By Pass System RCD-1 to SP-3 RCD-2 to SP2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

CALCULATION OF BY PASS CONVEYOR C - 12A

1 Belt Capacity Required t/h 825

2 Belt Width B mm 1200

3 Belt Speed Required v m/s 1.13

4 Angle of Inclination φ 12.8

5 Belt Center Distance L m 154.4

Vertical height to elevate= Lsi H m 18

Skirt board length each side m 3 sbl = 6

6 Material / Bulk density ץ 1.4

7 Capacity Factor k 0.89 H/L = 0.28

8 Trough Angle λ 35 β 10

9 Total Moisture % 28

Material Temperature 35

Lump Size mm 100

10 Weight of Moving Part Conv. G kg/m 45 see table 7

if s1 and s2 and density < 1.5 s1 m 1 see table 7

s2 m 3 see table 7

11 Additional l m 100 see table 8

if center distance >100 m. L m 154.4 see table 8

12 Coefficient of friction of rolling parts

parts f 0.023 see table 9

Check Theoritical Capacity Qt

1 Qt' = = 584.22m3/h

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

Q't = 614 m3/h

with ;

Belt Width B mm 1200

Trough Angle λ 35 β 15

2 Qt = Q't x v x k = 619.32 m3/h

3 Q = = 867.05 t/h

Q2

o

t/m3

o o

oC

{Q2/(v x ץ x k)}

o o

Qt x ץ

Q > Q2

By Pass System RCD-1 to SP-3 RCD-2 to SP2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

Power Requirement

1 Power Required to drive empty Conveyor N1 (kW)

= {G(L+l)fxv}/102 = 2.93 kW

2 Power Required to convey material on the level N2 (kW)

= {Q(L+l)f}/367 = 13.82 kW

3 Power Required to elevated material N3 (kW )

= (QxH)/367 = 42.53 kW

4 Additional Power Requirement N4 (kW), see table 10

= = 0.54 kW

* Theoritical Necessary Motor Capacity Nn (kW)

Nn = = 59.82 kW

* Motor Capacity (Nm)

Nm = Nn / ŋ = 70.38 Kw

* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

see table 16

D1 = Driving Pulley = 500 mm D1 = 733 mm

D2 = Tail Pulley = 400 mm D2 = 530 mm

D3 = Snub Pulley = 315 mm D3 = 330 mm

GEAR REDUCER SELECTION

Service Factor sf= 2

* Nominal Power Rating = Pm x sf = 140.75 kW

* Gear Reducer output speed = (v x 60)/(3.14 x D1) = 29.54 rpm

* Gear Reducer Ratio i = = 50.77

* Thermal Rating = = 149.29 kW

= 143

According above mention , choice gear reducer type and size ;

FLENDER type : B3HH11 i = 50 or

HANSEN P4 type: QHRF3 i = 50

N1

N2

N3

N40.08x v x length of

skirt board

N1 + N2 + N3 + N4

PN

n2

1500 / n2

PG PG1 x 0.87 x 1.2

PG1

PN < PG the Gear Reducer no need extra cooling.

By Pass System RCD-1 to SP-3 RCD-2 to SP2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

By Pass System RCD-1 to SP-3 RCD-2 to SP2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

By Pass System RCD-1 to SP-3 RCD-2 to SP2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

By Pass System RCD-1 to SP3 RCD-2 to SP2Pelabuhan Batubara Tarahan.

PT. Protech Asia Engineering.

CALCULATION OF BY PASS CONVEYOR C - 12A

1 Belt Capacity Required t/h 1650

2 Belt Width B mm 1200

3 Belt Speed Required v m/s 4.5

4 Angle of Inclination φ 16

5 Belt Center Distance L m 15.5

Vertical height to elevate= Lsi H m 4.06

Skirt board length each side m 3 sbl = 6

6 Material / Bulk density ץ 0.9

7 Capacity Factor k 0.89 H/L = 0.28

8 Trough Angle λ 35 β 10

9 Total Moisture % 28

Material Temperature 35

Lump Size mm 100

10 Weight of Moving Part Conv. G kg/m 45 see table 7

if s1 and s2 and density < 1.5 s1 m 1.5 see table 7

s2 m 3 see table 7

11 Additional l m 50 see table 8

if center distance < 30 m. L m 15.5 see table 8

12 Coefficient of friction of rolling parts

parts f 0.023 see table 9

Check Theoritical Capacity Qt

1 Qt' = = 457.76m3/h

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

Q't = 493 m3/h

with ;

Belt Width B mm 1200

Trough Angle λ 20 β 15

2 Qt = Q't x v x k = 1974.47 m3/h

3 Q = = 1777.02 t/h

Q2

o

t/m3

o o

oC

{Q2/(v x ץ x k)}

o o

Qt x ץ

Q > Q2

By Pass System RCD-1 to SP3 RCD-2 to SP2Pelabuhan Batubara Tarahan.

