Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
System Information
Calculation method .......................................... CEMA 5th
Conveyor Length / Height .............................. 814 / 6.1 m
Material lift .............................................................. 6.1 m
Ambient temperature range ............................ 30 to 35 °C
Material Properties
Type .......................................... Coal, Bituminous, Mined
Design Tonnage ................................................... 2125 t/h
Density .............................................................. 850 kg/m3
Maximum lump size .............................................. 50 mm
Surcharge angle ...................................................... 20 deg
Belt Properties
Type .................................................................. Steel cord
Width ................................................................. 1200 mm
Rating............................................................. 1250 N/mm
Speed ................................................................... 3.58 m/s
Top / bottom cover thickness ....................... 6.0 x 2.0 mm
Total thickness ....................................................... 12 mm
Weight (new / worn) ............................... 23.9 / 18.5 kg/m
Modulus ....................................................... 90,000 kN/m
Tape length .......................................................... 1,636 m
Belt cycle time ...................................................... 7.6 min
Tension Summary
Maximum tension (kN)
Minimum safety factor
Minimum tension (kN)
Maximum belt sag (%)
Running
88.3
16.98
28.4
0.93
Momentary
127
11.83
17.1
2.03
Cross Sectional Loading
Material mass (wm) ......................................... 165.0 kg/m
Combined mass (wm + wb) .............................. 188.9 kg/m
Edge distance (required / actual)..................... 89 / 44 mm
Cross sectional area ............................................ 0.194 m²
Cross sectional loading (utility / total) ......... 120 % / 85 %
Bed depth ............................................................. 277 mm
Flooded belt tonnage........................................... 2,503 t/h
Flooded (wm + wb) .......................................... 218.3 kg/m
Idler Set Data
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Carry
Manufacture
Melco
Series name
Series 30
Bearing
6206
Number of rolls
3
Trough angle (deg)
35
Type
Inline
Idler spacing (m)
1.50
Number of idler sets
537
Roll diameter
152
Roll rpm
448
Total drag (N)
12.4
Drag range (N)
6.2 - 12.4
Roll length
450
Shaft diameter (mm)
30.0
Dynamic capacity (kN)
20.3
L10 life1 (1000 hrs)
350.0 / 265.1
Shaft deflection (min)
32.62 / 2.93
1
Return
Melco
Series 25
6205
2
10
Inline
3.00
270
152
448
5.9
3.0 - 5.9
635
25.0
14.8
350.0
23.18
L10 life above which 95% of idlers exceed
Drive Station
Type .......................................... Fluid coupling (TV-366)
Synchronous RPM ...........................................1500 RPM
Motor quantity / rating .................................... 1 / 250 kW
Total installed power ............................................ 250 kW
Nominal empty / full power ........ (36 / 95%) 90 / 239 kW
Min / max demand power............ (20 / 95%) 49 / 239 kW
Frame Size.................................................................447T
Motor Voltage ......................................................... 380 V
Efficiency .................................................... 92.5 to 94.5%
Maximum starting torque ......................................... 157%
Inertia - Motor ................................................... 5.6 kg·m²
Inertia - Fluid Coupling ..................................... 0.9 kg·m²
Pulley lagging type ...............................................Ceramic
Motor wrap angles....................................................... 208
Lagging friction factor (run / accel) ................. 0.35 / 0.42
Take-up Data
Type ...................................................................... Gravity
Location ................................................. Head / Pulley #4
Required belt line tension ..................................... 28.5 kN
Counterweight mass ..........................................5.8 tonnes
Required pulley displacement ................................ 3.25 m
Dynamic displacement (incl thermal) .............. 0.55 m
Permanent elongation ...................................... 0.82 m
Splice length (2 included) ................................ 1.13 m
Clearance ......................................................... 0.75 m
Backstops
Location ...............................................Head on Pulley #1
Backstop (quantity x type) ......................... 1 x Low speed
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Torque rating at low speed shaft .................... 44,983 N·m
Total Installed Power Multiplier ................................ 1.60
Pulley diameter .................................................... 828 mm
Brakes
Brake type .................................................. None installed
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Splice step length ................................................. 340 mm
Transition length (each side) ................................ 150 mm
22 degree bias angle ............................................. 485 mm
Total splice length .............................................. 1125 mm
Cable diameter ...................................................... 4.3 mm
Number of cables .......................................................... 78
Cable pitch / cable gap in splice .............. 14.62 / 2.96 mm
Reducer Information
Manufacture ......................................................... Siemens
Frame size .......................................................... B3SH-11
Reducer ratio.......................................................... 17.400
RPM (High Speed) .......................................... 1500 RPM
RPM (Low Speed) ............................................ 86.2 RPM
Configuration ................................................ Shaft Mount
Number of stages ............................................................ 3
Service factor ............................................................... 1.4
Power rating ................................................................ 538
Motor Torque
100% Motor Torque - High Speed................... 1,616 N·m
Motor Shaft Torque - Running (FN) ................ 1,586 N·m
Motor Shaft Torque - Starting (FN) ................. 2,537 N·m
100% Motor Torque - Low Speed ................. 28,115 N·m
Low Speed Shaft Torque - Running (FN)...... 25,555 N·m
Low Speed Shaft Torque - Running (Max) ... 25,555 N·m
Low Speed Shaft Torque - Starting (FN) ....... 41,604 N·m
Low Speed Shaft Torque - Starting (Max)..... 41,604 N·m
Starting and Stopping
Start control ............................................. Constant torque
Start time........................................................ 3.3 to 17.9 s
Operational stop control............................................. Drift
Operational stop time ................................... 11.3 to 18.4 s
Emergency stop control ............................................. Drift
Emergency stop time ................................... 11.3 to 18.4 s
Material buildup in chute ........................................ 6.4 m³
Tension Ratios
Allowable (running)................................................... 3.57
Running tension ratio ................................................. 3.12
Allowable (dynamic) ................................................. 4.61
Starting tension ratio .................................................. 4.50
Transition Lengths
