Correa 130 H351654-3120-240-202-0002

CODELCO CHILE, DIRECCIÓN DE PROYECTOS DCH
009 - INGENIERÍA DE DETALLES PROYECTO LIXIVIACIÓN RIPIOS Y

RECURSOS ARTIFICIALES
MEMORIA DE CÁLCULO CORREAS TRANSPORTADORAS OVERLAND (2 / 2) - 5 de Abril de 2017
4600014651-FXA-HATCH-DCH-MDCME02-3105-0002
Tabla de Contenidos
1. Introducción .......................................................................................................................................... 4
1.1 Antecedentes ................................................................................................................................ 5

2. Objetivos ............................................................................................................................................... 6
3. Bases de Cálculo .................................................................................................................................. 7
4. Objetivos ............................................................................................................................................... 8
5. Cálculos y resultados .......................................................................................................................... 9
5.1 Correa 130-CV-03......................................................................................................................... 9

5.2 Correa 130-CV-04....................................................................................................................... 12
5.3 Correa 130-CV-05....................................................................................................................... 15
6. Recomendaciones y conclusiones ................................................................................................... 19
6.1 Correa 130-CV-03....................................................................................................................... 19

6.2 Correa 130-CV-04....................................................................................................................... 19
6.3 Correa 130-CV-05....................................................................................................................... 19
Lista de Anexos
Anexo A
Resultados Correa 130-CV-03

Anexo B

Anexo C

Anexo D
Rediseño Poleas Correa 130-CV-03
Anexo E
Anexo F
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1. Introducción
El tratamiento de minerales mediante el uso de bateas se realizó desde 1915 hasta 1972,
generando los Ripios Mina Chuquicamata (RCH) también conocidos como ripios rojos. Una
vez finalizado este periodo, empieza a operar la Mina Sur y comienza la generación y
depositación de los Ripios Mina Sur (RMS) hasta el año 2004. Con la entrada de la
Extensión Norte de la Mina Sur (ENMS), inicia sus operaciones la PTMP (Planta Tratamiento
Minerales Pila) con pilas removibles, cuyos ripios se depositan al sur de la PTMP.
Estudios metalúrgicos y geotécnicos previos realizados por División Chuquicamata (DCH),

han indicado que es posible procesar y obtener beneficios de los RMS mezclados con los
RCH en proporción 70% / 30% respectivamente, lo que confecciona un material de buen
comportamiento para la percolación de la solución lixiviante y de una apropiada estabilidad
geotécnica para la confección de pilas.
El Plan de Negocio y Desarrollo 2015 de la División Chuquicamata, indica que, para las
instalaciones que corresponden a la línea Óxido de la Gerencia de Extracción y Lixiviación,
el último año de producción es el 2016, quedando una disponibilidad de activos en las
diferentes plantas de tratamiento que son parte de esta división.
La Gerencia de Extracción y Lixiviación (GEL) de división Chuquicamata, ha encargado a

Hatch el desarrollo de la Ingeniería de detalles del proyecto denominado “Lixiviación Ripios y
Recursos Artificiales” requerido para re-lixiviar alrededor de 145 millones de toneladas de
recursos artificiales, ripios provenientes del tratamiento de lixiviación de minerales mediante
el uso de bateas. La ley promedio de los ripios es de 0,35% de cobre total y con una
recuperación estimada de 70%, lo que implica obtener del orden de 40,7 ktCuf anuales por
un período de 9 años.
El proyecto considera la lixiviación de los recursos artificiales de DCH mediante uso de las
instalaciones de la PTMP. En particular, la lixiviación se desarrollará sobre el actual pad de
lixiviación dinámica, el cual consta de 108 módulos de lixiviación a lo largo de dos pilas
continuas dispuestas en modalidad de hipódromo. El posterior tratamiento del PLS producto
de lixiviación a ser realizado en instalaciones de Extracción por Solvente (SX) y
Electrowinning (EW) de la Gerencia de Extracción y Lixiviación de DCH (GEL) queda
excluido del alcance del Proyecto.
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1.1 Antecedentes
Los siguientes antecedentes fueron considerados en la modelación y cálculos de las correas
transportadoras:
Nro Documento Descripción

1
N15XX09_DD-F-JACOBS-3100- Memoria de Cálculo Correas Aglomerado
MDCME-3100-005
1
N15XX09_DD-F-JACOBS-0000- Balance de Masa y Agua
BDMPR-0000-001
2
25064-220-V1A-MHFB-00074 130-CV-03 – Disposición General 1/2
2
25064-220-V1A-MHFB-00075 130-CV-03 – Disposición General 2/2
2
25064-220-V1A-MHFB-00100 130-CV-04 – Disposición General
2
25064-220-V1A-MHFB-00047 130-CV-05 – Disposición General
Tabla 1: Documentos y Planos de Referencia
1
“Lixiviación de Ripios y Recursos Artificiales – Factibilidad”, Jacobs
2
“Planta Tratamiento Minerales Pila (PTMP)”, Codelco - Edyce
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2. Objetivos
El Objetivo del presente documento es el cálculo y verificación del diseño de las Correas
transportadoras overland y alimentación a silo de acidificación 130-CV-03, 130-CV-04 y 130-
CV-05 para las condiciones de operación definidas en el proyecto “Lixiviación de Ripios y
Recursos Artificiales”.
Las características principales a verificar son:
• Potencia Sistema motriz
• Tensiones de Trabajo
• Verificación de componentes mecánicos
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3. Bases de Cálculo
Para el cálculo de las correas, se consideraron los siguientes parámetros de operación, en
base a los cálculos realizados en la etapa de factibilidad:
• Material Transportado : Ripios
• Densidad aparente (húmeda) : 1595 kg/m3
• Tamaño máximo de partícula : 20 mm
• Angulo de sobrecarga : 20°
• Flujo de diseño : 2780 t/h
• Factor de diseño : 1.15
Adicionalmente, se analizará un escenario considerando la densidad aparente húmeda de

1500 kg/m3, según lo indicado en el balance de masa y agua de la etapa de factibilidad y un
ángulo de sobrecarga de 15°, que es un valor usual para ripios.
Todos los cálculos se realizarán en 4 condiciones de operación:
• Fricción Nominal: Escenario óptimo de operación, con componentes bien alineados, con
poco desgaste, equipos bien lubricados, limpios y sin fallas
• Fricción Nominal, partida con chute atollado: Escenario de Fricción Normal,

considerando que el chute de alimentación se encuentra en situación de Atollo.
• Fricción Alta: Escenario de deficiente operación, polines mal alineados, desgastados,

algunos polines faltantes, limpieza deficiente, equipos mal lubricados, etc.
• Fricción Alta – partida con chute atollado: Escenario de Fricción Normal, considerando
que el chute de alimentación se encuentra en situación de Atollo. Representa la peor
condición de operación.
El cálculo es realizado por medio del programa computacional llamado Sidewinder Plus
v6.51, de reconocida aplicación en este tipo de equipos. Todos los resultados son calculados
utilizando la norma CEMA 7ª edición, en el escenario conservador.
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4. Objetivos
El Objetivo del presente documento es el cálculo y verificación del diseño de las Correas
Transportadoras 130-CV-03, 130-CV-04 y 130-CV-05 para las condiciones de operación
definidas en el proyecto “Lixiviación de Ripios y Recursos Artificiales”.
Las características principales a verificar son:
• Potencia Sistema motriz
• Tensiones de Trabajo
• Verificación de componentes mecánicos
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5. Cálculos y resultados
El detalle de los cálculos se encuentran en anexos.
5.1 Correa 130-CV-03

La siguiente tabla muestra los resultados de los cálculos de llenado de la correa 130-CV-03
en los escenario Nominal y Alternativo:
Escenario Flujo de Cálculo [t/h] Velocidad [m/s] Ancho [mm] % Carga CEMA
Nominal (δ=1595 2,780 4.4 1,067 85%
kg/m3, β=20°)
Alternativo (δ=1500 2,780 4.4 1,067 99%
kg/m3, β=15°)
Tabla 2: Llenado de Cinta
La siguiente tabla muestra los principales resultados de la correa 130-CV-03. Los cálculos
fueron realizados en el escenario “Nominal”, con 1595 kg/m3 de densidad y 20° de ángulo de
sobrecarga.
Descripción Unidad Fricción Fricción Fricción Alta Fricción Alta,

Nominal Nominal, Atollo Atollo
Potencia instalada kW 560 560 560 560
Potencia consumida kW 334 351 469 490
Potencia consumida % 60% 63% 84% 87%
Torque Partida motor % 128% 130% 141% 143%

req/nom
Ancho Cinta mm (’’) 1,067 1,067 1,067 1,067
Tipo - ST-1600 ST-1600 ST-1600 ST-1600
Cubierta Sup/inf mm 12/6 12/6 12/6 12/6
Tensión operación kN 136.7 140.6 164.9 169.6
Tensión Partida kN 217.1 219.2 230.7 233.2
FS Operación - 12.49 12.15 10.35 10.07
FS Partida - 7.86 7.79 7.40 7.32
Tabla 3: Resultados Correas 130-CV-03
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Los resultados del cálculo del sistema tensor se muestran en la siguiente tabla:
Descripción Unidad Valor existente Valor Proyectado
Tipo - Gravitacional Gravitacional
Tensión Cinta en operación N No disponible 70,000
Masa Contrapeso Kg 8,000 13,700
Desplazamiento total Polea m 3.1 4.4
Tabla 4: Sistema Tensor
Se realizó una verificación de las poleas de la correa, la que considera el cálculo de eje y el
manto de la polea. Las tensiones en cada polea se encuentran en la siguiente tabla:
Tensión Operación (kN) Tensión Momentánea (kN)
Abrace
Polea Fuerza
(°) T1 T2 T1 T2 Fuerza Total
Total
Motriz 180 170 71.4 241 233 71.6 305
Desviadora 83 71.2 94.9 71.4 95.0
Tensora 180 70.0 141 70.0 141
Desviadora 90 72.4 103 72.5 103
Cola 180 87.6 177 125 252
Tabla 5: Tensiones en poleas
Los Resultados de cálculo de los ejes de las poleas se muestra en la siguiente tabla:
Deflexión Deflexión L10 Fuerza Angulo Torque

Masa Total
Polea FS en Hub en centro Rodam. resultante Fuerza Total
Polea (kg)
(min) (% largo) 1000 hrs (kN) (deg) (kN·m)
Motriz 2.07 4.13 0.050 8 1175 267 189 43.9
Desviadora 2.24 2.65 0.028 38 559 122 316 0.1
Tensora 1.60 3.69 0.038 12 559 171 90 0.3
Desviadora 2.07 2.87 0.030 29 559 132 226 0.2
Cola 1.24 4.78 0.050 5 559 221 359 0.4
Tabla 6: Resultados eje poleas
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El cálculo de esfuerzos en los mantos de poleas se muestra en la siguiente tabla:
Espesor Manto
Espesor Tambor
Polea Requerido Sitzwohl
(mm)
(mm)
Motriz 22 19
Desviadora 16 14
Tensora 16 14
Desviadora 16 14
Cola 16 16
Tabla 7: Resultados espesor de manto por polea
Dados los resultados anteriores se debe rediseñar la polea de cola. Las nuevas dimensiones
de la polea se muestran en el plano H351654-3130-240-264-0001. Los resultados de la
nueva polea se muestran a continuación

