By Pass System RCD-1 to SP-3 RCD-2 to SP2

Pelabuhan Batubara Tarahan

1 Belt Capacity Required Q
2
t/h 825
2 Belt Width B mm 1200
3 Belt Speed Required v m/s 1.13
4 Angle of Inclination
o
12.8
5 Belt Center Distance L m 154.4
Vertical height to elevate= Lsin H m 18
Skirt board length each side m 3 sbl = 6
6 Material / Bulk density t/m
3
1.4
7 Capacity Factor k 0.89 H/L = 0.28
8 Trough Angle
o
35
o
10
9 Total Moisture % 28
Material Temperature
o
C 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' = = 584.22 m3/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
o
35
o
15
2 Qt = = 619.32 m3/h
3 Q = = 867.05 t/h
Q > Q
2
CALCULATION OF BY PASS CONVEYOR C - 12A
{Q2/(v x x k)}
Q't x v x k
Qt x
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP-3 RCD-2 to SP2
Pelabuhan Batubara Tarahan
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW)
N
1
= = 2.93 kW
2 Power Required to convey material on the level N2 (kW)
N
2
= = 13.82 kW
3 Power Required to elevated material N3 (kW )
N
3
= = 42.53 kW
4 Additional Power Requirement N4 (kW), see table 10
N
4
= = 0.54 kW
* Theoritical Necessary Motor Capacity Nn (kW)
Nn = = 59.82 kW
* Motor Capacity (Nm)
Nm = = 70.38 Kw
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;
see table 16
D1 = Driving Pulley = 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 P
N
= = 140.75 kW
* Gear Reducer output speed n
2
= = 29.54 rpm
* Gear Reducer Ratio i = = 50.77
* Thermal Rating P
G
= = 149.29 kW
P
G1
= 143
According above mention , choice gear reducer type and size ;
FLENDER type : i = 50 or
HANSEN P4 type: i = 50
B3HH11
QHRF3
(QxH)/367
0.08x v x length of
skirt board
500 mm
Pm x sf
(v x 60)/(3.14 x D1)
1500 / n
2
P
G1
x 0.87 x 1.2
P
N
< P
G
the Gear Reducer no need extra cooling.
{G(L+l)fxv}/102
{Q(L+l)f}/367
N
1
+ N
2
+ N
3
+ N
4
Nn /
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP2
Pelabuhan Batubara Tarahan.
1 Belt Capacity Required Q
2
t/h 1650
2 Belt Width B mm 1200
3 Belt Speed Required v m/s 4.5
4 Angle of Inclination
o
16
5 Belt Center Distance L m 15.5
Vertical height to elevate= Lsin H m 4.06
Skirt board length each side m 3 sbl = 6
6 Material / Bulk density t/m
3
0.9
7 Capacity Factor k 0.89 H/L = 0.28
8 Trough Angle
o
35
o
10
9 Total Moisture % 28
Material Temperature
o
C 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' = = 457.76 m3/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
o
20
o
15
2 Qt = = 1974.47 m3/h
3 Q = = 1777.02 t/h
Q > Q
2
CALCULATION OF BY PASS CONVEYOR C - 12A
Q't x v x k
Qt x
{Q2/(v x x k)}
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP2
Pelabuhan Batubara Tarahan.
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW)
N1 = = 2.99 kW
2 Power Required to convey material on the level N2 (kW)
N2 = = 7.29 kW
3 Power Required to elevated material N3 (kW )
N3 = = 19.66 kW
4 Additional Power Requirement N4 (kW), see table 10
N4 = = 2.16 kW
* Theoritical Necessary Motor Capacity Nn (kW)
Nn = = 32.10 kW
* Motor Capacity (Nm)
Nm = = 37.77 Kw
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;
see table 16
D1 = Driving Pulley = 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 = = 75.54 kW
* Gear Reducer output speed n2 = = 136.49 rpm
* Gear Reducer Ratio i = = 10.99
* Thermal Power Rating P
G
= = 53.24 kW
P
G1
= 51
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
N1 + N2 + N3 + N4
Nn /
{G(L+l)fxv}/102
{Q(L+l)f}/367
(QxH)/367
P
G1
x 0.87 x 1.2
PN < PG the Gear Reducer no need extra cooling.
