30 Sep 2020 05:42 Conveyor Design Summary Page 1/10

PT. SIKO TECHNO

Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 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 4.20 m Design Capacity 3.7 tonnes/hr
Nett Lift / Lower (-) 0.05 m Belt Speed 0.05 m/s
Belt Details
Belt Width Selected 650 mm Calculated Belt % Full 98.4 %
Belt Class & Run Safety Factor EP 300/3 38.08 Top Cover Thickness 10 mm
Belt Rated Tension 40 kN/m Bottom Cover Thickness 3 mm
Belt Total Length 12.6 m Belt Mass 12.21 kg/m
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded 2.63 kN Belt Power - Empty Belt 0.13 kW
Maximum Tension Tmax 5.12 kN Belt Power - Inclines Loaded 0.13 kW
Minimum Tension Tmin 2.54 kN Belt Power - Declines Loaded 0.13 kW
Sag Tension 0.5 % 2.41 kN Belt Power - Fully Loaded 0.13 kW
Takeup Type Fixed Centres Drive Efficiency 95.0 %
Takeup Mass 700 kg Absorbed Power Fully Loaded .14 kW
Takeup Pulley Belt Tension 3.43 kN Installed Motor Power 1.5 kW
Carry and Return Idlers
Carry Idler Trough Angle 10 º Return Idler Trough Angle 0 º
Carry Idler Spacing 0.3 m Return Idler Spacing 2 m
Carry Idler No Rolls x Dia 3 x 108 mm Return Idler No Rolls x Dia 1 x 133 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 0.15 sec Stop Time - Loaded, Braking 2.22 sec
Starting Time - Empty 0.14 sec Stop Time - Loaded, Coasting 2.22 sec
Designers Comments

Helix
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30 Sep 2020 05:42 Tension Calculations - Summary Run / Start Page 2/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

Drive Torque Start-up Factor Loaded 150 %

Drive Torque Start-up Factor Empty 150 % Takeup Mass 700 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 3.12 3.13 3.12 3.12 3.00 3.02 3.06 3.07 3.06 3.07

2 Hopper 3.17 3.18 3.17 3.17 3.17 3.19 3.10 3.11 3.10 3.11

3 Drive 5.12 5.07 5.12 5.09 5.21 5.14 5.05 5.00 5.05 5.00

4 Snub 3.08 3.09 3.08 3.08 3.04 3.06 3.16 3.16 3.16 3.16

5 Int. Pt 3.13 3.14 3.13 3.13 3.13 3.15 3.20 3.20 3.20 3.20

Minimum Ten 3.08 3.09 3.08 3.08 3.00 3.02 3.06 3.07 3.06 3.07
Maximum Ten 5.12 5.07 5.12 5.09 5.21 5.14 5.05 5.00 5.05 5.00
Effective Ten 2.63 2.57 2.63 2.60

Ave. Belt Ten 3.44 3.44 3.44 3.44 3.44 3.44 3.44 3.44 3.44 3.44
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
 30 Sep 2020 05:42 Belt Details Report Page 3/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