Masa Total
Polea (kg)
Cola 2.52 4.88 0.052 189 643 221 358 0.4
Tabla 8: Resultados eje polea Cola rediseñada
Los resultados del cálculo de polines son los siguientes:
Polin Tipo L10 mínima (hrs) Diámetro (mm)
Carga D6 196,000 152
Retorno D6 350,000 152
Tabla 9: Resultados vida útil polines
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Nominal (δ=1595 2,780 4.4 1,067 86
kg/m3, β=20°)
Alternativo (δ=1500 2,780 4.4 1,067 99
kg/m3, β=15°)
sobrecarga.


req/nom
Ancho Cinta mm (’’) 1,067 1,067 1,067 1,067
Tipo - EP-900/4 EP-900/4 EP-900/4 EP-900/4
FS Operación - 12.01 11.44 11.45 10.83
FS Partida - 10.01 9.47 9.72 9.14
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Descripción Unidad Valor Existente Valor
Desplazamiento total Polea m 2.9 3
Abrace
Polea Fuerza
(°) T1 T2 T1 T2 Fuerza Total
Total
Motriz 180 83.9 33.1 117 105 33.2 138
Desviadora 80 32.9 42.5 33.0 42.6
Tensora 180 31.8 64.0 31.8 64.1
Desviadora 100 33.3 51.1 33.5 51.5
Cola 180 30.4 61.2 33.8 68.2
Deflexión Deflexión L10 Masa Fuerza Angulo Torque

Polea FS en Hub en centro Rodam. Total resultante Fuerza Total
(min) (% largo) 1000 hrs Polea (kg) (kN) (deg) (kN·m)
Motriz 1.56 5.84 0.068 61 914 130 194 18.3
Desviadora 3.07 7.48 0.076 467 352 55.4 317 0.0
Tensora 2.22 10.33 0.105 160 352 76.5 90 0.1
Desviadora 2.55 8.99 0.091 254 352 66.6 232 0.1
Cola 2.24 10.26 0.104 163 352 76.0 7 0.1
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Espesor Manto
Espesor Tambor
Polea Requerido Sitzwohl
(mm)
(mm)
Motriz 22 12
Desviadora 16 9
Tensora 16 8
Desviadora 16 9
Cola 16 8
Tabla 15: Resultados espesor de manto por polea
Dados los resultados anteriores se debe rediseñar las poleas tensora, deflectora y cola. Las
nuevas dimensiones de las poleas se muestran en los planos H351654-3130-240-264-0004,
H351654-3130-240-264-0005 y H351654-3130-240-264-0006 respectivamente. Los
resultados de las nuevas poleas se muestran a continuación:

Masa Total
Polea (kg)
Tensora 3.06 6.06 0.064 500 405 75.7 90 0.1
Desviadora 3.47 5.34 0.056 500 405 66.7 232 0.1
Cola 3.07 6.05 0.064 500 403 75.5 7 0.1
Tabla 16: Resultados eje poleas rediseñadas
Carga D6 350,000 152
Retorno D6 350,000 152
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Nominal (δ=1595 2,780 4.4 1,067 85.8%
kg/m3, β=20°)
Alternativo (δ=1500 2,780 4.4 1,067 99%
kg/m3, β=15°)
sobrecarga.


req/nom
Ancho Cinta mm (’’) 1,067 1,067 1,067 1,067
Tipo - EP-630/3 EP-630/3 EP-630/3 EP-630/3
FS Operación - 14.72 13.55 14.09 12.78
FS Partida - 10.06 9.65 9.95 9.48
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Descripción Unidad Valor existente Valor Proyectado
Desplazamiento total Polea m 2 2
Abrace
Polea Resultant Resultant
(°) T1 T2 T1 T2
Force Force
Descarga 175 52.1 105 69.2 139
Desviadora Tripper 163 51.8 103 69.4 138
Motriz 180 52.6 24.0 76.4 70.9 26.0 96.9
Desviadora 76 23.9 29.5 24.4 29.9
Tensora 180 23.0 46.3 23.0 47.3
Desviadora 104 24.3 38.5 25.8 41.7
Cola 180 24.0 48.4 27.6 56.6

Descarga 1.06 10.63 0.124 40 568 117 197 0.1
Desviadora T. 1.31 9.76 0.099 45 459 113 6 0.1
Motriz 1.33 11.10 0.112 120 429 84.2 183 7.9
Desviadora 2.01 8.46 0.085 500 349 39.1 318 0.0
Tensora 1.45 11.76 0.119 217 349 54.4 90 0.1
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Desviadora 1.55 10.99 0.111 272 349 50.8 234 0.1
Cola 1.32 12.92 0.130 159 349 59.7 11 0.1
Espesor Tambor Espesor Manto Requerido

Polea
(mm) Sitzwohl (mm)
Descarga 22 11
Desviadora Tripper 18 11
Motriz 18 9
Desviadora 18 7
Tensora 18 7
Desviadora 18 7
Cola 18 7
Tabla 23: Resultados espesor manto poleas
Dados los resultados anteriores se debe rediseñar las poleas tensora, deflectora y cola. Las
nuevas dimensiones de las poleas se muestran en los planos H351654-3130-240-264-
0007@0013. Los resultados de las nuevas poleas se muestran a continuación:
Descarga 2.03 7.71 0.091 500 606 116 198 0.1
Desviadora T. 2.60 6.55 0.069 500 552 112 6 0.1

Motriz 2.77 6.60 0.069 500 470 84.0 183 7.9
Desviadora 4.78 4.31 0.045 500 400 39.5 317 0.0
Tensora 3.50 5.88 0.061 500 400 53.9 90 0.1
Desviadora 3.69 5.59 0.058 500 400 51.2 235 0.1
Cola 3.17 6.50 0.068 500 400 59.6 10 0.1
Tabla 24: Resultados eje poleas rediseñadas
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Carga D6 350,000 152
Retorno D6 350,000 152
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6. Recomendaciones y conclusiones
El llenado en el escenario “nominal” es de un 85%, bajo el valor considerado en la etapa de
factibilidad de 90%. Sin embargo, al utilizar la densidad indicada en el balance de masa y un
ángulo de sobrecarga de 15°, que es un valor común para ripios, el llenado puede
sobrepasar el 100% de llenado CEMA. Si bien esta condición no necesariamente implica
caída de material desde la cinta, es una condición que no cumpliría con lo indicado en el
criterio de diseño. Se recomienda realizar un seguimiento a esta condición durante el Ramp
up para determinar el escenario real de operación.
Para asegurar el funcionamiento de la cinta en cualquier condición de operación es

necesario instalar un sistema motriz de 560 kW y aumentar la velocidad a 4.4 m/s. También
se debe cambiar la cinta actual por una cinta ST-1600 de 1,067 mm de ancho.
El cálculo de las poleas indica que la polea de cola tiene un factor de seguridad menor a 1.5,
por lo que debe ser reemplazada.


necesario instalar un sistema motriz de 315 kW y aumentar la velocidad a 4.4 m/s. También
se debe cambiar la cinta actual por una cinta EP-900/4 de 1,067 mm de ancho, debido a que
la cinta actual EP-800/4 no cumple con los factores de seguridad requeridos para las nuevas
condiciones de operación.
El cálculo de las poleas indica que todos los ejes tienen un factor de seguridad mayor a 1.5,
sin embargo, las poleas tensora, deflectora y cola tienen una deformación mayor a 8 min,
valor máximo de deflexión en el HUB según norma CEMA para correas con cinta de tela. Se
recomienda reemplazar dichas poleas.

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necesario instalar un sistema motriz de 175 kW y aumentar la velocidad a 4.4 m/s. No es
necesario cambiar la cinta actual.
El cálculo de poleas indica que se deben reemplazar las 7 poleas por fallas en ejes. 5 de las
7 poleas presentan un factor de seguridad menor a 1.5. Las poleas restantes presentan
deformación en el Hub sobre los 8 minutos, valor límite según norma CEMA.
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Anexo A
(15 páginas)
H351654-3120-240-202-0002, Rev. 0
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Client Name CODELCO Designer G. Tarsetti
Project Name ODS - 9 Company Hatch
Conveyor Name 130-CV-03 Filename 130-cv-03 - final - 560swi
Location PTMP Date January 19, 2017
Description
Idler Set Data

System Information Carry Return
Calculation method ............................ CEMA 7th (type 3) Series name D6 D6
Conveyor Length / Height ............................ 1063 / 3.8 m Number of rolls 3 2
Material lift .............................................................. 3.8 m Trough angle (deg) 35 15
Ambient temperature range ............................. -5 to 10 °C Type Inline Inline
Kt factor at minimum temperature ............................. 1.06 Idler spacing (m) 1.50 3.00
Number of idler sets 714 353
Material Properties Roll diameter 152 152
Type ........................................................................ Ripios Roll rpm 562 562
Design Tonnage ................................................... 2762 t/h Total drag (N) 6.7 4.4
Density ............................................................ 1595 kg/m3 Drag range (N) 23.4 - 39.6 15.9 - 25.7
Maximum lump size .............................................. 20 mm Roll length 388 576
Surcharge angle ...................................................... 20 deg Shaft diameter (mm) 25.0 25.0
Rating (N) 5,338 3,781
Calc Idler Load (N) 3,461 1,205
Belt Properties L10 life1 (1000 hrs) 208.4 350.0
Type .................................................................. Steel cord 1
L10 life above which 95% of idlers exceed
Width ................................................................. 1067 mm
Rating............................................................. 1600 N/mm Drive Station
Speed ................................................................... 4.49 m/s
Type ........................................................... Fluid coupling
Top / bottom cover thickness ..................... 12.0 x 6.0 mm
Synchronous RPM ...........................................1500 RPM
Total thickness ....................................................... 23 mm
Motor quantity / rating .................................... 1 / 560 kW
Weight .............................................................. 36.3 kg/m
Total installed power ............................................ 560 kW
Modulus ..................................................... 115,200 kN/m
Nominal empty / full power ...... (33 / 60%) 185 / 334 kW
Tape length .......................................................... 2,136 m
Min / max demand power.......... (33 / 87%) 185 / 490 kW
Belt cycle time ...................................................... 7.9 min
Frame Size.......................................................... IEC 400J
Tension Summary Running Momentary Motor Voltage ............................................. Not Specified
Maximum tension (kN) 170 233 Efficiency .................................................... 91.5 to 92.5%
Minimum safety factor 10.07 7.32 Maximum starting torque ......................................... 143%
Minimum tension (kN) 70.0 51.5 Inertia - Motor ................................................. 12.5 kg·m²
Maximum belt sag (%) 0.44 0.75 Inertia - Fluid Coupling ..................................... 0.6 kg·m²
Pulley lagging type ................................................ Rubber
Cross Sectional Loading Motor wrap angles....................................................... 180
Material mass (wm) ......................................... 171.1 kg/m Lagging friction factor (run / accel) ................. 0.32 / 0.38
Combined mass (wm + wb) .............................. 207.4 kg/m
Edge distance (required / actual)................... 82 / 112 mm Take-up Data
Cross sectional area ............................................ 0.107 m²
Type ...................................................................... Gravity
Cross sectional loading (utility / total) ........... 85 % / 59 %
Location ................................................. Head / Pulley #3
Bed depth ............................................................. 197 mm
Required belt line tension ..................................... 70.0 kN
Counterweight mass ........................................ 14.3 tonnes
Required pulley displacement ................................ 4.34 m

Dynamic displacement (incl thermal) .............. 0.80 m
Permanent elongation ...................................... 1.07 m
Splice length (2 included) ................................ 1.48 m
Clearance ......................................................... 1.00 m
Backstops
Flooded belt tonnage........................................... 4,638 t/h Backstop type ............................................. None installed
Flooded (wm + wb) .......................................... 323.6 kg/m
Sidewinder v6.51 - Conveyor Design Software
Advanced Conveyor Technologies, Inc.
Page 1 / 15
Description
Brakes Total splice length .............................................. 1475 mm

