Tensioning System Evaluation of CV 205

CODELCO DRT Tensioning system for CV 205

Annex 1: Conveyor Calculation

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220-CV-205-Rev0 page 1 of 4 31.07.2017 10:13:35
Radomiro
Spemann/Dr. Dilefeld

main data

belt width 1700 mm

belt speed 7,00 m/s
mass flow 12500 t/h
volume flow 7576 m³/h

fictitous friction coefficient (maximum) 0,021

friction coefficient belt-pulley 0,350

belt geometry

No. x y length incline

m m m °
Pkt. 0 0,000 2932,245 10,000 0,000
Pkt. 1 10,000 2932,245 1390,113 0,731
Pkt. 2 1400,000 2949,975 779,164 1,752
Pkt. 3 2178,800 2973,790

bulk material

type of material Ripios

density 1,65 t/m³

max. grain size 63 mm
surcharge angle 13 °
allowable belt incline 20 °

belt

belt Steel cord 1700 St 4000 22/8

thickness 39,0 mm
unit weight 106,5 kg/m
elastic modulus 252000 N/mm

actual safety
steady state 9,81
steady state kurzeitig auftretend 9,81
start 8,30
stop 14,87

cross section of conveyor

carrying belt
trough form 3-roll deep troughed
trough angle 40 °
capacity utilization 82 %

return belt
trough form 2-roll troughed
trough angle 10 °

drive unit base configuration

type of drive unit wound rotor induction motor with resistor starter
efficiency 0,96
service factor max. 1,20

pulley
diameter 1465 mm
220-CV-205-Rev0 page 2 of 4 31.07.2017 10:13:35
Radomiro
Spemann/Dr. Dilefeld

motor
power rating 1000 kW
nominal revolutions 1000 rpm
moment of inertia 55,40 kgm²

coupling RWB 450

moment of inertia 20,00 kgm²

gear unit
ratio 10,74
moment of inertia 7,89 kgm²

idlers

section idlers tilt

spacing D J bearing type amount angle
m mm kgm² % °
idlers CB rigid 1,500 152 0,255 6308 plain 0 0,00
idlers RB rigid 3,000 152 0,230 6307 plain 0 0,00

material feed

location point bulk quantity loading acceleration fall distance feeding chute
speed section length inside
dimension
% m/s m m m m
CB 1 100 0,00 5,14 2,55 12,00 1,30

pulleys

pulley D (c/w lagging) width J angle of wrap actual resultant

belt tension
m m kgm² ° kN
head-end (1) drive pulley 1,465 1,900 1400,000 174 1320,8
head-end (2) drive pulley 1,465 1,900 1400,000 181 798,2
head-end (3) takeup pulley 1,026 1,900 680,300 180 912,0
tail-end (1) drive pulley 1,465 1,900 1400,000 183 704,5

take-up station

location head-end (3)

type winch take-up

take-up force in empty run 607,2 kN

takeup distance 1,643 m

driving power

installed power 5000,0 kW

head-end (1) 2* 1000,0 kW
head-end (2) 2* 1000,0 kW
tail-end (1) 1000,0 kW

required power
decisive 4260,0 kW
maximum 4260,0 kW

all sections loaded 4260,0 kW

all sections loaded (min. resistance) 3002,6 kW
all sections empty 923,2 kW
ascending sections loaded 4260,0 kW
descending sections loaded 573,4 kW
beginning conveyance 4260,0 kW
ending conveyance 3989,0 kW

moment of inertia

all sections loaded 7991,36 kgm²

all sections empty 3054,25 kgm²
ascending sections loaded 7991,36 kgm²
descending sections loaded 3054,25 kgm²
220-CV-205-Rev0 page 3 of 4 31.07.2017 10:13:35
Radomiro
Spemann/Dr. Dilefeld

start

loading run-up time acceleration

s m/s²
all sections loaded 58,46 0,14
all sections empty 10,49 0,64
ascending sections loaded 58,46 0,14
descending sections loaded 10,27 0,65

stop

braking torque actual 20000,0 Nm (5x 4000 Nm)

holding torque actual 20000,0 Nm necessary 92,0 Nm

loading braking time braking distance acceleration

s m m/s²
all sections loaded 17,17 60,96 -0,44
all sections empty 10,89 38,67 -0,71
ascending sections loaded 10,89 38,67 -0,71
descending sections loaded 17,17 60,96 -0,44