500 mm
Pm x sf
(v x 60)/(3.14 x D1)
1500 / n2
PT. Protech Asia Engineering.
1 Belt Capacity Required Q
2
t/h 1650
2 Belt Width B mm 1200
3 Belt Speed Required v m/s 4.5
4 Angle of Inclination
o
16
5 Belt Center Distance L m 17
Vertical height to elevate= Lsin H m 4.06
Skirt board length each side m 3 sbl = 6
6 Material / Bulk density t/m
3
1.1
7 Capacity Factor k 0.89 H/L = 0.28
8 Trough Angle
o
35
o
10
9 Total Moisture % 28
Material Temperature
o
C 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 s
1
m 1.5 see table 7
s
2
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' = = 374.53 m3/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
o
30
o
15
2 Qt = = 1585.98 m3/h
CALCULATION OF BY PASS CONVEYOR C - 12A
{Q2/(v x x k)}
Q't x v x k
3 Q = = 1744.58 t/h
Q > Q
2
No need to modify the speed , belt size , trough angle
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW)
N1 = = 5.94 kW
2 Power Required to convey material on the level N2 (kW)
N2 = = 9.55 kW
3 Power Required to elevated material N3 (kW )
N3 = = 19.30 kW
4 Additional Power Requirement N4 (kW), see table 10
N4 =
=
2.16 kW
* Theoritical Necessary Motor Capacity Nn (kW)
Nn = = 36.96 kW
* Motor Capacity (Nm)
Nm = = 43.48 Kw
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;
see table 16
D1 = Driving Pulley = 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 T
A
= 525 Nm
* Driven machine
Belt Conveyor P
2
= 45 kW
{G(L+l)fxv}/102
{Q(L+l)f}/367
(QxH)/367
0.08x v x length of
skirt board
Qt x
N1 + N2 + N3 + N4
Nn /
Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )
500 mm
* Output rotation need n
2
= = 136.49 rpm
* Gear Reducer Ratio i = = 10.99
* Service factor for Gear Units with 24 hours operation.
Factor for driven machine Belt onveyor. = f
1
1.30 table 1, page 12
Factor for prime mover use electric motor = f
2
1.00 table 2, page 12
Peak torque factor with load peaks per hour 6 - 30 = f
3
0.95 table 3, page 12
Thermal factor = f
4
0.71 table 4, page 12
Thermal factor with cooling = f
5
1.19 table 5, page 12
Factor for altitude = f
6
1.00 table 6, page 12
Factor for altitude with cooling = f
7
1.00 table 7, page 12
Oil supply factor for horz. = f
8
0.95 table 8, page 13
Thermal capacity = f
9
1.20 table 9, page 13
Thermal capacity factor with fan = f
10
1.49 table 10, page 13
* Determination of Nominal Power P
N
= 58.50 kW
rating
* Selected from power rating table: type B2 gear unit size 4 , with P
N
= 81 kW page :22
= = 149.85 kW
* Checking the starting torque P
N
= 78.34 kW
* Thermal Power Rating without P
G1
= 51 page:23
auxiliary cooling
* Thermal capacity for gear units P
G
= = 41.28 kW
without auxiliary cooling
Check thermal power rating with auxiliary fan cooling
* Thermal Power Rating with P
G2
= 67 page:23
( v x 60 )/( 3.14 x D1 )
n
1
/ n
2
P
2
x f
1
x f
2
3.33 x P
2
P
N
P
G
= 41.28 kW < P
2
= 45 kW
Gear unit need auxiliary fan cooling
149.85 kW > PN = 82 kW
(T
A
x n
1
) / 9550 x f
3
P
N
= 81 kW > 78.34 kW
P
G1
x f
4
x f
6
x f
8
x f
9
auxiliary fan cooling
* Thermal capacity for gear units P
G
= = 67.34 kW
with auxiliary fan cooling
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
`
P
G2
x f
4
x f
6
x f
8
x f
10
P
G
= 67.88 kW > P
2
= 45 kW
63.2238
54.3467
59.1293 63.9373 power yang diminta
75
2
150
97.5
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
1 Belt Capacity Required Q
2
t/h 1650
2 Belt Width B mm 1200
3 Belt Speed Required v m/s 4.5
4 Angle of Inclination
o
16
5 Belt Center Distance L m 15.5
Vertical height to elevate= Lsin H m 4.06
Skirt board length each side m 3 sbl = 6
6 Material / Bulk density t/m
3
1.1
7 Capacity Factor k 0.89 H/L = 0.28
8 Trough Angle
o
35
o
10
9 Total Moisture % 28
Material Temperature
o
C 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 s
1
m 1.5 see table 7
s
2
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' = = 374.53 m3/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
o
30
o
15
2 Qt = = 1585.98 m3/h
3 Q = = 1744.58 t/h
Q > Q
2
CALCULATION OF BY PASS CONVEYOR C - 12A
{Q2/(v x x k)}
Q't x v x k
Qt x
No need to modify the speed , belt size , trough angle
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
Power Requirement
1 Power Required to drive empty Conveyor N1 (kW)
N1 = = 5.81 kW
2 Power Required to convey material on the level N2 (kW)
N2 = = 9.34 kW
3 Power Required to elevated material N3 (kW )
N3 = = 19.30 kW
4 Additional Power Requirement N4 (kW), see table 10
N4 =
=
2.16 kW
* Theoritical Necessary Motor Capacity Nn (kW)
Nn = = 36.61 kW
* Motor Capacity (Nm)
Nm = = 43.07 Kw
* Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization;
see table 16
D1 = Driving Pulley = 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 T
A
= 525 Nm
* Driven machine
Belt Conveyor P
2
= 45 kW
* Output rotation need n
2
= = 136.49 rpm
* Gear Reducer Ratio i = = 10.99
* Service factor for Gear Units with 24 hours operation.
Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor )
{G(L+l)fxv}/102
{Q(L+l)f}/367
(QxH)/367
0.08x v x length of
skirt board
N1 + N2 + N3 + N4
Nn /
500 mm
n
1
/ n
2
( v x 60 )/( 3.14 x D1 )
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
Factor for driven machine Belt onveyor. = f
1
1.30 table 1, page 12
Factor for prime mover use electric motor = f
2
1.00 table 2, page 12
Peak torque factor with load peaks per hour 6 - 30 = f
3
0.95 table 3, page 12
Thermal factor = f
4
0.71 table 4, page 12
Thermal factor with cooling = f
5
1.19 table 5, page 12
Factor for altitude = f
6
1.00 table 6, page 12
Factor for altitude with cooling = f
7
1.00 table 7, page 12
Oil supply factor for horz. = f
8
0.95 table 8, page 13
Thermal capacity = f
9
1.20 table 9, page 13
Thermal capacity factor with fan = f
10
1.49 table 10, page 13
* Determination of Nominal Power P
N
= 58.50 kW
rating
* Selected from power rating table: type B2 gear unit size 4 , with P
N
= 81 kW page :22
= = 149.85 kW
* Checking the starting torque P
N
= 78.34 kW
* Thermal Power Rating without P
G1
= 51 page:23
auxiliary cooling
* Thermal capacity for gear units P
G
= = 41.28 kW
without auxiliary cooling
Check thermal power rating with auxiliary fan cooling
* Thermal Power Rating with P
G2
= 67 page:23
auxiliary fan cooling
* Thermal capacity for gear units P
G
= = 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
`
P
G2
x f
4
x f
6
x f
8
x f
10
P
G
= 67.88 kW > P
2
= 45 kW
P
N
= 81 kW > 78.34 kW
P
G1
x f
4
x f
6
x f
8
x f
9
P
G
= 41.28 kW < P
2
= 45 kW
Gear unit need auxiliary fan cooling
P
2
x f
1
x f
2
3.33 x P
2
P
N
149.85 kW > PN = 82 kW
(T
A
x n
1
) / 9550 x f
3
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
63.2238
53.8366
58.5742 63.3371 power yang diminta
75
2
PT. Protech Asia Engineering.
By Pass System RCD-1 to SP3 RCD-2 to SP-2
Pelabuhan Batubara Tarahan
150
97.5
PT. Protech Asia Engineering.
h 10 Nama Umur Nama O.T Alamat
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t 6.8 b 9 ak kp
c 5 h 10 ao rt

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