Brake type .................................................. None installed Cable diameter ...................................................... 4.8 mm
Number of cables .......................................................... 74
Cable pitch / cable gap in splice .............. 13.59 / 4.14 mm
Reducer Information
Manufacture ................................................................N/A
Frame size ...................................................................N/A Other Information
Reducer ratio .......................................................... 13.840
Loaded beltline mass (excluding motors)........ 278,543 kg
Catalog reducer ratio ................................................ 0.000
Total inertia (ref HS shaft) ............................... 240 kg·m2
RPM (High Speed) .......................................... 1500 RPM
RPM (Low Speed) .......................................... 108.4 RPM Demand Power (kW)
Configuration ................................................ Shaft Mount Demand % Motor
Number of stages ............................................................ 3 Case
power Nameplate
Service factor ............................................................... 1.4 Empty - Normal Frict. 185 33.1
Power rating .................................................................... 0 Full - Normal Frict. 334 59.6
Full - High Frict. 469 83.7
Motor Torque Chute Atollado - Normal Frict. 351 62.7
100% Motor Torque - High Speed................... 3,619 N·m Chute Atollado - High Frict. 490 87.4
Motor Shaft Torque - Running (FN) ................ 2,184 N·m
Motor Shaft Torque - Starting (FN) ................. 4,626 N·m Din Factor and Total Equivalent Mass
100% Motor Torque - Low Speed ................. 50,092 N·m Belt line
Case Din factor
Low Speed Shaft Torque - Running (FN) ...... 27,073 N·m mass (kg)
Low Speed Shaft Torque - Running (Max) ... 40,904 N·m Empty - Normal Frict. 0.0318 111,713
Low Speed Shaft Torque - Starting (FN) ....... 59,874 N·m Full - Normal Frict. 0.0191 293,020
Low Speed Shaft Torque - Starting (Max)..... 66,822 N·m Full - High Frict. 0.0287 297,786
Chute Atollado - Normal Frict. 0.0191 293,276
Starting and Stopping Chute Atollado - High Frict. 0.0286 298,107
Start control ............................................. Constant torque Maximum Belt Tensions (kN)
Start time........................................................ 4.6 to 20.9 s Case Running Dynamic
Operational stop control............................................. Drift
Empty - Normal Frict. 104 198
Operational stop time ................................... 12.9 to 18.7 s
Full - Normal Frict. 137 217
Emergency stop control ............................................. Drift
Full - High Frict. 165 231
Emergency stop time ................................... 12.9 to 18.7 s
Chute Atollado - Normal Frict. 141 219
Material buildup in chute ........................................ 4.5 m³
Chute Atollado - High Frict. 170 233
Tension Ratios Belt Safety Factor
Allowable (running)................................................... 2.73 Case Running Dynamic
Running tension ratio ................................................. 2.38 Empty - Normal Frict. 16.41 8.62
Allowable (dynamic) ................................................. 3.30 Full - Normal Frict. 12.49 7.86
Starting tension ratio .................................................. 3.28 Full - High Frict. 10.35 7.40
Chute Atollado - Normal Frict. 12.15 7.79
Transition Lengths Chute Atollado - High Frict. 10.07 7.32
Transition method ............................................... CEMA 7
Minimum Belt Tensions (kN)
Tail transition length (inline) ................................. 3.90 m
Case Running Dynamic
Head transition length (inline) ............................... 5.60 m
Empty - Normal Frict. 70.0 66.8
Full - Normal Frict. 70.0 51.9
Estimated Splice Data Full - High Frict. 70.0 51.5
Splice type .............................................................. 2-Step Chute Atollado - Normal Frict. 70.0 52.2
Splice step length ................................................. 370 mm Chute Atollado - High Frict. 70.0 51.8
Transition length (each side)................................ 150 mm
22 degree bias angle............................................. 435 mm
Page 2 / 15
Description
Maximum Belt Sag (%)

Full - High Frict. 0.42 0.75
Chute Atollado - High Frict. 0.40 0.75

Page 3 / 15
Description
Conveyor Profile
Overall length = 1063 m - Overall height = 3.8 m - True Length = 1063.3 m
Tail Arrangement Head Arrangement
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 170 71.4 241 233 71.6 305
Pulley 2 2-LT 83 71.2 94.9 71.4 95.0
Take-up Pulley 2-LT 180 70.0 141 70.0 141
Pulley 4 2-LT 90 72.4 103 72.5 103
Tail Pulley 2-LT 180 87.6 177 125 252
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Page 4 / 15
Description
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Pulley Safety Slope at Deflection T1 T2
L10 Life Shaft Force Angle Torque Moment
# Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 2.07 4.13 0.050 8 187 78.4 1175 267 189 43.9 51.0
2 2.24 2.65 0.028 38 89.0 89.3 559 122 316 0.1 14.2
3 1.60 3.69 0.038 12 87.5 88.6 559 171 90 0.3 19.8
4 2.07 2.87 0.030 29 90.5 91.2 559 132 226 0.2 15.4
5 1.24 4.78 0.050 5 110 111 559 221 359 0.4 25.7
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1.10 on high tension
pulleys, and a multiplier of 1.25 on all other pulleys.
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
1 Rubber 762 19.0 800 1219 216 151 1800 3134 23936 1,398
2 Rubber 508 15.0 538 1219 178 100 1560 522 23024 635
Pulley Shaft Information

Hub Bearing Overhung
Yield Tensile Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)
B-LOC
1 AISI 1045 505.0 584.4 263.0 216 1035 120 98 0.0 0
115
B-LOC
2 AISI 1045 505.0 584.4 263.0 178 1095 93 117 0.0 0
106

Page 5 / 15
Description
Conveyor Load Cases

During the course of operation, the conveyor experiences different operating conditions at various frequencies. Normal
operating conditions, such as steady state running, loading and unloading, and other common load cases are designated as
Design Level 1. Unusual operating conditions, such as when all incline or decline section are simultaneously loaded, are
defined as Design Level 2. These design levels allow easy summarization of the various possible loading conditions.
For this conveyor, there are three Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
3. Chute Atollado
In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.
Empty
Fully Loaded (Material Lift = 3.8 m)

Page 6 / 15
Description
Chute Atollado (Material Lift = 3.8 m)

Page 7 / 15
Description
Take-up Displacement Summary

1. Type ...................................................................................................................................................Gravity
2. Location .............................................................................................................................. Head / Pulley #3
3. Belt line tension ................................................................................................................................ 70.0 kN
4. Take-up pulley displacement range
a. Running ......................................................................................................................... -0.05 to 0.08 m
b. Momentary .................................................................................................................... -0.40 to 0.40 m
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) ................................................................................................. 0.80 m
2. Permanent elongation ......................................................................................................................... 1.07 m
3. Splice length (2 included) ................................................................................................................... 1.48 m
4. Clearance ............................................................................................................................................ 1.00 m
5. Required displacement ....................................................................................................................... 4.34 m

Page 8 / 15
Description
Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases and dynamic conditions. Running tensions have an added multiplier of 1.10 on high tension
Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.
Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 187 78.4 267 279 78.7 359
Pulley 2 2-LT 83 89.0 122 78.5 108
Take-up Pulley 2-LT 180 87.5 171 77.0 150
Pulley 4 2-LT 90 90.5 132 79.7 117
Tail Pulley 2-LT 180 110 221 138 277
Required Pulley Diameter (Tension based on a safety factor of 6.67)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 Head (10) 1 - HT 180 762 1000 66 91
Pulley 2 Head (12) 2 - LT 83 508 630 28 28
Take-up Pulley Head (14) 2 - LT 180 508 630 28 28
Pulley 4 Head (16) 2 - LT 90 508 630 29 29
Tail Pulley Tail (29) 2 - LT 180 508 630 35 49
Pulley Shaft Stress Analysis (Individual Pulleys)

Hub Hub Fillet Fillet Fillet Von Hub Von Overhung
Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises Von Mises
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 1 2.07 4.13 51.6 22.2 57.6 65.2 64.4 126.8 0.0
2 2 2.24 2.65 25.8 0.1 65.0 0.4 25.8 65.0 0.0
3 2 1.60 3.69 35.9 0.3 90.7 1.6 35.9 90.7 0.0
4 2 2.07 2.87 27.9 0.2 70.3 1.1 27.9 70.4 0.0
5 2 1.24 4.78 46.5 0.4 117.3 2.2 46.5 117.3 0.0

Page 9 / 15
Description
Running Drive Tensions by Load Case (kN)

Motor 1
Load Case Resultant
T1 T2
Force
Empty - Normal Frict. 104 71.4 175
Full - Normal Frict. 137 71.4 208
Full - High Frict. 165 71.3 236
Chute Atollado - Normal Frict. 141 71.4 212
Chute Atollado - High Frict. 170 71.3 241
Pulley Tension Summary - All Load Cases and Conditions

Load Case Running Starting O-Stop E-Stop
Pulley T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)
Motor 1 104 71.4 198 70.8 69.9 71.6 69.9 71.6
Empty - Pulley 2 71.2 71.4 70.8 71.3 71.4 71.5 71.4 71.5
EM-N Normal Take-up Pulley 70.0 70.6 70.0 70.9 70.0 70.5 70.0 70.5
Frict. Pulley 4 72.0 72.4 72.4 73.2 71.9 72.2 71.9 72.2
Tail Pulley 82.2 83.1 125 126 66.8 67.6 66.8 67.6
Motor 1 137 71.4 217 71.2 67.9 71.5 67.9 71.5
Full - Pulley 2 71.2 71.4 71.1 71.4 71.3 71.5 71.3 71.5
FL-N Normal Take-up Pulley 70.0 70.6 70.0 70.7 70.0 70.5 70.0 70.5
Frict. Pulley 4 72.0 72.4 72.1 72.7 71.9 72.3 71.9 72.3
Tail Pulley 82.2 83.0 94.8 95.8 71.7 72.5 71.7 72.5
Motor 1 165 71.3 231 71.1 67.6 71.5 67.6 71.5
Pulley 2 71.1 71.5 71.0 71.4 71.3 71.5 71.3 71.5
Full - High
FL-H Take-up Pulley 70.0 70.9 70.0 71.0 70.0 70.8 70.0 70.8
Frict.
Pulley 4 72.4 73.0 72.5 73.1 72.2 72.7 72.2 72.7
Tail Pulley 87.6 88.9 98.1 99.5 72.5 73.7 72.5 73.7
Motor 1 141 71.4 219 71.2 68.0 71.5 68.0 71.5
Chute Pulley 2 71.2 71.4 71.1 71.4 71.3 71.5 71.3 71.5
Atollado -
CA-N Take-up Pulley 70.0 70.6 70.0 70.7 70.0 70.5 70.0 70.5
Normal
Frict. Pulley 4 72.0 72.4 72.1 72.6 71.9 72.3 71.9 72.3
Tail Pulley 82.2 83.0 93.9 94.9 71.4 72.2 71.4 72.2
Motor 1 170 71.3 233 71.2 67.7 71.5 67.7 71.5
Chute Pulley 2 71.1 71.5 71.0 71.4 71.3 71.5 71.3 71.5
CA-H Atollado - Take-up Pulley 70.0 70.9 70.0 71.0 70.0 70.8 70.0 70.8
High Frict. Pulley 4 72.4 73.0 72.5 73.1 72.2 72.7 72.2 72.7
Tail Pulley 87.6 88.9 97.2 98.5 72.1 73.3 72.1 73.3

