 0.00131 4.4 0.0300
2 Hopper 25.27 1.00 0.0300 0.00748 44.3 879 0.00521 30.8 0.00317 18.8 0.00102 6.1 0.0300
3 Drive 0.87 1.00 0.0300 0.00748 50.7 879 0.00307 20.8 0.00317 21.5 0.00102 7.0 0.0300
4 Snub * 27.38 3.00 0.0300 0.00493 16.4 2043 0.00043 1.4 0.02346 77.9 0.00131 4.4 0.0300
* Indicates Return conveyor section

30 Dec 2022 Conveyor Belt Resonance Report Page: 16/33
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Running Fully Loaded Belt Resonance

Carry Roll Diameter 127 mm Belt Speed 1 m/s
Return Roll Diameter 127 mm Takeup Mass 2650 kg
Belt Resonance +/- Tolerance 2%
Station / Section Critical Critical Idler

Start End Belt Transverse Idler Roll Section Idler Idler Spacing
Belt Belt Wave Frequency Excitation Idler Spacing Spacing Within
Tension Tension Range Frequency Spacing Start End +/- 2% Mode
Station Description kN kN Hz to Hz Hz m m m m
1 Takeup Tail 12.06 12.46 16.53 16.81 2.51 1 6.6 6.71 OK

2 Hopper Incoming Chute 12.46 17.02 6.53 7.65 2.51 1 2.61 3.05 OK
3 Drive Head Pulley 11.75 12.38 16.32 16.75 2.51 1 6.51 6.68 OK
4 Snub Snub 12.46 11.97 5.6 5.49 2.51 3 6.71 6.57 OK
All Figures are Running Fully Loaded Scenario

30 Dec 2022 Takeup Travel Report Page: 17/33
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Takeup Travel
Takeup Type Fixed Centres
Takeup Mass Calculation Method Manual
Takeup Mass Step Increment 100 kg
Max number of calc Increments 100
Takeup Mass kg (manual input) 2,650 kg
Takeup Tension (manual input) 12.99 kN
Takeup Mass calculated 2,650 kg

Takeup Travel Estimate
Safety Margin Top + 0.50 m
Belt Splice Allowance + 2.00 m
Dynamic Travel Up + 0.50 m
Dynamic Travel Down + 1.00 m
Safety Margin Bottom + 0.50 m
Thermal Expansion Distance
Minimum Site Temperature 0 °C
Maximum Site Temperature 50 °C
Belt Expansion Coefficient mm per °C 0.0000117 mm/°C
Total Belt Length 58.20 m
Thermal Expansion Distance + 0.017 m
Permanent Belt Stretch
Permanent Stretch Co-efficient
% of belt Length 0.15 %
Permanent Belt Stretch Distance + 0.044 m

Total Takeup Travel Distance = 0.00 m

30 Dec 2022 Drive Details Report Page: 18/33
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Drive Number 1 Drive Pulley Number 3

Drive Description Head Pulley Condition Wet
Load Share on Drive Pulley 100 % Pulley Lagging Type Ceramic
Starting Torque Factor Fully Loaded 240 % Belt Wrap Angle 203 °
Starting Torque Factor Empty 240 % Coefficient of Friction Running 0.25
Number of Motors on Drive Pulley 1 Drive Factor Cw Running 1.00
Motor Description Siemens 7.5kW 4 Pole Coefficient of friction Starting 0.35
Motor Power Rating 7.5 kW Drive Factor Cw Starting 0.71
Motor Voltage 415 V Pulley and Shaft Dimensions
Gearbox Description EON K Series Pulley Shell Diameter 500 mm
Drive Efficiency 95 % Pulley Lagging Thickness 12 mm
Fluid Coupling Pulley Outside Diameter 524 mm
Fluid Coupling No Selection - Direct Drive Pulley Shaft Diameter at Hub 110 mm
Fluid Coupling Size Pulley Shaft Diameter at Bearing 90 mm
High Speed Coupling Pulley and Belt Speed
HS Coupling Make Elecon Motor Full Load Speed 1470 rpm
HS Coupling Model ED 130 Required Gearbox Ratio 40.332 :1
Low Speed Coupling Selected Gearbox Ratio 37.92 :1
LS Coupling Make Elecon Required Pulley Speed 36.45 rpm
LS Coupling Model ED 1000 Calculated Pulley Speed for Reducer 38.77 rpm
Brake Required Belt Speed 1 m/s
Brake Location High Speed Calculated Belt Speed 1.06 m/s
Low Speed Brake Torque Input 0 kNm Drive Inertia
Equivalent HS Brake Torque 0 kN Motor Inertia 0.046 kg-m2
HoldBack High Speed Coupling Inertia 0.005 kg-m2
Static Analysis RunBack Force Fv 3,135 N High Speed Brake Disc Inertia 0 kg-m2
Static Analysis Horizontal Force Fh 2,215 N FlyWheel Inertia 0 kg-m2
Calculated HoldBack Torque 531 Nm Gearbox Inertia HSS 0.008 kg-m2
HoldBack Required (Yes/No) Fv>Fh/2 Yes Total Drive Inertia 0.059 kg-m2
HoldBack Req Torque 3x Motor FLT 5,895 Nm Total Drive Equivalent Mass 1,398 kg
HoldBack Make Not Installed
HoldBack Model
HoldBack Rated Torque 0 Nm

