15 Sep 2020 21:13 Conveyor Design Summary Page 1/8

PT. SIKO TECHNO

Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Conveyed Material
Material Description Lump Coal Surcharge Angle 20 deg
Low Bulk Density 800 kg/m3 Angle of Repose 30 deg
High Bulk Density 900 kg/m3 Material Lump size 30 mm
Conveyor Data
Conveying Distance 29.32 m Design Capacity 3.7 tonnes/hr
Nett Lift / Lower (-) 7.58 m Belt Speed 1 m/s
Belt Details
Belt Width Selected 500 mm Calculated Belt % Full 5.6 %
Belt Class & Run Safety Factor EP300/3 25.35 Top Cover Thickness 3 mm
Belt Rated Tension 25 kN/m Bottom Cover Thickness 1.5 mm
Belt Total Length 63.1 m Belt Mass 3.80 kg/m
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded 1.11 kN Belt Power - Empty Belt 1.02 kW
Maximum Tension Tmax 1.97 kN Belt Power - Inclines Loaded 1.11 kW
Minimum Tension Tmin 0.89 kN Belt Power - Declines Loaded 1.03 kW
Sag Tension 1.5 % 0.4 kN Belt Power - Fully Loaded 1.11 kW
Takeup Type Fixed Centres Drive Efficiency 95.0 %
Takeup Mass 250 kg Absorbed Power Fully Loaded 1.17 kW
Takeup Pulley Belt Tension 1.23 kN Installed Motor Power 2.2 kW
Carry and Return Idlers
Carry Idler Trough Angle 30 º Return Idler Trough Angle 0 º
Carry Idler Spacing 1 m Return Idler Spacing 3 m
Carry Idler No Rolls x Dia 3 x 89 mm Return Idler No Rolls x Dia 1 x 89 mm
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded 150 % CEMA Temperature Factor Kt 1.00
Startup Factor - Empty 150 % Total Braking Torque LSS 0.00 kNm
Starting Time - Fully Loaded 0.95 sec Stop Time - Loaded, Braking 1.78 sec
Starting Time - Empty 0.90 sec Stop Time - Loaded, Coasting 1.78 sec
Designers Comments

Helix
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15 Sep 2020 21:13 Tension Calculations - Summary Run / Start Page 2/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Drive Torque Start-up Factor Loaded 150 %

Drive Torque Start-up Factor Empty 150 % Takeup Mass 250 kg

Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
1 Takeup 1.23 1.25 1.23 1.25 1.14 1.17 1.24 1.26 1.24 1.26

2 Hopper 1.28 1.30 1.28 1.30 1.30 1.33 1.24 1.26 1.24 1.26

3 Int. Pt 1.94 1.88 1.94 1.88 2.27 2.21 1.72 1.69 1.72 1.69

4 Drive 1.97 1.91 1.97 1.91 2.32 2.26 1.75 1.72 1.75 1.72

5 Bend 1.28 1.30 1.28 1.30 0.94 0.94 1.49 1.50 1.49 1.50

6 Int. Pt 1.29 1.31 1.29 1.31 1.00 1.01 1.47 1.48 1.47 1.48

7 Int. Pt 1.04 1.06 1.04 1.06 0.99 1.02 1.09 1.10 1.09 1.10

Minimum Ten 1.04 1.06 1.04 1.06 0.94 0.94 1.09 1.10 1.09 1.10
Maximum Ten 1.97 1.91 1.97 1.91 2.32 2.26 1.75 1.72 1.75 1.72
Effective Ten 1.11 1.02 1.11 1.03

Ave. Belt Ten 1.38 1.38 1.38 1.38 1.38 1.38 1.38 1.38 1.38 1.38
Belt Elong. m 0 0 0 0 0 0 0 0 0 0
T/up Travel m 0 0 0 0 0 0 0 0 0 0
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
 15 Sep 2020 21:13 Belt Details Report Page 3/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Low BD = 800kg/m3 High BD = 900kg/m3

