C3048-PNJ-CAL-B-0002 - B Conveyor 11-CV-01

J Resources Gold UK Limited Penjom Gold Expansion Project Penjom Kuala Lipis, Pahang, Malaysia
Project No.: 3048
CALCULATION OF CONVEYOR CV-01
SUBJECT: Doc. No.: Project Reference: Reference Drawings and/or Data:
CALCULATION PNJ-CAL-B-0002 C3048 As Attached
Issue
Descriptions
Date
Prepared By
Checked By
Approved By
B A
Issued for Client Review Issued for Internal Review
14/03/12 12/03/12 RBO AJA AJA
PROJECT No. DOC No.
: : : : : RBO AJA REV DATE DATE
C3048 C3048-PNJ-CAL-B-0002
CONVEYOR CV-01 CALCULATION
SHEET BY CHKD
: March 14, 2012 : March 14, 2012
TABLE OF CONTENT
1 2 3 GENERAL ..................................................................................................................................... 2 REFERENCE DOCUMENT ........................................................................................................... 2 HELIX OUTPUT RESULT ............................................................................................................. 2
PROJECT No. DOC No.
: : : : : RBO AJA REV DATE DATE
C3048 C3048-PNJ-CAL-B-0002
CONVEYOR CV-01 CALCULATION
SHEET BY CHKD
: March 14, 2012 : March 14, 2012
GENERAL
This document is the mechanical calculation of conveyor CV-01 for Penjom Gold Expansion Project.
REFERENCE DOCUMENT
PNJ-DOC-G-0001 PNJ-DWG-F-0001 PNJ-DWG-F-0002 PNJ-DWG-F-0004 Project Design Basis and Scope of Work. Process Plant Up Grade Schematic Diagram Proposed Nordberg Ball Mill Line Crushing & Grinding Process Flow Diagram Proposed Kobe SAG Mill Line Crushing & Grinding Circuit Process Flow Diagram
HELIX OUTPUT RESULT
15 Mar 2012 08:41

Project Project No. Conveyor No.
Conveyor Design Summary
Page
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PT Resindo Resources Indonesia J Resources Penjom Gold Expansion Client C3048 Prepared By RBO 11-CV-01 Design Date 07 Maret 2012
Conveyed Material Surcharge Angle Gold Ore Angle of Repose 1600 kg/m3 Material Lump size 1600 kg/m3 Conveyor Data Conveying Distance Design Capacity 7,70 m Nett Lift / Lower (-) Belt Speed -0,05 m Belt Details Belt Width Selected Calculated Belt % Full 800 mm Belt Class & Run Safety Factor 250/3 38,33 Top Cover Thickness Belt Rated Tension Bottom Cover Thickness 25 kN/m Belt Total Length Belt Mass 25,5 m Belt Tensions and Power Calculations ISO Effective Tens. Fully Loaded Belt Power - Empty Belt 1,34 kN Maximum Tension Tmax Belt Power - Inclines Loaded 5,22 kN Minimum Tension Tmin Belt Power - Declines Loaded 3,92 kN Sag Tension Belt Power - Fully Loaded 2% 3,35 kN Takeup Type Drive Efficiency Screw Take-Up Takeup Mass Absorbed Power Fully Loaded 1000 kg Installed Motor Power Takeup Pulley Belt Tension 4,90 kN Carry and Return Idlers Carry Idler Trough Angle Return Idler Trough Angle 35 Carry Idler Spacing Return Idler Spacing 1,2 m Carry Idler No Rolls x Dia Return Idler No Rolls x Dia 3 x 127 mm Material Description Low Bulk Density High Bulk Density Startup Factor - Fully Loaded Startup Factor - Empty Starting Time - Fully Loaded Starting Time - Empty
Designers Comments
20 deg 30 deg 30 mm 120 tonnes/hr 1 m/s 29,7 8 2 12,16 1,14 1,34 1,27 1,34 82,0 1,63 4 % mm mm kg/m kW kW kW kW % kW kW
0 3 m 1 x 127 mm 1,00 0,00 kNm 1,05 sec 1,05 sec
Dynamics and Miscellaneous Data CEMA Temperature Factor Kt 140 % Total Braking Torque LSS 140 % Stop Time - Loaded, Braking 0,40 sec Stop Time - Loaded, Coasting 0,31 sec
C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources
Helix
Technologies
15 Mar 2012 08:41

Conveyor Sections - Input Data
Page
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Station / Section Station

1 Takeup 2 Hopper 3 Int. Pt 4 Int. Pt 5 Drive 6 Int. Pt 7 Int. Pt Totals:
Section Section Length Lift Description m m

4,30 4,40 2,50 0,80 1,19 8,80 2,00 23,99 0,00 0,00 0,00 -0,05 0,15 0,00 0,00 0,10
X coord m
0,00 4,30 8,70 11,20 12,00 10,80 2,00
Y coord m
0,00 0,00 0,00 0,00 0,00 0,00 0,00
Z coord m
0,00 0,20 0,20 0,20 -0,10 -0,20 -0,20
Capacity tph
0 120 120 120 0 0 0
Ten Idler Skirt Friction Adj. Spacing Length No. of Factor Scrapers Input kN m m
1,20 0,30 1,20 1,20 3,00 3,00 3,00 0,00 7,50 1 3 2 7,50 0,0000 0,0000 0,0000 0,0000 0,0000 0,0000 0,0000
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Takeup & Drive Traction Calculation
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Drive Torque Start-up Factor Loaded Drive Torque Start-up Factor Empty
140 % 140 %
Running
Takeup Mass
Starting Fully Loaded Empty Belt
1000 kg
Braking Fully Loaded Empty Belt
Drive Number
Fully Loaded
Empty Belt
Drive No. Pulley No. 5 Wrap Angle Co-efficient of Friction Drive Factor Cw
1 Drive Lagging Type 185 0,25 0,805 kN kN kN kN 5,21 3,92 1,04 2,88
Rubber 185 0,25 0,805 5,01 3,92 0,88 3,04
185 0,35 0,477 7,14 3,69 1,65 2,04
Rubber 185 0,35 0,477 6,67 3,52 1,5 2,02
185 0,35 0,477 4,47 4,15 0,15 4
Rubber 185 0,35 0,477 4,5 4,16 0,16 4
Calculated Belt Tension T1 Calculated Belt Tension T2 Minimum Required T2 Surplus T2 Tension (T1-T2)
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Summary Run / Start
Page
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Drive Torque Start-up Factor Loaded Drive Torque Start-up Factor Empty
140 % 140 % Takeup Mass 1000 kg
Running Fully Loaded Tension kN

4,90 4,97 5,19 5,22 5,21 4,57 4,59 4,57 5,22 1,34 4,80 -0,002 -0,001
Starting Declines Loaded Tension kN

4,90 4,97 5,15 5,16 5,15 4,57 4,59 4,57 5,16 1,27 4,79 -0,002 -0,001 5,28 0,007 0,004 5,20 0,006 0,003
Braking Fully Loaded Tension kN

4,90 4,75 4,62 4,52 4,47 4,77 4,67 4,47 4,90
Coasting Fully Loaded Tension kN

4,90 4,75 4,62 4,52 4,47 4,77 4,67 4,47 4,90
Station No
1 Takeup 2 Hopper 3 Int. Pt 4 Int. Pt 5 Drive 6 Int. Pt 7 Int. Pt Minimum Ten Maximum Ten Effective Ten Ave. Belt Ten Belt Elong. m T/up Travel m
Empty Tension kN
4,90 4,97 5,00 5,01 5,01 4,57 4,59 4,57 5,01 1,14 4,76 -0,003 -0,002
Inclines Loaded Tension kN

4,90 4,97 5,19 5,22 5,22 4,57 4,59 4,57 5,22 1,34 4,80 -0,002 -0,001
Fully Loaded Tension kN

4,90 5,56 6,67 7,03 7,14 4,40 4,75 4,40 7,14
Empty Tension kN
4,90 5,73 6,43 6,61 6,67 4,25 4,69 4,25 6,67
Empty Tension kN
4,90 4,74 4,56 4,52 4,50 4,78 4,67 4,50 4,90
Empty Tension kN
4,90 4,74 4,56 4,52 4,50 4,78 4,67 4,50 4,90
4,68 -0,004 -0,002
4,68 -0,004 -0,002
4,68 -0,004 -0,002
4,68 -0,004 -0,002
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Belt Details Report
Page
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Low BD = 1600kg/m3 Conveyed Material Material Description Low Bulk Density High Bulk Density Surcharge Angle Angle of Repose Material Lump size Belt Make & Class Belt Category Belt Description Belt Class / Plies Belt Reinforcement Fibre Belt Width Selected Belt Modulus Gold Ore 1600 1600 20 30
High BD = 1600kg/m3 Belt Speed & Capacity Belt Speed Belt Design Capacity Input Section Loading Max Capacity Carry Idler Trough Angle Belt Dimensions Top Cover Thickness Bottom Cover Thickness Belt Carcass Thickness Belt Total Thickness Belt Total Belt Length (L) Time for 1 Revolution 1 120 120 35 m/s tonnes/hr tonnes/hr
kg/m3 kg/m3 deg deg
30 mm Goodyear Fabric GOODYEAR PLYLON-HI 250/3 3 Fabric 800 mm 1660 kN/m
8 mm 2 mm 3,6 mm 13,6 mm 25,5 m 25,5 sec
Belt Tensions Belt Rated Tension / m width Calculated Tension / m width Belt Rated Tension for width Calculated Max Run Tension Minimum Tension Tmin Allowable Tension Rise, Starting Allowable Belt Tension, Starting Actual Belt Tension, Starting Belt and Material Mass Belt Top Cover Mass Belt Bottom Cover Mass Belt Carcass Mass Belt Mass Wb (per linear m) Material Mass Wm Total Mass (Wb + Wm) Total Belt Mass (Wb x L)
Designers Comments
25 6,5 20 5,22 3,92 140 28 7,14
kN/m kN/m kN kN kN % kN kN
Belt Load Area and Capacity at 1600kg/m3 Minimum Rec. Edge Distance 67 mm Actual Edge Distance Low BD 194 mm Load Burden Depth 76 mm Load Burden Width 389 mm Belt Load Area at Minimum 0,0702 m2 Recommended Edge Distance Belt Load Area Utilised at Low Bulk Density Belt Actual % Full at Low BD 0,0208 m2 29,7 %
Belt Load Area and Capacity at 1600kg/m3 Minimum Rec. Edge Distance 67 mm Actual Edge Distance High BD 194 mm Belt Load Area Utilised at High 0,0208 m2 Bulk Density Belt Actual % Full at High BD 29,7 % Flooded Belt Capacity at 1600kg/m3 Flooded Belt Load Area at Zero 0,1031 m2 Edge Distance Flooded Belt Capacity Flooded Belt Material Mass 594 tonnes/hr 165 kg/m
7,2 1,8 3,1 12,2 33,3 45,5 310
kg/m kg/m kg/m kg/m kg/m kg/m kg
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Summary Belt Sag
Page
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Allowable Belt Sag % Running Allowable Belt Sag % Start / Stop
2 % 5 % Takeup Mass 1000 kg
Running Fully Loaded Tension kN