30 Dec 2022 Motor Report Page: 19/33
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Drive Description Head Total Motor Power on Drive 7.5 kW
Number of Motors on Drive Pulley 1 Absorbed Power at Pulley 5.35 kW
Motor Category Siemens LV IE3 Drive Efficiency 95 %
Motor Description Siemens 7.5kW 4 Pole Absorbed Power at Motor 5.63 kW
Motor Power Rating 7.5 kW Motor Full Load Speed 1470 rpm
Motor Voltage 415 V Motor Full Load Torque 49 Nm
Number of Poles 4 Motor Full Load Current 14.3 Amps
Motor Frame Size 132 M Motor Efficiency at Duty Point 91.1 %
Motor Shaft Diameter 38 mm Motor Power Factor at Duty Point 0.84
Motor Shaft Height 132 mm Mass of Motor 80 kg
Motor Inertia 0.05 kgm2 Selection Mode Manual

30 Dec 2022 Fluid Coupling Report Page: 20/33
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Drive Description Head Coupling Size
Number of Motors on Drive Pulley 1 Motor Power Rating 7.5 kW
Selection Mode Auto Motor Full Load Speed 1470 rpm
Coupling Category Voith Coupling Rated Slip 0%
Coupling Description No Selection - Direct Drive Peak Torque 0 % FLT
Coupling Size Run-up Torque % (2 sec) 0 % FLT
Coupling Power Rating 0 kW Coupling Output Speed 1470 rpm
Min Required Ramping Time 0.00 s Mass of Coupling 0 kg
Max Starting Time 0s

30 Dec 2022 Drive Gearbox Details Report Page: 21/33
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Drive Description Head Motor Power Rating 7.5 kW
Number of Motors on Drive Pulley 1 Motor Full Load Speed 1470 rpm
Selection Mode Manual Motor Torque @ FL Speed 49 Nm
Gearbox Category Elecon Motor Torque at Pulley Speed 1965 Nm
Description EON K Series Gearbox Rated Torque 2710 Nm
Type Bevel Helical Gear Service Factor Required 1.5
Size 15 Service Factor Calculated 1.38
Code K3H15
Ratio 37.92 Plus Speed Selection Tolerance 5%
Number of Stages 3 Minus Speed Selection Tolerance 5%
Fluid Coupling Slip 0%
Design Efficiency (input) 95 % Required Gearbox Ratio 40.332 :1
Gearbox actual Efficiency 94 % Selected Gearbox Ratio 37.92 :1
Maximum Input Shaft Speed 1500 rpm Required Pulley Speed 36.45 rpm
Minimum Input Shaft Speed 750 rpm Calculated Pulley Speed for Reducer 38.77 rpm
Input Shaft Diameter 24 mm Required Belt Speed 1 m/s
Output Shaft Diameter 55 mm Calculated Belt Speed 1.06 m/s
Gearbox Inertia 0.008 kg/m2 Mass of Gearbox 100 kg

30 Dec 2022 Brake Details Report Page: 22/33
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Drive Description Head Brake Location High Speed
Load Share on Drive Pulley 100 % Disc Material Mild Steel
Brake Category Svendborg BSFH 200 Disc Diameter 600 mm
Brake Description Svendborg Disc Thickness 30 mm
Caliper BSFH 204 Co-eff of Friction (Pad-Disc) 0.4
Number of Motors on Drive Pulley 1
Selection Mode Auto
Brake Selection Input Data Caliper Clamping Force Minimum 4000 N
Low Speed Brake Torque Input 0 kNm Caliper Clamping Force Maximum 5600 N
Equivalent HS Brake Torque 0 Nm Pad Offset Width W 60 mm
Design Braking Torque Input 397 Nm Air Gap 3 mm
Selected Brake's Torque Rating 760 Nm Recomended working airgap is 1mm
Design Stopping Time 10 sec Disc Initial Speed 1480 rpm
Consecutive number of Stops 3 Disc Moment of Inertia 3 kgm2
Average number of Stops per hour 6 Required Gearbox Ratio 40.332 :1
Ambient Temperature 40 deg C Drive Efficiency 95 %
Disc Temp after stops 65 deg C Mass of Caliper 26 kg