Transition method ............................................... CEMA 7
Tail transition length (inline) ................................. 3.50 m
Head transition length (inline) ............................... 0.00 m
Other Information
Loaded beltline mass (excluding motors)........ 194,719 kg
Total inertia (ref HS shaft) ............................... 110 kg·m2
Demand Power (kW)
Case
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
Demand % Motor
power Nameplate
90
36.0
239
95.4
239
95.4
49
19.5
Din Factor and Total Equivalent Mass
Case
Din factor
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
0.0264
0.0227
0.0227
0.0161
Belt line
mass (kg)
71,953
205,691
205,691
63,003
Maximum Belt Tensions (kN)
Case
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
Running
47.2
88.3
88.3
38.3
Dynamic
99.6
127
127
94.6
Belt Safety Factor
Case
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
Running
31.77
16.98
16.98
39.12
Dynamic
15.06
11.83
11.83
15.85
Minimum Belt Tensions (kN)
Case
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
Running
28.4
28.4
28.4
28.5
Dynamic
25.1
17.1
17.1
26.6
Estimated Splice Data
Splice type .............................................................. 1-Step
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Maximum Belt Sag (%)
Case
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
Running
0.30
0.93
0.93
0.24
Dynamic
0.35
2.03
2.03
0.26
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Conveyor Profile
Overall length = 814 m - Overall height = 6.1 m - True Length = 814.3 m
Tail Arrangement
Head Arrangement
Maximum Pulley Tensions (without any additional safety factors)
Steady State Tensions (kN)
Wrap
Pulley
Type
Resultant
(deg)
T1
T2
Momentary Tensions (kN)
T1
Force
Mtr 1 - Bstp 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
1-HT
3-SN
2-MT
2-MT
2-MT
2-MT
208
50
69
180
83
180
88.3
28.4
28.4
28.7
28.5
29.8
33.5
114
24.2
32.7
57.7
39.9
67.9
Resultant
Force
T2
127
28.8
28.9
28.9
28.5
30.2
56.6
153
24.5
32.8
58.0
40.8
114
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results
Pulley
#
Safety
Factor
1
2
3
4
5
6
1.63
3.24
4.16
2.96
3.44
2.23
Shaft
Shaft
Design
Bearing
Slope at Deflection
T1
L10 Life
Hub
at Center
Tension
1000 hrs
(min)
(% span)
(kN)
4.63
4.20
2.44
3.43
2.96
4.55
0.045
0.037
0.023
0.032
0.027
0.042
500
500
500
500
500
500
97.2
35.5
35.9
35.6
37.2
41.9
Design
Pulley & Resultant Resultant Resultant Bending
T2
Shaft
Force
Angle
Torque Moment
Tension
Mass (kg)
(kN)
(deg)
(kN·m) (kN·m)
(kN)
31.2
36.1
36.4
36.5
37.9
42.9
1094
486
794
794
794
794
125
35.0
45.8
64.3
55.4
85.2
178
266
317
90
228
355
27.3
0.1
0.2
0.3
0.2
0.3
14.2
2.8
4.2
5.9
5.1
7.9
Design tensions for shaft fatigue are based on all design level 1 cases and dynamic conditions. Running tensions have an added
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
multiplier of 1.10 on high tension pulleys, and a multiplier of 1.25 on all other pulleys.
Pulley Geometry Details (Pulley Types)
Type
Lagging
Type
1
2
3
Ceramic
Rubber
Rubber
Diameter
Lagging
with
Diameter
Thickness
Lagging
(mm)
(mm)
(mm)
800
630
500
12.0
12.0
12.0
824
654
524
Face
Width
(mm)
1400
1400
1400
Shaft
Bearing
Bearing
Center
Center Plummer
Diameter
Diameter
Distance
Block
(mm)
(mm)
(mm)
160
140
110
135
115
90
1715
1675
1625
530
526
520
Bearing
Series
Pulley
Shaft
Bearing
Mass (kg)
23230
23226
23220
1,203
861
518
Pulley Shaft Information
Type
1
2
3
Locking
Device
B-LOC
115
B-LOC
106
B-LOC
106
Hub
Bearing
Fatigue
Hub
Center to Fillet
Strength Diameter
Distance Distance
(MPa)
(mm)
(mm)
(mm)
Overhung
Overhung
Moment
Load
Arm
(kN)
(mm)
Shaft
Material
Yield
Strength
(MPa)
Tensile
Strength
(MPa)
SAE 1018
220.0
444.4
200.0
160
1260
96
38
0.0
0
SAE 1018
220.0
444.4
200.0
140
1305
84
38
0.0
0
SAE 1018
220.0
444.4
200.0
110
1310
69
30
0.0
0
Fillet
Radius
(mm)
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
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 two Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
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 = 6.1 m)
There are two Design Level 2 loads, which are:
1. All Inclines + Flat Sections
2. Declines Only
All Inclines + Flat Sections
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Declines Only
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Take-up Displacement Summary
1. Type ...................................................................................................................................................Gravity
2. Location .............................................................................................................................. Head / Pulley #4
3. Belt line tension ................................................................................................................................ 28.5 kN
4. Take-up pulley displacement range
a. Running ......................................................................................................................... -0.03 to 0.00 m
b. Momentary .................................................................................................................... -0.23 to 0.32 m
Take-up Pulley Displacement Summary
1. Dynamic displacement (incl thermal) ................................................................................................. 0.55 m
2. Permanent elongation ......................................................................................................................... 0.82 m
3. Splice length (2 included) ................................................................................................................... 1.13 m
4. Clearance ............................................................................................................................................ 0.75 m
5. Required displacement ....................................................................................................................... 3.25 m
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
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, and a multiplier of 1.25 on all other pulleys.
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)
Wrap
Pulley
Type
Resultant
(deg)
T1
T2
Structural Design Tension (kN)
T1
Force
Motor 1 - Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
1-HT
3-SN
2-MT
2-MT
2-MT
2-MT
208
50
69
180
83
180
97.2
31.2
125
35.0
45.8
64.3
55.4
85.2
35.5
35.9
35.6
37.2
41.9
T2
147
31.7
31.7
31.8
31.4
33.3
62.2
Resultant
Force
175
31.7
41.0
56.1
50.3
126
Required Pulley Diameter (Tension based on a safety factor of 6.67)
Pulley
Location
Pulley
Type
Motor 1 - Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
Head (18)
Head (20)
Head (22)
Head (24)
Head (26)
Tail (39)
1 - HT
3 - SN
2 - MT
2 - MT
2 - MT
2 - MT
Wrap
(deg)
Diameter
(mm)
208
50
69
180
83
180
800
500
630
630
630
630
Required
Pulley
Diameter
(mm)
800
500
630
630
630
630
%
% Running
Momentary
Tension
tension
39
13
13
13
13
15
56
13
13
13
14
26
Pulley Shaft Stress Analysis (Individual Pulleys)
Pulley
Type
#
1
2
3
4
5
6
1
3
2
2
2
2
Safety
Factor
Shaft Slope
at Hub
(min)
Hub
Bending
Stress
(MPa)
Hub
Torsion
Stress
(MPa)
Fillet
Bending
Stress
(MPa)
Fillet
Torsion
Stress
(MPa)
Fillet Von
Mises
Stress
(MPa)
Hub Von
Mises
Stress
(MPa)
Overhung
Von Mises
Stress
(MPa)
1.63
3.24
4.16
2.96
3.44
2.23
4.63
4.20
2.44
3.43
2.96
4.55
35.3
21.1
15.7
22.1
19.0
29.2
34.0
0.6
0.3
0.5
0.4
0.6
33.4
22.3
17.1
24.0
20.6
31.8
56.5
1.0
0.5
0.9
0.7
1.1
68.6
21.1
15.7
22.1
19.0
29.3
103.5
22.4
17.1
24.0
20.7
31.8
0.0
0.0
0.0
0.0
0.0
0.0
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Client Name
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Conveyor Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Running Drive Tensions by Load Case (kN)
Motor 1 - Backstop 1
Load Case
Resultant
Empty - Normal Frict.
