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17 Oct 2014 13:37

Project
Project No.
Conveyor No.

Conveyor Design Summary

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

1/27

Page

PT.PETROKIMIA GRESIK
JSA

Conveyed Material
Material Description
Low Bulk Density
High Bulk Density

POTASSIUM SULPHATE
Surcharge Angle
1040 kg/m3
Angle of Repose
1040 kg/m3
Material Lump size
Conveyor Data
Conveying Distance
4.60 m
Design Capacity
Nett Lift / Lower (-)
0.07 m
Belt Speed
Belt Details
Belt Width Selected
750 mm
Calculated Belt % Full
Belt Class & Run Safety Factor
PN800/4
13.57 Top Cover Thickness
Belt Rated Tension
90 kN/m
Bottom Cover Thickness
Belt Total Length
13.1 m
Belt Mass
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded
2.47 kN
Belt Power - Empty Belt
Maximum Tension Tmax
44.22 kN
Belt Power - Inclines Loaded
Minimum Tension Tmin
41.98 kN
Belt Power - Declines Loaded
Sag Tension
1.5 %
1.49 kN
Belt Power - Fully Loaded
Takeup Type
Fixed Centres
Drive Efficiency
Takeup Mass
8800 kg
Absorbed Power Fully Loaded
Takeup Pulley Belt Tension
43.15 kN
Installed Motor Power
Carry and Return Idlers
Carry Idler Trough Angle
30
Return Idler Trough Angle
Carry Idler Spacing
1 m
Return Idler Spacing
Carry Idler No Rolls x Dia
3 x 152 mm
Return Idler No Rolls x Dia
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded
140 %
CEMA Temperature Factor Kt
Startup Factor - Empty
140 %
Total Braking Torque LSS
Starting Time - Fully Loaded
0.13 sec
Stop Time - Loaded, Braking
Starting Time - Empty
0.13 sec
Stop Time - Loaded, Coasting

30 deg
46 deg
3 mm
2.2 tonnes/hr
0.5 m/s
1.8
8
6
16.96
1.23
1.24
1.23
1.24
95.0
1.31
2.2

%
mm
mm
kg/m
kW
kW
kW
kW
%
kW
kW

0
3 m
1 x 152 mm
1.00
22.00 kNm
0.01 sec
0.19 sec

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Station / Sectio
Station

Page

Conveyor Sections - Input Data

Section Section
Length
Lift
Description
m
m

PT.PETROKIMIA GRESIK
JSA

X coord m

Y coord m

Z coord m

Capacity
tph

Ten
Idler
Skirt
Friction
Adj. Spacing Length No. of
Factor
Scrapers Input
kN
m
m

1 Takeup

1.00

-0.05

0.00

0.00

0.00

2 Hopper

0.50

0.00

1.00

0.00

0.20

2.2

3 Int. Pt

4.10

0.07

1.50

0.00

0.20

2.2

1.50

4 Drive

5.60

0.12

5.60

0.00

-0.05

2.00

11.20

0.13

Totals:

2/27

1.00
1.00

1.00

0.35

0.0300
2.00

0.0300
0.0300
3

2.00

0.0300

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive Torque Start-up Factor Loaded

140 %

Drive Torque Start-up Factor Empty

140 %

Drive
Number

Drive No.
Pulley No. 4
Wrap Angle

Fully
Loaded

PT.PETROKIMIA GRESIK
JSA

Takeup Pulley Belt Tension


Takeup Mass

Running

Starting

Empty
Belt

3/27

Page

Takeup & Drive Traction Calculation

Fully
Loaded

43.15 kN
8800 kg
Braking

Empty
Belt

Fully
Loaded

Empty
Belt

1 Drive
Lagging Type

Co-efficient of Friction
Drive Factor Cw

180

Rubber
180

180

Rubber
180

180

Rubber
180

0.25
0.838

0.25
0.838

0.35
0.499

0.35
0.499

0.35
0.499

0.35
0.499

Calculated Belt Tension T1

kN

44.22

44.21

45.26

45.24

23.67

23.88

Calculated Belt Tension T2


Minimum Required T2

kN
kN

41.98
1.88

41.98
1.87

41.11
2.07

41.1
2.07

58.82
17.54

58.85
17.45

Surplus T2 Tension (T1-T2)

kN

40.1

40.11

39.04

39.03

6.13

6.43

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive Torque Start-up Factor Loaded