4,90 1,20 0,36 4,97 0,30 0,34 5,19 1,20 1,29 5,22 1,20 1,28 5,21 3,00 0,86 4,57 3,00 0,98 4,59 3,00 0,97 4,57 1,29 0,97 4,57 0,98 0,97 4,57 1,29 0,97 4,57 1,3 0,98 4,59 0,98 4,59 0,98 4,59 0,89 4,57 0,86 4,57 0,87 4,57 0,36 5,01 0,34 5,22 1,3 5,15 0,36 5,01 1,29 5,22 1,3 5,16 0,09 5,00 0,34 5,19 0,34 5,15 0,36 4,97 0,36 4,97 0,36 4,97
Starting Declines Loaded Tension kN

4,90
Braking Fully Loaded Tension kN

4,90 0,36 4,75 0,35 4,62 1,45 4,52 1,48 4,47 1 4,77 0,94 4,67 0,96 4,47 1,48
Coasting Fully Loaded Tension kN

4,90 0,36 4,75 0,35 4,62 1,45 4,52 1,48 4,47 1 4,77 0,94 4,67 0,96 4,47 1,48
Station No
1 Takeup Idler Spacing m Belt Sag % 2 Hopper Idler Spacing m Belt Sag % 3 Int. Pt Idler Spacing m Belt Sag % 4 Int. Pt Idler Spacing m Belt Sag % 5 Drive Idler Spacing m Belt Sag % 6 Int. Pt Idler Spacing m Belt Sag % 7 Int. Pt Idler Spacing m Belt Sag % Minimum Ten Maximum Sag
Empty Tension kN
4,90
Inclines Loaded Tension kN

4,90
Fully Loaded Tension kN

4,90 0,36 5,56 0,3 6,67 1 7,03 0,95 7,14 0,63 4,40 1,02 4,75 0,94 4,40 1,02
Empty Tension kN
4,90 0,36 5,73 0,08 6,43 0,28 6,61 0,27 6,67 0,67 4,25 1,05 4,69 0,95 4,25 1,05
Empty Tension kN
4,90 0,36 4,74 0,09 4,56 0,39 4,52 0,4 4,50 0,99 4,78 0,93 4,67 0,96 4,50 0,99
Empty Tension kN
4,90 0,36 4,74 0,09 4,56 0,39 4,52 0,4 4,50 0,99 4,78 0,93 4,67 0,96 4,50 0,99
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Run Fully Loaded
Page
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Takeup Mass
1000 kg
Station / Pulley Station

1 Takeup 2 Hopper 3 Int. Pt 4 Int. Pt 5 Drive 6 Int. Pt 7 Int. Pt Totals: Maximum Tension Minimum Tension
Section Section Length Lift m m

4,30 4,40 2,50 0,80 1,19 8,80 2,00 0,00 0,00 0,00 -0,05 0,15 0,00 0,00
Tensions Tp T1 Run T2 Run Pulley kN kN

4,90 4,97 5,19 5,22 5,21 4,57 4,59 4,95 4,97 5,19 5,22 3,92 4,57 4,59 0,10 5,22 kN 3,92 kN 4,80 kN 4,90 kN -0,1 kN 1,3 0,05 1,28 0,05
Drive Te kN
ISO Ten Material Skirt Scraper Section Adj. Accel. Friction Friction Effective Friction kN kN kN Tension Factor kN 0,02 0,03 0,11 0,07 0,03 -0,01 0,63 0,02 0,02 0,31 0,00 0,03 0,11 0,94 0,00 0,15 1,34 kN 1,34 kW 1660 kN/m 25,50 m -0,002 m -0,001 m 0,0198 0,0194 0,0233 0,0233 0,016 0,016 0,016
Total Effective Tension Total Belt Power (Te x V) Belt Modulus Total Belt Length Belt Elastic Elongation Takeup Movement
Average Tension Fully Loaded Average Tension Belt Stationary Average Tension Difference
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Run Empty
Page
8/27


4,30 4,40 2,50 0,80 1,19 8,80 2,00 0,00 0,00 0,00 -0,05 0,15 0,00 0,00

4,90 4,97 5,00 5,01 5,01 4,57 4,59 4,95 4,97 5,00 5,01 3,92 4,57 4,59 0,10 5,01 kN 3,92 kN 4,76 kN 4,90 kN -0,14 kN 1,09 0,05 1,09 0,05
Drive Te kN
ISO Ten Material Skirt Scraper Section Adj. Accel. Friction Friction Effective Friction kN kN kN Tension Factor kN 0,02 0,03 0,01 0,00 0,63 0,02 0,02 0,31 0,00 0,94 0,00 0,10 1,14 kN 1,14 kW 1660 kN/m 25,50 m -0,003 m -0,002 m 0,0198 0,0194 0,0233 0,0233 0,016 0,016 0,016
Average Tension Fully Loaded Average Tension Belt Stationary Average Tension Difference
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Run Inclines Loaded
Page
9/27