Full - Normal Frict.
Inclines+Flat - Normal Frict.
Declines - Low Frict.
T1
T2
47.2
88.3
88.3
38.3
28.4
28.4
28.4
28.6
Pulley Tension Summary - All Load Cases and Conditions
Load Case
Running
Pulley
T1
T2
ID Description
(kN)
(kN)
Mtr 1 - Bstp 1
47.2
28.4
Pulley 2
28.4
28.9
Empty Pulley 3
28.7
29.1
EM-N
Normal
Take-up Pulley
28.5
29.2
Frict.
Pulley 5
29.8
30.3
Tail Pulley
33.5
34.4
Mtr 1 - Bstp 1
88.3
28.4
Pulley 2
28.4
28.9
Full Pulley 3
28.7
29.1
FL-N
Normal
Take-up Pulley
28.5
29.2
Frict.
Pulley 5
29.8
30.3
Tail Pulley
33.5
34.4
Mtr 1 - Bstp 1
88.3
28.4
Pulley 2
28.4
28.9
Inclines+Fl
Pulley 3
28.7
29.1
IF-N at - Normal
Take-up Pulley
28.5
29.2
Frict.
Pulley 5
29.8
30.3
Tail Pulley
33.5
34.4
Mtr 1 - Bstp 1
38.3
28.6
Pulley 2
28.7
28.9
Pulley 3
28.8
29.0
Declines DO-L
Low Frict.
Take-up Pulley
28.5
28.8
Pulley 5
29.3
29.6
Tail Pulley
30.9
31.4
Force
73.4
114
114
65.0
Starting
T1
T2
(kN)
(kN)
99.6
27.6
27.7
28.4
28.3
29.0
28.5
29.5
30.2
31.1
56.6
57.8
127
28.2
28.3
28.8
28.6
29.1
28.5
29.3
29.9
30.5
38.7
39.6
127
28.2
28.3
28.8
28.6
29.1
28.5
29.3
29.9
30.5
38.7
39.6
94.6
27.7
27.8
28.4
28.3
28.9
28.5
29.3
29.8
30.6
55.1
56.0
O-Stop
T1
T2
(kN)
(kN)
27.5
28.6
28.7
29.1
28.9
29.1
28.5
29.0
29.6
30.0
25.1
25.7
27.2
28.6
28.7
29.0
28.9
29.1
28.5
29.0
29.6
30.0
25.6
26.3
27.2
28.6
28.7
29.0
28.9
29.1
28.5
29.0
29.6
30.0
25.6
26.3
27.9
28.8
28.9
29.0
28.9
29.0
28.5
28.7
29.2
29.4
26.6
26.9
E-Stop
T1
T2
(kN)
(kN)
27.5
28.6
28.7
29.1
28.9
29.1
28.5
29.0
29.6
30.0
25.1
25.7
27.2
28.6
28.7
29.0
28.9
29.1
28.5
29.0
29.6
30.0
25.6
26.3
27.2
28.6
28.7
29.0
28.9
29.1
28.5
29.0
29.6
30.0
25.6
26.3
27.9
28.8
28.9
29.0
28.9
29.0
28.5
28.7
29.2
29.4
26.6
26.9
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#1 - Motor 1 - Backstop 1
Pulley Location and Geometry
1. Name (Type-1)....................... Motor 1 - Backstop 1
2. Pulley Diameter ..........................................800 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................. Ceramic
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................824 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 88.3 kN
29. Running T2 Tension ................................. 28.4 kN
30. Design T1 Tension ................................... 97.2 kN
31. Design T2 Tension ................................... 31.2 kN
32. Wrap angle ................................................208 deg
33. Design Resultant Tension.......................... 125 kN
34. Resultant Angle .........................................178 deg
35. Resultant Moment ................................ 14.2 kN·m
36. Resultant Torque .................................. 27.3 kN·m
37. Estimated Pulley & Shaft Mass ............... 1,094 kg
38. Estimated Mass with Bearings ................ 1,203 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................160 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1260 mm
12. Shaft diameter at hub ................................160 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 115
15. Size ........................................................ 160 x 210
16. Hub width ...................................................80 mm
17. Hub pressure .................................... 143.0 N/mm²
18. Maximum torque ............................... 48,764 N·m
19. Hub outer diameter ...................................346 mm
39. Shaft slope at hub ................................. 4.63 (min)
40. Shaft slope at bearing ........................... 5.62 (min)
41. Shaft deflection at center ......................... 0.77 mm
42. Shaft deflection at center (%) ....................... 0.045
43. Shaft Safety Factor (CEMA) .......................... 1.63
44. Shaft Safety Factor (AS1403) ........................ 1.08
45. Bending Stress........................................ 35.3 MPa
46. Torsional Stress ...................................... 34.0 MPa
47. Von Mises Stress .................................... 68.6 MPa
48. Fillet Von Mises Stress ........................ 103.5 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 22 mm
50. Sitzwohl reqd shell thickness1 .................... 12 mm
51. Sitzwohl shell stress ............................... 22.5 MPa
52. Shell stress at 180 wa ............................. 12.3 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1715 mm
21. Shaft diameter at bearing ..........................135 mm
22. Bearing to Fillet Distance ...........................96 mm
23. Turndown radius at bearing ........................38 mm
24. Bearing......................................................... 23230
25. SNL Plummer Block ........................................ 530
26. Dynamic Capacity .................................. 1,080 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 33 mm
54. End disk stress ........................................ 43.2 MPa
Design Tensions and Loads
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Conveyor Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#2 - Pulley 2
Pulley Location and Geometry
1. Name (Type-3)............................................Pulley 2
2. Pulley Diameter ..........................................500 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................... Rubber
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................524 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 28.4 kN
29. Running T2 Tension ................................. 28.9 kN
30. Design T1 Tension ................................... 35.5 kN
31. Design T2 Tension ................................... 36.1 kN
32. Wrap angle ..................................................50 deg
33. Design Resultant Tension......................... 35.0 kN
34. Resultant Angle .........................................266 deg
35. Resultant Moment ................................ 2.76 kN·m
36. Resultant Torque .................................. 0.15 kN·m
37. Estimated Pulley & Shaft Mass .................. 486 kg
38. Estimated Mass with Bearings ................... 518 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................110 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1310 mm
12. Shaft diameter at hub ................................110 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 106
15. Size ........................................................ 110 x 155
16. Hub width ...................................................28 mm
17. Hub pressure .................................... 130.0 N/mm²
18. Maximum torque ............................... 10,891 N·m
19. Hub outer diameter ...................................242 mm
39. Shaft slope at hub ................................. 4.20 (min)
40. Shaft slope at bearing ........................... 4.82 (min)