140 %

Drive Torque Start-up Factor Empty

140 %

Fully
Loaded
Tension
kN

Starting

Empty
Tension
kN

Inclines
Loaded
Tension
kN

Declines
Loaded
Tension
kN

4/27

PT.PETROKIMIA GRESIK
JSA

Takeup Mass

Running

Station
No

Page

Tension Calculations - Summary Run / Start

8800 kg

Braking

Fully
Loaded
Tension
kN

Empty
Tension
kN

Fully
Loaded
Tension
kN

Coasting

Empty
Tension
kN

Fully
Loaded
Tension
kN

Empty
Tension
kN

1 Takeup

42.93

42.93

42.93

42.93

42.52

42.52

51.29

51.27

43.20

43.20

2 Hopper

43.16

43.16

43.16

43.16

43.64

43.64

33.88

33.74

42.80

42.80

3 Int. Pt

44.17

44.17

44.17

44.17

44.74

44.75

32.97

32.87

43.75

43.75

4 Drive

44.22

44.21

44.22

44.21

45.26

45.24

23.67

23.88

43.47

43.47

Minimum Ten

42.93

42.93

42.93

42.93

42.52

42.52

23.67

23.88

42.80

42.80

Maximum Ten

44.22

44.21

44.22

44.21

45.26

45.24

51.29

51.27

43.75

43.75

Effective Ten

2.47

2.46

2.47

2.46

Ave. Belt Ten

42.99

42.99

42.99

42.99

42.99

42.99

42.99

42.99

42.99

42.99

Belt Elong. m

T/up Travel m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

PT.PETROKIMIA GRESIK
JSA

Low BD = 1040kg/m3
High BD = 1040kg/m3
Conveyed Material
Belt Speed & Capacity
Material Description
POTASSIUM SULPHATE
Belt Speed
Low Bulk Density
1040 kg/m3
Belt Design Capacity Input
High Bulk Density
1040 kg/m3
Section Loading Max Capacity
Surcharge Angle
30 deg
Carry Idler Trough Angle
Angle of Repose
46 deg
Belt Dimensions
Material Lump size

3 mm

Belt Make & Class


Belt Category
Apex PN Fabric - Spliced
Belt Description
Apex PN 200 Standard
Belt Class / Plies
PN800/4
4
Belt Reinforcement Fibre
Fabric
Belt Width Selected
750 mm
Belt Modulus
9200 kN/m

Belt Tensions
Belt Rated Tension / m width
Calculated Tension / m width
Belt Rated Tension for width
Calculated Max Run Tension
Minimum Tension Tmin
Allowable Tension Rise, Starting
Allowable Belt Tension, Starting
Actual Belt Tension, Starting
Belt and Material Mass
Belt Top Cover Mass
Belt Bottom Cover Mass
Belt Carcass Mass
Belt Mass Wb (per linear m)
Material Mass Wm
Total Mass (Wb + Wm)
Total Belt Mass (Wb x L)

90
59
67.5
44.22
41.98
140
94.5
58.85

kN/m
kN/m
kN
kN
kN
%
kN
kN

Top Cover Thickness


Bottom Cover Thickness
Belt Carcass Thickness
Belt Total Thickness
Belt Total Belt Length (L)
Time for 1 Revolution

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

0.5
2.2
2.2
30

m/s
tonnes/hr
tonnes/hr

8 mm
6 mm
5.3
19.3
13.1
26.2

mm
mm
m
sec

Belt Load Area and Capacity at 1040kg/m3


Minimum Rec. Edge Distance
64 mm
Actual Edge Distance Low BD
262 mm
Load Burden Depth
37 mm
Load Burden Width
237 mm
Belt Load Area at Minimum
0.0664 m2
Recommended Edge Distance
Belt Load Area Utilised at Low
Bulk Density
Belt Actual % Full at Low BD

0.0012 m2
1.8 %

Belt Load Area and Capacity at 1040kg/m3


Minimum Rec. Edge Distance
64 mm
Actual Edge Distance High BD
262 mm
Belt Load Area Utilised at High
0.0012 m2
Bulk Density
Belt Actual % Full at High BD

6.8
5.1
5.1
17
1.2
18.2
222

5/27

Page

Belt Details Report

1.8 %

Flooded Belt Capacity at 1040kg/m3


Flooded Belt Load Area at Zero
0.0994 m2
Edge Distance
Flooded Belt Capacity
Flooded Belt Material Mass

186 tonnes/hr
103.4 kg/m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Allowable Belt Sag % Running