4,30 4,40 2,50 0,80 1,19 8,80 2,00 0,00 0,00 0,00 -0,05 0,15 0,00 0,00

4,90 4,97 5,19 5,22 5,22 4,57 4,59 4,95 4,97 5,19 5,22 3,92 4,57 4,59 0,10 5,22 kN 3,92 kN 4,80 kN 4,90 kN -0,1 kN 1,28 0,05 1,29 0,05
Drive Te kN
ISO Ten Material Skirt Scraper Section Friction Adj. Accel. Friction Friction Effective kN kN kN Tension Factor kN 0,02 0,03 0,11 0,07 0,03 0,00 0,63 0,02 0,02 0,31 0,00 0,03 0,11 0,94 0,00 0,15 1,34 kN 1,34 kW 1660 kN/m 25,50 m -0,002 m -0,001 m 0,0197 0,0194 0,0233 0,0196 0,016 0,016 0,016
Average Tension Inclines Loaded Average Tension Belt Stationary Average Tension Difference
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Tension Calculations - Run Declines Loaded
Page
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4,30 4,40 2,50 0,80 1,19 8,80 2,00 0,00 0,00 0,00 -0,05 0,15 0,00 0,00

4,90 4,97 5,15 5,16 5,15 4,57 4,59 4,95 4,97 5,15 5,16 3,92 4,57 4,59 0,10 5,16 kN 3,92 kN 4,79 kN 4,90 kN -0,11 kN 1,3 0,05 1,22 0,05
Drive Te kN
ISO Ten Material Skirt Scraper Section Friction Adj. Accel. Friction Friction Effective kN kN kN Tension Factor kN 0,02 0,03 0,11 0,03 0,01 -0,01 0,63 0,02 0,02 0,31 0,00 0,03 0,11 0,94 0,00 0,15 1,27 kN 1,27 kW 1660 kN/m 25,50 m -0,002 m -0,001 m 0,0198 0,0194 0,0233 0,0233 0,016 0,016 0,016
Average Tension Declines Loaded Average Tension Belt Stationary Average Tension Difference
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Conveyor Starting and Stopping
Page
11/27
System Masses Mass of Belt Mass of Material Carry Idler Equivalent Mass Return Idler Equivalent Mass Pulley Equivalent Mass Drive Equivalent Mass Total System Equivalent Mass
310 257 231 36 326 244 1.404
kg kg kg kg kg kg kg
Tensions and Accelerating Forces Effective Tens. Fully Loaded 1,34 kN Effective Tension Empty 1,14 kN Total Braking Force 0,00 kN Tension Available to Accelerate Conveyor Accelerating Tension - Loaded 3,5 kN Accelerating Tension - Empty 3,66 kN Starting Times & Acceleration Rates Starting Time - Fully Loaded 0,40 sec Starting Time - Empty 0,31 sec Acceleration Rate - Loaded 2,49 m/s2 Accelerating Rate - Empty 3,19 m/s2 Belt Tension Rise Starting / Braking Max Belt Tension, Start/Brake 7,14 kN Belt Width 800 mm Maximum Belt Tension / width 8,93 kN/m Belt Rated Tension / width 25 kN/m Actual Max Tension, Start/Brake 35,7 %
Input Data Belt Speed Belt Rated Tension Allow. Belt Start Tension Rise Drive Inertia Total Braking Torque Start-up Factor - Loaded Start-up Factor - Empty Installed Power Drive Efficiency (Average)
1 25 140 0,0109 0 140 140 4 82
m/s kN/m % kg-m2 kNm % % kW %
Stopping Times & Deceleration Rates Stopping Time Loaded Braking 1,05 sec Stopping Time Loaded Coasting 1,05 sec Stopping Time Empty Braking 1,00 sec Stopping Time Empty Coasting 1,00 sec Deceleration - Loaded Braking Deceleration - Loaded Coasting Deceleration - Empty Braking Deceleration - Empty Coasting -0,95 m/s2 -0,95 m/s2 -1,00 m/s2 -1,00 m/s2
Stopping Distances & Discharge Volumes Stopping Distance Loaded Braking 0,53 m Stopping Distance Loaded Coasting 0,53 m Stopping Distance Empty Braking 0,5 m Stopping Distance Empty Coasting 0,5 m Discharge Mass, Braking Discharge Mass, Coasting Discharge Volume, Braking Discharge Volume, Coasting 18 18 0,01 0,01 kg kg m3 m3
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Conveyor Idler Details Report
Page
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Idler Category Idler Description Idler Design Belt Width Idler Series Drawing Number Nominal Idler Spacing Total Number of Idlers Idler Price Troughing Angle Idler Shaft Diameter Idler Bearing Diameter Number of Idler Rolls Idler Roll Diameter Idler Rotation Speed Roll Face Width Roll Bearing Centres Shaft Support Centres Idler Support Fixing Width Idlerset Rotating Mass Idlerset Total Mass
Carry Side Idlers Sandvik Carry Series 15 3 Roll Carry 127 Plain Inline 800 mm 15 1,2 22 0 35,0 25,0 25,0 3 127 150 296 239,8 320 1050 10,5 27,2 m
Return Side Idlers Sandvik Flat Return Series 15 1 Roll Flat Carry 127 Dia 800 mm 15 3 4 0 0,0 27,0 25,0 1 127 150 896 839,8 920 1050 9 16,2 m
deg mm mm mm rpm mm mm mm mm kg kg
deg mm mm mm rpm mm mm mm mm kg kg
Idler Vertical Misalignment Allowance Dynamic Load Factor Belt Deviation Load Total Load on Centre Roll Type of Bearing Bearing Designation Bearing Dynamic Load Rating C Bearing L10h Life Allowable Shaft Deflection at Bearing Actual Shaft Deflection at Bearing
Designers Comments
3,0 mm 1,01 500 N 926 N Ball 6205 14.000 3.064.374 8,00 1,90
5,0 mm 1,40 500 N 1.162 N Ball 6205 14.000 1.551.716 10,00 6,14
N hrs min min
N hrs min min
Helix
Technologies
15 Mar 2012 08:41