30 Dec 2022 Shaft Coupling Report Page: 23/33
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Drive Description Head Motor Power Rating 7.5 kW
Load Share on Drive Pulley 100 % Motor Full Load Speed 1470 rpm
Starting Torque Factor Fully Loaded 240 % Motor Torque at Full Load Speed 49 Nm
Starting Torque Factor Empty 240 % Motor Torque at Pulley Speed 1965 Nm
Number of Motors on Drive Pulley 1 Pulley Shaft Diameter at Brg 90 mm
Drive Efficiency 95 %
High Speed Coupling Low Speed Coupling

HS Coupling Category Elecon Geared Couplings LS Coupling Category Elecon Geared Couplings
HS Coupling Make Elecon LS Coupling Make Elecon
HS Coupling Model ED 130 LS Coupling Model ED 1000
Coupling Type Geared Couplings Coupling Type Geared Couplings
Coupling Torque Rating 260 Nm Coupling Torque Rating 2000 Nm
Service Factor Required 1.5 Service Factor Required 1.5
Service Factor Calculated 5.34 Service Factor Calculated 1.02
Maximum Shaft Bore 45 mm Maximum Shaft Bore 95 mm
Minimum Shaft Bore 15 mm Minimum Shaft Bore 35 mm
Maximum Rotation Speed 7000 rpm Maximum Rotation Speed 5100 rpm
High Speed Coupling Inertia 0.005 kg-m2 Low Speed Coupling Inertia 0.101 kg-m2
Drawing Number Drawing Number
High Speed Coupling Mass 4 kg Low Speed Coupling Mass 25 kg
High Speed Coupling Price 0 Low Speed Coupling Price 0
Fluid Coupling
Direct Drive Yes
Fluid Coupling No Selection - Direct Drive
Fluid Coupling Size

30 Dec 2022 Conveyor Pulley Shafts Page: 24/33
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Station / Section Calculated Selected
Shaft Wrap T1 T2 Resultant T1 Defl. Dt. Shaft Brg Brg Shaft
Length Angle Run Run Force Start Dia Dia Dia Dia Ctrs Mass
Station Description mm deg kN kN kN kN mm mm mm mm mm kg
1 Takeup Tail * 1500 180.0 12.0 12.1 24.0 10.8 99.0 96.4 90 80 1400 75
3 Drive Head Pulley * 1700 192.0 17.0 11.8 28.6 22.0 103.5 103.8 110 90 1400 127
4 Snub Snub * 1500 12.0 12.4 12.5 2.6 9.9 56.8 45.9 75 65 1400 52
* Indicates Manual pulley shaft dimensions entered

30 Dec 2022 Conveyor Pulleys Page: 25/33
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Station / Section
Shell Face Shaft Brg Shaft Brg Wrap Pulley Pulley Mom of
Dia Lagging Width Length Ctrs Dia Dia Angle Speed & Shaft Inertia
Station Description mm mm mm mm mm mm mm deg RPM Mass kg kgm2
1 Takeup * 400 10 950 1500 1400 90 80 180.0 45.5 234 5.3

3 Drive * 500 12 950 1700 1400 110 90 192.0 36.4 414 13.6
4 Snub * 315 10 950 1500 1400 75 65 12.0 57.0 155 2.3
* Indicates Manual pulley dimensions entered

30 Dec 2022 Conveyor Pulley Dimensions Page: 26/33
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Belt Width 800 mm Belt Class 315/3

Station / Section Pulley
Shell Calc Face Shaft Shaft Brg & Shaft Mom of
Dia Shell t Shell t Lagging OD Width Length Dia Dia Mass Inertia
Station Description mm mm mm mm mm mm mm mm mm kg kgm2
1 Takeup * 400 10 5.8 10 420 950 1500 90 80 234 5.3

3 Drive * 500 12 6.3 12 524 950 1700 110 90 414 13.6
4 Snub * 315 10 5.9 10 335 950 1500 75 65 155 2.3
* Indicates Manual pulley dimensions entered