5 %

Starting

Fully
Loaded
Tension
kN

Empty
Tension
kN

Inclines
Loaded
Tension
kN

42.93

42.93

42.93

0.05
43.16

1 Takeup

1.00

Belt Sag %
2 Hopper

0.05
43.16

Idler Spacing m

0.35

Belt Sag %
3 Int. Pt
Idler Spacing m
Belt Sag %
4 Drive

0.02
44.17

PT.PETROKIMIA GRESIK
JSA

Takeup Mass

Running

Idler Spacing m

6/27

1.5 %

Allowable Belt Sag % Start / Stop

Station
No

Page

Tension Calculations - Summary Belt Sag

Declines
Loaded
Tension
kN

8800 kg

Braking

Coasting

Fully
Loaded
Tension
kN

Empty
Tension
kN

Fully
Loaded
Tension
kN

Empty
Tension
kN

Fully
Loaded
Tension
kN

Empty
Tension
kN

42.93

42.52

42.52

51.29

51.27

43.20

43.20

0.05
43.16

0.05
43.16

0.05
43.64

0.05
43.64

0.04
33.88

0.04
33.74

0.05
42.80

0.05
42.80

0.02
44.17

0.02
44.17

0.02
44.17

0.02
44.74

0.02
44.75

0.02
32.97

0.02
32.87

0.02
43.75

0.02
43.75

0.07
44.21

0.08
44.22

0.07
44.21

0.07
45.26

0.07
45.24

0.1
23.67

0.09
23.88

0.08
43.47

0.07
43.47

1.50
0.08
44.22

Idler Spacing m

2.00

Belt Sag %

0.09

0.09

0.09

0.09

0.09

0.09

0.18

0.17

0.1

0.1

Minimum Ten

42.93

42.93

42.93

42.93

42.52

42.52

23.67

23.88

42.80

42.80

Maximum Sag

0.09

0.09

0.09

0.09

0.09

0.09

0.18

0.17

0.1

0.1

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Page

Tension Calculations - Run Fully Loaded

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

PT.PETROKIMIA GRESIK
JSA

Takeup Mass

Station / Pulley
Station

Section Section
Length
Lift
m
m

Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley

1 Takeup

1.00

-0.05

42.93

43.16

2 Hopper

0.50

0.00

43.16

43.16

3 Int. Pt

4.10

0.07

44.17

44.17

4 Drive

5.60

0.12

44.22

41.98

Totals:
Maximum Tension

Drive
Te kN

8800 kg

Ten Material Skirt Scraper Section CEMA


Adj. Accel. Friction Friction Effective Friction
kN
kN
kN
kN
Tension Factor

0.23
1.00

0.23

2.24

0.46

2.2

7/27

0.00

0.89
1.00

0.00

0.00

0.89

0.00

0.03

0.01

0.03

0.05

0.03

0.06

0.03

0.12

44.22 kN

Total Effective Tension

2.47 kN

Minimum Tension

41.98 kN

Total Belt Power (Te x V)

1.24 kW

Average Tension Fully Loaded

42.99 kN

Belt Modulus

9200 kN/m

Average Tension Belt Stationary

42.99 kN

Total Belt Length

13.10 m

Average Tension Difference

0 kN

Belt Elastic Elongation

0 m

Takeup Movement

0 m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

Licenced to PT Krakatau Engineering

Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Station / Pulley
Station

Page

Tension Calculations - Run Empty

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Section Section
Length
Lift
m
m

Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley

1 Takeup

1.00

-0.05

42.93

43.16

2 Hopper

0.50

0.00

43.16

43.16

3 Int. Pt

4.10

0.07

44.17

44.17

4 Drive

5.60

0.12

44.21

41.98

Totals:

Drive
Te kN

PT.PETROKIMIA GRESIK
JSA

Ten Material Skirt Scraper Section CEMA


Adj. Accel. Friction Friction Effective Friction
kN
kN
kN
kN
Tension Factor

0.23
1.00

0.23

2.23

0.46

2.23

8/27

0.89
1.00

0.89

0.00

0.03

0.01

0.03

0.04

0.03

0.06

0.03

0.11

Maximum Tension

44.21 kN

Total Effective Tension

Minimum Tension

41.98 kN

Total Belt Power (Te x V)

1.23 kW

Average Tension Fully Loaded

42.99 kN

Belt Modulus

9200 kN/m

Average Tension Belt Stationary

42.99 kN

Total Belt Length

13.10 m

Average Tension Difference

0 kN

2.46 kN

Belt Elastic Elongation

0 m

Takeup Movement

0 m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Licenced to PT Krakatau Engineering

Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Station / Pulley
Station

Page

Tension Calculations - Run Inclines Loaded

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Section Section
Length
Lift
m
m

Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley

1 Takeup

1.00

-0.05

42.93

43.16

2 Hopper

0.50

0.00

43.16

43.16

3 Int. Pt

4.10

0.07

44.17

44.17

4 Drive

5.60

0.12

44.22

41.98

Totals:

Drive
Te kN

PT.PETROKIMIA GRESIK
JSA

Ten Material Skirt Scraper Section CEMA


Adj. Accel. Friction Friction Effective Friction
kN
kN
kN
kN
Tension Factor

0.23
1.00

0.23

2.24

0.46

2.24

9/27

0.00

0.89
1.00

0.00

0.00

0.89

0.00

0.03

0.01

0.03

0.05

0.03

0.06

0.03

0.12

Maximum Tension

44.22 kN

Total Effective Tension

Minimum Tension

41.98 kN

Total Belt Power (Te x V)

1.24 kW

Average Tension Inclines Loaded

42.99 kN

Belt Modulus

9200 kN/m

Average Tension Belt Stationary

42.99 kN

Total Belt Length

13.10 m

Average Tension Difference

0 kN

2.47 kN

Belt Elastic Elongation

0 m

Takeup Movement

0 m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Station / Pulley
Station

Page

Tension Calculations - Run Declines Loaded

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Section Section
Length
Lift
m
m

Tensions
T1 Run T2 Run
Tp
kN
kN
Pulley

1 Takeup

1.00

-0.05

42.93

43.16

2 Hopper

0.50

0.00

43.16

43.16

3 Int. Pt

4.10

0.07

44.17

44.17

4 Drive

5.60

0.12

44.21

41.98

Totals:

Drive
Te kN

PT.PETROKIMIA GRESIK
JSA

Ten Material Skirt Scraper Section CEMA


Adj. Accel. Friction Friction Effective Friction
kN
kN
kN
kN
Tension Factor

0.23
1.00

0.23

2.23

0.46

2.2

10/27

0.00

0.89
1.00

0.00

0.00

0.89

0.00

0.03

0.01

0.03

0.04

0.03

0.06

0.03

0.12

Maximum Tension

44.21 kN

Total Effective Tension

Minimum Tension

41.98 kN

Total Belt Power (Te x V)

1.23 kW

Average Tension Declines Loaded

42.99 kN

Belt Modulus

9200 kN/m

Average Tension Belt Stationary

42.99 kN

Total Belt Length

13.10 m

Average Tension Difference

0 kN

2.46 kN

Belt Elastic Elongation

0 m

Takeup Movement

0 m

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Conveyor Starting and Stopping

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

System Masses
Mass of Belt
Mass of Material
Carry Idler Equivalent Mass
Return Idler Equivalent Mass
Pulley Equivalent Mass
Drive Equivalent Mass
Total System Equivalent Mass

221
6
81
41
524
46
919

kg
kg
kg
kg
kg
kg
kg

Tensions and Accelerating Forces


Effective Tens. Fully Loaded
2.47 kN
Effective Tension Empty
2.46 kN
Total Braking Force
67.28 kN
Tension Available to Accelerate Conveyor
Accelerating Tension - Loaded
3.5 kN
Accelerating Tension - Empty
3.51 kN
Starting Times & Acceleration Rates
Starting Time - Fully Loaded
0.13 sec
Starting Time - Empty
0.13 sec
Acceleration Rate - Loaded
3.81 m/s2
Accelerating Rate - Empty
3.85 m/s2
Belt Tension Rise Starting / Braking
Max Belt Tension, Start/Brake
58.85 kN
Belt Width
750 mm
Maximum Belt Tension / width
78.47 kN/m
Belt Rated Tension / width
90 kN/m
Actual Max Tension, Start/Brake
87.2 %

Page

11/27

PT.PETROKIMIA GRESIK
JSA

Input Data
Belt Speed
Belt Rated Tension
Allow. Belt Start Tension Rise
Drive Inertia
Total Braking Torque
Start-up Factor - Loaded
Start-up Factor - Empty
Installed Power
Drive Efficiency (Average)

0.5
90
140
0.0012
22
140
140
2.2
95

m/s
kN/m
%
kg-m2
kNm
%
%
kW
%

Stopping Times & Deceleration Rates


Stopping Time Loaded Braking
0.01 sec
Stopping Time Loaded Coasting
0.19 sec
Stopping Time Empty Braking
0.01 sec
Stopping Time Empty Coasting
0.19 sec
Deceleration - Loaded Braking
Deceleration - Loaded Coasting
Deceleration - Empty Braking
Deceleration - Empty Coasting

-75.90 m/s2
-2.69 m/s2
-76.38 m/s2
-2.70 m/s2

Stopping Distances & Discharge Volumes


Stopping Distance Loaded Braking
0m
Stopping Distance Loaded Coasting
0.05 m
Stopping Distance Empty Braking
0m
Stopping Distance Empty Coasting
0.05 m
Discharge Mass, Braking
Discharge Mass, Coasting
Discharge Volume, Braking
Discharge Volume, Coasting

0
0
0
0

kg
kg
m3
m3

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Project
Project No.
Conveyor No.

Conveyor Idler Details Report

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Idler Category
Idler Description
Idler Design Belt Width
Idler Series
Drawing Number
Nominal Idler Spacing
Total Number of Idlers
Idler Price

Carry Side Idlers


Sandvik Carry
Series 20 3 Roll Carry 152 Plain
Inline
750 mm
20
1
5
0

Troughing Angle
Idler Shaft Diameter
Idler Bearing Diameter
Number of Idler Rolls
Idler Roll Diameter
Idler Rotation Speed
Roll Face Width
Roll Bearing Centres
Shaft Support Centres
Idler Support Fixing Width
Idlerset Rotating Mass
Idlerset Total Mass
Idler Vertical Misalignment Allowance
Dynamic Load Factor
Belt Deviation Load
Total Load on Centre Roll
Type of Bearing
Bearing Designation
Bearing Dynamic Load Rating C
Bearing L10h Life
Allowable Shaft Deflection at Bearing
Actual Shaft Deflection at Bearing

30.0
27.0
25.0
3
152
63

deg
mm
mm

283
226.8
307
1000
16.2
31.7

PT.PETROKIMIA GRESIK
JSA

Return Side Idlers


Sandvik Flat Return
Series 30 1 Roll Flat Carry
152 Dia
750 mm
30
3
3
0

deg
mm
mm

mm
rpm

0.0
30.0
25.0
1
152
63

mm
mm
mm
mm
kg
kg

849
785.4
873
1000
13.8
23.1

mm
mm
mm
mm
kg
kg

3.0 mm
1.00
500 N
734 N
Ball
6205
14,000
14,720,410
8.00
1.05

12/27

Page

N
hrs
min
min

mm
rpm

56.3 mm
1.40
1,501 N
2,446 N
Ball
6305
22,500
1,652,498
10.00
8.66

N
hrs
min
min

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Vertical Curve Radius Calculations