Page 10 / 15
Description
#1 - Motor 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension .................................. 137 kN
1. Name (Type-1)............................................ Motor 1 29. Running T2 Tension ................................. 71.4 kN
2. Pulley Diameter ..........................................762 mm 30. Design T1 Tension .................................... 187 kN
3. Face Width ................................................1219 mm 31. Design T2 Tension ................................... 78.4 kN
32. Wrap angle ................................................180 deg
33. Design Resultant Tension.......................... 267 kN
Lagging
34. Resultant Angle .........................................189 deg
4. Lagging Type ............................................... Rubber
35. Resultant Moment ................................ 51.0 kN·m
5. Lagging Thickness ........................................19 mm
36. Resultant Torque .................................. 43.9 kN·m
6. Diameter with lagging ................................800 mm
37. Estimated Pulley & Shaft Mass ............... 1,175 kg
38. Estimated Mass with Bearings ................ 1,398 kg
Shaft Specification
7. Shaft Center Diameter ................................216 mm
Shaft Stresses & Deflections
8. Shaft Material ......................................... AISI 1045
39. Shaft slope at hub ..................................4.13 (min)
9. Yield Strength ........................................ 505.0 MPa
40. Shaft slope at bearing ............................6.13 (min)
10. Fatigue Strength ................................... 263.0 MPa
41. Shaft deflection at center ......................... 0.89 mm
42. Shaft deflection at center (%) ....................... 0.050
Locking Device 43. Shaft Safety Factor (CEMA) .......................... 2.07
11. Hub Center Distance ...............................1035 mm 44. Shaft Safety Factor (AS1403) ........................ 1.79
12. Shaft diameter at hub ................................216 mm 45. Bending Stress ........................................ 51.6 MPa
13. Turndown radius at hub ................................0 mm 46. Torsional Stress ...................................... 22.2 MPa
14. Locking Device ................................... B-LOC 115 47. Von Mises Stress .................................... 64.4 MPa
15. Size ........................................................ 216 x 285 48. Fillet Von Mises Stress ........................ 126.8 MPa
16. Hub width .................................................110 mm
17. Hub pressure .................................... 121.0 N/mm²
Shell Dimension and Stresses
18. Maximum torque ..............................116,872 N·m
49. Shell thickness ............................................ 22 mm
19. Hub outer diameter ...................................430 mm
50. Sitzwohl reqd shell thickness1 .................... 19 mm
51. Sitzwohl shell stress ............................... 26.8 MPa
Bearing Specifications 52. Shell stress at 180 wa ............................. 26.8 MPa
20. Bearing Center Distance .........................1800 mm 1
Assumes 180 deg wrap and allowable stress of 34.0 MPa
21. Shaft diameter at bearing ..........................151 mm
22. Bearing to Fillet Distance .........................120 mm End Disk Dimension and Stresses
23. Turndown radius at bearing ........................98 mm 53. End disk thickness ...................................... 33 mm
24. Bearing......................................................... 23936 54. End disk stress ........................................ 86.7 MPa
25. SNL Plummer Block ...................................... 3134
26. Dynamic Capacity ..................................... 431 kN
27. Bearing L10 ........................................ 7,902 hours

Page 11 / 15
Description
#2 - Pulley 2 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension ................................. 71.2 kN
1. Name (Type-2)............................................Pulley 2 29. Running T2 Tension ................................. 71.4 kN
2. Pulley Diameter ..........................................508 mm 30. Design T1 Tension ................................... 89.0 kN
32. Wrap angle ..................................................83 deg
Lagging
37. Estimated Pulley & Shaft Mass .................. 559 kg
38. Estimated Mass with Bearings ................... 635 kg
Shaft Specification
13. Turndown radius at hub ................................0 mm 46. Torsional Stress ........................................ 0.1 MPa
15. Size ........................................................ 178 x 235 48. Fillet Von Mises Stress .......................... 65.0 MPa
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
18. Maximum torque ................................36,463 N·m
22. Bearing to Fillet Distance ...........................93 mm End Disk Dimension and Stresses
23. Turndown radius at bearing ......................117 mm 53. End disk thickness ...................................... 24 mm
25. SNL Plummer Block ........................................ 522
27. Bearing L10 ...................................... 37,644 hours

Page 12 / 15
Description
#3 - Take-up Pulley Design Tensions and Loads

1. Name (Type-2)................................ Take-up Pulley 29. Running T2 Tension ................................. 70.6 kN
32. Wrap angle ................................................180 deg
Lagging
34. Resultant Angle ...........................................90 deg
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
27. Bearing L10 ...................................... 12,400 hours

Page 13 / 15
Description

32. Wrap angle ..................................................90 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
27. Bearing L10 ...................................... 28,905 hours

Page 14 / 15
Description
#5 - Tail Pulley Design Tensions and Loads

1. Name (Type-2)....................................... Tail Pulley 29. Running T2 Tension ................................. 83.0 kN
3. Face Width ................................................1219 mm 31. Design T2 Tension .................................... 111 kN
32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
27. Bearing L10 ........................................ 5,259 hours

Page 15 / 15
Anexo B
(15 páginas)
H351654-3120-240-202-0002, Rev. 0
© DCH-DPRRO.COM - 06-04-2017 9:13:00
Client Name Codelco Designer G. Tarsetti
Project Name ODS 9 Company Hatch
Conveyor Name 130-CV-04 Filename 130-CV-04 - final
Description
Idler Set Data

Conveyor Length / Height ............................ 123 / 21.0 m Number of rolls 3 2
Material lift ............................................................ 20.6 m Trough angle (deg) 35 15
Type ............................................................... Unspecified Roll rpm 558 558
Rating (N) 5,338 3,781
Calc Idler Load (N) 2,573 817
Type ............................................................ Fabric (4-Ply) 1
Width ................................................................. 1067 mm
Rating............................................................... 900 N/mm Drive Station
Speed ................................................................... 4.45 m/s
Top / bottom cover thickness ....................... 9.0 x 3.0 mm
Weight .............................................................. 21.8 kg/m
Modulus ......................................................... 7,955 kN/m
Nominal empty / full power ........ (14 / 75%) 46 / 235 kW
Tape length .......................................................... 260.4 m
Min / max demand power............ (14 / 89%) 46 / 279 kW
Belt cycle time ............................................................ 58 s
Frame Size......................................................... IEC 355L
Maximum tension (kN) 83.9 105 Efficiency .................................................... 91.5 to 92.5%
Minimum tension (kN) 29.9 29.1 Inertia - Motor ................................................... 7.0 kg·m²
Maximum belt sag (%) 0.81 0.88 Inertia - Fluid Coupling ..................................102.0 kg·m²
Type ...................................................................... Gravity
Location ................................................. Head / Pulley #3
Bed depth ............................................................. 198 mm
Counterweight mass .......................................... 6.5 tonnes

Clearance ......................................................... 0.35 m
Backstops
Flooded belt tonnage........................................... 4,619 t/h Location ...............................................Head on Pulley #1
Flooded (wm + wb) .......................................... 309.9 kg/m Backstop (quantity x type) ......................... 1 x Low speed

Page 1 / 15
Description
Torque rating at low speed shaft .................... 34,050 N·m Splice type ...............................................................3-Step
Total Installed Power Multiplier ................................ 1.50 Splice step length ................................................. 250 mm
Pulley diameter .................................................... 654 mm 22 degree bias angle ............................................. 435 mm
Total splice length .............................................. 1185 mm
Brakes
Brake type .................................................. None installed
Other Information
Reducer Information Loaded beltline mass (excluding motors).......... 31,171 kg
Total inertia (ref HS shaft) .............................. 18.6 kg·m2
Manufacture ................................................................N/A
Frame size ...................................................................N/A Demand Power (kW)
Reducer ratio .......................................................... 13.380 Demand % Motor
Catalog reducer ratio ................................................ 0.000 Case
power Nameplate
RPM (High Speed) .......................................... 1800 RPM Empty - Normal Frict. 46 14.5
RPM (Low Speed) .......................................... 134.5 RPM Full - Normal Frict. 235 74.6
Configuration ........................................................ Parallel Full - High Frict. 258 81.8
Number of stages ............................................................ 3 Chute Atollado - Normal Frict. 253 80.2
Service factor ............................................................... 1.4 Chute Atollado - High Frict. 279 88.6
Power rating .................................................................... 0
Din Factor and Total Equivalent Mass
Motor Torque Belt line
Case Din factor
100% Motor Torque - High Speed................... 1,697 N·m mass (kg)
Motor Shaft Torque - Running (FN) ................ 1,289 N·m Empty - Normal Frict. 0.0477 191,945
Motor Shaft Torque - Starting (FN) ................. 2,308 N·m Full - Normal Frict. 0.0227 213,065
100% Motor Torque - Low Speed ................. 22,700 N·m Full - High Frict. 0.0336 213,469
Low Speed Shaft Torque - Running (FN) ...... 15,729 N·m Chute Atollado - Normal Frict. 0.0225 213,119
Low Speed Shaft Torque - Running (Max) ... 18,819 N·m Chute Atollado - High Frict. 0.0334 213,535
Low Speed Shaft Torque - Starting (FN) ....... 21,100 N·m
Low Speed Shaft Torque - Starting (Max)..... 24,274 N·m Maximum Belt Tensions (kN)
Starting and Stopping Empty - Normal Frict. 38.4 47.9
Start control ............................................. Constant torque Full - High Frict. 83.9 98.8
Start time........................................................ 4.2 to 10.6 s Chute Atollado - Normal Frict. 83.9 101
Operational stop control............................................. Drift Chute Atollado - High Frict. 88.7 105
Operational stop time ................................... 16.7 to 93.5 s
Emergency stop control ............................................. Drift Belt Safety Factor
Emergency stop time ................................... 16.7 to 93.5 s Case Running Dynamic
Material buildup in chute ........................................ 4.7 m³ Empty - Normal Frict. 25.00 20.05
Tension Ratios Full - High Frict. 11.45 9.72
Allowable (running)................................................... 2.73 Chute Atollado - Normal Frict. 11.44 9.47
Running tension ratio ................................................. 2.54 Chute Atollado - High Frict. 10.83 9.14
Allowable (dynamic) ................................................. 3.30
Starting tension ratio .................................................. 3.19 Splice Safety Factor
Transition Lengths Empty - Normal Frict. 18.75 15.04
Estimated Splice Data
Page 2 / 15
Description



Page 3 / 15
Description
Conveyor Profile

Wrap
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Bstp 1 1-HT 180 83.9 33.1 117 105 33.2 138
Pulley 2 2-LT 80 32.9 42.5 33.0 42.6
Take-up Pulley 2-LT 180 31.8 64.0 31.8 64.1
Pulley 4 2-LT 100 33.3 51.1 33.5 51.5
Tail Pulley 3-LT 180 30.4 61.2 33.8 68.2

Page 4 / 15
Description

1 1.56 5.84 0.068 61 92.2 36.4 914 130 194 18.3 24.0
2 3.07 7.48 0.076 467 41.1 41.3 352 55.4 317 0.0 6.5
3 2.22 10.33 0.105 160 39.8 40.2 352 76.5 90 0.1 9.0
4 2.55 8.99 0.091 254 41.6 42.0 352 66.6 232 0.1 7.8
5 2.24 10.26 0.104 163 38.0 38.5 352 76.0 7 0.1 8.9

(mm) (mm) (mm)
1 Rubber 610 19.1 648 1219 165 165 1800 3038 23938 1,198
2 Rubber 406 15.0 436 1219 113 87 1560 520 23120 406
3 Rubber 406 15.0 436 1219 113 87 1560 520 23120 406