41. Shaft deflection at center ......................... 0.61 mm
42. Shaft deflection at center (%) ....................... 0.037
43. Shaft Safety Factor (CEMA) .......................... 3.24
44. Shaft Safety Factor (AS1403) ........................ 3.64
45. Bending Stress........................................ 21.1 MPa
46. Torsional Stress ........................................ 0.6 MPa
47. Von Mises Stress .................................... 21.1 MPa
48. Fillet Von Mises Stress .......................... 22.4 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 18 mm
50. Sitzwohl reqd shell thickness1 ...................... 8 mm
51. Sitzwohl shell stress ............................... 18.5 MPa
52. Shell stress at 180 wa ............................... 9.0 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1625 mm
21. Shaft diameter at bearing ............................90 mm
22. Bearing to Fillet Distance ...........................69 mm
23. Turndown radius at bearing ........................30 mm
24. Bearing......................................................... 23220
25. SNL Plummer Block ........................................ 520
26. Dynamic Capacity ..................................... 475 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 27 mm
54. End disk stress ........................................ 18.8 MPa
Design Tensions and Loads
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Client Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#3 - Pulley 3
Pulley Location and Geometry
1. Name (Type-2)............................................Pulley 3
2. Pulley Diameter ..........................................630 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................... Rubber
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................654 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 28.7 kN
29. Running T2 Tension ................................. 29.1 kN
30. Design T1 Tension ................................... 35.9 kN
31. Design T2 Tension ................................... 36.4 kN
32. Wrap angle ..................................................69 deg
33. Design Resultant Tension......................... 45.8 kN
34. Resultant Angle .........................................317 deg
35. Resultant Moment ................................ 4.23 kN·m
36. Resultant Torque .................................. 0.15 kN·m
37. Estimated Pulley & Shaft Mass .................. 794 kg
38. Estimated Mass with Bearings ................... 861 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................140 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1305 mm
12. Shaft diameter at hub ................................140 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 106
15. Size ........................................................ 140 x 190
16. Hub width ...................................................36 mm
17. Hub pressure .................................... 125.0 N/mm²
18. Maximum torque ............................... 21,270 N·m
19. Hub outer diameter ...................................291 mm
39. Shaft slope at hub ................................. 2.44 (min)
40. Shaft slope at bearing ........................... 2.88 (min)
41. Shaft deflection at center ......................... 0.38 mm
42. Shaft deflection at center (%) ....................... 0.023
43. Shaft Safety Factor (CEMA) .......................... 4.16
44. Shaft Safety Factor (AS1403) ........................ 4.78
45. Bending Stress........................................ 15.7 MPa
46. Torsional Stress ........................................ 0.3 MPa
47. Von Mises Stress .................................... 15.7 MPa
48. Fillet Von Mises Stress .......................... 17.1 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 22 mm
50. Sitzwohl reqd shell thickness1 ...................... 8 mm
51. Sitzwohl shell stress ............................... 16.3 MPa
52. Shell stress at 180 wa ............................... 6.6 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1675 mm
21. Shaft diameter at bearing ..........................115 mm
22. Bearing to Fillet Distance ...........................84 mm
23. Turndown radius at bearing ........................38 mm
24. Bearing......................................................... 23226
25. SNL Plummer Block ........................................ 526
26. Dynamic Capacity ..................................... 780 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 33 mm
54. End disk stress ........................................ 16.0 MPa
Design Tensions and Loads
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Client Name
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Conveyor Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#4 - Take-up Pulley
Pulley Location and Geometry
1. Name (Type-2)................................ Take-up Pulley
2. Pulley Diameter ..........................................630 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................... Rubber
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................654 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 28.5 kN
29. Running T2 Tension ................................. 29.2 kN
30. Design T1 Tension ................................... 35.6 kN
31. Design T2 Tension ................................... 36.5 kN
32. Wrap angle ................................................180 deg
33. Design Resultant Tension......................... 64.3 kN
34. Resultant Angle ...........................................90 deg
35. Resultant Moment ................................ 5.95 kN·m
36. Resultant Torque .................................. 0.27 kN·m
37. Estimated Pulley & Shaft Mass .................. 794 kg
38. Estimated Mass with Bearings ................... 861 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................140 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1305 mm
12. Shaft diameter at hub ................................140 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 106
15. Size ........................................................ 140 x 190
16. Hub width ...................................................36 mm
17. Hub pressure .................................... 125.0 N/mm²
18. Maximum torque ............................... 21,270 N·m
19. Hub outer diameter ...................................291 mm
39. Shaft slope at hub ................................. 3.43 (min)
40. Shaft slope at bearing ........................... 4.04 (min)
41. Shaft deflection at center ......................... 0.53 mm
42. Shaft deflection at center (%) ....................... 0.032