Sistem Reaktor 36.R-101


13.M501,0,5 m/s

17 Oct 2014 13:37

Vertical Curve Radius Calculations

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

Station

Curve
Type

750
16.96
6.78
5.08
12.72
62.5
1.22

2 Hopper
3 Int. Pt

Concave

mm
kg/m
kg/m
kg/m
kg/m
%
kg/m

Design
Running
Vertical
Load
Fully Loaded
Empty
Curve
Capacity Radius Tension Radius
Tension Radius
tonnes/hr
m
kN
m
kN
m

1 Takeup

Page

% Belt Mass for Lift-off Calculation


Curve Tension Safety Factor
Average Drive Torque Start-up Factor - Loaded
Average Drive Torque Start-up Factor - Empty
Belt Modulus
Belt Rated Tension
90 kN/m
Allowable Edge Tension - Running:
115 % Starting
Starting
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m

75
1
140
140
9200
67.5
140

Braking
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m

42.93

42.93

42.52

42.52

51.29

51.27

43.16

43.16

43.64

43.64

33.88

33.74

44.17

44.17

44.74

44.75

32.97

32.87

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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Page

Helix Technologies Pty Ltd


Client
PT.PETROKIMIA GRESIK
Prepared By JSA
Design Date

13/27

%
%
%
kN/m
kN
%
Largest
Reqd.
Radius
m

Helix
Licenced to PT Krakatau Engineering

Technologies

17 Oct 2014 13:37

Vertical Curve Radius Calculations

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

Station

Curve
Type

750
16.96
6.78
5.08
12.72
62.5
1.22

Design
Running
Vertical
Load
Fully
Loaded
Empty
Curve
Capacity Radius Tension Radius
Tension Radius
tonnes/hr
m
kN
m
kN
m

Belt Tension at Curve kN

44.17

Min. Concave Lift Off Radius


Min. Edge Tension Radius
Max. Centre Tension Radius
4 Drive

mm
kg/m
kg/m
kg/m
kg/m
%
kg/m

44.17
356
13
9

44.22

% Belt Mass for Lift-off Calculation


Curve Tension Safety Factor
Average Drive Torque Start-up Factor - Loaded
Average Drive Torque Start-up Factor - Empty
Belt Modulus
Belt Rated Tension
90 kN/m
Allowable Edge Tension - Running:
115 % Starting
Starting
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
44.74

356
13
9
44.21

44.75
364
13
9

45.26

75
1
140
140
9200
67.5
140

Braking
Fully Loaded
Empty
Tension Radius
Tension Radius
kN
m
kN
m
32.97

364
13
9
45.24

14/27

Page

%
%
kN/m
kN
%
Largest
Reqd.
Radius
m

32.87
199
23
5

23.67

198
23
5

364

23.88

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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Technologies

17 Oct 2014 13:37

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Project
Project No.
Conveyor No.

Page

Viscoelastic Friction Factor Report

15/27

PT.PETROKIMIA GRESIK
JSA

Viscoelastic Calculations Input Data


Belt Rubber Description
Rubber description ...
6 N/mm2
Top Cover Dynamic Modulus E'
Top Cover Dynamic Loss Factor Tan(delta)
0.13
Belt Top Cover Temperature
30 deg C
Rolling Resistance Factor RRF Top
0.072 RRF Bot.
0.072
Bottom Cover Dynamic Modulus E'
6 N/mm2
Bot Cover Dynamic Loss Factor Tan(delta)
0.13
Belt Bottom Cover Temperature
30 deg C
Belt & Material Flexure Adjustment factor
1
Belt has Turnover on Return Run
Station / Section

No

Total
Loaded
Section
Idler Friction
Length Spacing factor f

Carry Idler Centre Roll Dia


Carry Idler Centre Roll Drag
Carry Idler Wing Roll Dia
Carry Idler Wing Roll Drag
Return Idler Centre Roll Dia
Return Idler Centre Roll Drag
Return Idler Wing Roll Dia
Return Idler Wing Roll Drag
Idlerset Skew Angle
Idlerset Forward Tilt angle

friction factor f (loaded)


Indentation
Matl.& Belt
Idler Drag
Indent Indent
Freq Flexure Flexure Drag
Drag
factor factor uency friction friction factor factor
fi
%
rad/s
fm
%
fr
%

152
2
152
2
152
2
152
2
0.1
0.1

mm
N
mm
N
mm
N
mm
N
deg
deg
Empty

Idler Skew & Tilt


Tilt
Tilt
friction friction
ft
%

Empty
Friction
factor f

1.00

1.00

0.0300 0.00000

0.0

0.00000

0.0

0.00000

0.0

0.00000

0.0

0.0300

0.50

0.35

0.0300 0.00000

0.0

0.00000

0.0

0.00000

0.0

0.00000

0.0

0.0300

4.10

1.50

0.0300 0.00000

0.0

0.00000

0.0

0.00000

0.0

0.00000

0.0

0.0300

5.60

2.00

0.0300 0.00000

0.0

0.00000

0.0

0.00000

0.0

0.00000

0.0

0.0300

Totals:

11.20

0.13

1.00

2.00

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Carry Roll Diameter


Return Roll Diameter
Station / Sectio

Station

Description

152 mm
152 mm

PT.PETROKIMIA GRESIK
JSA

Belt Speed
Takeup Mass
Belt Resonance +/- Tolerance

Running Fully Loaded Belt Resonance


Start
End
Belt
Belt
Tension Tension
kN
kN

16/27

Page

Conveyor Belt Resonance Report

Belt Transverse
Idler Roll Section
Wave Frequency Excitation
Idler
Range
Frequency Spacing
Hz
to Hz
Hz
m

0.5 m/s
8800 kg
10 %

Critical Critical
Idler
Idler
Spacing Spacing
Start
End
m

Idler
Spacing
within
+/- 10%
m

1 Takeup

43.16

44.17

25.22

25.51

1.05

24.09

24.37

OK

2 Hopper

43.16

44.22

69.59

70.44

1.05

0.35

23.26

23.55

OK

3 Int. Pt

44.17

42.93

16.43

16.2

1.05

1.5

23.53

23.2

OK

4 Drive

41.98

42.93

12.44

12.58

1.05

23.75

24.02

OK

Mode

17 Oct 2014 13:37

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Takeup Travel Report

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Takeup Travel
Takeup Type

Page

17/27

PT.PETROKIMIA GRESIK
JSA

Fixed Centres

Auto Calc Takeup Mass


Takeup Mass step increment
200 kg
Max no. of Calc Increments
100
Takeup Mass kg (Manual
Input)
Takeup Mass Calculated
Takeup Travel Estimate
Safety Margin Top
+
Belt Splice Allowance +
Dynamic Travel Up
+
Dynamic Travel Down +
Safety Margin Bottom +
Thermal Expansion Distance
Minimum Site Temperature
Maximum Site Temperature
Belt Expansion co-efficient
m/m per degree C
Total Belt Length
Thermal Expansion Distance +
Permanent Belt Stretch
Permanent Stretch coefficient % of Belt Length
Permanent Belt Stretch
Distance
+
Total Takeup Travel Distance

8800 kg
8800 kg
0
0.5
0
0
0

m
m
m
m
m

0 deg
30 deg
1.17E-05
13.10 m
0.002 m

0.15 %
0.009 m
0.51 m

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive No.

1 Drive

Pulley No.

Drive Description
Load Share on Drive Pulley

Head
100 %

Starting Torque Factor, Fully Loaded


Starting Torque Factor, Empty

140 %
140 %

Number of Motors on Drive Pulley


Motor Description
Motor Power Rating
Motor Voltage
Gearbox Description

Electric Motor
2.2 kW
380 Volts
Flender Helical Bevel Gear

Drive Efficiency

95 %

High Speed Coupling


HS Coupling Make
Low Speed Coupling
LS Coupling Make

1020T

Brake Location

Static Analysis Horizontal Force Fh


Calculated Holdback Torque
Holdback Required (Yes / No)
Holdback Torque 3 x Motor FLT
Holdback Make
Holdback Model

180
0.25

Drive Factor Cw, Running

0.84

Coefficient of Friction, Starting


Drive Factor Cw, Starting

0.35
0.5

Pulley and Shaft Dimensions


Pulley Shell Diameter

630 mm

Pulley Lagging Thickness

1 N
2469 N
N/A Nm
No Fv>Fh/2
4317 Nm

12 mm

Pulley Outside Diameter


Pulley Shaft Diameter at Hub

654 mm
150 mm

Pulley Shaft Diameter at Brg

125 mm

Calculated Belt Speed

22 kNm
362 Nm

Moist
Rubber

Belt Wrap Angle


Coefficient of Friction, Running

Calculated Pulley Speed for Reducer


Required Belt Speed

High Speed

Holdback
Static Analysis Runback Force Fv

Pulley Condition
Pulley Lagging Type

Selected Gearbox Ratio


Required Pulley Speed

RFK140

Low Speed Brake Torque Input


Equiv HS Brake Torque

Required Gearbox Ratio

Ringspann

LS Coupling Model
Brake

PT.PETROKIMIA GRESIK
JSA

Pulley and Belt Speed


Motor Full Load Speed

Falk

HS Coupling Model

18/27

Page

Drive Details Report

Drive Inertia
Motor Inertia

935 rpm
64.035 :1
31.5 :1
14.6 rpm
29.68 rpm
0.5 m/s
1.02 m/s
0.0012 kg-m2

High Speed Coupling Inertia


High Speed Brake Disc Inertia

0 kg-m2
0 kg-m2

Flywheel Inertia

0 kg-m2

Gearbox Inertia (HSS)


Total Drive Inertia
Total Drive Equivalent Mass

0 kg-m2
0.0012 kg-m2
46 kg

Not Installed

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive No.

Page

Drive Motor Details Report

1 Drive

Pulley No.

Drive Description
Head
Number of Motors on Drive Pulley
1
Motor Category
Metric Motor
Motor Description
Electric Motor
Motor Power Rating
2.2 kW
Motor Voltage
380 Volts
Number of poles
6
Motor Frame Size
DX112M
Motor Shaft Diameter
28 mm
Motor Shaft Height
112 mm
Motor Inertia
0.0012 kg-m2

19/27

PT.PETROKIMIA GRESIK
JSA

Total Motor Power on Drive


Absorbed Power at Pulley
Drive Efficiency
Absorbed Power at Motor
Motor Full Load Speed
Motor Full Load Torque
Motor Full Load Current
Motor Efficiency @ Duty Point
Motor Power Factor @ Duty Pt
Mass of Motor

2
1.24
95
1.31
935
22.5
5.9
76.49
0.62
48

kW
kW
%
kW
rpm
Nm
Amps
%
kg

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Drive Fluid Coupling Details Report

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive No.

1 Drive

Pulley No.

Drive Description
Head
Number of Motors on Drive Pulley
1
Selection Mode
Auto
Coupling Category
Flender
Coupling Description
No Selection - Direct Drive
Coupling Power Rating
0 kW
Min. Required Ramping Time
sec
Max Starting Time
0 sec

Page

20/27

PT.PETROKIMIA GRESIK
JSA

Coupling Size
Motor Power Rating
Motor Full Load Speed
Coupling Rated Slip
Peak Torque %
Run-up Torque % (2 sec)
Coupling Output Speed
Mass of Coupling

2.2
935
0
0
0
935
0

kW
rpm
%
% FLT
% FLT
rpm
kg

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Drive Gearbox Details Report

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive No.

1 Drive

Pulley No.

Drive Description
Head
Number of Motors on Drive Pulley
1
Selection Mode
Manual
Gearbox Category
Flender
Gearbox Description
Flender Helical Bevel Gear
Type
Helical Bevel Gear
Size
4
Code
B3SH4
Ratio
31.5
Number of Stages
B3SH4
Design Efficiency (Input)
Gearbox Actual Efficiency
Maximum Input Shaft Speed
Minimum Input Shaft Speed
Input Shaft Diameter
Output Shaft Diameter
Gearbox Inertia

95
93
1500
700
30
80

%
%
rpm
rpm
mm
mm
kg-m2

Page

21/27

PT.PETROKIMIA GRESIK
JSA

Motor Power Rating


Motor Full Load Speed
Motor Torque @ FL Speed
Motor Torque at Pulley Speed
Gearbox Rated Torque
Service Factor Required
Service Factor Calculated
Plus Speed Selection Tolerance
Minus Speed Selection Tolerance
Fluid Coupling Slip
Required Gearbox Ratio
Selected Gearbox Ratio
Required Pulley Speed
Calculated Pulley Speed for Reducer
Required Belt Speed
Calculated Belt Speed
Mass of Gearbox

2.2
935
22
1439
6400
1.5
4.45

kW
rpm
Nm
Nm
Nm

5
5
0
64.035
31.5
14.6
29.68
0.5
1.02
210

%
%
%
:1
:1
rpm
rpm
m/s
m/s
kg

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Page

Brake Details Report

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive / Brake No.

1 Drive

Brake Selection Input Data


Low Speed Brake Torque Input
Equiv HS Brake Torque
Design Braking Torque Input
Selected Brake's Torque Rating
Design Stopping Time
Consecutive No of Stops
Average No of Stops
Ambient Temperature
Disc Temperature after stops

PT.PETROKIMIA GRESIK
JSA

Pulley No.

Description
Head
Load Share on Drive Pulley
100 %
Brake Category
Svendborg BSFH 200
Brake Description
Svendborg
Caliper
BSFH 202
Number of Motors on Drive Pulley
1
22
362
1210
-43
10.0
3
6
40
NaN

kNm
Nm
Nm
Nm
sec

deg C
deg C

22/27

Brake Location
Disc Material
Disc Diameter
Disc Thickness
Co-eff of Friction (Pad-Disc)
Caliper Clamping Force Minimum
Caliper Clamping Force Maximum
Pad offset Width W
Maximum Air Gap

High Speed
Mild Steel
0 mm
0 mm
0.4
2000
3500
60
3

N
N
mm
mm

Recommended working airgap is 1mm

Disc Initial Speed


Disc Moment of Inertia
Required Gearbox Ratio
Drive Efficiency
Mass of Caliper
Brake Caliper Price

0
0.0
64.035
95
26
$0.00

rpm
kg-m2
:1
%
kg

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Drive No.

1 Drive

Drive Description
Load Share on Drive Pulley
Starting Torque Factor, Fully Loaded
Starting Torque Factor, Empty
Number of Motors on Drive Pulley
Drive Efficiency

Pulley No.
Head
100
140
140
1
95

%
%
%

23/27

Page

Shaft Coupling Report

PT.PETROKIMIA GRESIK
JSA

Motor Power Rating


Motor Full Load Speed
Motor Torque @ FL Speed
Motor Torque at Pulley Speed
Pulley Shaft Diameter at Brg

2.2
935
22
1439
125

kW
rpm
Nm
Nm
mm

High Speed Coupling


HS Coupling Category
Falk SteelFlex Grid
HS Coupling Make
Falk
HS Coupling Model
1020T
Coupling Type
Grid
Coupling Torque Rating
52 Nm
Service Factor Required
1.5
Service Factor Calculated
2.31
Maximum Shaft Bore
28 mm
Minimum Shaft Bore
0 mm
Maximum Rotation Speed
4500 rpm
High Speed Coupling Inertia
0.0014 kg-m2
Drawing Number
High Speed Coupling Mass
1.91 kg
High Speed Coupling Price
0
Fluid Coupling
Direct Drive
Fluid Coupling
No Selection - Direct Drive
Fluid Coupling Size

Low Speed Coupling


LS Coupling Category
LS Coupling Make
LS Coupling Model
Coupling Type
Coupling Torque Rating
Service Factor Required
Service Factor Calculated
Maximum Shaft Bore
Minimum Shaft Bore
Maximum Rotation Speed
Low Speed Coupling Inertia
Drawing Number
Low Speed Coupling Mass
Low Speed Coupling Price

Falk SteelFlex Grid


Ringspann
RFK140
Rigid Flanged
56000
1.5
38.92
140
115
3800
2.9

Nm

mm
mm
rpm
kg-m2

800 kg
0

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

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17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

Station / Sectio

T1
Run

T2
Run

kN

kN

180.0

42.9

43.2

180.0

44.2

42.0

Shaft
Length
mm

Wrap
Angle
deg

1 Takeup

1610

4 Drive

1610

Station

Description

Resultant
Force
kN

PT.PETROKIMIA GRESIK
JSA

kN

Calculated
Defl.
Dt.
Dia
Dia
mm
mm

86.1

42.5

123.6

127.5

150

125

1270

223

86.2

45.3

123.6

127.7

150

125

1270

223

T1
Start

Selected
Shaft
Brg
Dia
Dia
mm
mm

Brg
Ctrs
mm

Shaft
Mass
kg

* Denotes manual pulley shaft dimensions entered

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


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Page

Conveyor Pulley Shafts

Licenced to PT Krakatau Engineering

Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Page

Conveyor Pulleys

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

25/27

PT.PETROKIMIA GRESIK
JSA

Station / Sectio
Station

Shell Lagging
Description Dia mm
mm

Face
Width
mm

Shaft
Length
mm

Brg
Ctrs
mm

Shaft
Dia
mm

Brg
Dia
mm

Wrap
Angle
deg

Pulley Pulley & Mom of


Speed
Shaft
Inertia
rpm Mass kg kgm2

1 Takeup

500

12

850

1610

1270

150

125

180.0

18.2

475

12.7

4 Drive

630

12

850

1610

1270

150

125

180.0

14.6

718

36.2

* Denotes manual pulley dimensions entered

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

Licenced to PT Krakatau Engineering

Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Page

Conveyor Pulley Dimensions

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

26/27

PT.PETROKIMIA GRESIK
JSA

Station / Sectio
Station

Shell Lagging
Description Dia mm
mm

OD
mm

Face
Width
mm

Shaft
Length
mm

Brg
Ctrs
mm

Shaft
Dia
mm

Brg
Dia
mm

Belt
Width
mm

Pulley & Mom of


Shaft Inertia
Mass kg kgm2

1 Takeup

500

12

524

850

1610

1270

150

125

750

475

12.7

4 Drive

630

12

654

850

1610

1270

150

125

750

718

36.2

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

Licenced to PT Krakatau Engineering

Helix
Technologies

17 Oct 2014 13:37


Project
Project No.
Conveyor No.

Page

Conveyor Pulleys Data Sheet

Helix Technologies Pty Ltd


Sistem Reaktor 36.R-101
Client
Prepared By
13.M501,0,5 m/s
Design Date

27/27

PT.PETROKIMIA GRESIK
JSA

Station / Sectio
Station

Shell Lagging
Description Dia mm
mm

Face
Width
mm

Brg
Ctrs
mm

1 Takeup

500

12

850

1270

4 Drive

630

12

850

1270

Drive
Power
kW

2.2

Wrap Pulley
Angle Speed
deg
rpm

T1
Run
kN

T2
Run
kN

T1
Start
kN

T2
Start
kN

180.0

18.2

42.93
43.16
Running Full

51.29
37.46
Braking Full

180.0

14.6

44.22
41.98
Running Full

45.26
41.11
Starting Full

Designers Comments

E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml


Ver 6.0.15

Licenced to PT Krakatau Engineering

Helix
Technologies