30 Dec 2022 Conveyor Pulleys Data Sheet Page: 27/33
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Station / Section
Shell Face Brg Drive Wrap Pulley T1 T2 T1 T2
Dia Lagging Width Ctrs Power Angle Speed Run Run Start Start
Station Description mm mm mm mm kW deg rpm kN kN kN kN
1 Takeup Tail 400 10 950 1400 180.0 45.5 11.97 12.06 12.85 12.88
Running Full Braking Empty
3 Drive Head Pulley 500 12 950 1400 7.5 192.0 36.4 17.02 11.75 22.01 9.17
Running Full Starting Full
4 Snub Snub 315 10 950 1400 12.0 57.0 12.38 12.46 13.56 13.6
Running Full Braking Empty

30 Dec 2022 Conveyor Tension Graphs Report Page: 28/33
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Conveyor Tension Graphs

Calculation Method ISO

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30 Dec 2022 Conveyor Design Summary Page: 1/33

Macawber Beekay Private Limited

Helix DeltaT Conveyor Design program version: 1.1.16

1 Takeup Tail 3.07 0.65 0.00 0.00 0.00 0 1 1 0.03000

Totals: 56.59 0.11 0.00 5.00 3.00

Helix DeltaT Conveyor Design program version: 1.1.16

Helix DeltaT Conveyor Design program version: 1.1.16

Running Starting Braking Coasting

Helix DeltaT Conveyor Design program version: 1.1.16

Conveyed Material Belt Speed & Capacity

Helix DeltaT Conveyor Design program version: 1.1.16

Allowable Belt Sag % Running 2% Takeup Pulley Belt Tension 12.99 kN

Running Starting Braking Coasting

Idler Spacing m 1.00

Idler Spacing m 1.00

Idler Spacing m 1.00

Idler Spacing m 3.00

Helix DeltaT Conveyor Design program version: 1.1.16

Run Fully Loaded

Tensions ISO 5048(1) Section ISO

1 Takeup 3.07 0.65 11.97 12.06 0.09 0.31 0.09 0.0300

2 Hopper 25.27 5.23 12.46 12.46 0.06 0.18 4.32 0.0300

4 Snub 27.38 -5.71 12.38 12.46 0.08 -0.49 0.0300

Totals 0.25 5.27 0.00 0.06 0.18 0.94 3.92

Helix DeltaT Conveyor Design program version: 1.1.16

Tensions ISO 5048(1) Section ISO

1 Takeup 3.07 0.65 12.80 12.89 0.09 0.31 0.09 0.0300

2 Hopper 25.27 5.23 13.29 13.29 0.74 0.0300

4 Snub 27.38 -5.71 13.21 13.29 0.08 -0.49 0.0300

Totals 0.24 1.45 0.00 0.94 0.34

Helix DeltaT Conveyor Design program version: 1.1.16

Run Inclines Loaded

Tensions ISO 5048(1) Section ISO

1 Takeup 3.07 0.65 11.97 12.06 0.09 0.31 0.09 0.0300

2 Hopper 25.27 5.23 12.46 12.46 0.06 0.18 4.32 0.0300

4 Snub 27.38 -5.71 12.38 12.46 0.08 -0.49 0.0300

Totals 0.25 5.27 0.00 0.06 0.18 0.94 3.92

Helix DeltaT Conveyor Design program version: 1.1.16

Run Declines Loaded

Tensions ISO 5048(1) Section ISO

1 Takeup 3.07 0.65 12.74 12.83 0.09 0.31 0.09 0.0300

2 Hopper 25.27 5.23 13.23 13.23 0.06 0.18 0.74 0.0300

4 Snub 27.38 -5.71 13.15 13.23 0.08 -0.49 0.0300

Totals 0.24 1.69 0.00 0.06 0.18 0.94 0.34

Helix DeltaT Conveyor Design program version: 1.1.16

System Masses Input Data

Helix DeltaT Conveyor Design program version: 1.1.16

Carry Side Idlers Return Side Idlers

Idler Design Belt Width 800 mm 800 mm

Helix DeltaT Conveyor Design program version: 1.1.16

Belt Width 800 mm % Belt Mass for Lift off Calculation 80 %

Station / Section Information Running Starting Braking

1 Takeup 11.97 12.80 10.79 12.19 12.48 12.85

2 Hopper 220 12.46 13.29 11.80 13.74 12.73 13.24

3 Drive 17.02 14.03 22.01 17.71 14.72 13.66

Helix DeltaT Conveyor Design program version: 1.1.16

4 Snub 12.38 13.21 9.89 9.94 13.58 13.56

Helix DeltaT Conveyor Design program version: 1.1.16

Viscoelastic Calculations Input Data

* Indicates Return conveyor section