Conveyed Material Belt Speed & Capacity
Material Description Lump Coal Belt Speed 1 m/s
Low Bulk Density 800 kg/m3 Belt Design Capacity Input 3.7 tonnes/hr
High Bulk Density 900 kg/m3 Section Loading Max Capacity 3.7 tonnes/hr
Surcharge Angle 20 deg Carry Idler Trough Angle 30 º
Angle of Repose 30 deg Belt Dimensions
Material Lump size 30 mm Top Cover Thickness 3 mm
Belt Make & Class Bottom Cover Thickness 1.5 mm
Belt Category Bando Conveyor Belt Belt Carcass Thickness 3.3 mm
Belt Description Fabric Multi-Ply Conveyor Belt Total Thickness 7.8 mm
Belt
Belt Class / Plies EP300/3 3 Belt Total Belt Length (L) 63.1 m
Belt Reinforcement Fibre Fabric Time for 1 Revolution 63.1 sec
Belt Width Selected 500 mm Belt Load Area and Capacity at 800kg/m3
Belt Modulus 2300 kN/m Minimum Rec. Edge Distance 50 mm
Actual Edge Distance Low BD 161 mm
Load Burden Depth 15 mm
Load Burden Width 171 mm
Belt Tensions Belt Load Area at Minimum
Recommended Edge Distance 0.0228 m2
Belt Rated Tension / m width 25 kN/m
Calculated Tension / m width 3.9 kN/m Belt Load Area Utilised at Low
Belt Rated Tension for width 12.5 kN Bulk Density 0.0013 m2
Calculated Max Run Tension 1.97 kN Belt Actual % Full at Low BD 5.6 %
Minimum Tension Tmin 0.89 kN Belt Load Area and Capacity at 900kg/m3
Allowable Tension Rise, Starting 150 % Minimum Rec. Edge Distance 50 mm
Allowable Belt Tension, Starting 18.8 kN Actual Edge Distance High BD 163 mm
Actual Belt Tension, Starting 2.32 kN Belt Load Area Utilised at High
Bulk Density 0.0011 m2
Belt and Material Mass Belt Actual % Full at High BD 5 %
Belt Top Cover Mass 2.1 kg/m Flooded Belt Capacity at 900kg/m3
Belt Bottom Cover Mass 1.1 kg/m Flooded Belt Load Area at Zero
Edge Distance 0.0375 m2
Belt Carcass Mass 0.6 kg/m
Belt Mass Wb (per linear m) 3.8 kg/m Flooded Belt Capacity 122 tonnes/hr
Material Mass Wm 1 kg/m Flooded Belt Material Mass 33.8 kg/m
Total Mass (Wb + Wm) 4.8 kg/m
Total Belt Mass (Wb x L) 240 kg
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
 15 Sep 2020 21:13 Conveyor Idler Details Report Page 4/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Carry Side Idlers Return Side Idlers

Idler Category Rumelca Rumelca
Idler Description Carrier Idler Return Idler
Idler Design Belt Width 500 mm 500 mm
Idler Series PSV-1 PSV-1
Drawing Number
Nominal Idler Spacing 1 m 3 m
Total Number of Idlers 31 30
Idler Price 0 0
Troughing Angle 30.0 deg 0.0 deg
Idler Shaft Diameter 20.0 mm 20.0 mm
Idler Bearing Diameter 20.0 mm 20.0 mm
Number of Idler Rolls 3 1
Idler Roll Diameter 89 mm 89 mm
Idler Rotation Speed 215 rpm 215 rpm
Roll Face Width 200 mm 600 mm
Roll Bearing Centres 131.8 mm 536.8 mm
Shaft Support Centres 222 mm 622 mm
Idler Support Fixing Width 750 mm 750 mm
Idlerset Rotating Mass 6 kg 4.6 kg
Idlerset Total Mass 14.3 kg 8.9 kg
Idler Vertical Misalignment Allowance 6.3 mm 5.0 mm
Dynamic Load Factor 1.01 1.40
Belt Deviation Load 1,000 N 500 N
Total Load on Centre Roll 1,082 N 739 N
Type of Bearing Ball Ball
Bearing Designation 6204 6204
Bearing Dynamic Load Rating C 13,500 N 13,500 N
Bearing L10h Life 1,206,501 hrs 3,784,981 hrs
Allowable Shaft Deflection at Bearing 8.00 min 10.00 min
Actual Shaft Deflection at Bearing 3.35 min 8.81 min
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
 15 Sep 2020 21:13 Takeup Travel Report Page 5/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Takeup Travel
Takeup Type Fixed Centres
Auto Calc Takeup Mass
Takeup Mass step increment 50 kg
Max no. of Calc Increments 100
Takeup Mass kg (Manual 0 kg
Input)
Takeup Mass Calculated 250 kg
Takeup Travel Estimate
Safety Margin Top + 0 m
Belt Splice Allowance + 0.65 m
Dynamic Travel Up + 0 m
Dynamic Travel Down + 0 m
Safety Margin Bottom + 0 m
Thermal Expansion Distance
Minimum Site Temperature 0 deg
Maximum Site Temperature 45 deg
Belt Expansion co-efficient
1.17E-05
m/m per degree C
Total Belt Length 63.10 m
Thermal Expansion Distance + 0.017 m
Permanent Belt Stretch
Permanent Stretch co-
0.15 %
efficient % of Belt Length
Permanent Belt Stretch 0.047 m
Distance +
Total Takeup Travel Distance 0.71 m