43. Shaft Safety Factor (CEMA) .......................... 2.96
44. Shaft Safety Factor (AS1403) ........................ 3.40
45. Bending Stress........................................ 22.1 MPa
46. Torsional Stress ........................................ 0.5 MPa
47. Von Mises Stress .................................... 22.1 MPa
48. Fillet Von Mises Stress .......................... 24.0 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 22 mm
50. Sitzwohl reqd shell thickness1 ...................... 8 mm
51. Sitzwohl shell stress ................................. 6.6 MPa
52. Shell stress at 180 wa ............................... 6.6 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1675 mm
21. Shaft diameter at bearing ..........................115 mm
22. Bearing to Fillet Distance ...........................84 mm
23. Turndown radius at bearing ........................38 mm
24. Bearing......................................................... 23226
25. SNL Plummer Block ........................................ 526
26. Dynamic Capacity ..................................... 780 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 33 mm
54. End disk stress ........................................ 22.5 MPa
Design Tensions and Loads
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#5 - Pulley 5
Pulley Location and Geometry
1. Name (Type-2)............................................Pulley 5
2. Pulley Diameter ..........................................630 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................... Rubber
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................654 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 29.8 kN
29. Running T2 Tension ................................. 30.3 kN
30. Design T1 Tension ................................... 37.2 kN
31. Design T2 Tension ................................... 37.9 kN
32. Wrap angle ..................................................83 deg
33. Design Resultant Tension......................... 55.4 kN
34. Resultant Angle .........................................228 deg
35. Resultant Moment ................................ 5.12 kN·m
36. Resultant Torque .................................. 0.21 kN·m
37. Estimated Pulley & Shaft Mass .................. 794 kg
38. Estimated Mass with Bearings ................... 861 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................140 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1305 mm
12. Shaft diameter at hub ................................140 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 106
15. Size ........................................................ 140 x 190
16. Hub width ...................................................36 mm
17. Hub pressure .................................... 125.0 N/mm²
18. Maximum torque ............................... 21,270 N·m
19. Hub outer diameter ...................................291 mm
39. Shaft slope at hub ................................. 2.96 (min)
40. Shaft slope at bearing ........................... 3.48 (min)
41. Shaft deflection at center ......................... 0.46 mm
42. Shaft deflection at center (%) ....................... 0.027
43. Shaft Safety Factor (CEMA) .......................... 3.44
44. Shaft Safety Factor (AS1403) ........................ 3.95
45. Bending Stress........................................ 19.0 MPa
46. Torsional Stress ........................................ 0.4 MPa
47. Von Mises Stress .................................... 19.0 MPa
48. Fillet Von Mises Stress .......................... 20.7 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 22 mm
50. Sitzwohl reqd shell thickness1 ...................... 8 mm
51. Sitzwohl shell stress ............................... 16.8 MPa
52. Shell stress at 180 wa ............................... 6.9 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1675 mm
21. Shaft diameter at bearing ..........................115 mm
22. Bearing to Fillet Distance ...........................84 mm
23. Turndown radius at bearing ........................38 mm
24. Bearing......................................................... 23226
25. SNL Plummer Block ........................................ 526
26. Dynamic Capacity ..................................... 780 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 33 mm
54. End disk stress ........................................ 19.4 MPa
Design Tensions and Loads
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
#6 - Tail Pulley
Pulley Location and Geometry
1. Name (Type-2)....................................... Tail Pulley
2. Pulley Diameter ..........................................630 mm
3. Face Width ................................................1400 mm
Lagging
4. Lagging Type ............................................... Rubber
5. Lagging Thickness ........................................12 mm
6. Diameter with lagging ................................654 mm
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
28. Running T1 Tension ................................. 33.5 kN
29. Running T2 Tension ................................. 34.4 kN
30. Design T1 Tension ................................... 41.9 kN
31. Design T2 Tension ................................... 42.9 kN
32. Wrap angle ................................................180 deg
33. Design Resultant Tension......................... 85.2 kN
34. Resultant Angle .........................................355 deg
35. Resultant Moment ................................ 7.88 kN·m
36. Resultant Torque .................................. 0.34 kN·m
37. Estimated Pulley & Shaft Mass .................. 794 kg
38. Estimated Mass with Bearings ................... 861 kg
Shaft Stresses & Deflections
Shaft Specification
7. Shaft Center Diameter ................................140 mm
8. Shaft Material ......................................... SAE 1018
9. Yield Strength ........................................ 220.0 MPa
10. Fatigue Strength ................................... 200.0 MPa
Locking Device
11. Hub Center Distance ...............................1305 mm
12. Shaft diameter at hub ................................140 mm
13. Turndown radius at hub ................................0 mm
14. Locking Device ................................... B-LOC 106
15. Size ........................................................ 140 x 190
16. Hub width ...................................................36 mm
17. Hub pressure .................................... 125.0 N/mm²
18. Maximum torque ............................... 21,270 N·m
19. Hub outer diameter ...................................291 mm
39. Shaft slope at hub ................................. 4.55 (min)
40. Shaft slope at bearing ........................... 5.35 (min)
41. Shaft deflection at center ......................... 0.70 mm
42. Shaft deflection at center (%) ....................... 0.042
43. Shaft Safety Factor (CEMA) .......................... 2.23
44. Shaft Safety Factor (AS1403) ........................ 2.57
45. Bending Stress........................................ 29.2 MPa
46. Torsional Stress ........................................ 0.6 MPa
47. Von Mises Stress .................................... 29.3 MPa
48. Fillet Von Mises Stress .......................... 31.8 MPa
Shell Dimension and Stresses
49. Shell thickness............................................ 22 mm
50. Sitzwohl reqd shell thickness1 ...................... 9 mm
51. Sitzwohl shell stress ................................. 7.8 MPa
52. Shell stress at 180 wa ............................... 7.8 MPa
1
Bearing Specifications
20. Bearing Center Distance .........................1675 mm
21. Shaft diameter at bearing ..........................115 mm
22. Bearing to Fillet Distance ...........................84 mm
23. Turndown radius at bearing ........................38 mm
24. Bearing......................................................... 23226
25. SNL Plummer Block ........................................ 526
26. Dynamic Capacity ..................................... 780 kN
27. Bearing L10 .................................... 500,000 hours
Assumes 180 deg wrap and allowable stress of 34.0 MPa
End Disk Dimension and Stresses
53. End disk thickness ...................................... 33 mm
54. End disk stress ........................................ 29.8 MPa
Design Tensions and Loads
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Client Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Belt Flap Summary
Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers. If belt flap is
severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be avoided.
The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt. If this ratio
is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and result in
resonance.
The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of the empty
belt under the normal friction case. The shaded pink areas should be avoided.
*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Belt Transition Length Requirements
The table below lists the required transition length at head and tail pulleys. Transition lengths are based on the CEMA 7th
Method. The figure below shows the geometry of the inline transition and elevated pulley transition.
Geometry of inline and elevated pulley transition
Required transition lengths
Tail pulley transition (m)
Inline transition (L1)
Elevated pulley transition (L2)
Pulley elevation (h)
4.32
2.88
71.697
Head pulley transition
(m)
0.00
0.00
71.697
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Client Name
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Material Loading Profiles
Material Properties
Type .......................................... Coal, Bituminous, Mined
Design Tonnage ................................................... 2125 t/h
Density .............................................................. 850 kg/m3
Maximum lump size .............................................. 50 mm
Surcharge angle ...................................................... 20 deg
Material 1 on Idler Set 3
Tonnage ............................................................... 2125 t/h
Belt speed ............................................................ 3.58 m/s
Material mass .................................................. 165.0 kg/m
Edge distance (required / actual)..................... 89 / 44 mm
Cross sectional loading (utility / total) ......... 120 % / 85 %
Bed depth ............................................................. 277 mm
Material 1 on Idler Set 1
Tonnage ............................................................... 2125 t/h
Belt speed ............................................................ 3.58 m/s
Material mass .................................................. 165.0 kg/m
Edge distance (required / actual)..................... 89 / 44 mm
Cross sectional loading (utility / total) ......... 120 % / 85 %
Bed depth ............................................................. 277 mm
Empty Idler Set 4
Empty Idler Set 2
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Idler Specifications
Idler Specifications
Type
Number of rolls
Trough angle (deg)
Roll diameter (mm)
Roll length (mm)
Shaft diameter (mm)
Bearing series
Maximum roll RPM
Min Life (1000 hrs)
95% life1 (1000 hrs)
Shaft deflection (min)
Mass per Roll (kg)
Rotating mass for set (kg)
Wk2 for set (kg·mm²)
Idler Spacing and Count Summary
General
Idler spacing (m)
Number of idler sets
Number of rolls
Total drag (N)
Nominal friction
High friction
Low friction
Equal Roll
Trough
3
35
152
450
30.0
6206
448
/ 255
350 / 265
32.62 / 2.93
8.7
26.2
133,355
2
10
152
635
25.0
6205
448
3
350
23.18
11.8
23.6
122,357
Equal Roll
Trough
3
35
152
450
30.0
6206
448
350 / 350
350 / 350
0.83 / 2.18
8.7
26.2
133,355
Equal Roll
Trough
3
35
152
450
25.0
6205
450
350 / 350
/
0.59 / 0.79
8.7
26.1
132,250
Carry
1.50
537
1,611
Return
3.00
270
540
Impact
0.30
16
48
Transition
1.50
2
6
12.4
12.4
6.2
5.9
5.9
3.0
12.4
12.4
6.2
8.9
8.9
4.4
VEE
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Idler Life and Shaft Deflection Summary-Carry Side
#
1
2
3
4
5
6
7
8
9-12
13-14
15
16-17
18
Vertical
Station (m) Length (m)
Radius (m)
0.0
3.5
6.5
35.7
38.7
51.8
54.8
84.1
87.1
757.8
766.5
796.0
797.7
3.5
3.0
29.2
3.0
13.1
3.0
29.2
3.0
670.7
8.7
30.0
1.7
16.1
-50
10
Idler
Spacing
(m)
Idler
Type
Wing L10
Life
(hours)
1.50
0.30
1.50
0.30
1.50
0.30
1.50
0.30
1.50
1.50
1.50
1.50
1.50
4
3
1
3
1
3
1
3
1
1
1
1
1
350,000
350,000
350,000
350,000
350,000
350,000
350,000
350,000
350,000
350,000
350,000
63
350,000
Idler
Spacing
(m)
Idler
Type
Wing L10
Life
(hours)
3.00
3.00
3.00
3.00
3.00
2
2
2
2
2
350,000
2,544
350,000
350,000
350,000
Center
Center L10 Wing Shaft
Shaft
Life
Deflection
Deflection
(hours)
(min)
(min)
350,000
0.59
0.79
350,000
0.83
2.18
281,719
1.19
2.83
350,000
0.61
1.18
280,274
1.19
2.84
350,000
0.62
1.20
279,379
1.19
2.84
350,000
0.64
1.22
265,147
1.23
2.90
350,000
1.40
271,903
1.23
2.87
350,000
32.62
255,207
1.26
2.93
Idler Life and Shaft Deflection Summary-Return Side
#
28-29
30-31
32
33-34
35-39
Vertical
Station (m) Length (m)
Radius (m)
810.0
797.7
796.1
766.5
757.7
12.3
1.6
30.0
8.8
757.8
9
-50
Center
Center L10 Wing Shaft
Shaft
Life
Deflection
Deflection
(hours)
(min)
(min)
2.18
23.18
2.16
2.19