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

Conveyed Material Belt Speed & Capacity
Material Description Lump Coal Belt Speed 0.05 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 10 º
Angle of Repose 30 deg Belt Dimensions
Material Lump size 30 mm Top Cover Thickness 10 mm
Belt Make & Class Bottom Cover Thickness 3 mm
Belt Category Bando Conveyor Belt Belt Carcass Thickness 2.3 mm
Belt Description Fabric Multi-Ply Conveyor Belt Total Thickness 15.2 mm
Belt
Belt Class / Plies EP 300/3 3 Belt Total Belt Length (L) 12.6 m
Belt Reinforcement Fibre Fabric Time for 1 Revolution 252.0 sec
Belt Width Selected 650 mm Belt Load Area and Capacity at 800kg/m3
Belt Modulus 1750 kN/m Minimum Rec. Edge Distance 59 mm
Actual Edge Distance Low BD 61 mm
Load Burden Depth 74 mm
Load Burden Width 505 mm
Belt Tensions Belt Load Area at Minimum
Recommended Edge Distance 0.0261 m2
Belt Rated Tension / m width 40 kN/m
Calculated Tension / m width 7.9 kN/m Belt Load Area Utilised at Low
Belt Rated Tension for width 26 kN Bulk Density 0.0257 m2
Calculated Max Run Tension 5.12 kN Belt Actual % Full at Low BD 98.4 %
Minimum Tension Tmin 2.54 kN Belt Load Area and Capacity at 900kg/m3
Allowable Tension Rise, Starting 150 % Minimum Rec. Edge Distance 59 mm
Allowable Belt Tension, Starting 39 kN Actual Edge Distance High BD 75 mm
Actual Belt Tension, Starting 5.21 kN Belt Load Area Utilised at High
Bulk Density 0.0228 m2
Belt and Material Mass Belt Actual % Full at High BD 87.4 %
Belt Top Cover Mass 9.1 kg/m Flooded Belt Capacity at 900kg/m3
Belt Bottom Cover Mass 2.7 kg/m Flooded Belt Load Area at Zero
Edge Distance 0.0401 m2
Belt Carcass Mass 0.4 kg/m
Belt Mass Wb (per linear m) 12.2 kg/m Flooded Belt Capacity 6 tonnes/hr
Material Mass Wm 20.6 kg/m Flooded Belt Material Mass 36.1 kg/m
Total Mass (Wb + Wm) 32.8 kg/m
Total Belt Mass (Wb x L) 154 kg
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
 30 Sep 2020 05:42 Conveyor Idler Details Report Page 4/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

Carry Side Idlers Return Side Idlers

Idler Category Rumelca Rumelca
Idler Description PSV-1 PSV-3
Idler Design Belt Width 650 mm 650 mm
Idler Series PSV-1 PSV-3
Drawing Number
Nominal Idler Spacing 0.3 m 2 m
Total Number of Idlers 16 5
Idler Price 0 0
Troughing Angle 10.0 deg 0.0 deg
Idler Shaft Diameter 20.0 mm 25.0 mm
Idler Bearing Diameter 25.0 mm 25.0 mm
Number of Idler Rolls 3 1
Idler Roll Diameter 108 mm 133 mm
Idler Rotation Speed 9 rpm 7 rpm
Roll Face Width 246 mm 746 mm
Roll Bearing Centres 189.8 mm 689.8 mm
Shaft Support Centres 270 mm 770 mm
Idler Support Fixing Width 900 mm 900 mm
Idlerset Rotating Mass 9 kg 7.6 kg
Idlerset Total Mass 23.3 kg 13.1 kg
Idler Vertical Misalignment Allowance 0.6 mm 25.0 mm
Dynamic Load Factor 1.00 1.40
Belt Deviation Load 300 N 1,000 N
Total Load on Centre Roll 443 N 1,470 N
Type of Bearing Ball Ball
Bearing Designation 6204 6305
Bearing Dynamic Load Rating C 13,500 N 23,400 N
Bearing L10h Life 425,349,986 hrs 74,961,772 hrs
Allowable Shaft Deflection at Bearing 8.00 min 10.00 min
Actual Shaft Deflection at Bearing 1.76 min 8.68 min
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
 30 Sep 2020 05:42 Takeup Travel Report Page 5/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 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 700 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 12.60 m
Thermal Expansion Distance + 0.003 m
Permanent Belt Stretch
Permanent Stretch co-
0.15 %
efficient % of Belt Length
Permanent Belt Stretch 0.01 m
Distance +
Total Takeup Travel Distance 0.66 m

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
30 Sep 2020 05:42 Drive Details Report Page 6/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

