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Conveyor Design Summary17 Oct 2014 13:37 1/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Material Description POTASSIUM SULPHATE Conveyed Material
High Bulk Density 1040 1040 Low Bulk Density kg/m3
kg/m3 Angle of Repose 46
30 Surcharge Angle degdeg
Material Lump size 3 mmConveyor Data
Nett Lift / Lower (-) 0.074.60Conveying Distance m
mDesign Capacity 2.2 tonnes/hr Belt Speed 0.5 m/s
Belt Details
Belt Class & Run Safety Factor PN800/4750 Belt Width Selected mm Calculated Belt % Full 1.8 %
Top Cover Thickness 8 mm
Belt Total Length 13.190 Belt Rated Tension kN/m
mBottom Cover Thickness 6 mmBelt Mass 16.96 kg/m
Belt Tensions and Power Calculations CEMA
Maximum Tension Tmax 44.222.47Effective Tens. Fully Loaded kN Belt Power - Empty Belt 1.23 kW
Belt Power - Inclines Loaded 1.24 kW
Sag Tension 1.4941.98Minimum Tension Tmin kN
kNBelt Power - Declines Loaded 1.23 kWBelt Power - Fully Loaded 1.24 kW1.5 %
kN
Takeup Type Fixed CentresTakeup Mass 8800 kg Absorbed Power Fully Loaded 1.31 kW
Installed Motor Power 2.2 kW
Drive Efficiency 95.0 %
Carry and Return Idlers
Carry Idler Spacing 130 Carry Idler Trough Angle 0
3 m3 x 152 Carry Idler No Rolls x Dia mm 1 x 152 mm
Return Idler SpacingReturn Idler Trough Angle
Return Idler No Rolls x Diam
Dynamics and Miscellaneous Data
Startup Factor - Empty 140 140 Startup Factor - Fully Loaded 1.00
22.00 kNm0.13Starting Time - Fully Loaded sec 0.01 sec
Total Braking Torque LSSCEMA Temperature Factor Kt
Stop Time - Loaded, Braking0.13Starting Time - Empty sec 0.19 secStop Time - Loaded, Coasting
%%
Takeup Pulley Belt Tension 43.15 kN
13.57
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Sections - Input Data17 Oct 2014 13:37 2/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
FrictionFactor InputDescription
No. of Scrapers
SkirtLengthm
Idler Spacingm
Cap-acitytph
Y co-ord m
X co-ord mStation
Section Lift m
SectionLength m
Station / Sectio
Z co-ord m
TenAdj.kN
1 0.00 0.001.00 -0.05 0 1.00Takeup 0.03000.00
2 1.00 0.000.50 0.00 2.2 0.35Hopper 2.00 0.03000.20 1.00
3 1.50 0.004.10 0.07 2.2 1.50Int. Pt 0.03000.20
4 5.60 0.005.60 0.12 0 2.00Drive 3 0.0300-0.05
Totals: 11.20 1.00 2.00 30.13
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Takeup & Drive Traction Calculation17 Oct 2014 13:37 3/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Drive Torque Start-up Factor LoadedDrive Torque Start-up Factor Empty
140 %%140 Takeup Mass 8800 kg
Takeup Pulley Belt Tension 43.15 kN
Running
DriveNumber
FullyLoaded
EmptyBelt
Starting Braking
FullyLoaded
EmptyBelt
FullyLoaded
EmptyBelt
1Drive No. Drive
Wrap Angle 180Co-efficient of Friction 0.25Drive Factor Cw
Calculated Belt Tension T1 kN Calculated Belt Tension T2Minimum Required T2Surplus T2 Tension (T1-T2)
0.838
kN kN kN
1.88
44.2241.98
40.1
Lagging Type180
0.250.838
1.87
44.2141.98
40.11
Rubber 180
0.350.499
2.07
45.2641.11
39.04
1800.35
0.499
2.07
45.2441.1
39.03
Rubber 180
0.350.499
17.54
23.6758.82
6.13
Rubber 180
0.350.499
17.45
23.8858.85
6.43
Pulley No. 4
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Summary Run / Start17 Oct 2014 13:37 4/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Drive Torque Start-up Factor Loaded
Drive Torque Start-up Factor Empty
140 %
140 % Takeup Mass 8800 kg
Running
StationNo
FullyLoadedTension
kN
EmptyTension
kN
InclinesLoadedTension
kN
DeclinesLoadedTension
kN
Starting
FullyLoadedTension
kN
EmptyTension
kN
Braking
EmptyTension
kN
FullyLoadedTension
kN
Coasting
FullyLoadedTension
kN
EmptyTension
kN
1 42.93 42.9342.93 42.93Takeup 43.20 43.2051.29 51.2742.52 42.52
2 43.16 43.1643.16 43.16Hopper 42.80 42.8033.88 33.7443.64 43.64
3 44.17 44.1744.17 44.17Int. Pt 43.75 43.7532.97 32.8744.74 44.75
4 44.22 44.2144.22 44.21Drive 43.47 43.4723.67 23.8845.26 45.24
Minimum Ten 42.93Maximum Ten
Effective Ten
42.93 42.93 42.93 42.5242.52 23.8823.67 42.8042.8044.22 44.21 44.22 44.21 45.26 45.24 51.29 51.27 43.75 43.75
42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99 42.99
2.47 2.46 2.47 2.46
Ave. Belt Ten
Belt Elong. m
T/up Travel m
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Belt Details Report17 Oct 2014 13:37 5/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Low BD = 1040kg/m3 High BD = 1040kg/m3
kNBelt Rated Tension for width 67.5
Belt Reinforcement Fibre Fabric PN800/4
Apex PN 200 Standard Belt Description Apex PN Fabric - Spliced Belt Category
Belt Make & Class
Belt Dimensions
Belt Speed & Capacity Conveyed Material
Carry Idler Trough Angle 30
kNMinimum Tension Tmin 41.98
kN Allowable Belt Tension, Starting 94.5
kg/m17Belt Mass Wb (per linear m)
mm6 Bottom Cover Thickness
m
kN/mBelt Rated Tension / m width 90
13.1Belt Total Belt Length (L)
mm8 Top Cover Thickness
mmBelt Width Selected 750
4Belt Class / Plies
m/s0.5 Belt Speedtonnes/hr 2.2 Belt Design Capacity Input
mm3Material Lump sizedegdegSurcharge Angle 30
46 Angle of Repose
kg/m3kg/m3Low Bulk Density 1040
1040 High Bulk Density
POTASSIUM SULPHATE Material Description
Belt Tensions
kN/mCalculated Tension / m width 59
Calculated Max Run Tension 44.22 kN
mm5.3Belt Carcass Thicknessmm19.3Belt Total Thickness
sec26.2Time for 1 Revolution
Actual Belt Tension, Starting 58.85
Allowable Tension Rise, Starting 140 %
kN
Belt Modulus 9200 kN/m
Belt and Material Masskg/m6.8Belt Top Cover Masskg/m5.1Belt Bottom Cover Masskg/m5.1Belt Carcass Mass
kg/m1.2Material Mass Wmkg/m18.2Total Mass (Wb + Wm)
Flooded Belt Material Mass 103.4 kg/mtonnes/hr 186Flooded Belt Capacity
kg222Total Belt Mass (Wb x L)
Belt Load Area and Capacity at 1040kg/m3
m20.0664Belt Load Area at MinimumRecommended Edge Distance
m20.0994Flooded Belt Load Area at ZeroEdge Distance
mm64Minimum Rec. Edge Distancemm262 Actual Edge Distance Low BD
mm37Load Burden Depthmm237Load Burden Width
Belt Actual % Full at Low BD %1.8
Belt Load Area Utilised at LowBulk Density 0.0012 m2
Belt Load Area Utilised at HighBulk Density 0.0012 m2
mm262 Actual Edge Distance High BD
Belt Load Area and Capacity at 1040kg/m3Minimum Rec. Edge Distance 64 mm
Belt Actual % Full at High BD 1.8 % Flooded Belt Capacity at 1040kg/m3
tonnes/hr 2.2 Section Loading Max Capacity
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Summary Belt Sag17 Oct 2014 13:37 6/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Allowable Belt Sag % Running
Allowable Belt Sag % Start / Stop
1.5 %
%5 Takeup Mass 8800 kg
Running
StationNo
FullyLoadedTension
kN
EmptyTension
kN
InclinesLoadedTension
kN
DeclinesLoadedTension
kN
Starting
FullyLoadedTension
kN
EmptyTension
kN
Braking
EmptyTension
kN
FullyLoadedTension
kN
Coasting
FullyLoadedTension
kN
EmptyTension
kN
1 42.93 42.9342.93 42.93Takeup 43.20 43.2051.29 51.2742.52 42.52
Belt Sag % 0.05
Idler Spacing m 1.00
0.05 0.05 0.05 0.05 0.05 0.04 0.04 0.05 0.052 43.16 43.1643.16 43.16Hopper 42.80 42.8033.88 33.7443.64 43.64
Belt Sag % 0.02
Idler Spacing m 0.35
0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.023 44.17 44.1744.17 44.17Int. Pt 43.75 43.7532.97 32.8744.74 44.75
Belt Sag % 0.08
Idler Spacing m 1.50
0.07 0.08 0.07 0.07 0.07 0.1 0.09 0.08 0.074 44.22 44.2144.22 44.21Drive 43.47 43.4723.67 23.8845.26 45.24
Belt Sag % 0.09
Idler Spacing m 2.00
0.09 0.09 0.09 0.09 0.09 0.18 0.17 0.1 0.1
Minimum Ten 42.93
Maximum Sag
42.93 42.93 42.93 42.5242.52 23.8823.67 42.8042.80
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 Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Fully Loaded17 Oct 2014 13:37 7/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Takeup Mass 8800 kg
FrictionFactor
SectionEffectiveTension
Scraper Friction
kN
SkirtFriction
kN
Tensions MaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
Section Lift m
SectionLength
m
Station / Pulley TpPulley
TenAdj.kN
CEMA
1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23
2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00
3 44.17 44.174.10 0.07Int. Pt 0.05 0.03
4 44.22 41.985.60 0.12 2.24Drive 0.89 0.06 0.030.23
Totals: 0.46 2.2 1.00 0.00 0.00 0.89 0.12
Maximum Tension
Minimum Tension
44.22
41.98
kN
kN Average Tension Fully Loaded 42.99 kN
Average Tension Belt Stationary 42.99 kN
Average Tension Difference 0 kN
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
2.47
1.24
9200
13.10
0 m
m
kN/m
kW
kN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s
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Tension Calculations - Run Empty17 Oct 2014 13:37 8/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
FrictionFactor
SectionEffectiveTension
Scraper Friction
kN
SkirtFriction
kN
Tensions MaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
Section Lift m
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23
2 43.16 43.160.50 0.00Hopper 0.01 0.031.00
3 44.17 44.174.10 0.07Int. Pt 0.04 0.03
4 44.21 41.985.60 0.12 2.23Drive 0.89 0.06 0.030.23
Totals: 0.46 2.23 1.00 0.89 0.11
Maximum Tension
Minimum Tension
44.21
41.98
kN
kN
Average Tension Fully Loaded 42.99 kN
Average Tension Belt Stationary 42.99 kN
Average Tension Difference 0 kN
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
2.46
1.23
9200
13.10
0 mm
kN/m
kW
kN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s
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Tension Calculations - Run Inclines Loaded17 Oct 2014 13:37 9/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
FrictionFactor
SectionEffectiveTension
Scraper Friction
kN
SkirtFriction
kN
Tensions MaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
Section Lift m
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23
2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00
3 44.17 44.174.10 0.07Int. Pt 0.05 0.03
4 44.22 41.985.60 0.12 2.24Drive 0.89 0.06 0.030.23
Totals: 0.46 2.24 1.00 0.00 0.00 0.89 0.12
Maximum Tension
Minimum Tension
44.22
41.98
kN
kN
Average Tension Inclines Loaded 42.99 kN
Average Tension Belt Stationary 42.99 kN
Average Tension Difference 0 kN
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
2.47
1.24
9200
13.10
0 mm
kN/m
kW
kN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Declines Loaded17 Oct 2014 13:37 10/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
FrictionFactor
SectionEffectiveTension
Scraper Friction
kN
SkirtFriction
kN
Tensions MaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
Section Lift m
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 42.93 43.161.00 -0.05Takeup 0.00 0.030.23
2 43.16 43.160.50 0.00 0.00Hopper 0.01 0.031.00
3 44.17 44.174.10 0.07Int. Pt 0.04 0.03
4 44.21 41.985.60 0.12 2.23Drive 0.89 0.06 0.030.23
Totals: 0.46 2.2 1.00 0.00 0.00 0.89 0.12
Maximum Tension
Minimum Tension
44.21
41.98
kN
kN
Average Tension Declines Loaded 42.99 kN Average Tension Belt Stationary 42.99 kN
Average Tension Difference 0 kN
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
2.46
1.23
9200
13.100 m
m
kN/m
kW
kN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Starting and Stopping17 Oct 2014 13:37 11/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Mass of BeltSystem Masses
Carry Idler Equivalent Mass 816Mass of Material kg
kg
Input Data
Pulley Equivalent Mass 52441Return Idler Equivalent Mass kg
kg
Belt Rated TensionBelt Speed 0.5 m/s
Total Braking Force 67.28
2.46Effective Tension Empty kN
3.5Tension Available to Accelerate Conveyor
kN
kN
221 kg
Total System Equivalent Mass 91946Drive Equivalent Mass kg
kg
90 kN/m
Drive Inertia Allow. Belt Start Tension Rise 140 %
0.0012 kg-m2
Start-up Factor - LoadedTotal Braking Torque 22 kNm
140 Start-up Factor - Empty 140
Drive Efficiency (Average)Installed Power 2.2 kW
95
%%
%Tensions and Accelerating Forces
Stopping Times & Deceleration RatesEffective Tens. Fully Loaded 2.47 kN
3.51 Accelerating Tension - Empty kN
Starting Times & Acceleration Rates
Acceleration Rate - Loaded 3.810.13Starting Time - Empty sec
3.85 Accelerating Rate - Empty m/s2m/s2
Starting Time - Fully Loaded 0.13 sec
Belt Tension Rise Starting / Braking
Maximum Belt Tension / width 78.47750Belt Width mm
90Belt Rated Tension / width kN/mkN/m
Max Belt Tension, Start/Brake 58.85 kN
87.2 Actual Max Tension, Start/Brake %
0.19Stopping Time Loaded Coasting secStopping Time Loaded Braking 0.01 sec
0.19Stopping Time Empty Coasting secStopping Time Empty Braking 0.01 sec
-2.69Deceleration - Loaded Coasting m/s2Deceleration - Loaded Braking -75.90 m/s2
-2.70Deceleration - Empty Coasting m/s2Deceleration - Empty Braking -76.38 m/s2
Stopping Distances & Discharge Volumes
Stopping Distance Loaded Coasting mStopping Distance Loaded Braking m
Stopping Distance Empty Coasting mStopping Distance Empty Braking m
Discharge Mass, Coasting kgDischarge Mass, Braking kg
Discharge Volume, Coasting m3Discharge Volume, Braking m3
00.05
00.05
0000
Accelerating Tension - Loaded
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s
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Conveyor Idler Details Report17 Oct 2014 13:37 12/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Idler Category Sandvik Carry
Idler Design Belt Width 750
Series 20 3 Roll Carry 152 PlainInline
Idler Description
mm
Drawing Number 20 Idler Series
Total Number of Idlers 51Nominal Idler Spacing m
Troughing Angle 30.0
0 Idler Price
deg
Idler Bearing Diameter 25.0 27.0 Idler Shaft Diameter mm
Idler Roll Diameter 152 3Number of Idler Rolls
mm
mm
Idler Rotation Speed 63
Roll Face Width 283 mm
307 Shaft Support Centres1000 Idler Support Fixing Width mm
Idlerset Total Mass 31.7 16.2 Idlerset Rotating Mass
3.0 Idler Vertical Misalignment Allowance mm1.00Dynamic Load Factor
mm
kgkg
Roll Bearing Centres 226.8 mm
Carry Side Idlers Return Side Idlers
500 Belt Deviation Load N734Total Load on Centre Roll N
Ball Type of Bearing6205 Bearing Designation
14,000 Bearing Dynamic Load Rating C N14,720,410Bearing L10h Life hrs
8.00 Allowable Shaft Deflection at Bearing min1.05 Actual Shaft Deflection at Bearing min
rpm
Sandvik Flat Return
750
Series 30 1 Roll Flat Carry 152 Dia
mm30
33 m
0.0
0
deg
25.0 30.0 mm
152 1
mm
mm
63
849 mm
8731000 mm
23.113.8
56.3 mm1.40
mm
kgkg
785.4 mm
1,501 N2,446 N
Ball 6305
22,500 N1,652,498 hrs
10.00 min8.66 min
rpm
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s
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Vertical Curve Radius Calculations17 Oct 2014 13:37 13/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/s
JSA
17 Oct 2014 13:37 Vertical Curve Radius Calculations Page 13/27
Belt Mass - New Belt 16.96 kg/mTop Cover Mass - New Belt 6.78 kg/mBottom Cover Mass 5.08 kg/mWorn Belt Mass 12.72 kg/mReduction of Top Cover Mass 62.5 %Conveyed Material Mass 1.22 kg/m
% Belt Mass for Lift-off Calculation 75 %Curve Tension Safety Factor 1
Average Drive Torque Start-up Factor - Loaded 140 % Average Drive Torque Start-up Factor - Empty 140 %
Allowable Edge Tension - Running: 140 %
Belt Modulus 9200 kN/mBelt Rated Tension 67.5 kN
Belt Width 750 mm
90 kN/m115 % Starting
CurveType
Fully Loaded
Running
Station
DesignVerticalCurve
RadiusLoad
Capacity
Station / Sectio
Empty
tonnes/hr mTension Radius
kN mRadius
mTension
kN
Starting
Fully LoadedRadius
mkNTension
EmptyTension Radius
mkN
Braking
Fully LoadedRadius
mkNTension
EmptyTension Radius
mkN
Largest
Reqd.Radius
m
1 42.93Takeup 42.93 42.52 42.52 51.29 51.27
2 43.162Hopper 43.16 43.64 43.64 33.88 33.74
3 44.172Int. Pt Concave 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 Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
8/10/2019 13.M501 Potasium Sulphate BW 750,0.5 m s
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17 Oct 2014 13:37 Vertical Curve Radius Calculations Page 14/27
Belt Mass - New Belt 16.96 kg/mTop Cover Mass - New Belt 6.78 kg/mBottom Cover Mass 5.08 kg/mWorn Belt Mass 12.72 kg/mReduction of Top Cover Mass 62.5 %Conveyed Material Mass 1.22 kg/m
% Belt Mass for Lift-off Calculation 75 %Curve Tension Safety Factor 1
Average Drive Torque Start-up Factor - Loaded 140 % Average Drive Torque Start-up Factor - Empty 140 %
Allowable Edge Tension - Running: 140 %
Belt Modulus 9200 kN/mBelt Rated Tension 67.5 kN
Belt Width 750 mm
90 kN/m115 % Starting
CurveType
Fully LoadedRunning
Station
DesignVerticalCurve
RadiusLoad
Capacity
Station / Sectio
Empty
tonnes/hr mTension Radius
kN mRadius
mTension
kN
StartingFully Loaded
RadiusmkN
TensionEmpty
Tension RadiusmkN
BrakingFully Loaded
RadiusmkN
TensionEmpty
Tension RadiusmkN
LargestReqd.
Radius
m
32.8732.9744.7544.7444.1744.17Belt Tension at Curve kN
364198199364364356356Min. Concave Lift Off Radius
523
523
913
913
991313
Max. Centre Tension RadiusMin. Edge Tension Radius
4 44.22Drive 44.21 45.26 45.24 23.67 23.88
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Viscoelastic Friction Factor Report17 Oct 2014 13:37 15/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
deg0.1Idlerset Forward Tilt angle
N/mm2
deg C
Belt has Turnover on Return Run
degNmmNmmNmmNmm
0.12
152 2
152 2
152
152 2
Idlerset Skew AngleReturn Idler Wing Roll DragReturn Idler Wing Roll DiaReturn Idler Centre Roll DragReturn Idler Centre Roll DiaCarry Idler Wing Roll DragCarry Idler Wing Roll DiaCarry Idler Centre Roll DragCarry Idler Centre Roll Dia
130
0.136
deg C30 0.13
N/mm2Rubber description ...
6
Belt Bottom Cover TemperatureBelt & Material Flexure Adjustment factor
Bottom Cover Dynamic Modulus E'Bot Cover Dynamic Loss Factor Tan(delta)
Top Cover Dynamic Loss Factor Tan(delta)Belt Top Cover Temperature
Top Cover Dynamic Modulus E'Belt Rubber Description
Rolling Resistance Factor 0.072 0.072 RRF Bot.RRF Top
Viscoelastic Calculations Input Data
EmptyFrictionfactor f
SectionLength
Tiltfriction
%
Tiltfriction
ft
Dragfactor
%
Flexurefriction
%
Frequencyrad/s
Indentfactor
%No
Indentfactor
fi
TotalLoadedFrictionfactor f
Station / Section
Flexurefriction
fm
Dragfactor
fr Idler
Spacing
Indentation Matl.& Belt Idler Drag Idler Skew & TiltEmptyfriction factor f (loaded)
1 0.00.0300 0.000001.00 1.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000
2 0.00.0300 0.000000.50 0.35 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000
3 0.00.0300 0.000004.10 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000
4 0.00.0300 0.000005.60 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.03000
Totals: 11.20 1.00 2.00 30.13
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Belt Resonance Report17 Oct 2014 13:37 16/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
DescriptionSection
Idler Spacing
Idler RollExcitationFrequency
Belt TransverseWave Frequency
RangeStation
EndBelt
Tension
Station / Sectio
Hz
Running Fully Loaded Belt Resonance
to Hz
CriticalIdler
SpacingStart
CriticalIdler
SpacingEnd
Idler Spacing
within+/- 10%
m m mmkNkN
StartBelt
TensionHz
M o d e
Belt Speed 0.5 m/sCarry Roll Diameter 152 mmReturn Roll Diameter 152 mm Takeup Mass 8800 kg
Belt Resonance +/- Tolerance 10 %
1 25.22 25.5143.16 44.17 1.05 1Takeup 24.37 OK24.09
2 69.59 70.4443.16 44.22 1.05 0.35Hopper 23.55 OK23.26
3 16.43 16.244.17 42.93 1.05 1.5Int. Pt 23.2 OK23.53
4 12.44 12.5841.98 42.93 1.05 2Drive 24.02 OK23.75
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Takeup Travel Report17 Oct 2014 13:37 17/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Takeup Travel
m0 Safety Margin Top +
kg
kgTakeup Mass kg (ManualInput)
8800
8800Takeup Mass Calculated
kgTakeup Mass step increment 200 100 Max no. of Calc Increments
Fixed CentresTakeup Type
Auto Calc Takeup Mass
Takeup Travel Estimate
m0.5 Belt Splice Allowance +m0 Dynamic Travel Up +m0 Dynamic Travel Down +m0 Safety Margin Bottom +
deg0 Minimum Site Temperature Thermal Expansion Distance
deg30 Maximum Site Temperature
1.17E-05 Belt Expansion co-efficientm/m per degree C
m13.10Total Belt Lengthm0.002Thermal Expansion Distance +
%0.15 Permanent Stretch co-efficient % of Belt Length
Permanent Belt Stretch
m0.009Permanent Belt StretchDistance +
m0.51Total Takeup Travel Distance
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Details Report17 Oct 2014 13:37 18/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
%95Drive Efficiency
:1:1
m/s1.02Calculated Belt Speedm/s0.5Required Belt Speedrpm29.68Calculated Pulley Speed for Reducer rpm14.6Required Pulley Speed
31.5Selected Gearbox Ratio64.035Required Gearbox Ratio
Flender Helical Bevel Gear Gearbox Description380 VoltsMotor Voltage
kg46
rpm935Motor Full Load Speed
0.0012
kg-m20.0012Total Drive Inertiakg-m20Gearbox Inertia (HSS)kg-m20Flywheel Inertiakg-m20High Speed Brake Disc Inertia
%140Starting Torque Factor, Empty%140Starting Torque Factor, Fully Loaded
kg-m20High Speed Coupling Inertiakg-m2Motor Inertia
2.2
1
125Pulley Shaft Diameter at Brg mm150Pulley Shaft Diameter at Hub mm
mm
654Pulley Outside Diameter
630Pulley Shell Diameter
mm
kW
%
0.5Drive Factor Cw, Starting
0.84Drive Factor Cw, Running0.35Coefficient of Friction, Starting
12Pulley Lagging Thickness
0.25Coefficient of Friction, Running
MoistPulley ConditionHeadDrive DescriptionRubber
Electric Motor
100 Pulley Lagging Type
Total Drive Equivalent Mass
Motor Power RatingMotor DescriptionNumber of Motors on Drive Pulley
mm
Load Share on Drive Pulley180 Belt Wrap Angle
1Drive No. Drive Pulley No. 4
Drive Inertia
Pulley and Belt Speed
Pulley and Shaft Dimensions
Holdback
BrakeBrake Location High SpeedLow Speed Brake Torque Input 22
Static Analysis Runback Force Fv 1 NStatic Analysis Horizontal Force Fh 2469 N
Holdback Required (Yes / No) NoNm
Equiv HS Brake Torque 362
Holdback Torque 3 x Motor FLT
Calculated Holdback Torque N/A
Nm4317
Fv>Fh/2
kNmNm
High Speed Coupling
Low Speed Coupling
HS Coupling MakeHS Coupling Model 1020T
Falk
LS Coupling MakeLS Coupling Model RFK140
Ringspann
Holdback Make Not InstalledHoldback Model
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Motor Details Report17 Oct 2014 13:37 19/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
380 VoltsMotor Voltage
0.0012 kg-m2Motor Inertia
2.2
1
kW
HeadDrive Description
Electric Motor Motor Power RatingMotor Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 4
Motor Category Metric Motor
DX112MMotor Frame Size6Number of poles
112 mmMotor Shaft Height28 mmMotor Shaft Diameter
935 rpmMotor Full Load Speed
1.24 kW Absorbed Power at Pulley2 kWTotal Motor Power on Drive
1.31 kW Absorbed Power at Motor 95 %Drive Efficiency
48 kgMass of Motor
5.9 AmpsMotor Full Load Current22.5 NmMotor Full Load Torque
0.62Motor Power Factor @ Duty Pt76.49 %Motor Efficiency @ Duty Point
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Fluid Coupling Details Report17 Oct 2014 13:37 20/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
0 % FLTPeak Torque %0
1
kW
HeadDrive Description
No Selection - Direct DriveCoupling Power RatingCoupling Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 4
Coupling Category Flender
0Max Starting TimeMin. Required Ramping Time
sec
0 %Coupling Rated Slip
2.2 kWMotor Power RatingCoupling Size
935 rpmMotor Full Load Speed
0 kg935 rpmCoupling Output Speed
0Run-up Torque % (2 sec)
Mass of Couplingsec
% FLT
Selection Mode Auto
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Gearbox Details Report17 Oct 2014 13:37 21/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
1439Motor Torque at Pulley Speed
Helical Bevel Gear
1HeadDrive Description
Flender Helical Bevel Gear TypeGearbox Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 4
Gearbox Category Flender
B3SH4Code4Size
22Motor Torque @ FL Speed
2.2 kWMotor Power Rating935 rpmMotor Full Load Speed
210 kgkg-m2Gearbox Inertia
6400Gearbox Rated Torque
Mass of Gearbox
Selection Mode Manual
Number of Stages31.5
B3SH4
Service Factor Required
Ratio
1.5
Gearbox Actual Efficiency
95Design Efficiency (Input)
93 rpm
mmrpm
Maximum Input Shaft Speed 1500Minimum Input Shaft Speed 700
Output Shaft Diameter 80Input Shaft Diameter 30
Service Factor Calculated 4.45
5 %Plus Speed Selection Tolerance5Minus Speed Selection Tolerance %
Fluid Coupling Slip 0
NmNmNm
:1
:1
m/s1.02Calculated Belt Speedm/s0.5Required Belt Speedrpm29.68Calculated Pulley Speed for Reducer rpm14.6Required Pulley Speed 31.5Selected Gearbox Ratio
64.035Required Gearbox Ratio%
mm
%
%
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Brake Details Report17 Oct 2014 13:37 22/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
%95Drive Efficiency
SvendborgBrake Description
Brake Location
mm3
Mild Steel
mm60Pad offset Width WN3500Caliper Clamping Force Maximum
0.4Co-eff of Friction (Pad-Disc)mm0Disc Thicknessmm0Disc Diameter
Disc Material
BSFH 202
%HeadDescription
Svendborg BSFH 200100
Maximum Air Gap
Caliper
Brake CategoryLoad Share on Drive Pulley
1Drive / Brake No. Drive Pulley No. 4High Speed
Low Speed Brake Torque Input 22Equiv HS Brake Torque 362
kNmNm
Brake Selection Input Data
Design Braking Torque InputSelected Brake's Torque Rating -43
1210
Number of Motors on Drive Pulley 1
NmNm
Design Stopping TimeConsecutive No of Stops 310.0 sec
Average No of Stops Ambient Temperature 40
6deg C
Disc Temperature after stops NaN deg C
Recommended working airgap is 1mm
kg-m20.0
rpm0Disc Initial Speed
Disc Moment of InertiaRequired Gearbox Ratio 64.035 : 1
Mass of Caliper 26 kgBrake Caliper Price $0.00
Caliper Clamping Force Minimum 2000 N
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Shaft Coupling Report17 Oct 2014 13:37 23/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
%95Drive Efficiency
%140Starting Torque Factor, Empty%140Starting Torque Factor, Fully Loaded
kg-m20.0014High Speed Coupling Inertia
1 125Pulley Shaft Diameter at Brg mm
%HeadDrive Description
100
Number of Motors on Drive Pulley
Load Share on Drive Pulley
1Drive No. Drive Pulley No. 4
Fluid Coupling No Selection - Direct DriveFluid Coupling Size
High Speed Coupling Low Speed Coupling
Fluid Coupling
HS Coupling MakeHS Coupling Model 1020T
Falk LS Coupling MakeLS Coupling Model RFK140
Ringspann
1439Motor Torque at Pulley Speed22Motor Torque @ FL Speed
2.2 kWMotor Power Rating935 rpmMotor Full Load Speed
Service Factor Required 1.5Service Factor Calculated 2.31
NmNm
Coupling Type Grid
Nm
HS Coupling Category Falk SteelFlex Grid LS Coupling Category Falk SteelFlex Grid
Coupling Torque Rating 52
Maximum Shaft Bore 28 mmMinimum Shaft Bore 0 mmMaximum Rotation Speed 4500 rpm
Drawing Number High Speed Coupling Mass 1.91 kgHigh Speed Coupling Price 0
kg-m22.9Low Speed Coupling Inertia
Service Factor Required 1.5Service Factor Calculated 38.92
Coupling Type Rigid Flanged
NmCoupling Torque Rating 56000
Maximum Shaft Bore 140 mmMinimum Shaft Bore 115 mmMaximum Rotation Speed 3800 rpm
Drawing Number Low Speed Coupling Mass 800 kgLow Speed Coupling Price 0
Direct Drive
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulley Shafts17 Oct 2014 13:37 24/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Description
ShaftMass
kg
WrapAngle
deg
Defl.Diamm
T1Run
Station
ShaftLength
mm
Station / Sectio Resul-tant
ForceDt.DiammkN kN
T2Run
kN
T1Start
kN
CalculatedShaftDiamm
SelectedBrgDiamm
BrgCtrsmm
1 42.9 43.21610 125123.6180.0Takeup 150 22386.1 127.542.5 1270
4 44.2 42.01610 125123.6180.0Drive 150 22386.2 127.745.3 1270
Designers Comments * Denotes manual pulley shaft dimensions entered
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulleys17 Oct 2014 13:37 25/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Mom of Inertiakgm2Description
Pulley &Shaft
Mass kg
PulleySpeed
rpm
WrapAngle
deg
ShaftDiamm
ShaftLength
mm
FaceWidth
mmStationLagging
mmShell
Dia mm
Station / SectioBrgCtrsmm
BrgDiamm
1 850 1610500 12 150 180.0Takeup 18.2 475 12.71270 125
4 850 1610630 12 150 180.0Drive 14.6 718 36.21270 125
Designers Comments * Denotes manual pulley dimensions entered
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulley Dimensions17 Oct 2014 13:37 26/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
Mom of Inertiakgm2Description
Pulley &Shaft
Mass kg
ShaftDiamm
ShaftLength
mm
FaceWidth
mmStationLagging
mmShell
Dia mm
Station / SectioBrgCtrsmm
BrgDiamm
ODmm
BeltWidth
mm
1 850 1610500 12 150Takeup 475 12.71270 125524 750
4 850 1610630 12 150Drive 718 36.21270 125654 750
Designers Comments
E:\PROPOSAL PETRO\Helix\13.M501-Potasium Sulphate -BW-750,0.5 m-s.xml Helix TechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulleys Data Sheet17 Oct 2014 13:37 27/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
ProjectProject No.Conveyor No.
ClientPrepared ByDesign Date
Sistem Reaktor 36.R-101
13.M501,0,5 m/sJSA
DescriptionPulleySpeed
rpm
WrapAngle
deg
DrivePower
kW
FaceWidth
mmStationLagging
mmShell
Dia mm
Station / Sectio
BrgCtrsmm
T1RunkN
T2RunkN
T1Start
kN
T2Start
kN
1 850500 12 51.29180.0Takeup 18.21270 37.4642.93 43.16Braking FullRunning Full
4 850630 12 45.26180.0Drive 14.62.21270 41.1144.22 41.98Starting FullRunning Full
Designers Comments