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 1,898 t/h have also been included. This specific load case results in 97% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 160% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 1,898 t/h under steady state and dynamic conditions + 110% multiplier
Pulley
Motor 1 Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
Shaft
Wrap Hub
Type
(deg) Slope
(min)
Shaft
stress
safety
factor
Shaft
Center
Def.
(mm)
1
208
6.49
1.19
1.08
3
2
2
2
2
50
69
180
83
180
3.80
2.19
3.00
2.69
6.73
3.24
4.16
2.96
3.44
2.23
0.55
0.34
0.46
0.41
1.04
Minimum Tensions (kN)
Maximum Tensions (kN)
T1
T2
Resultant
Force
T1
T2
Resultant
Force
24.5
24.8
46.3
147
31.7
175
24.9
25.4
25.6
26.3
22.6
26.1
34.2
43.7
40.7
46.4
31.7
31.8
31.4
33.3
62.2
31.7
41.0
56.1
50.3
126
Bearing Reaction Forces (excluding any overhung loads)
Pulley
Motor 1 Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
Bearing Horizontal Direction (kN)
Entry Exiting Pulley,
Wrap Vector Vector Shaft & Structural
Structural
FL-N
(deg) Angle Angle Bearings
Max
Min
Case
(deg) (deg) Mass (kg) Tension
Tension
Bearing Vertical Direction (kN)
Structural
Min
Tension
FL-N
Case
Structural
Max
Tension
208
180
152
1,203
-46.3
-113
-175
0.02
1.70
3.28
50
69
180
83
180
332
22
90
270
0
202
270
90
174
0
518
861
861
861
861
-1.82
23.9
-0.40
-26.1
45.7
-1.85
27.0
-0.44
-29.9
67.9
-1.81
29.8
-0.49
-33.8
126
-26.3
-25.1
43.1
-31.8
-8.31
-29.2
-27.0
49.2
-34.9
-8.25
-32.0
-28.8
55.5
-38.0
-8.08
The idler stringer loading should be based on the flooded belt surge capacity of 2,503 t/h and 218.3 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
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Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
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Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Summary Details
Tension Summary
Power Summary
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
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March 21, 2018
Vertical Curve Summary
Summary of Vertical Curve on Carry Strand
Elements
Station (m)
Type
Radius (m)
13-15
16-18
758 - 766
796 - 798
concave
convex
-50
10
Running Tension
Req'd Radius
Reason
(m)
-329
Lift Off
180
Min Stress
Momentary Tension
Req'd Radius
Reason
(m)
-511
Lift Off
228
Min Stress
Running Tension
Req'd Radius
Reason
(m)
-125
Lift Off
225
Min Stress
Momentary Tension
Req'd Radius
Reason
(m)
-171
Lift Off
232
Min Stress
Summary of Vertical Curve on Return Strand
Elements
Station (m)
Type
Radius (m)
33-35
30-32
758 - 767
796 - 798
concave
convex
-50
9
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TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Summary Details
Summary of Conveyor Elements
#
Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Transition
Loading Point
Loading Point
Loading Point
Loading Point
Motor 1 - Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
Station
(m)
Elevation
(m)
Length
(m)
Height
(m)
Slope
(deg)
0.0
3.5
6.5
35.7
38.7
51.8
54.8
84.1
87.1
254.7
422.4
590.1
757.8
762.1
766.5
796.0
796.9
797.7
813.8
813.6
813.0
812.7
811.1
810.9
810.9
810.3
810.3
810.0
805.7
797.7
796.9
796.1
766.5
762.1
757.7
569.3
380.9
192.5
4.1
0.0
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.19
0.76
5.97
6.08
6.12
6.12
5.35
5.69
5.71
5.06
4.76
2.18
2.18
4.72
5.04
5.52
5.52
5.48
5.38
0.16
-0.41
-0.60
-0.61
-0.61
-0.61
-0.61
-0.64
3.5
3.0
29.2
3.0
13.1
3.0
29.2
3.0
167.7
167.7
167.7
167.7
4.4
4.4
30.0
0.9
0.9
16.1
0.8
0.7
0.2
1.8
0.4
2.6
0.7
2.5
0.4
4.3
8.0
0.8
0.8
30.0
4.4
4.4
188.4
188.4
188.4
188.4
4.1
0.7
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.19
0.57
5.21
0.11
0.04
0.00
-0.77
0.35
0.01
-0.64
-0.31
-2.57
-0.01
2.54
0.32
0.47
0.00
-0.04
-0.11
-5.21
-0.57
-0.19
0.00
0.00
0.00
0.00
-0.02
0.65
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.50
7.50
10.00
7.50
2.50
0.00
--28.44
---21.58
---89.50
--89.62
--6.26
0.01
-2.49
-7.50
-10.00
-7.50
-2.50
0.00
0.00
0.00
0.00
-0.34
---
Vertical
Radius
(m)
-50
-50
10
10
9
9
-50
-50
Idler
Spacing
(m)
1.50
0.30
1.50
0.30
1.50
0.30
1.50
0.30
1.50
1.50
1.50
1.50
1.50
1.50
1.50
1.50
1.50
1.50
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
Idler
Type
4
3
1
3
1
3
1
3
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Min/Max Tension Summary per Element
Element Tension (kN)
#
Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Transition
Loading Point
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Loading Point
Loading Point
Loading Point
Motor 1 Backstop 1
Pulley 2
Pulley 3
Take-up Pulley
Pulley 5
Tail Pulley
Maximum
34.4
34.4
37.4
39.1
39.9
40.7
41.5
43.2
44.0
52.8
60.8
68.0
74.7
75.2
76.5
87.3
87.6
87.7
Running
Minimum
34.4
34.4
34.8
35.1
35.5
35.7
36.1
36.5
36.9
38.9
41.0
43.0
45.1
45.2
45.4
47.0
47.0
47.0
%Sag
0.13
0.20
0.93
0.18
0.87
0.17
0.84
0.16
0.79
0.66
0.57
0.51
0.46
0.46
0.45
0.40
0.40
0.40
Maximum
57.8
57.9
58.6
60.0
60.7
61.3
61.9
63.3
64.0
71.9
83.3
97.4
111
112
113
125
125
126
Momentary
Minimum
25.7
25.7
25.9
25.9
26.1
26.1
26.2
26.2
26.4
26.3
24.1
20.9
17.1
17.4
18.3
27.3
27.4
27.5
%Sag
0.17
0.26
1.26
0.25
1.25
0.25
1.24
0.25
1.23
1.31
1.44
1.66
2.03
2.00
1.90
1.27
1.26
1.26
88.3
47.2
0.00
127
27.2
0.00
28.4
28.4
28.9
28.7
29.1
28.5
29.2
29.8
30.3
30.4
30.5
30.5
30.4
29.4
29.3
29.3
30.3
31.4
32.4
33.5
33.5
28.4
28.4
28.9
28.7
29.1
28.5
29.2
29.8
30.3
30.4
30.5
30.5
30.4
29.4
29.3
29.3
30.3
31.4
32.4
33.5
33.5
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.29
0.29
0.29
0.29
0.29
0.30
0.30
0.30
0.29
0.28
0.27
0.26
0.00
28.8
28.9
29.1
28.9
29.1
28.5
29.5
30.2
31.1
31.3
31.6
31.6
31.6
31.4
31.4
31.5
37.7
44.0
50.2
56.5
56.6
27.6
27.7
28.4
28.3
28.9
28.5
28.7
29.2
29.4
29.5
29.5
29.4
29.4
28.4
28.3
28.3
27.6
26.8
25.9
25.1
25.1
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.29
0.29
0.29
0.29
0.29
0.31
0.31
0.31
0.32
0.33
0.34
0.35
0.00
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Client Name
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Te Tension Summary per Load Cases
Belt Tension Summary per Load Case (N)
EM-N
Total (Beltline)
18,681
Total (Power)
24,473
FL-N
59,784
66,654
IF-N
59,784
66,654
DO-L
9,577
13,178
Lift Force
Frictional Drag
Motor Pulley/Reducer Drag
0
18,681
5,792
9,901
49,883
6,871
9,901
49,883
6,871
0
9,577
3,601
Rolling Resistance
Material+Belt Flexure
Idler Bearing Drag
Idler Alignment
Pulleys & Accessories
Loading Point
5,984
0
8,717
261
2,669
1,051
32,780
0
8,717
1,153
2,669
4,565
32,780
0
8,717
1,153
2,669
4,565
3,158
0
4,358
201
1,334
525
Mechanical Losses
Motor Pulley Drag Componets
3,852
1,940
4,931
1,940
4,931
1,940
2,631
970
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KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Pulley Summary Table - All Cases
Pulley Geometry Details
Type
Lagging Type
Diameter (mm)
Lagging Thickness (mm)
Diameter with Lagging (mm)
Face Width (mm)