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
15 Sep 2020 21:13 Drive Details Report Page 6/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Drive No. 1 Drive Pulley No. 4

Drive Description Head Pulley Condition Moist
Load Share on Drive Pulley 100 % Pulley Lagging Type Rubber
Starting Torque Factor, Fully Loaded 150 % Belt Wrap Angle 194.99 º
Starting Torque Factor, Empty 150 % Coefficient of Friction, Running 0.25
Number of Motors on Drive Pulley 1 Drive Factor Cw, Running 0.75
Motor Description SIMOTICS XP Coefficient of Friction, Starting 0.35
Motor Power Rating 2.2 kW Drive Factor Cw, Starting 0.44
Motor Voltage 380 Volts Pulley and Shaft Dimensions
Gearbox Description Cyclo Pulley Shell Diameter 424 mm
Drive Efficiency 95 % Pulley Lagging Thickness 12 mm
Pulley Outside Diameter 448 mm
Pulley Shaft Diameter at Hub 70 mm
Pulley Shaft Diameter at Brg 60 mm
High Speed Coupling Pulley and Belt Speed
HS Coupling Make Tsubaki Motor Full Load Speed 1455 rpm
HS Coupling Model CR4016K Required Gearbox Ratio 34.13 :1
Low Speed Coupling Selected Gearbox Ratio 35 :1
LS Coupling Make Tsubaki Required Pulley Speed 42.63 rpm
LS Coupling Model CR6022K Calculated Pulley Speed for Reducer 41.57 rpm
Brake Required Belt Speed 1 m/s
Brake Location None Calculated Belt Speed 0.98 m/s
Low Speed Brake Torque Input 0 kNm Drive Inertia
Equiv HS Brake Torque 0 Nm Motor Inertia 0.0086 kg-m2
Holdback High Speed Coupling Inertia 0 kg-m2
Static Analysis Runback Force Fv 77 N High Speed Brake Disc Inertia 0 kg-m2
Static Analysis Horizontal Force Fh 1033 N Flywheel Inertia 0 kg-m2
Calculated Holdback Torque N/A Nm Gearbox Inertia (HSS) 0.0458 kg-m2
Holdback Required (Yes / No) No Fv>Fh/2 Total Drive Inertia 0.0495 kg-m2
Holdback Torque 3 x Motor FLT 1479 Nm Total Drive Equivalent Mass 1149 kg
Holdback Make Tsubaki BS
Holdback Model BS160HS
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
15 Sep 2020 21:13 Conveyor Pulleys Page 7/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Station / Sectio
Face Shaft Brg Shaft Brg Wrap Pulley Pulley & Mom of
Shell Lagging Width Length Ctrs Dia Dia Angle Speed Shaft Inertia
Station Description Dia mm mm mm mm mm mm mm deg rpm Mass kg kgm2
1 Takeup 320 * 0 600 1050 860 60 50 180.0 59.7 113 2.0

4 Drive 424 * 12 600 1050 860 70 60 210.0 42.6 204 5.4

5 Bend 273 * 0 600 1050 860 50 40 30.0 70.0 79 0.8

Designers Comments * Denotes manual pulley dimensions entered

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
15 Sep 2020 21:13 Conveyor Pulleys Data Sheet Page 8/8
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. - Prepared By ISK
Conveyor No. ZC01-CV001 Design Date

Station / Sectio
Face Brg Drive Wrap Pulley T1 T2 T1 T2
Shell Lagging Width Ctrs Power Angle Speed Run Run Start Start
Station Description Dia mm mm mm mm kW deg rpm kN kN kN kN
1 Takeup 320 0 600 860 180.0 59.7 1.23 1.25 1.26 1.24
Running Full Coasting Empty

4 Drive 424 12 600 860 2.2 210.0 42.6 1.97 0.89 1.72 1.11
Running Full Coasting Empty

5 Bend 273 0 600 860 30.0 70.0 1.28 1.31 1.5 1.5
Running Full Braking Empty

Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies