36.m111 potasium sulphate bw 750,1.67 m s
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8/10/2019 36.M111 Potasium Sulphate BW 750,1.67 m s
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Conveyor Design Summary17 Oct 2014 11:16 1/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Material Description POTASSIUM SULPHATE
Conveyed Material
High Bulk Density 1040
1040Low Bulk Density kg/m3
kg/m3
Angle of Repose 46
30Surcharge Angle deg
deg
Material Lump size 3 mm
Conveyor Data
Nett Lift / Lower (-) 0.00
21.83Conveying Distance m
m
Design Capacity 1.4 tonnes/hr
Belt Speed 1.67 m/s
Belt Details
Belt Class & Run Safety Factor PN800/4
750Belt Width Selected mm Calculated Belt % Full 0.3 %
Top Cover Thickness 8 mm
Belt Total Length 52.7
90Belt Rated Tension kN/m
m
Bottom Cover Thickness 6 mm
Belt Mass 16.96 kg/m
Belt Tensions and Power Calculations CEMA
Maximum Tension Tmax 41.60
3.64Effective Tens. Fully Loaded kN Belt Power - Empty Belt 6.07 kW
Belt Power - Inclines Loaded 6.07 kW
Sag Tension 1.4
38.18Minimum Tension Tmin kN
kN
Belt Power - Declines Loaded 6.07 kW
Belt Power - Fully Loaded 6.07 kW1.5 %
kN
Takeup Type Fixed Centres
Takeup Mass 8100 kg Absorbed Power Fully Loaded 6.40 kW
Installed Motor Power 11 kW
Drive Efficiency 95.0 %
Carry and Return Idlers
Carry Idler Spacing 130Carry Idler Trough Angle 0
3 m
3 x 152Carry Idler No Rolls x Dia mm 1 x 152 mm
Return Idler SpacingReturn Idler Trough Angle
Return Idler No Rolls x Dia
m
Dynamics and Miscellaneous Data
Startup Factor - Empty 140
140Startup Factor - Fully Loaded 1.00
22.00 kNm
0.74Starting Time - Fully Loaded sec 0.06 sec
Total Braking Torque LSS
CEMA Temperature Factor Kt
Stop Time - Loaded, Braking
0.74Starting Time - Empty sec 1.08 secStop Time - Loaded, Coasting
%
%
Takeup Pulley Belt Tension 39.72 kN
14.42
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Sections - Input Data17 Oct 2014 11:16 2/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
FrictionFactorInputDescription
No. ofScrapers
SkirtLength
m
IdlerSpacing
m
Cap-acitytph
Y co-ord m
X co-ord mStation
SectionLiftm
SectionLength
m
Station / Sectio
Z co-ord m
TenAdj.kN
1 0.00 0.003.60 0.00 0 0.50Takeup 0.00000.00
2 3.60 0.001.40 0.00 1.4 0.35Hopper 2.00 0.00000.25 1.00
3 5.00 0.007.00 0.00 1.4 1.50Int. Pt 0.00000.25
4 12.00 0.002.00 0.00 1.4 1.50Hopper 2.00 0.00000.25 1.00
5 14.00 0.0011.43 0.00 1.4 2.00Int. Pt 0.00000.25
6 25.43 0.0025.43 0.13 0 2.00Drive 3 0.0000-0.07
Totals: 50.85 2.00 4.00 30.13
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Takeup & Drive Traction Calculation17 Oct 2014 11:16 3/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Drive Torque Start-up Factor Loaded
Drive Torque Start-up Factor Empty
140 %
%140 Takeup Mass 8100 kg
Takeup Pulley Belt Tension 39.72 kN
Running
DriveNumber
FullyLoaded
EmptyBelt
Starting Braking
FullyLoaded
EmptyBelt
FullyLoaded
EmptyBelt
1Drive No. Drive
Wrap Angle 180
Co-efficient of Friction 0.35
Drive Factor Cw
Calculated Belt Tension T1 kNCalculated Belt Tension T2
Minimum Required T2
Surplus T2 Tension (T1-T2)
0.499
kN
kN
kN
1.71
41.638.18
36.47
Lagging Type
180
0.35
0.499
1.71
41.638.18
36.47
Rubber
180
0.45
0.321
2.22
43.4536.53
34.31
180
0.45
0.321
2.22
43.4436.53
34.31
Rubber
180
0.45
0.321
13.8
16.9359.93
3.13
Rubber
180
0.45
0.321
13.79
1759.96
3.21
Pulley No. 6
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Summary Run / Start17 Oct 2014 11:16 4/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Drive Torque Start-up Factor Loaded
Drive Torque Start-up Factor Empty
140 %
140 % Takeup Mass 8100 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 39.16 39.1639.16 39.16Takeup 39.40 39.4044.81 44.7938.74 38.74
2 39.43 39.4339.43 39.43Hopper 39.09 39.0933.84 33.8039.85 39.85
3 40.46 40.4640.46 40.46Int. Pt 39.99 39.9932.20 32.1641.08 41.08
4 40.51 40.5140.51 40.51Hopper 39.73 39.7326.20 26.1941.59 41.59
5 41.53 41.5341.53 41.53Int. Pt 40.67 40.6725.69 25.7042.72 42.716 41.60 41.6041.60 41.60Drive 40.28 40.2916.93 17.0043.45 43.44
Minimum Ten 39.16
Maximum Ten
Effective Ten
39.16 39.16 39.16 38.7438.74 17.0016.93 39.0939.09
41.60 41.60 41.60 41.60 43.45 43.44 44.81 44.79 40.67 40.67
39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72 39.72
3.64 3.63 3.64 3.64
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\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Belt Details Report17 Oct 2014 11:16 5/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Low BD = 1040kg/m3 High BD = 1040kg/m3
kNBelt Rated Tension for width 67.5
Belt Reinforcement Fibre Fabric
PN800/4
Apex PN 200 StandardBelt Description
Apex PN Fabric - SplicedBelt Category
Belt Make & Class
Belt Dimensions
Belt Speed & CapacityConveyed Material
Carry Idler Trough Angle 30
kNMinimum Tension Tmin 38.18
kNAllowable Belt Tension, Starting 94.5
kg/m17Belt Mass Wb (per linear m)
mm6Bottom Cover Thickness
m
kN/mBelt Rated Tension / m width 90
52.7Belt Total Belt Length (L)
mm8Top Cover Thickness
mmBelt Width Selected 750
4Belt Class / Plies
m/s1.67Belt Speed
tonnes/hr1.4Belt Design Capacity Input
mm3Material Lump size
deg
degSurcharge Angle 30
46Angle of Repose
kg/m3
kg/m3Low Bulk Density 1040
1040High Bulk Density
POTASSIUM SULPHATEMaterial Description
Belt Tensions
kN/mCalculated Tension / m width 55.5
Calculated Max Run Tension 41.60 kN
mm5.3Belt Carcass Thickness
mm19.3Belt Total Thickness
sec31.6Time for 1 Revolution
Actual Belt Tension, Starting 59.96
Allowable Tension Rise, Starting 140 %
kN
Belt Modulus 9200 kN/m
Belt and Material Mass
kg/m6.8Belt Top Cover Mass
kg/m5.1Belt Bottom Cover Mass
kg/m5.1Belt Carcass Mass
kg/m0.2Material Mass Wm
kg/m17.2Total Mass (Wb + Wm)
Flooded Belt Material Mass 103.4 kg/m
tonnes/hr621Flooded Belt Capacity
kg894Total 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 Distance
mm267Actual Edge Distance Low BD
mm35Load Burden Depthmm227Load Burden Width
Belt Actual % Full at Low BD %0.3
Belt Load Area Utilised at LowBulk Density 0.0002 m2
Belt Load Area Utilised at HighBulk Density 0.0002 m2
mm267Actual Edge Distance High BD
Belt Load Area and Capacity at 1040kg/m3
Minimum Rec. Edge Distance 64 mm
Belt Actual % Full at High BD 0.3 %
Flooded Belt Capacity at 1040kg/m3
tonnes/hr1.4Section Loading Max Capacity
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Summary Belt Sag17 Oct 2014 11:16 6/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Allowable Belt Sag % Running
Allowable Belt Sag % Start / Stop
1.5 %
%5 Takeup Mass 8100 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 39.16 39.1639.16 39.16Takeup 39.40 39.4044.81 44.7938.74 38.74
Belt Sag % 0.03
Idler Spacing m 0.50
0.03 0.03 0.03 0.03 0.03 0.02 0.02 0.03 0.03
2 39.43 39.4339.43 39.43Hopper 39.09 39.0933.84 33.8039.85 39.85
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 0.02
3 40.46 40.4640.46 40.46Int. Pt 39.99 39.9932.20 32.1641.08 41.08
Belt Sag % 0.08
Idler Spacing m 1.50
0.08 0.08 0.08 0.08 0.08 0.1 0.1 0.08 0.08
4 40.51 40.5140.51 40.51Hopper 39.73 39.7326.20 26.1941.59 41.59
Belt Sag % 0.08
Idler Spacing m 1.50
0.08 0.08 0.08 0.08 0.07 0.12 0.12 0.08 0.08
5 41.53 41.5341.53 41.53Int. Pt 40.67 40.6725.69 25.7042.72 42.71
Belt Sag % 0.1
Idler Spacing m 2.00
0.1 0.1 0.1 0.1 0.1 0.16 0.16 0.1 0.1
6 41.60 41.6041.60 41.60Drive 40.28 40.2916.93 17.0043.45 43.44
Belt Sag % 0.1
Idler Spacing m 2.00
0.1 0.1 0.1 0.1 0.1 0.25 0.24 0.1 0.1
Minimum Ten 39.16
Maximum Sag
39.16 39.16 39.16 38.7438.74 17.0016.93 39.0939.09
0.1 0.1 0.1 0.1 0.1 0.1 0.25 0.24 0.1 0.1
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Fully Loaded17 Oct 2014 11:16 7/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Takeup Mass 8100 kg
FrictionFactor
SectionEffectiveTension
ScraperFriction
kN
SkirtFriction
kN
TensionsMaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
SectionLiftm
SectionLength
m
Station / PulleyTp
Pulley
TenAdj.kN
CEMA
1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22
2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00
3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161
4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00
5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016
6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22
Totals: 0.43 3.4 2.00 0.00 0.00 0.89 0.31
Maximum Tension
Minimum Tension
41.6
38.18
kN
kN
Average Tension Fully Loaded 39.72 kN
Average Tension Belt Stationary 39.72 kN
Average Tension Difference 0 kN
Total Effective Tension
Total Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
3.64
6.07
9200
52.70
0 m
m
kN/m
kW
kN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Empty17 Oct 2014 11:16 8/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
FrictionFactor
SectionEffectiveTension
ScraperFriction
kN
SkirtFriction
kN
TensionsMaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
SectionLiftm
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22
2 39.43 39.431.40 0.00Hopper 0.03 0.0161.00
3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161
4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00
5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016
6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22
Totals: 0.44 3.42 2.00 0.89 0.31
Maximum TensionMinimum Tension
41.638.18
kNkN
Average Tension Fully Loaded 39.72 kN
Average Tension Belt Stationary 39.72 kN
Average Tension Difference 0 kN
Total Effective TensionTotal Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
3.636.07
9200
52.70
0 m
m
kN/m
kWkN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Inclines Loaded17 Oct 2014 11:16 9/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
FrictionFactor
SectionEffectiveTension
ScraperFriction
kN
SkirtFriction
kN
TensionsMaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
SectionLiftm
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22
2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00
3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161
4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00
5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016
6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22
Totals: 0.43 3.42 2.00 0.00 0.00 0.89 0.31
Maximum TensionMinimum Tension
41.638.18
kNkN
Average Tension Inclines Loaded 39.72 kN
Average Tension Belt Stationary 39.72 kN
Average Tension Difference 0 kN
Total Effective TensionTotal Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
3.646.07
9200
52.70
0 m
m
kN/m
kWkN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Tension Calculations - Run Declines Loaded17 Oct 2014 11:16 10/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
FrictionFactor
SectionEffectiveTension
ScraperFriction
kN
SkirtFriction
kN
TensionsMaterialAccel.
kNDriveTe kN
T2 RunkN
T1 RunkNStation
SectionLiftm
SectionLength
m
Station / Pulley
TpPulley
TenAdj.kN
CEMA
1 39.16 39.373.60 0.00Takeup 0.06 0.0160.22
2 39.43 39.431.40 0.00 0.00Hopper 0.03 0.0161.00
3 40.46 40.467.00 0.00Int. Pt 0.05 0.0161
4 40.51 40.512.00 0.00Hopper 0.01 0.0161.00
5 41.53 41.5311.43 0.00Int. Pt 0.07 0.016
6 41.60 38.1825.43 0.13 3.42Drive 0.89 0.09 0.0150.22
Totals: 0.43 3.4 2.00 0.00 0.00 0.89 0.31
Maximum TensionMinimum Tension
41.638.18
kNkN
Average Tension Declines Loaded 39.72 kN
Average Tension Belt Stationary 39.72 kN
Average Tension Difference 0 kN
Total Effective TensionTotal Belt Power (Te x V)
Belt Modulus
Total Belt Length
Belt Elastic Elongation
3.646.07
9200
52.70
0 m
m
kN/m
kWkN
Takeup Movement 0 m
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Starting and Stopping17 Oct 2014 11:16 11/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Mass of BeltSystem Masses
Carry Idler Equivalent Mass 373
5Mass of Material kg
kg
Input Data
Pulley Equivalent Mass 524
179Return Idler Equivalent Mass kg
kg
Belt Rated Tension
Belt Speed 1.67 m/s
Total Braking Force 67.28
3.63Effective Tension Empty kN
5.31
Tension Available to Accelerate Conveyor
kN
kN
894 kg
Total System Equivalent Mass 2,358
383Drive Equivalent Mass kg
kg
90 kN/m
Drive Inertia
Allow. Belt Start Tension Rise 140 %
0.0467 kg-m2
Start-up Factor - Loaded
Total Braking Torque 22 kNm
140
Start-up Factor - Empty 140
Drive Efficiency (Average)
Installed Power 11 kW
95
%
%
%Tensions and Accelerating Forces
Stopping Times & Deceleration Rates
Effective Tens. Fully Loaded 3.64 kN
5.31Accelerating Tension - Empty kN
Starting Times & Acceleration Rates
Acceleration Rate - Loaded 2.25
0.74Starting Time - Empty sec
2.26Accelerating Rate - Empty m/s2
m/s2
Starting Time - Fully Loaded 0.74 sec
Belt Tension Rise Starting / Braking
Maximum Belt Tension / width 79.95750Belt Width mm
90Belt Rated Tension / width kN/m
kN/m
Max Belt Tension, Start/Brake 59.96 kN
88.8Actual Max Tension, Start/Brake %
1.08Stopping Time Loaded Coasting secStopping Time Loaded Braking 0.06 sec
1.08Stopping Time Empty Coasting sec
Stopping Time Empty Braking 0.06 sec
-1.54Deceleration - Loaded Coasting m/s2
Deceleration - Loaded Braking -30.07 m/s2
-1.54Deceleration - Empty Coasting m/s2
Deceleration - Empty Braking -30.14 m/s2
Stopping Distances & Discharge Volumes
Stopping Distance Loaded Coasting m
Stopping Distance Loaded Braking m
Stopping Distance Empty Coasting mStopping Distance Empty Braking m
Discharge Mass, Coasting kg
Discharge Mass, Braking kg
Discharge Volume, Coasting m3
Discharge Volume, Braking m3
0.05
0.9
0.050.9
0
0
0
0
Accelerating Tension - Loaded
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Idler Details Report17 Oct 2014 11:16 12/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Idler Category Sandvik Carry
Idler Design Belt Width 750
Series 20 3 Roll Carry 152 PlainInline
Idler Description
mm
Drawing Number
20Idler Series
Total Number of Idlers 23
1Nominal Idler Spacing m
Troughing Angle 30.0
0Idler Price
deg
Idler Bearing Diameter 25.0
27.0Idler Shaft Diameter mm
Idler Roll Diameter 152
3Number of Idler Rolls
mm
mm
Idler Rotation Speed 210
Roll Face Width 283 mm
307Shaft Support Centres
1000Idler Support Fixing Width mm
Idlerset Total Mass 31.7
16.2Idlerset Rotating Mass
3.0Idler Vertical Misalignment Allowance mm1.04Dynamic Load Factor
mm
kg
kg
Roll Bearing Centres 226.8 mm
Carry Side Idlers Return Side Idlers
500Belt Deviation Load N
728Total Load on Centre Roll N
BallType of Bearing
6205Bearing Designation
14,000Bearing Dynamic Load Rating C N
4,525,995Bearing L10h Life hrs
8.00Allowable Shaft Deflection at Bearing min
1.04Actual Shaft Deflection at Bearing min
rpm
Sandvik Flat Carry
750
Series 30 1 Roll Flat Carry152 Dia
mm
30
13
3 m
0.0
0
deg
25.0
30.0 mm
152
1
mm
mm
210
849 mm
873
1000 mm
23.1
13.8
56.3 mm1.40
mm
kg
kg
785.4 mm
1,501 N
2,446 N
Ball
6305
22,500 N
494,760 hrs
10.00 min
8.66 min
rpm
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Vertical Curve Radius Calculations17 Oct 2014 11:16 13/27Page
PT.PETROKIMIA GRESIKHelix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
17 Oct 2014 11:16 Vertical Curve Radius Calculations Page 13/27
Belt Mass - New Belt 16.96 kg/m
Top Cover Mass - New Belt 6.78 kg/m
Bottom Cover Mass 5.08 kg/m
Worn Belt Mass 12.72 kg/m
Reduction of Top Cover Mass 62.5 %
Conveyed Material Mass 0.23 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/m
Belt Rated Tension 67.5 kN
Belt Width 750 mm
90 kN/m
115% Starting
CurveType
Fully Loaded
Running
Station
DesignVertical
CurveRadius
LoadCapacity
Station / Sectio
Empty
tonnes/hr m
Tension Radius
kN m
Radius
m
Tension
kN
Starting
Fully LoadedRadius
mkN
TensionEmpty
Tension Radius
mkN
Braking
Fully LoadedRadius
mkN
TensionEmpty
Tension Radius
mkN
Largest
Reqd.Radius
m
1 39.16Takeup 39.16 38.74 38.74 44.81 44.79
2 39.431Hopper 39.43 39.85 39.85 33.84 33.8
3 40.461Int. Pt 40.46 41.08 41.08 32.2 32.16
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17 Oct 2014 11:16 Vertical Curve Radius Calculations Page 14/27
Belt Mass - New Belt 16.96 kg/m
Top Cover Mass - New Belt 6.78 kg/m
Bottom Cover Mass 5.08 kg/m
Worn Belt Mass 12.72 kg/m
Reduction of Top Cover Mass 62.5 %
Conveyed Material Mass 0.23 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/m
Belt Rated Tension 67.5 kN
Belt Width 750 mm
90 kN/m
115% Starting
CurveType
Fully Loaded
Running
Station
DesignVerticalCurveRadius
LoadCapacity
Station / Sectio
Empty
tonnes/hr m
Tension Radius
kN m
Radius
m
Tension
kN
Starting
Fully Loaded
Radius
mkN
Tension
Empty
Tension Radius
mkN
Braking
Fully Loaded
Radius
mkN
Tension
Empty
Tension Radius
mkN
LargestReqd.Radius
m
4 40.511Hopper 40.51 41.59 41.59 26.2 26.19
5 41.531Int. Pt 41.53 42.72 42.71 25.69 25.7
6 41.6Drive 41.6 43.45 43.44 16.93 17.0
Designers Comments
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Viscoelastic Friction Factor Report17 Oct 2014 11:16 15/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
deg0.1Idlerset Forward Tilt angle
N/mm2
deg C
Belt has Turnover on Return Run
deg
N
mm
N
mm
N
mm
N
mm
0.1
2
152
2
152
2
152
152
2
Idlerset Skew Angle
Return Idler Wing Roll Drag
Return Idler Wing Roll Dia
Return Idler Centre Roll Drag
Return Idler Centre Roll Dia
Carry Idler Wing Roll Drag
Carry Idler Wing Roll Dia
Carry Idler Centre Roll Drag
Carry Idler Centre Roll Dia
1
30
0.13
6
deg C30
0.13
N/mm2
Rubber description ...
6
Belt Bottom Cover Temperature
Belt & 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
IdlerSpacing
Indentation Matl.& Belt Idler Drag Idler Skew & Tilt
Emptyfriction factor f (loaded)
1 0.00.0160 0.000003.60 0.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600
2 0.00.0160 0.000001.40 0.35 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600
3 0.00.0161 0.000007.00 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01610
4 0.00.0160 0.000002.00 1.50 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600
5 0.00.0160 0.0000011.43 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01600
6 0.00.0150 0.0000025.43 2.00 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.01500
Totals: 50.85 2.00 4.00 30.13
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Belt Resonance Report17 Oct 2014 11:16 16/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Description
SectionIdler
Spacing
Idler RollExcitationFrequency
Belt TransverseWave Frequency
RangeStation
EndBelt
Tension
Station / Sectio
Hz
Running Fully Loaded Belt Resonance
to Hz
CriticalIdler
SpacingStart
CriticalIdler
SpacingEnd
IdlerSpacingwithin
+/- 10%
m m mmkNkN
StartBelt
Tension
Hz Mode
Belt Speed 1.67 m/sCarry Roll Diameter 152 mm
Return Roll Diameter 152 mm Takeup Mass 8100 kgBelt Resonance +/- Tolerance 10 %
1 48.12 48.7939.37 40.46 3.5 0.5Takeup 6.97 OK6.88
2 68.33 69.2639.43 40.51 3.5 0.35Hopper 6.93 OK6.84
3 16.15 16.3640.46 41.53 3.5 1.5Int. Pt 7.02 OK6.93
4 16.16 16.3840.51 41.6 3.5 1.5Hopper 7.02 OK6.93
5 12.27 11.9241.53 39.16 3.5 2Int. Pt 6.81 OK7.02
6 11.85 1238.18 39.16 3.5 2Drive 6.86 OK6.78
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Takeup Travel Report17 Oct 2014 11:16 17/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Takeup Travel
m0Safety Margin Top +
kg
kgTakeup Mass kg (ManualInput)
8100
8100Takeup Mass Calculated
kgTakeup Mass step increment 200
100Max no. of Calc Increments
Fixed CentresTakeup Type
Auto Calc Takeup Mass
Takeup Travel Estimate
m0.5Belt Splice Allowance +
m0Dynamic Travel Up +
m0Dynamic Travel Down +
m0Safety Margin Bottom +
deg0Minimum Site Temperature
Thermal Expansion Distance
deg30Maximum Site Temperature
1.17E-05Belt Expansion co-efficientm/m per degree C
m52.70Total Belt Length
m0.009Thermal Expansion Distance +
%0.15Permanent Stretch co-efficient % of Belt Length
Permanent Belt Stretch
m0.04Permanent Belt StretchDistance +
m0.55Total Takeup Travel Distance
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Details Report17 Oct 2014 11:16 18/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
%95Drive Efficiency
:1
:1
m/s1.57Calculated Belt Speed
m/s1.67Required Belt Speed
rpm45.87Calculated Pulley Speed for Reducer
rpm48.77Required Pulley Speed
31.5Selected Gearbox Ratio
29.63Required Gearbox Ratio
Flender Helical Bevel GearGearbox Description
380 VoltsMotor Voltage
kg383
rpm1445Motor Full Load Speed
0.0467
kg-m20.0467Total Drive Inertia
kg-m20Gearbox Inertia (HSS)
kg-m20Flywheel Inertia
kg-m20High Speed Brake Disc Inertia
%140Starting Torque Factor, Empty
%140Starting Torque Factor, Fully Loaded
kg-m20High Speed Coupling Inertia
kg-m2Motor Inertia
11
1
125Pulley Shaft Diameter at Brg mm
150Pulley Shaft Diameter at Hub mm
mm
654Pulley Outside Diameter
630Pulley Shell Diameter
mm
kW
%
0.32Drive Factor Cw, Starting
0.5Drive Factor Cw, Running
0.45Coefficient of Friction, Starting
12Pulley Lagging Thickness
0.35Coefficient of Friction, Running
MoistPulley ConditionHeadDrive Description
Rubber
Electric Motor
100 Pulley Lagging Type
Total Drive Equivalent Mass
Motor Power Rating
Motor Description
Number of Motors on Drive Pulley
mm
Load Share on Drive Pulley
180 Belt Wrap Angle
1Drive No. Drive Pulley No. 6
Drive Inertia
Pulley and Belt Speed
Pulley and Shaft Dimensions
Holdback
Brake
Brake Location High Speed
Low Speed Brake Torque Input 22
Static Analysis Runback Force Fv 0 N
Static Analysis Horizontal Force Fh 3640 N
Holdback Required (Yes / No) No
Nm
Equiv HS Brake Torque 782
Holdback Torque 3 x Motor FLT
Calculated Holdback Torque N/A
Nm6462
Fv>Fh/2
kNm
Nm
High Speed Coupling
Low Speed Coupling
HS Coupling Make
HS Coupling Model 1040T
Falk
LS Coupling Make
LS Coupling Model RFK140
Ringspann
Holdback Make Not Installed
Holdback Model
Designers Comments
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Drive Motor Details Report17 Oct 2014 11:16 19/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
380 VoltsMotor Voltage
0.0467 kg-m2Motor Inertia
11
1
kW
HeadDrive Description
Electric Motor
Motor Power Rating
Motor Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 6
Motor Category Metric Motor
DX160MMotor Frame Size
4Number of poles
160 mmMotor Shaft Height
42 mmMotor Shaft Diameter
1445 rpmMotor Full Load Speed
6.08 kWAbsorbed Power at Pulley
11 kWTotal Motor Power on Drive
6.4 kWAbsorbed Power at Motor
95 %Drive Efficiency
134 kgMass of Motor
22.3 AmpsMotor Full Load Current
72.7 NmMotor Full Load Torque
0.76Motor Power Factor @ Duty Pt
86.44 %Motor Efficiency @ Duty Point
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Fluid Coupling Details Report17 Oct 2014 11:16 20/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
0 % FLTPeak Torque %
0
1
kW
HeadDrive Description
No Selection - Direct Drive
Coupling Power Rating
Coupling Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 6
Coupling Category Flender
0Max Starting Time
Min. Required Ramping Time
sec
0 %Coupling Rated Slip
11 kWMotor Power Rating
Coupling Size
1445 rpmMotor Full Load Speed
0 kg
1445 rpmCoupling Output Speed
0Run-up Torque % (2 sec)
Mass of Coupling
sec
% FLT
Selection Mode Auto
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Drive Gearbox Details Report17 Oct 2014 11:16 21/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
2154Motor Torque at Pulley Speed
Helical Bevel Gear
1
HeadDrive Description
Flender Helical Bevel Gear
Type
Gearbox Description
Number of Motors on Drive Pulley
1Drive No. Drive Pulley No. 6
Gearbox Category Flender
B3SH4Code
4Size
73Motor Torque @ FL Speed
11 kWMotor Power Rating
1445 rpmMotor Full Load Speed
210 kgkg-m2Gearbox Inertia
6400Gearbox Rated Torque
Mass of Gearbox
Selection Mode Manual
Number of Stages
31.5
B3SH4
Service Factor Required
Ratio
1.5
Gearbox Actual Efficiency
95Design Efficiency (Input)
93rpm
mm
rpm
Maximum Input Shaft Speed 1500
Minimum Input Shaft Speed 700
Output Shaft Diameter 80
Input Shaft Diameter 30
Service Factor Calculated 2.97
5 %Plus Speed Selection Tolerance
5Minus Speed Selection Tolerance %
Fluid Coupling Slip 0
Nm
Nm
Nm
:1
:1
m/s1.57Calculated Belt Speed
m/s1.67Required Belt Speed
rpm45.87Calculated Pulley Speed for Reducer
rpm48.77Required Pulley Speed31.5Selected Gearbox Ratio
29.63Required Gearbox Ratio
%
mm
%
%
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Brake Details Report17 Oct 2014 11:16 22/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
%95Drive Efficiency
SvendborgBrake Description
Brake Location
mm3
Mild Steel
mm60Pad offset Width W
N3500Caliper Clamping Force Maximum
0.4Co-eff of Friction (Pad-Disc)
mm0Disc Thickness
mm0Disc Diameter
Disc Material
BSFH 202
%
HeadDescription
Svendborg BSFH 200
100
Maximum Air Gap
Caliper
Brake Category
Load Share on Drive Pulley
1Drive / Brake No. Drive Pulley No. 6
High Speed
Low Speed Brake Torque Input 22
Equiv HS Brake Torque 782
kNm
Nm
Brake Selection Input Data
Design Braking Torque Input
Selected Brake's Torque Rating -43
782
Number of Motors on Drive Pulley 1
Nm
Nm
Design Stopping TimeConsecutive No of Stops 3
10.0 sec
Average No of Stops
Ambient Temperature 40
6
deg 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 29.63 : 1
Mass of Caliper 26 kg
Brake Caliper Price $0.00
Caliper Clamping Force Minimum 2000 N
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulley Shafts17 Oct 2014 11:16 24/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Description
ShaftMass
kg
WrapAngledeg
Defl.Diamm
T1Run
Station
ShaftLength
mm
Station / Sectio Resul-tant
ForceDt.DiammkN kN
T2Run
kN
T1Start
kN
Calculated
ShaftDiamm
Selected
BrgDiamm
BrgCtrsmm
1 39.2 39.41610 125120.8180.0Takeup 150 22378.5 123.738.7 1270
6 41.6 38.21610 125121.3180.0Drive 150 22379.8 124.743.4 1270
Designers Comments * Denotes manual pulley shaft dimensions entered
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulleys17 Oct 2014 11:16 25/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Mom ofInertiakgm2Description
Pulley &Shaft
Mass kg
PulleySpeedrpm
WrapAngledeg
ShaftDiamm
ShaftLength
mm
FaceWidthmmStation
Laggingmm
ShellDia mm
Station / Sectio
BrgCtrsmm
BrgDiamm
1 850 1610500 12 150 180.0Takeup 60.9 475 12.71270 125
6 850 1610630 12 150 180.0Drive 48.8 718 36.21270 125
Designers Comments * Denotes manual pulley dimensions entered
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulley Dimensions17 Oct 2014 11:16 26/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Mom ofInertiakgm2Description
Pulley &Shaft
Mass kg
ShaftDiamm
ShaftLength
mm
FaceWidthmmStation
Laggingmm
ShellDia mm
Station / Sectio
BrgCtrsmm
BrgDiamm
ODmm
BeltWidthmm
1 850 1610500 12 150Takeup 475 12.71270 125524 750
6 850 1610630 12 150Drive 718 36.21270 125654 750
Designers Comments
E:\PROPOSAL PETRO\Helix\36.M111-Potasium Sulphate -BW-750,1.67 m-s.xml HelixTechnologiesVer 6.0.15 Licenced to PT Krakatau Engineering
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Conveyor Pulleys Data Sheet17 Oct 2014 11:16 27/27Page
PT.PETROKIMIA GRESIK
Helix Technologies Pty Ltd
Project
Project No.
Conveyor No.
Client
Prepared By
Design Date
Sistem Reaktor 36.R-101
36.M111, 1.67 m/s
JSA
Description
PulleySpeed
rpm
WrapAngledeg
DrivePower
kW
FaceWidthmmStation
Laggingmm
ShellDia mm
Station / Sectio
BrgCtrsmm
T1RunkN
T2RunkN
T1StartkN
T2StartkN
1 850500 12 44.81180.0Takeup 60.91270 39.4539.16 39.37
Braking FullRunning Full
6 850630 12 43.45180.0Drive 48.8111270 36.5341.6 38.18
Starting FullRunning Full
Designers Comments
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