Shaft Center Diameter (mm)
Bearing Diameter (mm)
Bearing Center Distance (mm)
Plummer Block
Pulley & Shaft Mass (kg)
Locking Device
Hub Center Distance (mm)
Hub Diameter (mm)
Bearing to Fillet Distance (mm)
Fillet Radius (mm)
Shaft Material
Yield Strength (MPa)
Fatigue Strength (MPa)
1
Ceramic
800
12.0
824
1400
160
135
1715
530
1,094
B-LOC 115
1260
160
96
38
SAE 1018
220.0
200.0
2
Rubber
630
12.0
654
1400
140
115
1675
526
794
B-LOC 106
1305
140
84
38
SAE 1018
220.0
200.0
3
Rubber
500
12.0
524
1400
110
90
1625
520
486
B-LOC 106
1310
110
69
30
SAE 1018
220.0
200.0
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TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Tension Details per Case
Element Tension Breakdown - (EM) Empty - Normal
Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
(N)
Force (N)
(N)
(N)
(t/h)
1
34,351
36
23.9
14
21
2
34,386
398
23.9
11
124
263
3
34,785
365
23.9
119
246
4
35,150
398
23.9
11
124
263
5
35,548
163
23.9
53
111
6
35,712
398
23.9
11
124
263
7
36,110
363
23.9
117
246
8
36,473
398
23.9
11
124
263
9
36,872
2,072
23.9
658
1,413
10
38,943
2,056
23.9
642
1,413
11
40,999
2,043
23.9
630
1,413
12
43,042
2,043
23.9
630
1,413
13
45,085
98
23.9
45
16
37
14
45,183
187
23.9
134
16
37
15
45,370
1,589
23.9
1,223
113
253
16
46,959
41
23.9
27
7
7
17
47,000
23
23.9
9
7
7
18
47,023
196
23.9
60
135
19 - M
47,219
-18,867
23.9
-182
890
1,050
20
28,352
81
23.9
81
0
21 - P
28,434
448
23.9
3
445
22
28,882
-151
23.9
-151
0
23 - P
28,731
373
23.9
-72
445
24
29,103
-603
23.9
-604
0
25 - T
28,500
666
23.9
-1
667
26
29,166
597
23.9
597
0
27 - P
29,763
521
23.9
76
445
28
30,284
136
23.9
111
15
9
29
30,420
45
23.9
0
28
17
30
30,465
-4
23.9
-8
3
2
31
30,461
-20
23.9
-25
3
2
32
30,441
-1,054
23.9
-1,224
106
64
33
29,386
-110
23.9
-135
16
9
34
29,276
-20
23.9
-45
16
9
35
29,256
1,064
23.9
-1
664
401
36
30,320
1,064
23.9
-1
664
401
37
31,384
1,064
23.9
-1
664
401
38
32,448
1,064
23.9
-1
664
401
39
33,512
17
23.9
-6
14
9
40 - P
33,530
821
23.9
154
667
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Client Name
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Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Tension Breakdown - (FL) Fully Loaded - Normal
Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
Force (N)
(N)
(N)
(N)
(t/h)
1
34,351
36
23.9
14
21
2
34,386
2,973
2,125
188.9
120
128
2,725
3
37,359
1,725
2,125
188.9
1,447
278
4
39,085
853
2,125
188.9
112
128
613
5
39,938
756
2,125
188.9
631
125
6
40,694
850
2,125
188.9
109
128
613
7
41,544
1,646
2,125
188.9
1,368
278
8
43,190
845
2,125
188.9
104
128
613
9
44,034
8,800
2,125
188.9
7,202
1,598
10
52,835
7,956
2,125
188.9
6,358
1,598
11
60,790
7,249
2,125
188.9
5,651
1,598
12
68,039
6,668
2,125
188.9
5,071
1,598
13
74,707
523
2,125
188.9
353
129
42
14
75,231
1,226
2,125
188.9
1,055
129
42
15
76,456
10,825
2,125
188.9
9,650
889
286
16
87,281
276
2,125
188.9
211
57
8
17
87,557
135
2,125
188.9
71
57
8
18
87,693
629
2,125
188.9
476
153
19 - M
88,322
-59,969
23.9
-182
890
1,050
20
28,352
81
23.9
81
0
21 - P
28,434
448
23.9
3
445
22
28,882
-151
23.9
-151
0
23 - P
28,731
373
23.9
-72
445
24
29,103
-603
23.9
-604
0
25 - T
28,500
666
23.9
-1
667
26
29,166
597
23.9
597
0
27 - P
29,763
521
23.9
76
445
28
30,284
136
23.9
111
15
9
29
30,420
45
23.9
0
28
17
30
30,465
-4
23.9
-8
3
2
31
30,461
-20
23.9
-25
3
2
32
30,441
-1,054
23.9
-1,224
106
64
33
29,386
-110
23.9
-135
16
9
34
29,276
-20
23.9
-45
16
9
35
29,256
1,064
23.9
-1
664
401
36
30,320
1,064
23.9
-1
664
401
37
31,384
1,064
23.9
-1
664
401
38
32,448
1,064
23.9
-1
664
401
39
33,512
17
23.9
-6
14
9
40 - P
33,530
821
23.9
154
667
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Page 31 / 33
Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Tension Breakdown - (IF) All Inclines + Flat Sections - Normal
Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
Force (N)
(N)
(N)
(N)
(t/h)
1
34,351
36
23.9
14
21
2
34,386
2,973
2,125
188.9
120
128
2,726
3
37,359
1,725
2,125
188.9
1,447
278
4
39,085
853
2,125
188.9
112
128
613
5
39,938
756
2,125
188.9
631
125
6
40,694
850
2,125
188.9
109
128
613
7
41,544
1,646
2,125
188.9
1,368
278
8
43,190
845
2,125
188.9
104
128
613
9
44,034
8,800
2,125
188.9
7,202
1,598
10
52,835
7,956
2,125
188.9
6,358
1,598
11
60,790
7,249
2,125
188.9
5,651
1,598
12
68,039
6,668
2,125
188.9
5,071
1,598
13
74,707
523
2,125
188.9
353
129
42
14
75,231
1,226
2,125
188.9
1,055
129
42
15
76,456
10,825
2,125
188.9
9,650
889
286
16
87,281
276
2,125
188.9
211
57
8
17
87,557
135
2,125
188.9
71
57
8
18
87,693
629
2,125
188.9
476
153
19 - M
88,322
-59,969
23.9
-182
890
1,050
20
28,352
81
23.9
81
0
21 - P
28,434
448
23.9
3
445
22
28,882
-151
23.9
-151
0
23 - P
28,731
373
23.9
-72
445
24
29,103
-603
23.9
-604
0
25 - T
28,500
666
23.9
-1
667
26
29,166
597
23.9
597
0
27 - P
29,763
521
23.9
76
445
28
30,284
136
23.9
111
15
9
29
30,420
45
23.9
0
28
17
30
30,465
-4
23.9
-8
3
2
31
30,461
-20
23.9
-25
3
2
32
30,441
-1,054
23.9
-1,224
106
64
33
29,386
-110
23.9
-135
16
9
34
29,276
-20
23.9
-45
16
9
35
29,256
1,064
23.9
-1
664
401
36
30,320
1,064
23.9
-1
664
401
37
31,384
1,064
23.9
-1
664
401
38
32,448
1,064
23.9
-1
664
401
39
33,512
17
23.9
-6
14
9
40 - P
33,530
821
23.9
154
667
Sidewinder v5.65 - Conveyor Design Software
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Page 32 / 33
Client Name
Project Name
Conveyor Name
Location
Description
KERETA API BORNEO
TA1750 KAB
C-1.1
Kalimantan
Designer
Company
Filename
Date
Calculate C-1.1_rev
March 21, 2018
Element Tension Breakdown - (DO) Declines Only - Low
Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
Force (N)
(N)
(N)
(N)
(t/h)
1
31,371
18
18.5
7
11
2
31,389
200
18.5
6
62
131
3
31,588
187
18.5
62
124
4
31,775
200
18.5
6
62
131
5
31,975
84
18.5
28
56
6
32,058
200
18.5
6
62
131
7
32,258
186
18.5
62
124
8
32,444
200
18.5
6
62
131
9
32,644
1,066
18.5
352
714
10
33,710
1,062
18.5
348
714
11
34,771
1,058
18.5
344
714
12
35,829
1,053
18.5
340
714
13
36,882
62
18.5
34
8
19
14
36,944
130
18.5
103
8
19
15
37,074
1,131
18.5
944
60
128
16
38,205
28
18.5
21
4
4
17
38,233
14
18.5
7
4
4
18
38,248
100
18.5
32
68
19 - M
38,348
-9,720
18.5
-140
445
525
20
28,628
63
18.5
63
0
21 - P
28,690
225
18.5
2
222
22
28,915
-116
18.5
-117
0
23 - P
28,799
167
18.5
-56
222
24
28,965
-465
18.5
-466
0
25 - T
28,500
333
18.5
-1
334
26
28,833
461
18.5
461
0
27 - P
29,294
281
18.5
58
222
28
29,574
98
18.5
86
8
5
29
29,673
23
18.5
0
14
9
30
29,696
-4
18.5
-6
1
1
31
29,692
-17
18.5
-19
1
1
32
29,675
-856
18.5
-944
55
33
33
28,819
-91
18.5
-104
8
5
34
28,728
-22
18.5
-35
8
5
35
28,706
551
18.5
0
343
209
36
29,257
551
18.5
0
343
209
37
29,808
551
18.5
0
343
209
38
30,360
551
18.5
0
343
209
39
30,911
8
18.5
-4
7
5
40 - P
30,918
452
18.5
118
334
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