Drive No. 1 Drive Pulley No. 3

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 195 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 AF Motor for Inverter Coefficient of Friction, Starting 0.35
Motor Power Rating 1.5 kW Drive Factor Cw, Starting 0.44
Motor Voltage 400 Volts Pulley and Shaft Dimensions
Gearbox Description Cyclo Speed Reducer Pulley Shell Diameter 500 mm
Drive Efficiency 95 % Pulley Lagging Thickness 12 mm
Pulley Outside Diameter 524 mm
Pulley Shaft Diameter at Hub 140 mm
Pulley Shaft Diameter at Brg 125 mm
High Speed Coupling Pulley and Belt Speed
HS Coupling Make 0 Motor Full Load Speed 1750 rpm
HS Coupling Model 0 Required Gearbox Ratio 960.28 :1
Low Speed Coupling Selected Gearbox Ratio 1849 :1
LS Coupling Make Tsubaki Required Pulley Speed 1.82 rpm
LS Coupling Model CR12022K Calculated Pulley Speed for Reducer 0.95 rpm
Brake Required Belt Speed 0.05 m/s
Brake Location None Calculated Belt Speed 0.03 m/s
Low Speed Brake Torque Input 0 kNm Drive Inertia
Equiv HS Brake Torque 0 Nm Motor Inertia 0.0033 kg-m2
Holdback High Speed Coupling Inertia 0 kg-m2
Static Analysis Runback Force Fv 10 N High Speed Brake Disc Inertia 0 kg-m2
Static Analysis Horizontal Force Fh 2620 N Flywheel Inertia 0 kg-m2
Calculated Holdback Torque N/A Nm Gearbox Inertia (HSS) 0 kg-m2
Holdback Required (Yes / No) No Fv>Fh/2 Total Drive Inertia 0.0086 kg-m2
Holdback Torque 3 x Motor FLT 23582 Nm Total Drive Equivalent Mass 115529 kg
Holdback Make Not Installed
Holdback Model
Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
30 Sep 2020 05:42 Drive Gearbox Details Report Page 7/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

Drive No. 1 Drive Pulley No. 3

Drive Description Head Motor Power Rating 1.5 kW
Number of Motors on Drive Pulley 1 Motor Full Load Speed 1750 rpm
Selection Mode Manual Motor Torque @ FL Speed 8 Nm
Gearbox Category Sumitomo Drive Motor Torque at Pulley Speed 7871 Nm
Gearbox Description Cyclo Speed Reducer Gearbox Rated Torque 13600 Nm
Type AV Service Factor Required 1.5
Size 6225DA Service Factor Calculated 1.73
Code CHHM2
6225DA AV Plus Speed Selection Tolerance 5 %
Ratio 1849 Minus Speed Selection Tolerance 5 %
Number of Stages CHHM2 Fluid Coupling Slip 0 %
6225DA AV
Design Efficiency (Input) 95 % Required Gearbox Ratio 960.28 :1
Gearbox Actual Efficiency 94 % Selected Gearbox Ratio 1849 :1
Maximum Input Shaft Speed 1725 rpm Required Pulley Speed 1.82 rpm
Minimum Input Shaft Speed 110 rpm Calculated Pulley Speed for Reducer 0.95 rpm
Input Shaft Diameter 24 mm Required Belt Speed 0.05 m/s
Output Shaft Diameter 120 mm Calculated Belt Speed 0.03 m/s
Gearbox Inertia 0.0085 kg-m2 Mass of Gearbox 444 kg

Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
30 Sep 2020 05:42 Conveyor Pulleys Page 8/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 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 500 * 0 750 1350 1070 90 80 180.0 1.9 300 19.3

3 Drive 500 * 12 750 1440 1070 140 125 190.0 1.8 501 32.7

4 Snub 270 * 0 750 1290 1070 60 60 30.0 3.5 99 1.2

Designers Comments * Denotes manual pulley dimensions entered

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
30 Sep 2020 05:42 Conveyor Pulley Dimensions Page 9/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 Design Date

Station / Sectio
Face Shaft Brg Shaft Brg Belt Pulley & Mom of
Shell Lagging OD Width Length Ctrs Dia Dia Width Shaft Inertia
Station Description Dia mm mm mm mm mm mm mm mm mm Mass kg kgm2
1 Takeup 500 0 500 750 1350 1070 90 80 650 300 19.3

3 Drive 500 12 524 750 1440 1070 140 125 650 501 32.7

4 Snub 270 0 270 750 1290 1070 60 60 650 99 1.2

Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies
30 Sep 2020 05:42 Conveyor Pulleys Data Sheet Page 10/10
PT. SIKO TECHNO
Project EPCC TSL AUSMELT Client PT. TIMAH Tbk.
Project No. Prepared By ISK
Conveyor No. ZC01-FD001 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 500 0 750 1070 180.0 1.9 3.12 3.18 3.02 3.18
Running Full Starting Empty

3 Drive 500 12 750 1070 1.5 190.0 1.8 5.12 2.54 5 2.62
Running Full Coasting Empty

4 Snub 270 0 750 1070 30.0 3.5 3.08 3.14 3.16 3.22
Running Full Braking Empty

Designers Comments

Helix
Ver 6.0.15.0 Licenced to PT. Siko Techno Technologies