(mm) (mm) (mm)
1 XT-70 AISI 1045 505.0 584.4 263.0 165 1065 125 0 0.0 0
2 XT-45 AISI 1045 505.0 584.4 263.0 113 1090 85 38 0.0 0
3 XT-45 AISI 1045 505.0 584.4 263.0 113 1090 85 38 0.0 0

Page 5 / 15
Description
Conveyor Load Cases

For this conveyor, there are two Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
Empty
There are one Design Level 2 loads, which are:
1. Chute Atollado

Page 6 / 15
Description
Chute Atollado

Page 7 / 15
Description

1. Type ...................................................................................................................................................Gravity
2. Location .............................................................................................................................. Head / Pulley #3
a. Running ......................................................................................................................... -0.18 to 0.00 m
b. Momentary .................................................................................................................... -0.30 to 0.01 m

4. Clearance ............................................................................................................................................ 0.35 m

Page 8 / 15
Description
Pulley Details

Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 - Backstop 1 1-HT 180 92.2 36.4 130 129 36.5 167
Pulley 2 2-LT 80 41.1 55.4 36.3 49.2
Take-up Pulley 2-LT 180 39.8 76.5 35.0 67.0
Pulley 4 2-LT 100 41.6 66.6 36.8 59.3
Tail Pulley 3-LT 180 38.0 76.0 37.2 74.5
Required Pulley Diameter (Tension based on a safety factor of 10)

Required
%
tension
(mm)
Motor 1 - Backstop 1 Head (6) 1 - HT 180 610 800 87 109
Pulley 2 Head (8) 2 - LT 80 406 500 34 34
Pulley 4 Head (12) 2 - LT 100 406 500 35 35

Shaft Slope
Type at Hub
(min)
1 1 1.56 5.84 54.3 20.7 18.5 20.7 65.1 40.4 0.0
2 2 3.07 7.48 46.3 0.1 46.1 0.3 46.3 46.1 0.0
3 2 2.22 10.33 64.0 0.4 63.7 0.8 64.0 63.7 0.0
4 2 2.55 8.99 55.7 0.3 55.4 0.6 55.7 55.4 0.0
5 3 2.24 10.26 63.6 0.4 63.2 0.9 63.6 63.3 0.0

Page 9 / 15
Description

Motor 1 - Backstop 1
Load Case Resultant
T1 T2
Force
Empty - Normal Frict. 38.4 33.0 71.5
Full - Normal Frict. 79.9 33.0 113
Full - High Frict. 83.9 33.1 117
Chute Atollado - Normal Frict. 83.9 33.0 117
Chute Atollado - High Frict. 88.7 33.1 122

ID Description
Mtr 1 - Bstp 1 38.4 33.0 47.9 32.6 37.6 33.1 37.6 33.1
Empty - Pulley 2 32.9 33.0 32.5 32.8 32.9 33.0 32.9 33.0
Frict. Pulley 4 33.1 33.3 33.5 33.9 33.1 33.3 33.1 33.3
Tail Pulley 29.9 30.3 33.8 34.4 29.8 30.1 29.8 30.1
Mtr 1 - Bstp 1 79.9 33.0 95.9 32.8 70.8 33.1 70.8 33.1
Full - Pulley 2 32.9 33.0 32.7 32.9 33.0 33.0 33.0 33.0
Frict. Pulley 4 33.1 33.3 33.3 33.6 33.0 33.2 33.0 33.2
Tail Pulley 29.9 30.2 31.8 32.3 29.1 29.4 29.1 29.4
Mtr 1 - Bstp 1 83.9 33.1 98.8 32.9 73.8 33.2 73.8 33.2
Pulley 2 32.9 33.0 32.7 33.0 33.0 33.1 33.0 33.1
Full - High
Frict.
Pulley 4 33.3 33.6 33.5 33.8 33.2 33.5 33.2 33.5
Tail Pulley 30.4 30.8 32.2 32.8 29.4 29.8 29.4 29.8
Mtr 1 - Bstp 1 83.9 33.0 101 32.9 72.5 33.1 72.5 33.1
Chute Pulley 2 32.9 33.0 32.7 32.9 33.0 33.0 33.0 33.0
Atollado -
Normal
Frict. Pulley 4 33.1 33.3 33.3 33.6 33.0 33.2 33.0 33.2
Tail Pulley 29.9 30.2 31.6 32.0 29.1 29.3 29.1 29.3
Mtr 1 - Bstp 1 88.7 33.1 105 32.9 75.9 33.2 75.9 33.2
Chute Pulley 2 32.9 33.0 32.8 33.0 33.0 33.1 33.0 33.1
Tail Pulley 30.4 30.8 31.9 32.5 29.4 29.8 29.4 29.8

Page 10 / 15
Description
#1 - Motor 1 - Backstop 1 Design Tensions and Loads

1. Name (Type-1)....................... Motor 1 - Backstop 1 29. Running T2 Tension ................................. 33.0 kN
32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
14. Locking Device ........................................... XT-70 47. Von Mises Stress .................................... 65.1 MPa
16. Hub width ...................................................79 mm
17. Hub pressure ........................................ 0.0 N/mm²
18. Maximum torque ........................................ 0 N·m
23. Turndown radius at bearing ..........................0 mm 53. End disk thickness ...................................... 33 mm
27. Bearing L10 ...................................... 60,729 hours

Page 11 / 15
Description

32. Wrap angle ..................................................80 deg
33. Design Resultant Tension......................... 55.4 kN
Lagging
Shaft Specification
16. Hub width ...................................................54 mm
17. Hub pressure ........................................ 0.0 N/mm²
50. Sitzwohl reqd shell thickness1 ...................... 9 mm
21. Shaft diameter at bearing ............................87 mm
27. Bearing L10 .................................... 467,436 hours

Page 12 / 15
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
39. Shaft slope at hub ................................10.33 (min)
40. Shaft slope at bearing ..........................13.07 (min)
16. Hub width ...................................................54 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 159,663 hours

Page 13 / 15
Description

32. Wrap angle ................................................100 deg
Lagging
Shaft Specification
16. Hub width ...................................................54 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 253,594 hours

Page 14 / 15
Description

32. Wrap angle ................................................180 deg
Lagging
34. Resultant Angle .............................................7 deg
Shaft Specification
16. Hub width ...................................................54 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 163,144 hours

Page 15 / 15
Anexo C
(18 páginas)
H351654-3120-240-202-0002, Rev. 0
© DCH-DPRRO.COM - 06-04-2017 9:13:00
Conveyor Name 130-CV-05 Filename 130-CV-05
Description
Idler Set Data

Conveyor Length / Height ................................ 61 / 4.4 m Number of rolls 3 2
Material lift .............................................................. 7.8 m Trough angle (deg) 35 15
Type ........................................................................ Ripios Roll rpm 561 561
Rating (N) 5,338 3,781
Calc Idler Load (N) 2,423 746
Type ............................................................ Fabric (3-Ply) 1
Width ................................................................. 1067 mm
Rating............................................................... 630 N/mm Drive Station
Speed ................................................................... 4.47 m/s
Top / bottom cover thickness ....................... 9.0 x 3.0 mm
Weight .............................................................. 20.2 kg/m
Modulus ......................................................... 6,061 kN/m
Nominal empty / full power ........ (16 / 64%) 28 / 112 kW
Tape length .......................................................... 156.5 m
Min / max demand power............ (16 / 85%) 28 / 149 kW
Belt cycle time ............................................................ 35 s
Frame Size......................................................... IEC 315L
Maximum tension (kN) 52.6 70.9 Efficiency .................................................... 91.5 to 92.5%
Minimum tension (kN) 23.0 16.3 Inertia - Motor ................................................... 3.9 kg·m²
Maximum belt sag (%) 0.97 1.14 Inertia - Fluid Coupling ..................................... 0.2 kg·m²
Type ...................................................................... Gravity
Location ................................................... Tail / Pulley #5
Bed depth ............................................................. 197 mm
Counterweight mass .......................................... 4.7 tonnes

Clearance ......................................................... 0.25 m
Backstops
Flooded belt tonnage........................................... 4,644 t/h Location ...............................................Head on Pulley #3
Flooded (wm + wb) .......................................... 308.6 kg/m Backstop (quantity x type) ......................... 1 x Low speed

Page 1 / 18
Description
Torque rating at low speed shaft .................... 14,506 N·m Splice type ...............................................................2-Step
Total Installed Power Multiplier ................................ 1.50 Splice step length ................................................. 250 mm
Pulley diameter .................................................... 501 mm 22 degree bias angle ............................................. 435 mm
Total splice length ................................................ 935 mm
Brakes
Brake type .................................................. None installed
Other Information
Reducer Information Loaded beltline mass (excluding motors).......... 16,246 kg
Total inertia (ref HS shaft) .............................. 14.0 kg·m2
Manufacture ................................................................N/A
Frame size ...................................................................N/A Demand Power (kW)
Reducer ratio ............................................................ 8.550 Demand % Motor
Catalog reducer ratio ................................................ 0.000 Case
power Nameplate
RPM (High Speed) .......................................... 1500 RPM Empty - Normal Frict. 28.1 16.0
RPM (Low Speed) .......................................... 175.4 RPM Full - Normal Frict. 112.1 64.1
Configuration ................................................ Shaft Mount Full - High Frict. 126.9 72.5
Number of stages ............................................................ 3 Chute Atollado - Normal Frict. 129.8 74.2
Service factor ............................................................... 1.4 Chute Atollado - High Frict. 148.6 84.9
Power rating .................................................................... 0
Din Factor and Total Equivalent Mass
Motor Torque Belt line
Case Din factor
100% Motor Torque - High Speed................... 1,131 N·m mass (kg)
Motor Shaft Torque - Running (FN) ................... 735 N·m Empty - Normal Frict. 0.0464 10,943
Motor Shaft Torque - Starting (FN) ................. 1,473 N·m Full - Normal Frict. 0.0241 20,776
100% Motor Torque - Low Speed ................... 9,670 N·m Full - High Frict. 0.0355 21,015
Low Speed Shaft Torque - Running (FN) ........ 5,662 N·m Chute Atollado - Normal Frict. 0.0238 20,822
Low Speed Shaft Torque - Running (Max) ..... 7,644 N·m Chute Atollado - High Frict. 0.0351 21,071
Low Speed Shaft Torque - Starting (FN) ....... 11,685 N·m
Low Speed Shaft Torque - Starting (Max)..... 12,698 N·m Maximum Belt Tensions (kN)
Starting and Stopping Empty - Normal Frict. 27.4 49.4
Start control ............................................. Constant torque Full - High Frict. 47.7 67.6
Start time.......................................................... 0.9 to 4.4 s Chute Atollado - Normal Frict. 49.6 69.6
Operational stop control............................................. Drift Chute Atollado - High Frict. 52.6 70.9
Operational stop time ....................................... 3.3 to 8.4 s
Emergency stop control ............................................. Drift Belt Safety Factor
Emergency stop time ....................................... 3.3 to 8.4 s Case Running Dynamic
Material buildup in chute ........................................ 1.0 m³ Empty - Normal Frict. 24.55 13.61
Tension Ratios Full - High Frict. 14.09 9.95
Allowable (running)................................................... 2.73 Chute Atollado - Normal Frict. 13.55 9.65
Running tension ratio ................................................. 2.21 Chute Atollado - High Frict. 12.78 9.48
Allowable (dynamic) ................................................. 3.30
Starting tension ratio .................................................. 3.19 Splice Safety Factor
Transition Lengths Empty - Normal Frict. 16.37 9.07
Estimated Splice Data
Page 2 / 18
Description



Page 3 / 18
Description
Conveyor Profile
Pulleys
Pulleys - Top View

Wrap
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-HT 175 52.1 105 69.2 139
Pulley 2 4-HT 163 51.8 103 69.4 138
Mtr 1 - Bstp 1 1-HT 180 52.6 24.0 76.4 70.9 26.0 96.9
Pulley 4 2-LT 76 23.9 29.5 24.4 29.9
Take-up Pulley 2-LT 180 23.0 46.3 23.0 47.3
Pulley 6 2-LT 104 24.3 38.5 25.8 41.7
Tail Pulley 2-LT 180 24.0 48.4 27.6 56.6

Page 4 / 18
Description

1 1.06 10.63 0.124 40 57.3 57.7 568 117 197 0.1 21.3
2 1.31 9.76 0.099 45 57.0 57.4 459 113 6 0.1 13.1
3 1.33 11.10 0.112 120 57.9 26.2 429 84.2 183 7.9 9.7
4 2.01 8.46 0.085 500 29.9 30.1 349 39.1 318 0.0 4.6
5 1.45 11.76 0.119 217 28.8 29.1 349 54.4 90 0.1 6.3
6 1.55 10.99 0.111 272 30.4 30.7 349 50.8 234 0.1 5.9
7 1.32 12.92 0.130 159 30.0 30.5 349 59.7 11 0.1 6.9

(mm) (mm) (mm)
1 Rubber 457 19.1 495 1219 113 100 1550 522 23024 505
2 Rubber 406 15.0 436 1219 100 75 1560 517 22217 385
3 Rubber 457 15.0 487 1219 138 100 1800 522 23024 645
4 Rubber 457 15.0 487 1219 125 100 1550 522 23024 535

(mm) (mm) (mm)
1 XT-45 AISI 1045 505.0 584.4 263.0 113 1090 93 19 0.0 0
2 XT-40 AISI 1045 505.0 584.4 263.0 100 1095 68 38 0.0 0
3 XT-60 AISI 1045 505.0 584.4 263.0 138 1070 93 57 0.0 0
4 XT-50 AISI 1045 505.0 584.4 263.0 125 1085 93 37 0.0 0

Page 5 / 18
Description
Conveyor Load Cases

For this conveyor, there are three Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
3. Chute Atollado
Empty

Page 6 / 18
Description
Chute Atollado (Material Lift = 7.8 m)

Page 7 / 18
Description

1. Type ...................................................................................................................................................Gravity
2. Location ................................................................................................................................ Tail / Pulley #5
a. Running ......................................................................................................................... -0.12 to 0.00 m
b. Momentary .................................................................................................................... -0.20 to 0.01 m

4. Clearance ............................................................................................................................................ 0.25 m

Page 8 / 18
Description
Pulley Details

Wrap
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-HT 175 57.3 117 84.2 170
Pulley 2 4-HT 163 57.0 113 84.4 167
Motor 1 - Backstop 1 1-HT 180 57.9 26.2 84.2 86.0 28.6 115
Pulley 4 2-LT 76 29.9 39.1 26.8 35.1
Take-up Pulley 2-LT 180 28.8 54.4 25.3 48.6
Pulley 6 2-LT 104 30.4 50.8 28.4 48.5
Tail Pulley 2-LT 180 30.0 59.7 30.4 61.5

Required
%
tension
(mm)
Pulley 1 Head (5) 3 - HT 175 457 500 78 104
Pulley 2 Head (7) 4 - HT 163 457 500 78 104
Pulley 4 Tail (15) 2 - LT 76 406 315 36 36
Take-up Pulley Tail (17) 2 - LT 180 406 315 35 36
Pulley 6 Tail (19) 2 - LT 104 406 315 36 40

Shaft Slope
Type at Hub
(min)
1 3 1.06 10.63 82.4 0.2 67.7 0.5 82.4 67.7 0.0
2 4 1.31 9.76 68.2 0.2 69.1 0.5 68.2 69.1 0.0
3 1 1.33 11.10 68.3 28.0 55.4 40.4 83.8 89.3 0.0
4 2 2.01 8.46 46.3 0.1 40.6 0.4 46.3 40.6 0.0
5 2 1.45 11.76 64.4 0.4 56.4 0.9 64.4 56.4 0.0
6 2 1.55 10.99 60.2 0.3 52.7 0.7 60.2 52.7 0.0
7 2 1.32 12.92 70.7 0.5 61.9 1.2 70.7 62.0 0.0

Page 9 / 18
Description

Load Case Resultant
T1 T2
Force
Full - Normal Frict. 45.5 24.0 69.4
Full - High Frict. 47.7 23.8 71.5
Chute Atollado - Normal Frict. 49.4 24.0 73.4
Chute Atollado - High Frict. 52.6 23.8 76.4

Page 10 / 18
Description

ID Description
Pulley 1 27.3 27.4 43.4 45.0 25.5 25.4 25.5 25.4
Pulley 2 26.8 26.8 45.5 46.9 24.7 24.6 24.7 24.6
Empty - Mtr 1 - Bstp 1 27.1 24.0 49.4 16.3 24.6 24.8 24.6 24.8
EM-N Normal Pulley 4 23.9 24.0 22.3 23.5 24.1 24.0 24.1 24.0
Frict. Take-up Pulley 23.0 23.2 23.0 24.3 23.0 23.1 23.0 23.1
Pulley 6 24.2 24.3 25.8 27.1 24.0 24.0 24.0 24.0
Tail Pulley 23.8 24.1 27.6 29.0 23.4 23.6 23.4 23.6
Pulley 1 45.5 45.7 65.0 65.6 29.4 29.3 29.4 29.3
Pulley 2 45.0 45.2 65.3 65.9 28.4 28.3 28.4 28.3
Full - Mtr 1 - Bstp 1 45.5 24.0 66.8 21.7 28.1 25.6 28.1 25.6
FL-N Normal Pulley 4 23.9 24.0 23.5 23.8 24.3 24.1 24.3 24.1
Pulley 6 24.2 24.3 24.6 25.1 23.8 23.7 23.8 23.7
Tail Pulley 23.8 24.1 25.0 25.5 23.0 23.0 23.0 23.0
Pulley 1 47.3 47.7 65.4 66.2 29.3 29.2 29.3 29.2
Pulley 2 47.0 47.3 65.8 66.5 28.3 28.3 28.3 28.3
Mtr 1 - Bstp 1 47.7 23.8 67.6 21.6 28.1 25.8 28.1 25.8
Full - High
FL-H Pulley 4 23.9 24.1 23.5 23.9 24.3 24.2 24.3 24.2
Frict.
Take-up Pulley 23.0 23.3 23.0 23.6 23.0 23.0 23.0 23.0
Pulley 6 24.3 24.5 24.8 25.3 23.9 23.8 23.9 23.8
Tail Pulley 24.0 24.4 25.1 25.7 23.1 23.1 23.1 23.1
Pulley 1 49.4 49.6 68.2 68.8 30.1 30.0 30.1 30.0
Pulley 2 49.0 49.2 68.4 68.9 29.1 29.0 29.1 29.0
Chute Mtr 1 - Bstp 1 49.4 24.0 69.6 22.2 28.7 25.8 28.7 25.8
Atollado -
CA-N Pulley 4 23.9 24.0 23.6 23.9 24.3 24.1 24.3 24.1
Normal
Pulley 6 24.2 24.3 24.5 24.9 23.8 23.7 23.8 23.7
Tail Pulley 23.8 24.1 24.7 25.2 22.9 22.9 22.9 22.9
Pulley 1 52.1 52.5 69.2 69.8 30.1 30.0 30.1 30.0
Pulley 2 51.8 52.2 69.4 70.0 29.1 29.1 29.1 29.1
Chute Mtr 1 - Bstp 1 52.6 23.8 70.9 22.2 28.8 26.0 28.8 26.0
CA-H Atollado - Pulley 4 23.9 24.1 23.6 23.9 24.4 24.2 24.4 24.2
High Frict. Take-up Pulley 23.0 23.3 23.0 23.5 23.0 23.0 23.0 23.0
Pulley 6 24.3 24.5 24.6 25.1 23.9 23.8 23.9 23.8
Tail Pulley 24.0 24.4 24.8 25.4 23.0 23.0 23.0 23.0

Page 11 / 18
Description

32. Wrap angle ................................................175 deg
Lagging
Shaft Specification
16. Hub width ...................................................73 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 ...................................... 39,779 hours

Page 12 / 18
Description

32. Wrap angle ................................................163 deg
Lagging
Shaft Specification
16. Hub width ...................................................60 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 ...................................... 44,674 hours

Page 13 / 18
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................54 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 119,531 hours

Page 14 / 18
Description

32. Wrap angle ..................................................76 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure ........................................ 0.0 N/mm²
Bearing Specifications 52. Shell stress at 180 wa ............................... 8.3 MPa
27. Bearing L10 .................................... 500,000 hours

Page 15 / 18
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure ........................................ 0.0 N/mm²
51. Sitzwohl shell stress ................................. 8.0 MPa
27. Bearing L10 .................................... 217,255 hours

Page 16 / 18
Description

32. Wrap angle ................................................104 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 272,285 hours

Page 17 / 18
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure ........................................ 0.0 N/mm²
27. Bearing L10 .................................... 159,064 hours

Page 18 / 18
Anexo D
(9 páginas)
H351654-3120-240-202-0002, Rev. 0
© DCH-DPRRO.COM - 06-04-2017 9:13:00
Conveyor Name 130-CV-03 Filename 130-cv-03 - final - 560swi -
Location PTMP Date April 5, 2017
Description
Conveyor Profile

Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 170 71.4 241 233 71.6 305
Pulley 2 2-LT 83 71.2 94.9 71.4 95.0
Take-up Pulley 2-LT 180 70.0 141 70.0 141
Pulley 4 2-LT 90 72.4 103 72.5 103
Tail Pulley 3-LT 180 87.6 176 125 252

Page 1 / 9
Description

1 2.07 4.13 0.050 149 186 78.4 1175 266 189 43.9 51.0
2 2.24 2.65 0.028 216 89.0 89.3 559 122 316 0.1 14.2
3 1.60 3.69 0.038 71 87.5 88.6 559 171 90 0.3 19.8
4 2.07 2.87 0.030 166 90.5 91.2 559 132 226 0.2 15.4
5 2.52 4.88 0.052 189 110 111 643 221 358 0.4 29.2

(mm) (mm) (mm)
1 Rubber 762 19.0 800 1219 216 151 1800 3134 23134 1,398
2 Rubber 508 15.0 538 1219 178 100 1560 522 23222 635
3 Rubber 508 15.0 538 1219 180 150 1560 3134 23134 863

(mm) (mm) (mm)
B-LOC
1 AISI 1045 505.0 584.4 263.0 216 1035 120 98 0.0 0
115
B-LOC
2 AISI 1045 505.0 584.4 263.0 178 1095 93 117 0.0 0
106
B-LOC
3 AISI 1045 505.0 584.4 263.0 180 1030 120 45 0.0 0
115

Page 2 / 9
Description
Pulley Details

Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 186 78.4 266 279 78.7 359
Pulley 2 2-LT 83 89.0 122 78.5 108
Take-up Pulley 2-LT 180 87.5 171 77.0 150
Pulley 4 2-LT 90 90.5 132 79.7 117
Tail Pulley 3-LT 180 110 221 138 277
Required Pulley Diameter (Tension based on a safety factor of 6.67)

Required
%
tension
(mm)
Motor 1 Head (10) 1 - HT 180 762 1000 66 91
Pulley 2 Head (12) 2 - LT 83 508 630 28 28
Pulley 4 Head (16) 2 - LT 90 508 630 29 29

Hub Hub Fillet Fillet Fillet Von Hub Von 濲
Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises verhung
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Von Mises
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) Stress
1 1 2.07 4.13 51.6 22.2 57.6 65.1 64.3 126.7 0.0
2 2 2.24 2.65 25.8 0.1 65.0 0.4 25.8 65.0 0.0
3 2 1.60 3.69 35.9 0.3 90.7 1.6 35.9 90.7 0.0
4 2 2.07 2.87 27.9 0.2 70.3 1.1 27.9 70.4 0.0
5 3 2.52 4.88 51.1 0.4 53.5 0.6 51.1 53.5 0.0

Page 3 / 9
Description

Motor 1
Load Case Resultant
T1 T2
Force
Empty - Normal Frict. 104 71.4 175
Full - Normal Frict. 137 71.4 208
Full - High Frict. 165 71.3 236
Chute Atollado - Normal Frict. 141 71.4 212
Chute Atollado - High Frict. 170 71.3 241

ID Description
Motor 1 104 71.4 198 70.8 69.9 71.6 69.9 71.6
Empty - Pulley 2 71.2 71.4 70.8 71.3 71.4 71.5 71.4 71.5
Frict. Pulley 4 72.0 72.4 72.4 73.2 71.9 72.2 71.9 72.2
Tail Pulley 82.2 83.0 125 126 66.9 67.6 66.9 67.6
Motor 1 137 71.4 217 71.2 67.9 71.5 67.9 71.5
Full - Pulley 2 71.2 71.4 71.1 71.4 71.3 71.5 71.3 71.5
Frict. Pulley 4 72.0 72.4 72.1 72.7 71.9 72.3 71.9 72.3
Tail Pulley 82.2 83.0 94.8 95.7 71.7 72.5 71.7 72.5
Motor 1 165 71.3 231 71.1 67.6 71.5 67.6 71.5
Pulley 2 71.1 71.5 71.0 71.4 71.3 71.5 71.3 71.5
Full - High
Frict.
Pulley 4 72.4 73.0 72.5 73.1 72.2 72.7 72.2 72.7
Tail Pulley 87.6 88.8 98.1 99.4 72.5 73.6 72.5 73.6
Motor 1 141 71.4 219 71.2 68.0 71.5 68.0 71.5
Chute Pulley 2 71.2 71.4 71.1 71.4 71.3 71.5 71.3 71.5
Atollado -
Normal
Frict. Pulley 4 72.0 72.4 72.1 72.6 71.9 72.3 71.9 72.3
Tail Pulley 82.2 83.0 93.9 94.8 71.5 72.2 71.5 72.2
Motor 1 170 71.3 233 71.2 67.7 71.5 67.7 71.5
Chute Pulley 2 71.1 71.5 71.0 71.4 71.3 71.5 71.3 71.5
Tail Pulley 87.6 88.8 97.2 98.4 72.2 73.3 72.2 73.3

Page 4 / 9
Description
#1 - Motor 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension .................................. 137 kN
1. Name (Type-1)............................................ Motor 1 29. Running T2 Tension ................................. 71.4 kN
32. Wrap angle ................................................180 deg
Lagging
37. Estimated Pulley & Shaft Mass ............... 1,175 kg
Shaft Specification
39. Shaft slope at hub ................................. 4.13 (min)
40. Shaft slope at bearing ........................... 6.13 (min)
12. Shaft diameter at hub ................................216 mm 45. Bending Stress........................................ 51.6 MPa
16. Hub width .................................................110 mm
17. Hub pressure .................................... 121.0 N/mm²
18. Maximum torque ..............................116,872 N·m
49. Shell thickness............................................ 22 mm
26. Dynamic Capacity .................................. 1,040 kN
27. Bearing L10 .................................... 149,058 hours

Page 5 / 9
Description

32. Wrap angle ..................................................83 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
18. Maximum torque ............................... 36,463 N·m
27. Bearing L10 .................................... 216,489 hours

Page 6 / 9
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
27. Bearing L10 ...................................... 71,313 hours

Page 7 / 9
Description

32. Wrap angle ..................................................90 deg
Lagging
Shaft Specification
16. Hub width ...................................................48 mm
17. Hub pressure .................................... 104.0 N/mm²
27. Bearing L10 .................................... 166,230 hours

Page 8 / 9
Description

3. Face Width ................................................1219 mm 31. Design T2 Tension .................................... 111 kN
32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width .................................................115 mm
17. Hub pressure .................................... 137.0 N/mm²
24. Bearing......................................................... 23134 54. End disk stress ...................................... 123.0 MPa
26. Dynamic Capacity .................................. 1,040 kN
27. Bearing L10 .................................... 189,380 hours

Page 9 / 9
Anexo E
(9 páginas)
H351654-3120-240-202-0002, Rev. 0
© DCH-DPRRO.COM - 06-04-2017 9:13:00
Conveyor Name 130-CV-04 Filename 130-cv-04 - final poleas nuev
Description
Conveyor Profile

Wrap
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Bstp 1 1-HT 180 83.4 33.0 116 105 33.1 138
Pulley 2 2-LT 80 32.8 42.4 32.9 42.5
Take-up Pulley 4-LT 180 31.7 63.7 31.7 63.8
Pulley 4 4-LT 100 33.2 50.9 33.3 51.3
Tail Pulley 3-LT 180 30.2 60.9 33.7 67.9

Page 1 / 9
Description

1 1.57 5.81 0.067 62 91.8 36.3 914 130 194 18.2 23.9
2 2.86 7.76 0.081 472 41.0 41.2 353 55.3 317 0.0 7.0
3 3.06 6.06 0.064 500 39.6 40.0 405 75.7 90 0.1 9.7
4 3.47 5.34 0.056 500 41.5 41.8 405 66.7 232 0.1 8.6
5 3.07 6.05 0.064 500 37.8 38.3 403 75.5 7 0.1 9.7

(mm) (mm) (mm)
1 Rubber 610 19.1 648 1219 165 165 1800 3038 23938 1,198
2 Rubber 406 15.0 436 1219 113 87 1560 520 23120 407
3 Rubber 406 15.0 436 1219 130 110 1560 524 23224 501
4 Rubber 406 15.0 436 1219 130 110 1560 524 23224 502

(mm) (mm) (mm)
1 XT-70 AISI 1045 505.0 584.4 263.0 165 1065 125 0 0.0 0
B-LOC
2 AISI 1045 505.0 584.4 263.0 113 1055 85 38 0.0 0
115
B-LOC
3 AISI 1045 505.0 584.4 263.0 130 1045 98 30 0.0 0
115
B-LOC
4 AISI 1045 505.0 584.4 263.0 130 1045 98 30 0.0 0
115

Page 2 / 9
Description
Pulley Details

Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 - Backstop 1 1-HT 180 91.8 36.3 130 128 36.4 167
Pulley 2 2-LT 80 41.0 55.3 36.2 49.0
Take-up Pulley 4-LT 180 39.6 75.7 34.9 66.3
Pulley 4 4-LT 100 41.5 66.7 36.7 59.5
Tail Pulley 3-LT 180 37.8 75.5 37.1 74.1

Required
%
tension
(mm)
Pulley 2 Head (8) 2 - LT 80 406 500 34 34
Pulley 4 Head (12) 4 - LT 100 406 500 35 35

Shaft Slope
Type at Hub
(min)
1 1 1.57 5.81 54.1 20.6 18.4 20.6 64.8 40.1 0.0
2 2 2.86 7.76 49.7 0.1 46.0 0.3 49.7 46.0 0.0
3 4 3.06 6.06 45.2 0.2 38.2 0.4 45.2 38.2 0.0
4 4 3.47 5.34 39.8 0.2 33.7 0.3 39.8 33.7 0.0
5 3 3.07 6.05 45.1 0.3 38.1 0.4 45.1 38.1 0.0

Page 3 / 9
Description

Load Case Resultant
T1 T2
Force
Full - Normal Frict. 79.6 32.9 113
Full - High Frict. 83.4 33.0 116
Chute Atollado - Normal Frict. 83.6 32.9 117
Chute Atollado - High Frict. 88.3 33.0 121

ID Description
Mtr 1 - Bstp 1 38.1 32.9 47.5 32.5 37.3 33.0 37.3 33.0
Empty - Pulley 2 32.8 32.9 32.4 32.7 32.8 32.9 32.8 32.9
Frict. Pulley 4 33.0 33.2 33.3 33.7 33.0 33.2 33.0 33.2
Tail Pulley 29.8 30.1 33.7 34.2 29.6 29.9 29.6 29.9
Mtr 1 - Bstp 1 79.6 32.9 95.6 32.7 70.5 33.0 70.5 33.0
Full - Pulley 2 32.8 32.9 32.6 32.8 32.9 32.9 32.9 32.9
Frict. Pulley 4 33.0 33.2 33.2 33.5 32.9 33.1 32.9 33.1
Tail Pulley 29.8 30.1 31.7 32.1 29.0 29.2 29.0 29.2
Mtr 1 - Bstp 1 83.4 33.0 98.4 32.7 73.5 33.1 73.5 33.1
Pulley 2 32.8 32.9 32.6 32.9 32.9 33.0 32.9 33.0
Full - High
Frict.
Pulley 4 33.2 33.4 33.3 33.7 33.1 33.3 33.1 33.3
Tail Pulley 30.2 30.7 32.1 32.6 29.3 29.7 29.3 29.7
Mtr 1 - Bstp 1 83.6 32.9 101 32.8 72.2 33.0 72.2 33.0
Chute Pulley 2 32.8 32.9 32.6 32.8 32.9 32.9 32.9 32.9
Atollado -
Normal
Frict. Pulley 4 33.0 33.2 33.1 33.4 32.9 33.1 32.9 33.1
Tail Pulley 29.8 30.1 31.4 31.8 28.9 29.2 28.9 29.2
Mtr 1 - Bstp 1 88.3 33.0 105 32.8 75.6 33.1 75.6 33.1
Chute Pulley 2 32.8 32.9 32.7 32.9 32.9 33.0 32.9 33.0
Tail Pulley 30.2 30.7 31.8 32.3 29.3 29.6 29.3 29.6

Page 4 / 9
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................79 mm
17. Hub pressure ........................................ 0.0 N/mm²
23. Turndown radius at bearing ..........................0 mm 53. End disk thickness ...................................... 33 mm
27. Bearing L10 ...................................... 61,651 hours

Page 5 / 9
Description

32. Wrap angle ..................................................80 deg
Lagging
Shaft Specification
16. Hub width ...................................................90 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 471,697 hours

Page 6 / 9
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width .................................................100 mm
17. Hub pressure .................................... 146.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 7 / 9
Description

32. Wrap angle ................................................100 deg
Lagging
Shaft Specification
16. Hub width .................................................100 mm
17. Hub pressure .................................... 146.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 8 / 9
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width .................................................100 mm
17. Hub pressure .................................... 146.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 9 / 9
Anexo F
(12 páginas)
H351654-3120-240-202-0002, Rev. 0
© DCH-DPRRO.COM - 06-04-2017 9:13:00
Project Name ODS 9 Company
Conveyor Name 130-CV-05 Filename 130-cv-05 poleas nuevas
Description
Conveyor Profile
Pulleys
Pulleys - Top View

Wrap
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-HT 175 52.1 104 69.4 139
Pulley 2 4-HT 163 51.7 103 69.5 138
Mtr 1 - Bstp 1 1-HT 180 52.4 24.0 76.3 70.9 25.9 96.8
Pulley 4 2-LT 76 23.9 29.5 24.3 29.9
Take-up Pulley 2-LT 180 23.0 46.2 23.0 47.1
Pulley 6 2-LT 104 24.3 38.5 25.7 41.3
Tail Pulley 2-LT 180 24.0 48.3 27.4 56.0

Page 1 / 12
Description

1 2.03 7.71 0.091 500 57.3 57.6 606 116 198 0.1 22.0
2 2.60 6.55 0.069 500 56.9 57.2 552 112 6 0.1 14.2
3 2.77 6.60 0.069 500 57.7 26.2 470 84.0 183 7.9 10.6
4 4.78 4.31 0.045 500 29.9 30.1 400 39.5 317 0.0 5.0
5 3.50 5.88 0.061 500 28.8 29.1 400 53.9 90 0.1 6.8
6 3.69 5.59 0.058 500 30.4 30.6 400 51.2 235 0.1 6.5
7 3.17 6.50 0.068 500 30.0 30.4 400 59.6 10 0.1 7.5

(mm) (mm) (mm)
1 Rubber 457 19.1 495 1219 130 110 1550 524 23224 568
2 Rubber 406 15.0 436 1219 120 100 1560 522 23222 476
3 Rubber 457 15.0 487 1219 150 125 1800 528 23228 743
4 Rubber 457 15.0 487 1219 140 115 1550 526 23226 661

(mm) (mm) (mm)
B-LOC
1 AISI 1045 505.0 584.4 263.0 130 1045 98 30 0.0 0
115
B-LOC
2 AISI 1045 505.0 584.4 263.0 120 1055 93 30 0.0 0
115
B-LOC
3 AISI 1045 505.0 584.4 263.0 150 1045 108 38 0.0 0
115
B-LOC
4 AISI 1045 505.0 584.4 263.0 140 1045 100 38 0.0 0
115

Page 2 / 12
Description
Pulley Details

Wrap
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-HT 175 57.3 116 84.6 171
Pulley 2 4-HT 163 56.9 112 84.6 167
Motor 1 - Backstop 1 1-HT 180 57.7 26.2 84.0 86.1 28.5 115
Pulley 4 2-LT 76 29.9 39.5 26.8 35.4
Take-up Pulley 2-LT 180 28.8 53.9 25.3 47.9
Pulley 6 2-LT 104 30.4 51.2 28.2 48.6
Tail Pulley 2-LT 180 30.0 59.6 30.1 60.7

Required
%
tension
(mm)
Pulley 1 Head (5) 3 - HT 175 457 500 78 104
Pulley 2 Head (7) 4 - HT 163 457 500 77 104
Pulley 4 Tail (15) 2 - LT 76 406 315 36 36
Take-up Pulley Tail (17) 2 - LT 180 406 315 35 36
Pulley 6 Tail (19) 2 - LT 104 406 315 36 40

Shaft Slope
Type at Hub
(min)
1 3 2.03 7.71 66.4 0.1 43.7 0.2 66.4 43.7 0.0
2 4 2.60 6.55 52.6 0.1 49.8 0.3 52.6 49.8 0.0
3 1 2.77 6.60 49.2 18.3 42.4 30.2 58.5 67.3 0.0
4 2 4.78 4.31 29.4 0.1 24.9 0.1 29.4 24.9 0.0
5 2 3.50 5.88 40.1 0.2 34.0 0.3 40.1 34.0 0.0
6 2 3.69 5.59 38.1 0.2 32.3 0.3 38.1 32.3 0.0
7 2 3.17 6.50 44.3 0.3 37.6 0.5 44.3 37.6 0.0

Page 3 / 12
Description

Load Case Resultant
T1 T2
Force
Full - Normal Frict. 45.4 24.0 69.3
Full - High Frict. 47.6 23.8 71.4
Chute Atollado - Normal Frict. 49.3 24.0 73.3
Chute Atollado - High Frict. 52.4 23.8 76.3

Page 4 / 12
Description

ID Description
Pulley 1 27.3 27.3 43.7 44.9 25.5 25.4 25.5 25.4
Pulley 2 26.7 26.8 45.4 46.6 24.7 24.7 24.7 24.7
Empty - Mtr 1 - Bstp 1 27.0 24.0 49.2 16.0 24.7 24.8 24.7 24.8
EM-N Normal Pulley 4 23.9 24.0 22.4 23.4 24.1 24.0 24.1 24.0
Pulley 6 24.2 24.3 25.7 26.8 24.0 24.0 24.0 24.0
Tail Pulley 23.8 24.1 27.4 28.6 23.5 23.6 23.5 23.6
Pulley 1 45.4 45.6 65.3 65.7 29.4 29.3 29.4 29.3
Pulley 2 45.0 45.1 65.5 65.9 28.4 28.4 28.4 28.4
Full - Mtr 1 - Bstp 1 45.4 24.0 66.8 21.7 28.1 25.6 28.1 25.6
FL-N Normal Pulley 4 23.9 24.0 23.5 23.8 24.2 24.1 24.2 24.1
Pulley 6 24.2 24.3 24.6 25.0 23.8 23.8 23.8 23.8
Tail Pulley 23.8 24.1 24.8 25.4 23.1 23.1 23.1 23.1
Pulley 1 47.3 47.6 65.7 66.3 29.2 29.2 29.2 29.2
Pulley 2 46.9 47.2 65.9 66.5 28.3 28.3 28.3 28.3
Mtr 1 - Bstp 1 47.6 23.8 67.6 21.6 28.1 25.7 28.1 25.7
Full - High
FL-H Pulley 4 23.9 24.1 23.5 23.9 24.3 24.2 24.3 24.2
Frict.
Take-up Pulley 23.0 23.2 23.0 23.5 23.0 23.0 23.0 23.0
Pulley 6 24.3 24.5 24.7 25.2 23.9 23.9 23.9 23.9
Tail Pulley 24.0 24.3 25.0 25.5 23.1 23.3 23.1 23.3
Pulley 1 49.4 49.6 68.4 68.8 30.1 30.0 30.1 30.0
Pulley 2 48.9 49.1 68.5 68.9 29.1 29.0 29.1 29.0
Chute Mtr 1 - Bstp 1 49.3 24.0 69.6 22.2 28.7 25.7 28.7 25.7
Atollado -
CA-N Pulley 4 23.9 24.0 23.6 23.9 24.3 24.1 24.3 24.1
Normal
Pulley 6 24.2 24.3 24.5 24.8 23.8 23.8 23.8 23.8
Tail Pulley 23.8 24.1 24.6 25.1 23.0 23.1 23.0 23.1
Pulley 1 52.1 52.4 69.4 69.9 30.0 30.0 30.0 30.0
Pulley 2 51.7 52.0 69.5 70.0 29.1 29.1 29.1 29.1
Chute Mtr 1 - Bstp 1 52.4 23.8 70.9 22.2 28.9 25.9 28.9 25.9
CA-H Atollado - Pulley 4 23.9 24.1 23.7 23.9 24.3 24.2 24.3 24.2
High Frict. Take-up Pulley 23.0 23.2 23.0 23.4 23.0 23.0 23.0 23.0
Pulley 6 24.3 24.5 24.6 25.0 23.9 23.9 23.9 23.9
Tail Pulley 24.0 24.3 24.7 25.2 23.1 23.2 23.1 23.2

Page 5 / 12
Description

32. Wrap angle ................................................175 deg
Lagging
Shaft Specification
40. Shaft slope at bearing ......................... 10.74 (min)
16. Hub width .................................................100 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 6 / 12
Description

32. Wrap angle ................................................163 deg
Lagging
Shaft Specification
16. Hub width .................................................100 mm
17. Hub pressure .................................... 148.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 7 / 12
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width .................................................100 mm
17. Hub pressure .................................... 146.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 8 / 12
Description

32. Wrap angle ..................................................76 deg
Lagging
Shaft Specification
16. Hub width ...................................................90 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 9 / 12
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................90 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 10 / 12
Description

32. Wrap angle ................................................104 deg
Lagging
Shaft Specification
16. Hub width ...................................................90 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 11 / 12
Description

32. Wrap angle ................................................180 deg
Lagging
Shaft Specification
16. Hub width ...................................................90 mm
17. Hub pressure .................................... 140.0 N/mm²
27. Bearing L10 .................................... 500,000 hours

Page 12 / 12

Correa 130 H351654-3120-240-202-0002

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CODELCO CHILE, DIRECCIÓN DE PROYECTOS DCH

009 - INGENIERÍA DE DETALLES PROYECTO LIXIVIACIÓN RIPIOS Y

1.1 Antecedentes ................................................................................................................................ 5

3. Bases de Cálculo .................................................................................................................................. 7

5.1 Correa 130-CV-03......................................................................................................................... 9

6.1 Correa 130-CV-03....................................................................................................................... 19

Resultados Correa 130-CV-03

Resultados Correa 130-CV-04

Resultados Correa 130-CV-05

Rediseño Poleas Correa 130-CV-03

Rediseño Poleas Correa 130-CV-04

Rediseño Poleas Correa 130-CV-05

H351654-3120-240-202-0002, Rev. 0, Pág. iii

Estudios metalúrgicos y geotécnicos previos realizados por División Chuquicamata (DCH),

La Gerencia de Extracción y Lixiviación (GEL) de división Chuquicamata, ha encargado a

H351654-3120-240-202-0002, Rev. 0, Pág. 4

Nro Documento Descripción

Tabla 1: Documentos y Planos de Referencia

H351654-3120-240-202-0002, Rev. 0, Pág. 5

Las características principales a verificar son:

• Potencia Sistema motriz

• Verificación de componentes mecánicos

H351654-3120-240-202-0002, Rev. 0, Pág. 6

• Material Transportado : Ripios

• Densidad aparente (húmeda) : 1595 kg/m3

• Tamaño máximo de partícula : 20 mm

• Angulo de sobrecarga : 20°

• Flujo de diseño : 2780 t/h

• Factor de diseño : 1.15

Adicionalmente, se analizará un escenario considerando la densidad aparente húmeda de

Todos los cálculos se realizarán en 4 condiciones de operación:

• Fricción Nominal, partida con chute atollado: Escenario de Fricción Normal,

• Fricción Alta: Escenario de deficiente operación, polines mal alineados, desgastados,

H351654-3120-240-202-0002, Rev. 0, Pág. 7

Las características principales a verificar son:

• Potencia Sistema motriz

• Verificación de componentes mecánicos

H351654-3120-240-202-0002, Rev. 0, Pág. 8

5.1 Correa 130-CV-03

Descripción Unidad Fricción Fricción Fricción Alta Fricción Alta,

Potencia instalada kW 560 560 560 560

Potencia consumida kW 334 351 469 490

Potencia consumida % 60% 63% 84% 87%

Torque Partida motor % 128% 130% 141% 143%

Ancho Cinta mm (’’) 1,067 1,067 1,067 1,067

Tipo - ST-1600 ST-1600 ST-1600 ST-1600

Cubierta Sup/inf mm 12/6 12/6 12/6 12/6

Tensión operación kN 136.7 140.6 164.9 169.6

Tensión Partida kN 217.1 219.2 230.7 233.2

FS Operación - 12.49 12.15 10.35 10.07

FS Partida - 7.86 7.79 7.40 7.32

Tabla 3: Resultados Correas 130-CV-03

H351654-3120-240-202-0002, Rev. 0, Pág. 9

Descripción Unidad Valor existente Valor Proyectado

Tipo - Gravitacional Gravitacional

Tensión Cinta en operación N No disponible 70,000

Masa Contrapeso Kg 8,000 13,700

Desplazamiento total Polea m 3.1 4.4

Tabla 4: Sistema Tensor

Desviadora 83 71.2 94.9 71.4 95.0

Tensora 180 70.0 141 70.0 141

Desviadora 90 72.4 103 72.5 103

Cola 180 87.6 177 125 252

Tabla 5: Tensiones en poleas