PT. Protech Asia Engineering.

Power Requirement

1 Power Required to drive empty Conveyor N1 (kW)

N1 = {G(L+l)fxv}/102 = 2.99 kW

2 Power Required to convey material on the level N2 (kW)

N2 = {Q(L+l)f}/367 = 7.29 kW

3 Power Required to elevated material N3 (kW )

N3 = (QxH)/367 = 19.66 kW

4 Additional Power Requirement N4 (kW), see table 10

N4 = = 2.16 kW

* Theoritical Necessary Motor Capacity Nn (kW)

Nn = N1 + N2 + N3 + N4 = 32.10 kW

* Motor Capacity (Nm)

Nm = Nn / ŋ = 37.77 Kw

* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

see table 16

D1 = Driving Pulley = 500 mm D1 = 630 mm

D2 = Tail Pulley = 400 mm D2 = 530 mm

D3 = Snub Pulley = 315 mm D3 = 330 mm

GEAR REDUCER SELECTION

Service Factor sf= 2

* Nominal Power Rating PN = Pm x sf = 75.54 kW

* Gear Reducer output speed n2 = (v x 60)/(3.14 x D1) = 136.49 rpm

* Gear Reducer Ratio i = 1500 / n2 = 10.99

* Thermal Power Rating = = 53.24 kW

= 51

PN < PG the Gear Reducer no need extra cooling.

According above mention , choice gear reducer type and size ;

FLENDER type : B2HH4 i = 11.2 or

HANSEN P4 type: QHRA2 i = 11.2

0.08x v x length of skirt board

PG PG1 x 0.87 x 1.2

PG1

By Pass System RCD-1 to SP3 RCD-2 to SP2Pelabuhan Batubara Tarahan.

PT. Protech Asia Engineering.

By Pass System RCD-1 to SP3 RCD-2 to SP2Pelabuhan Batubara Tarahan.

PT. Protech Asia Engineering.

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

By Pass System RCD-1 to SP3 RCD-2 to SP2Pelabuhan Batubara Tarahan.

PT. Protech Asia Engineering.

Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

CALCULATION OF BY PASS CONVEYOR C - 12A

1 Belt Capacity Required t/h 1650

2 Belt Width B mm 1200

3 Belt Speed Required v m/s 4.5

4 Angle of Inclination φ 16

5 Belt Center Distance L m 17

Vertical height to elevate= Lsinφ H m 4.06

Skirt board length each side m 3 sbl = 6

6 Material / Bulk density ץ 1.1

7 Capacity Factor k 0.89 H/L = 0.28

8 Trough Angle λ 35 β 10

9 Total Moisture % 28

Material Temperature 35

Lump Size mm 100

10 Weight of Moving Part Conv. G kg/m 67 see table 7

if s1 and s2 and density < 1.5 m 1.5 see table 7

m 3 see table 7

11 Additional l m 50 see table 8

if center distance < 30 m. L m 17 see table 8

12 Coefficient of friction of rolling

parts, on dusty running periodic f 0.03 see table 9

overloaded.

Check Theoritical Capacity Qt

1 Qt' = = 374.53m3/h

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

Q't = 396 m3/h

with ;

Belt Width B mm 1000

Trough Angle λ 30 β 15

2 Qt = Q't x v x k = 1585.98 m3/h

3 Q = = 1744.58 t/h

Q2

o

t/m3

o o

oC

s1

s2

{Q2/(v x ץ x k)}

o o

Qt x ץ

Q > Q2

No need to modify the speed , belt size , trough angle

Power Requirement

1 Power Required to drive empty Conveyor N1 (kW)

N1 = {G(L+l)fxv}/102 = 5.94 kW

2 Power Required to convey material on the level N2 (kW)

N2 = {Q(L+l)f}/367 = 9.55 kW

3 Power Required to elevated material N3 (kW )

N3 = (QxH)/367 = 19.30 kW

4 Additional Power Requirement N4 (kW), see table 10

N4 = = 2.16 kW

* Theoritical Necessary Motor Capacity Nn (kW)

Nn = N1 + N2 + N3 + N4 = 36.96 kW

* Motor Capacity (Nm)

Nm = Nn / ŋ = 43.48 Kw

Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )

* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

see table 16

D1 = Driving Pulley = 500 mm D1 = 630 mm

D2 = Tail Pulley = 400 mm D2 = 530 mm

D3 = Snub Pulley = 315 mm D3 = 330 mm

GEAR REDUCER SELECTION

* Prime Mover

Electric motor P1 = 55 kW

Motor speed n1 = 1500 rpm

Max. starting torque = 525 Nm

* Driven machine

Belt Conveyor = 45 kW

* Output rotation need = ( v x 60 )/( 3.14 x D1 ) = 136.49 rpm

* Gear Reducer Ratio i = = 10.99

0.08x v x length of skirt board

TA

P2

n2

n1 / n2

* Service factor for Gear Units with 24 hours operation.

Factor for driven machine Belt onveyor. = 1.30 table 1, page 12

Factor for prime mover use electric motor = 1.00 table 2, page 12

Peak torque factor with load peaks per hour 6 - 30 = 0.95 table 3, page 12

Thermal factor = 0.71 table 4, page 12

Thermal factor with cooling = 1.19 table 5, page 12

Factor for altitude = 1.00 table 6, page 12

Factor for altitude with cooling = 1.00 table 7, page 12

Oil supply factor for horz. = 0.95 table 8, page 13

Thermal capacity = 1.20 table 9, page 13

Thermal capacity factor with fan = 1.49 table 10, page 13

* Determination of Nominal Power ≥ = 58.50 kW

rating

* page :22

= = 149.85 kW

149.85 kW > PN = 82 kW

* Checking the starting torque ≥ = 78.34 kW

* Thermal Power Rating without = 51 page:23

auxiliary cooling

* Thermal capacity for gear units = = 41.28 kW

without auxiliary cooling

Gear unit need auxiliary fan cooling

Check thermal power rating with auxiliary fan cooling

* Thermal Power Rating with = 67 page:23

auxiliary fan cooling

* Thermal capacity for gear units = = 67.34 kW

with auxiliary fan cooling

f1

f2

f3

f4

f5

f6

f7

f8

f9

f10

PN P2 x f1 x f2

Selected from power rating table: type B2 gear unit size 4 , with PN = 81 kW

3.33 x P2 ≥ PN

PN (TA x n1) / 9550 x f3

PN = 81 kW > 78.34 kW

PG1

PG PG1 x f4 x f6 x f8 x f9

PG = 41.28 kW < P2 = 45 kW

PG2

PG PG2 x f4 x f6 x f8 x f10

PG = 67.88 kW > P2 = 45 kW

According above mention , choice gear reducer type and size ;

FLENDER type : B2DH4 i = 11.2

Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan

`

m3/h

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

m3/h

m3/h

63.2238

54.347

Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )

59.129 63.937 power yang diminta

Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

752

table 1, page 12

table 2, page 12

table 3, page 12

table 4, page 12

table 5, page 12

table 6, page 12

table 7, page 12

table 8, page 13

table 9, page 13

table 10, page 13

150

97.5

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

CALCULATION OF BY PASS CONVEYOR C - 12A

1 Belt Capacity Required t/h 1650

2 Belt Width B mm 1200

3 Belt Speed Required v m/s 4.5

4 Angle of Inclination φ 16

5 Belt Center Distance L m 15.5

Vertical height to elevate= Lsinφ H m 4.06

Skirt board length each side m 3 sbl = 6

6 Material / Bulk density ץ 1.1

7 Capacity Factor k 0.89 H/L = 0.28

8 Trough Angle λ 35 β 10

9 Total Moisture % 28

Material Temperature 35

Lump Size mm 100

10 Weight of Moving Part Conv. G kg/m 67 see table 7

if s1 and s2 and density < 1.5 m 1.5 see table 7

m 3 see table 7

11 Additional l m 50 see table 8

if center distance < 30 m. L m 15.5 see table 8

12 Coefficient of friction of rolling

parts, on dusty running periodic f 0.03 see table 9

overloaded.

Check Theoritical Capacity Qt

1 Qt' = = 374.53m3/h

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

Q't = 396 m3/h

with ;

Belt Width B mm 1000

Trough Angle λ 30 β 15

2 Qt = Q't x v x k = 1585.98 m3/h

3 Q = = 1744.58 t/h

No need to modify the speed , belt size , trough angle

Q2

o

t/m3

o o

oC

s1

s2

{Q2/(v x ץ x k)}

o o

Qt x ץ

Q > Q2

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

Power Requirement

1 Power Required to drive empty Conveyor N1 (kW)

N1 = {G(L+l)fxv}/102 = 5.81 kW

2 Power Required to convey material on the level N2 (kW)

N2 = {Q(L+l)f}/367 = 9.34 kW

3 Power Required to elevated material N3 (kW )

N3 = (QxH)/367 = 19.30 kW

4 Additional Power Requirement N4 (kW), see table 10

N4 = = 2.16 kW

* Theoritical Necessary Motor Capacity Nn (kW)

Nn = N1 + N2 + N3 + N4 = 36.61 kW

* Motor Capacity (Nm)

Nm = Nn / ŋ = 43.07 Kw

Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )

* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

see table 16

D1 = Driving Pulley = 500 mm D1 = 630 mm

D2 = Tail Pulley = 400 mm D2 = 530 mm

D3 = Snub Pulley = 315 mm D3 = 330 mm

GEAR REDUCER SELECTION

* Prime Mover

Electric motor P1 = 55 kW

Motor speed n1 = 1500 rpm

Max. starting torque = 525 Nm

* Driven machine

Belt Conveyor = 45 kW

* Output rotation need = ( v x 60 )/( 3.14 x D1 ) = 136.49 rpm

* Gear Reducer Ratio i = = 10.99

0.08x v x length of skirt board

TA

P2

n2

n1 / n2

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

* Service factor for Gear Units with 24 hours operation.

Factor for driven machine Belt onveyor. = 1.30 table 1, page 12

Factor for prime mover use electric motor = 1.00 table 2, page 12

Peak torque factor with load peaks per hour 6 - 30 = 0.95 table 3, page 12

Thermal factor = 0.71 table 4, page 12

Thermal factor with cooling = 1.19 table 5, page 12

Factor for altitude = 1.00 table 6, page 12

Factor for altitude with cooling = 1.00 table 7, page 12

Oil supply factor for horz. = 0.95 table 8, page 13

Thermal capacity = 1.20 table 9, page 13

Thermal capacity factor with fan = 1.49 table 10, page 13

* Determination of Nominal Power ≥ = 58.50 kW

rating

* page :22

= = 149.85 kW

149.85 kW > PN = 82 kW

* Checking the starting torque ≥ = 78.34 kW

* Thermal Power Rating without = 51 page:23

auxiliary cooling

* Thermal capacity for gear units = = 41.28 kW

without auxiliary cooling

Gear unit need auxiliary fan cooling

Check thermal power rating with auxiliary fan cooling

* Thermal Power Rating with = 67 page:23

auxiliary fan cooling

* Thermal capacity for gear units = = 67.34 kW

with auxiliary fan cooling

According above mention , choice gear reducer type and size ;

FLENDER type : B2HH4 i = 11.2

Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan

f1

f2

f3

f4

f5

f6

f7

f8

f9

f10

PN P2 x f1 x f2

Selected from power rating table: type B2 gear unit size 4 , with PN = 81 kW

3.33 x P2 ≥ PN

PN (TA x n1) / 9550 x f3

PN = 81 kW > 78.34 kW

PG1

PG PG1 x f4 x f6 x f8 x f9

PG = 41.28 kW < P2 = 45 kW

PG2

PG PG2 x f4 x f6 x f8 x f10

PG = 67.88 kW > P2 = 45 kW

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

`

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out;

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

63.2238

53.837

58.574 63.337 power yang diminta

Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;

752

By Pass System RCD-1 to SP3 RCD-2 to SP-2Pelabuhan Batubara Tarahan

PT. Protech Asia Engineering.

150

97.5

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t 6.8 ab bdq 7 ad sbw 7.5 ac mny 8 as klr 8.2 an jie 8.6 am lob 9 ak kph 10 ao rt