Project Project No. Conveyor No. Penjom Gold Expansion C3048 11-CV-01
Vertical Curve Radius Calculations

PT Resindo Resources Indonesia J Resources Client Prepared By RBO Design Date 07 Maret 2012
Page
13/27
15 Mar 2012 08:41

Belt Width Belt Mass - New Belt Top Cover Mass - New Belt Bottom Cover Mass Worn Belt Mass Reduction of Top Cover Mass Conveyed Material Mass
Station / Section

800 12,16 7,23 1,81 9,12 42 33,33 mm kg/m kg/m kg/m kg/m % kg/m % Belt Mass for Lift-off Calculation Curve Tension Safety Factor Average Drive Torque Start-up Factor - Loaded Average Drive Torque Start-up Factor - Empty Belt Modulus Belt Rated Tension 25 kN/m Allowable Edge Tension - Running: 115 % Starting
Starting Fully Loaded Empty Tension Radius Tension Radius kN m kN m
4,9 4,9
Page 75 1 140 140 1660 20 140 %
13/27
% % kN/m kN %
Largest Reqd. Radius m
Station
Curve Type
Design Running Vertical Empty Fully Loaded Load Curve Capacity Radius Tension Radius Tension Radius tonnes/hr m kN m kN m
4,9 4,9
Braking Fully Loaded Empty Tension Radius Tension Radius kN m kN m

4,9 4,9
1 Takeup
2 Hopper
120
4,97
4,97
5,56
5,73
4,75
4,74
3 Int. Pt
120
5,19
5,0
6,67
6,43
4,62
4,56
Helix
Technologies
15 Mar 2012 08:41

Belt Width Belt Mass - New Belt Top Cover Mass - New Belt Bottom Cover Mass Worn Belt Mass Reduction of Top Cover Mass Conveyed Material Mass
Station / Section

800 12,16 7,23 1,81 9,12 42 33,33 mm kg/m kg/m kg/m kg/m % kg/m % Belt Mass for Lift-off Calculation Curve Tension Safety Factor Average Drive Torque Start-up Factor - Loaded Average Drive Torque Start-up Factor - Empty Belt Modulus Belt Rated Tension 25 kN/m Allowable Edge Tension - Running: 115 % Starting
Starting Fully Loaded Empty Tension Radius Tension Radius kN m kN m
Page 75 1 140 140 1660 20 140 %
14/27
% % kN/m kN %
Largest Reqd. Radius m
Station
Curve Type
Design Running Vertical Empty Fully Loaded Load Curve Capacity Radius Tension Radius Tension Radius tonnes/hr m kN m kN m
Braking Fully Loaded Empty Tension Radius Tension Radius kN m kN m
4 Int. Pt
Convex
120
5,22 5,22 8 30 0 5,22 5,22 5,21 26%
5,01 5,01 8 34 0 5,01 5,01 5,01 25%
7,03 7,03 8 17 0 7,03 7,03 7,14 35%
6,61 6,61 8 19 0 6,61 6,61 6,67 33%
4,52 4,52 7 44 0 4,52 4,52 4,47 23%
4,52 4,52 7 45 0 4,52 4,52 4,5 23% 45
Belt Tension at Curve kN Min. Edge Tension Radius Max. Buckling Radius Belt Edge Tension Rise at Curve kN Total Edge Tension at Curve kN and % Centre Tension at Curve kN 5 Drive
6 Int. Pt
Convex
4,57 4,57
4,57 4,57
4,4 4,4
4,25 4,25
4,77 4,77
4,78 4,78 0
Belt Tension at Curve kN Min. Edge Tension Radius Max. Buckling Radius Belt Edge Tension Rise at Curve kN Total Edge Tension at Curve kN and % Centre Tension at Curve kN 7 Int. Pt
Flat Belt
4,59
4,59
4,75
4,69
4,67
4,67
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Viscoelastic Friction Factor Report
Page
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Viscoelastic Calculations Input Data

Belt Rubber Description Rubber description ... 6 N/mm2 Top Cover Dynamic Modulus E' Top Cover Dynamic Loss Factor Tan(delta) 0,13 Belt Top Cover Temperature 30 deg C Rolling Resistance Factor RRF Top 0,072 RRF Bot. 0,072 Bottom Cover Dynamic Modulus E' 6 N/mm2 Bot Cover Dynamic Loss Factor Tan(delta) 0,13 Belt Bottom Cover Temperature 30 deg C Belt & Material Flexure Adjustment factor 1 Belt has Turnover on Return Run Station / Section Total Loaded Section Idler Friction Length Spacing factor f
4,30 4,40 2,50 0,80 1,19 8,80 2,00 1,20 0,30 1,20 1,20 3,00 3,00 3,00
Carry Idler Centre Roll Dia Carry Idler Centre Roll Drag Carry Idler Wing Roll Dia Carry Idler Wing Roll Drag Return Idler Centre Roll Dia Return Idler Centre Roll Drag Return Idler Wing Roll Dia Return Idler Wing Roll Drag Idlerset Skew Angle Idlerset Forward Tilt angle
127 2 127 2 127 2 127 2 0,1 0,1
mm N mm N mm N mm N deg deg Empty
No
1 2 3 4 5 6 7
friction factor f (loaded) Matl.& Belt Idler Drag Indentation Freq Flexure Flexure Drag Drag Indent Indent factor factor uency friction friction factor factor fm fr % rad/s % % fi
0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,10 0 0 0 0 0 0 0 0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 0,00 0,0 0,0 0,0 0,0 0,0 0,0 0,0
Idler Skew & Tilt Tilt Tilt friction friction ft %

0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 0,00000 7,50 0,0 0,0 0,0 0,0 0,0 0,0 0,0 3
Empty Friction factor f

0,0197 0,0160 0,0196 0,0196 0,0160 0,0160 0,0160
0,0198 0,00000 0,0194 0,00000 0,0233 0,00000 0,0233 0,00000 0,0160 0,00000 0,0160 0,00000 0,0160 0,00000 23,99
Totals:
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Conveyor Belt Resonance Report
Page
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Carry Roll Diameter Return Roll Diameter

Station / Section
127 127
mm mm
Belt Speed Takeup Mass
1 1000
Critical Critical Idler Idler Spacing Spacing Start End m
4,02 2,07 2,11 2,12 3,57 3,86 3,87
m/s kg
Idler Spacing within +/- 10% m
OK OK OK OK OK OK OK
Running Fully Loaded Belt Resonance End Start Belt Belt Tension Tension kN kN
4,95 4,97 5,19 5,22 3,92 4,57 4,59 5,19 5,22 5,21 4,57 4,59 4,9 4,9
Station
Description
Belt Transverse Idler Roll Section Wave Frequency Excitation Idler Range Frequency Spacing Hz to Hz m Hz
8,39 17,27 4,41 4,42 2,98 3,22 3,23 8,59 17,7 4,42 4,13 3,23 3,34 3,34 2,51 2,51 2,51 2,51 2,51 2,51 2,51 1,2 0,3 1,2 1,2 3 3 3
m
4,11 2,12 2,12 1,98 3,87 3,99 3,99
1 Takeup 2 Hopper 3 Int. Pt 4 Int. Pt 5 Drive 6 Int. Pt 7 Int. Pt
Designers Comments
Helix
Technologies
Mode
15 Mar 2012 08:41

Project Project No. Conveyor No. Takeup Travel Takeup Type
Takeup Travel Report
Page
17/27
Screw Take-Up
Auto Calc Takeup Mass Takeup Mass step increment 500 kg Max no. of Calc Increments 100 Takeup Mass kg (Manual Input) Takeup Mass Calculated Takeup Travel Estimate Safety Margin Top + Belt Splice Allowance + Dynamic Travel Up + Dynamic Travel Down + Safety Margin Bottom + Thermal Expansion Distance Minimum Site Temperature Maximum Site Temperature Belt Expansion co-efficient m/m per degree C Total Belt Length Thermal Expansion Distance + Permanent Belt Stretch Permanent Stretch coefficient % of Belt Length Permanent Belt Stretch Distance + Total Takeup Travel Distance 2000 kg 1000 kg 0 0 0 0 0 m m m m m
0 deg 45 deg 1,17E-05 25,50 m 0,007 m
1,5 % 0,191 m 0,2 m
Helix
Technologies
15 Mar 2012 08:41

Drive Details Report
Page
18/27
Drive No.
1 Drive Head 100 % 140 % 140 % 1
Drive Description Load Share on Drive Pulley Starting Torque Factor, Fully Loaded Starting Torque Factor, Empty Number of Motors on Drive Pulley Motor Description Motor Power Rating Motor Voltage Gearbox Description Drive Efficiency Fluid Coupling Fluid Coupling Fluid Coupling Size High Speed Coupling
5 Pulley Condition Pulley Lagging Type Belt Wrap Angle Coefficient of Friction, Running Drive Factor Cw, Running Coefficient of Friction, Starting Drive Factor Cw, Starting Pulley and Shaft Dimensions Pulley Shell Diameter Pulley Lagging Thickness Pulley Outside Diameter Pulley Shaft Diameter at Hub Pulley Shaft Diameter at Brg Pulley and Belt Speed Motor Full Load Speed Required Gearbox Ratio Selected Gearbox Ratio Required Pulley Speed Calculated Pulley Speed for Reducer Required Belt Speed
Pulley No.
Moist Rubber 185 0,25 0,81 0,35 0,48 500 mm 12 mm 524 mm 75 mm 70 mm 1430 rpm 37,273 :1 35,5 :1 38,37 rpm 38,27 rpm 1 m/s 1,05 m/s 0,0109 kg-m2 0 kg-m2 0 kg-m2 0 kg-m2 0 kg-m2 0,0109 kg-m2 244 kg
Electric Motor 4 kW 380 Volts Flender Helical Bevel Gear 82 % FENNER TRANSFLUID REDUCED FILL 8K
Low Speed Coupling LS Coupling Make LS Coupling Model Brake Brake Location Low Speed Brake Torque Input Equiv HS Brake Torque
No Selection
High Speed 0 kNm 0 Nm -16 N 1356 N N/A Nm No Fv>Fh/2 3144 Nm No Selection
Calculated Belt Speed Drive Inertia Motor Inertia High Speed Coupling Inertia High Speed Brake Disc Inertia Flywheel Inertia Gearbox Inertia (HSS) Total Drive Inertia Total Drive Equivalent Mass
Holdback Static Analysis Runback Force Fv Static Analysis Horizontal Force Fh Calculated Holdback Torque Holdback Required (Yes / No) Holdback Torque 3 x Motor FLT Holdback Make Holdback Model
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Drive Motor Details Report
Page
19/27
Drive No.
1 Drive
Drive Description Head Number of Motors on Drive Pulley 1 Motor Category Metric Motor Motor Description Electric Motor Motor Power Rating 4 kW Motor Voltage 380 Volts Number of poles 4 Motor Frame Size DX112M Motor Shaft Diameter 28 mm Motor Shaft Height 112 mm Motor Inertia 0,0109 kg-m2
Designers Comments
5 Total Motor Power on Drive Absorbed Power at Pulley Drive Efficiency Absorbed Power at Motor Motor Full Load Speed Motor Full Load Torque Motor Full Load Current Motor Efficiency @ Duty Point Motor Power Factor @ Duty Pt Mass of Motor
Pulley No.
4 1,34 82 1,63 1430 26,7 9 78,77 0,57 48
kW kW % kW rpm Nm Amps % kg
Helix
Technologies
15 Mar 2012 08:41

Drive Fluid Coupling Details Report
Page
20/27
Drive No.
1 Drive
Pulley No.
5 8K 4 1430 5 170 kW rpm % % FLT
Drive Description Head Number of Motors on Drive Pulley 1 Selection Mode Manual Coupling Category Transfluid Coupling Description FENNER TRANSFLUID REDUCED FILL Coupling Power Rating 5 kW Min. Required Ramping Time sec Max Starting Time 30 sec
Designers Comments
Coupling Size Motor Power Rating Motor Full Load Speed Coupling Rated Slip Peak Torque % Run-up Torque % (2 sec) Coupling Output Speed Mass of Coupling
160 % FLT 1358 rpm 6 kg
Helix
Technologies
15 Mar 2012 08:41

Drive Gearbox Details Report
Page
21/27
Drive No.
1 Drive
Pulley No.
5 4 1430 27 996 3400 1,5 3,41 5 5 5 37,273 35,5 38,37 38,27 1 1,05 130 kW rpm Nm Nm Nm
Drive Description Head Number of Motors on Drive Pulley 1 Selection Mode Auto Gearbox Category Flender Gearbox Description Flender Helical Bevel Gear Type Helical Bevel Gear Size 3 Code B3SH3 Ratio 35,5 Number of Stages B3SH3 Design Efficiency (Input) Gearbox Actual Efficiency Maximum Input Shaft Speed Minimum Input Shaft Speed Input Shaft Diameter Output Shaft Diameter Gearbox Inertia
Designers Comments
Motor Power Rating Motor Full Load Speed Motor Torque @ FL Speed Motor Torque at Pulley Speed Gearbox Rated Torque Service Factor Required Service Factor Calculated Plus Speed Selection Tolerance Minus Speed Selection Tolerance Fluid Coupling Slip Required Gearbox Ratio Selected Gearbox Ratio Required Pulley Speed Calculated Pulley Speed for Reducer Required Belt Speed Calculated Belt Speed Mass of Gearbox
82 93 1500 700 28 65
% % rpm rpm mm mm kg-m2
% % % :1 :1 rpm rpm m/s m/s kg
Helix
Technologies
15 Mar 2012 08:41

Brake Details Report
Page
22/27
Drive / Brake No.
1 Drive
Pulley No.
5 High Speed Mild Steel 600 mm 30 mm 0,4 N N mm mm 1480 0,1 37,273 82 rpm kg-m2 :1 % kg
Description Head Load Share on Drive Pulley 100 % Brake Category Brake Description No Selection Caliper Number of Motors on Drive Pulley 1 Brake Selection Input Data Low Speed Brake Torque Input Equiv HS Brake Torque Design Braking Torque Input Selected Brake's Torque Rating Design Stopping Time Consecutive No of Stops Average No of Stops Ambient Temperature Disc Temperature after stops 0 0 1000 10,0 3 6 40 0 kNm Nm Nm Nm sec
Brake Location Disc Material Disc Diameter Disc Thickness Co-eff of Friction (Pad-Disc) Caliper Clamping Force Minimum Caliper Clamping Force Maximum Pad offset Width W Maximum Air Gap
Recommended working airgap is 1mm
deg C deg C
Disc Initial Speed Disc Moment of Inertia Required Gearbox Ratio Drive Efficiency Mass of Caliper Brake Caliper Price
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Shaft Coupling Report
Page
23/27
Drive No.
1 Drive Head 100 140 140 1 82 % % % %
Pulley No.
5 4 1430 27 996 70 kW rpm Nm Nm mm
Drive Description Load Share on Drive Pulley Starting Torque Factor, Fully Loaded Starting Torque Factor, Empty Number of Motors on Drive Pulley Drive Efficiency High Speed Coupling HS Coupling Category HS Coupling Make HS Coupling Model Coupling Type Coupling Torque Rating Service Factor Required Service Factor Calculated Maximum Shaft Bore Minimum Shaft Bore Maximum Rotation Speed High Speed Coupling Inertia Drawing Number High Speed Coupling Mass High Speed Coupling Price Fluid Coupling Fluid Coupling Fluid Coupling Size
Motor Power Rating Motor Full Load Speed Motor Torque @ FL Speed Motor Torque at Pulley Speed Pulley Shaft Diameter at Brg Low Speed Coupling LS Coupling Category LS Coupling Make LS Coupling Model Coupling Type Coupling Torque Rating Service Factor Required Service Factor Calculated Maximum Shaft Bore Minimum Shaft Bore Maximum Rotation Speed Low Speed Coupling Inertia Drawing Number Low Speed Coupling Mass Low Speed Coupling Price
No Selection
No Selection
0 3,5 0 0 0 0 0
Nm
mm mm rpm kg-m2
0 3,5 0 0 0 0 0
Nm
mm mm rpm kg-m2
0 kg 0
0 kg 0
Direct Drive FENNER TRANSFLUID REDUCED FILL 8K
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Conveyor Pulley Shafts
Page
24/27

1 Takeup 5 Drive 11B
Description
Shaft Length mm
1620 1610
Wrap Angle deg

180,0 185,0
T1 Run kN
4,9 5,2
T2 Run kN
5,0 3,9
Resultant Force kN
9,8 9,1
T1 Start kN
4,9 7,1
Calculated Defl. Dt. Dia Dia mm mm

78,1 76,6 70,3 71,6
Selected Shaft Brg Dia Dia mm mm

80 75 75 70
Brg Ctrs mm
1370 1370
Shaft Mass kg
64 56
Designers Comments
* Denotes manual pulley shaft dimensions entered
Helix
Technologies
15 Mar 2012 08:41

Conveyor Pulleys
Page
25/27

1 Takeup 5 Drive
Shell Lagging Description Dia mm mm

400 500 0 12
Face Width mm
950 950
Shaft Length mm
1620 1610
Brg Ctrs mm
1370 1370
Shaft Dia mm
80 75
Brg Dia mm
75 70
Wrap Angle deg

180,0 185,0
Pulley Pulley & Mom of Speed Shaft Inertia rpm Mass kg kgm2
47,7 36,4 252 332 5,4 13,1
Designers Comments
* Denotes manual pulley dimensions entered
Helix
Technologies
15 Mar 2012 08:41

Conveyor Pulley Dimensions
Page
26/27

1 Takeup 5 Drive

400 500 0 12
OD mm
400 524
Face Width mm
950 950
Shaft Length mm
1620 1610
Brg Ctrs mm
1370 1370
Shaft Dia mm
80 75
Brg Dia mm
75 70
Belt Width mm
800 800
Pulley & Mom of Shaft Inertia Mass kg kgm2

252 332 5,4 13,1
Designers Comments
Helix
Technologies
15 Mar 2012 08:41

Conveyor Pulleys Data Sheet
Page
27/27

1 Takeup

400 0
Face Width mm
950
Brg Ctrs mm
1370
Drive Power kW
Wrap Pulley Angle Speed rpm deg

180,0 47,7
T1 Run kN
T2 Run kN
T1 Start kN
T2 Start kN
4,9 4,95 Running Full 5,21 3,92 Running Full
4,9 5,39 Starting Empty 7,14 3,69 Starting Full
5 Drive
500
12
950
1370
185,0
36,4
Designers Comments
Helix
Technologies

C3048-PNJ-CAL-B-0002 - B Conveyor 11-CV-01

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C3048-PNJ-CAL-B-0002 - B Conveyor 11-CV-01

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J Resources Gold UK Limited Penjom Gold Expansion Project Penjom Kuala Lipis, Pahang, Malaysia

Project No.: 3048

CALCULATION OF CONVEYOR CV-01

SUBJECT: Doc. No.: Project Reference: Reference Drawings and/or Data:

CALCULATION PNJ-CAL-B-0002 C3048 As Attached

Issued for Client Review Issued for Internal Review

14/03/12 12/03/12 RBO AJA AJA

PROJECT No. DOC No.

: : : : : RBO AJA REV DATE DATE

CONVEYOR CV-01 CALCULATION

: March 14, 2012 : March 14, 2012

PROJECT No. DOC No.

: : : : : RBO AJA REV DATE DATE

CONVEYOR CV-01 CALCULATION

: March 14, 2012 : March 14, 2012

HELIX OUTPUT RESULT

15 Mar 2012 08:41

Conveyor Design Summary

0 3 m 1 x 127 mm 1,00 0,00 kNm 1,05 sec 1,05 sec

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources

15 Mar 2012 08:41

Conveyor Sections - Input Data

Station / Section Station

Section Section Length Lift Description m m

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources

15 Mar 2012 08:41

Takeup & Drive Traction Calculation

Rubber 185 0,25 0,805 5,01 3,92 0,88 3,04

185 0,35 0,477 7,14 3,69 1,65 2,04

Rubber 185 0,35 0,477 6,67 3,52 1,5 2,02

185 0,35 0,477 4,47 4,15 0,15 4

Rubber 185 0,35 0,477 4,5 4,16 0,16 4

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources

15 Mar 2012 08:41

Tension Calculations - Summary Run / Start

140 % 140 % Takeup Mass 1000 kg

Running Fully Loaded Tension kN

Starting Declines Loaded Tension kN

Braking Fully Loaded Tension kN

Coasting Fully Loaded Tension kN

Inclines Loaded Tension kN

Fully Loaded Tension kN

4,68 -0,004 -0,002

4,68 -0,004 -0,002

4,68 -0,004 -0,002

4,68 -0,004 -0,002

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources

15 Mar 2012 08:41

Belt Details Report

kg/m3 kg/m3 deg deg

30 mm Goodyear Fabric GOODYEAR PLYLON-HI 250/3 3 Fabric 800 mm 1660 kN/m

8 mm 2 mm 3,6 mm 13,6 mm 25,5 m 25,5 sec

25 6,5 20 5,22 3,92 140 28 7,14

7,2 1,8 3,1 12,2 33,3 45,5 310

kg/m kg/m kg/m kg/m kg/m kg/m kg

C:\Boyke File\Calculation Helix\11-CV-01 rev.1.xml Ver 6.0.13 Licenced to PT Resindo Resources

15 Mar 2012 08:41

Tension Calculations - Summary Belt Sag

Allowable Belt Sag % Running Allowable Belt Sag % Start / Stop

2 % 5 % Takeup Mass 1000 kg

Running Fully Loaded Tension kN

Starting Declines Loaded Tension kN

Braking Fully Loaded Tension kN