belt tensions - steady state

location point #1 #2 #3 #4 #5
kN kN kN kN kN
tail-end (1)- 136,786 194,074 292,979 136,786 298,163
CB 1 137,068 194,244 293,261 137,068 298,332
CB 1 173,901 194,244 293,261 173,901 298,332
CB 2 454,744 404,174 351,066 454,744 340,425
head-end - (1) 693,177 602,875 397,959 693,177 378,512
head-end (1)- (2) 464,702 442,236 349,324 464,702 348,765
head-end (2)- 235,496 281,083 300,534 235,496 318,922
head-end - (3) 237,196 282,103 302,234 237,196 319,942
head-end (3)- 239,338 284,627 304,929 239,338 322,788
RB 2 233,631 271,250 299,222 233,631 309,411
RB 1 249,328 273,258 314,918 249,328 311,420
tail-end 249,574 273,406 315,164 249,574 311,567
tail-end - (1) 251,274 274,426 316,864 251,274 312,587

belt tensions - start

location point #1 #3 #4 #5
kN kN kN kN
tail-end (1)- 77,174 252,289 77,174 234,744
CB 1 77,643 253,436 77,643 235,797
CB 1 114,476 253,436 114,476 272,629
CB 2 514,522 431,370 514,522 437,532
head-end - (1) 819,769 545,594 819,769 544,455
head-end (1)- (2) 502,708 355,188 502,708 354,591
head-end (2)- 184,632 164,172 184,632 164,119
head-end - (3) 186,332 165,872 186,332 165,819
head-end (3)- 188,272 168,475 188,272 168,446
RB 2 195,372 222,105 195,372 215,730
RB 1 233,917 343,664 233,917 325,965
tail-end 234,327 344,672 234,327 326,891
tail-end - (1) 236,027 346,372 236,027 328,591

belt tensions - stop

location point #2 #3 #4 #5
kN kN kN kN
tail-end (1)- 382,727 337,773 337,773 382,727
CB 1 382,306 337,094 337,094 382,306
CB 1 382,306 337,094 337,094 382,306
CB 2 214,378 261,138 261,138 214,378
head-end - (1) 201,289 233,057 233,057 201,289
head-end (1)- (2) 322,270 343,640 343,640 322,270
head-end (2)- 443,638 454,578 454,578 443,638
head-end - (3) 443,638 454,578 454,578 443,638
head-end (3)- 446,805 457,380 457,380 446,805
RB 2 392,834 385,603 385,603 392,834
RB 1 322,416 283,422 283,422 322,416
tail-end 322,043 282,820 282,820 322,043
tail-end - (1) 322,043 282,820 282,820 322,043
220-CV-205-Rev0 page 4 of 4 31.07.2017 10:13:35
Radomiro
Spemann/Dr. Dilefeld

#1 all sections loaded

#2 all sections loaded (min. resistance)
#3 all sections empty
#4 ascending sections loaded
#5 descending sections loaded
 Tensioning System Evaluation of CV 205

CODELCO DRT Tensioning system for CV 205

Annex 2: Winch setup values

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TAKRAF GmbH
Project: DRT Upgrade Radomiro - Data for proposal 12,500 t/h, 5x1,000 kW
Date: 31, July 2017
Designed: Spemann/Dilefeld

Revision: 0

Take-up forces for automatic regulation - NORMAL OPERATION ONLY

Take-up force @ take-up pulley

Regulation upwards Values in Conveyor Operation Regulations downwards
Low-low level trip Winch Take-up force in Winch High-high level
Low Level Alarm Adjustment Lower Level (no Upper Level (no Adjustment High level Alarm
and alarm switch on empty running switch on Alarm and Trip
time readjustment!) readjustment!) time
value (Nominal Value) value
Belt Conveyor [kN] [kN] [kN] [sec] [kN] [kN] [kN] [kN] [sec] [kN] [kN]

220-CV-205 430 445 461 4 477 607 643 658 4 674 689

Rope force for Rope force measurement device @ fixed point

Regulation upwards Values in Conveyor Operation Regulations downwards
Low-low level trip Winch Take-up force in Winch High-high level
Low Level Alarm Adjustment Lower Level (no Upper Level (no Adjustment High level Alarm
and alarm switch on empty running switch on Alarm and Trip
time readjustment!) readjustment!) time
value (Nominal Value) value

Belt Conveyor [kN] [kN] [kN] [sec] kN] [kN] kN] kN] [sec] [kN] [kN]

220-CV-205 55,4 57,4 59,4 4 61,4 78,2 82,8 84,8 4 86,8 88,8

Tolerance for automatic regulation 2 kN

T/U Force limit tolerance 4 kN
high-high level trip & alarm tolerance 6 kN
 Tensioning System Evaluation of CV 205

CODELCO DRT Tensioning system for CV 205

Annex 3: Winch Motor Selection

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Annex 3: Take-up winch motor selection

Resultant Belt Tension in empty run Tres_empty  645 kN

Rope systems n rope  2

Rope ratio irope  4

Rope roller efficiency ηrope  0.98

Tres_empty
Rope force in winch operation Trope_empty 
irope
1  ηrope
n rope 
1  ηrope

Trope_empty  83.084kN


Rope pulley diameter d pulley  800 mm

Gear box ratio igear  1931

Gear box efficiency ηgear  0.98

d pulley 1
Required motor torque M mot  n rope  Trope_empty  
2 igear  ηgear

M mot  35.124N
 m
 Tensioning System Evaluation of CV 205

CODELCO DRT Tensioning system for CV 205

Annex 4: Winch Brake Selection

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Annex 4: Take-up winch brake selection

Maximum Resultant Belt Tension Tres_max  920  kN

Rope systems n rope  2

Rope ratio irope  4

Tres_max
Rope force in winch operation Trope_max 
n rope irope

Trope_max  115  kN

Rope pulley diameter d pulley  800  mm

Gear box ratio igear  1931

d pulley 1
Required brake torque M brake  n rope Trope_max 
2 igear

M brake  47.644 N m
 Tensioning System Evaluation of CV 205

CODELCO DRT Tensioning system for CV 205

Annex 5: Drawings

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 1 2 3 4 5 6 7 8
4365

2470
A
A

1173

690,07
690
N N
B
B

220
500
1190
1300
Ø30
800=60 m
Seilaufnahme

C
C

1427
D
D

rechtssteigend 2306 linkssteigend

Potentia nominal del motor : 2x5,5 KW ( Md Mot.36 Nm/72 Nm ) Capacidad de tensado del cable: 93 KN(9,3to)
Perforaciones de Motoroutput-Antriebsmotornennleistung
montaje pulling force per wirerope -Seilzugkraft je Seil
mounting holes Erforderliches Motormoment Velocidad enrrollado del cable : ca.1,9 m/min E
bei Nennseilzugkraft 2x93 KN : 2x21,4=42,8 Nm
E Befestigungsbohrungen
3200
Wire rop speed-Seilgeschwindigkeit

Erforderliches Bremsmoment bei

Stillstand zur Aufrechterhaltung der
Seilzugkraft 2x 136 KN : 2x31=64 Nm
140 2670 N-N 140
Installiert : 2 Stck Bremsen
a: Bremsmoment 100Nm : 2x 100=200 Nm
220

TAKRAF-tenova Projekt: Radomiro DRT Upgrade

Order Nr. H.042945
Numero de revoluciones del motor -TAG-No.
n25 Freigabedatum QM-System
con frecuencia nominal 50 Hz : n=1450 min-1 Freimaßtoleranzen
nach DIN 7168
Maßstab 1:10
. . nach
1190

Round per minuts- Motordrehzahl TAKRAF Order Nr. H.042945

750

EN ISO
2270 Voltaje-Voltage-Spannung : 400 V 9001:2000
Projekt Radomiro DRT Upgrade
Hadef Projekt Nr. 011.77.17.06.00
Relacion de transmision de engranaje: i= 1931 unbemaßte Ecken r = Datum Name
Reduction-Getriebeübersetzung unbemaßte Kanten = Ersteller 07.02.2017 HPC
E-Winch Fig.45/10 TWIN F
F Geprüft . .
220

Ersatz für
2x93 KN -2x5,5 kW - Seil ø30
Ersatz durch

Zeichnung Blatt
1
HEINRICH DE FRIES GMBH DÜSSELDORF 011.77.17.06.10 1 Bl.
www.hadef.com
Zust. Änderungsmitteilung Datum Name Alle Rechte an dieser Unterlage vorbehalten A2

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