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Helix T6 Calculation Conveyor 2500 TPH
Helix T6 Calculation Conveyor 2500 TPH
CALCULATION REPORT
Helix T6 Calculation CV 5A 2500 TPH
Detailed Design
South Kalimantan
CALCULATION REPORT
Submitted to:
PT. Tunas Inti Abadi
Jl. Propinsi KM 204, Sebamban
South Kalimantan, Indonesia
Distribution:
PT. Tunas Inti Abadi (1 Soft Copy)
PT. Zekon Inti Rekayasa (1 Soft Copy)
BLC 2500 TPH PRODUCTION PLAN DETAILED DESIGN
PT. TUNAS INTI ABADI
DOCUMENT CONTROL
Project : Perencanaan Peningkatan 2500 TPH Barge Loading Conveyor dan Jetty
Client : PT. Tunas Inti Abadi
Document Title : Technical Report
REV DESCRIPTION DATE ISSUED BY
00
© PT. Zekon Inti Rekayasa (2023)
AUTHOR
1. Author : Loga Ekaprasta
Signed :
REVIEWER
Signed :
APPROVAL
1. Approved by : Seto Wahyudi (Project Manager- ZEKON INTI REKAYASA)
Signed :
Conveyed Material
Material Description COAL - 50mm Surcharge Angle 20 deg
Low Bulk Density 870 kg/m3 Angle of Repose 35 deg
High Bulk Density 1000 kg/m3 Material Lump size 30 mm
Conveyor Data
Conveying Distance 79.89 m Design Capacity 2700 tonnes/hr
Nett Lift / Lower (-) 5.63 m Belt Speed 5.5 m/s
Belt Details
Belt Width Selected 1200 mm Calculated Belt % Full 96.7 %
Belt Class & Run Safety Factor 630/4 13.39 Top Cover Thickness 6 mm
Belt Rated Tension 63 kN/m Bottom Cover Thickness 3 mm
Belt Total Length 176.5 m Belt Mass 19.53 kg/m
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded 18.69 kN Belt Power - Empty Belt 21.76 kW
Maximum Tension Tmax 56.45 kN Belt Power - Inclines Loaded 102.11 kW
Minimum Tension Tmin 37.94 kN Belt Power - Declines Loaded 53.83 kW
Sag Tension 1.5 % 15.29 kN Belt Power - Fully Loaded 102.8 kW
Takeup Type Vertical Gravity Drive Efficiency 94.0 %
Takeup Mass 8000 kg Absorbed Power Fully Loaded 109.36 kW
Takeup Pulley Belt Tension 39.23 kN Installed Motor Power 160 kW
Carry and Return Idlers
Carry Idler Trough Angle 35 º Return Idler Trough Angle 0 º
Carry Idler Spacing 1.2 m Return Idler Spacing 3 m
Carry Idler No Rolls x Dia 3 x 139 mm Return Idler No Rolls x Dia 1 x 139 mm
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded 140 % CEMA Temperature Factor Kt 1.00
Startup Factor - Empty 140 % Total Braking Torque LSS 0.00 kNm
Starting Time - Fully Loaded 5.11 sec Stop Time - Loaded, Braking 5.67 sec
Starting Time - Empty 1.46 sec Stop Time - Loaded, Coasting 5.67 sec
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Sections - Input Data Page 2/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Station / Section
Section Section Cap- Ten Idler Skirt Friction
Length Lift X co- Y co- Z co- acity Adj. Spacing Length No. of Factor
Station Description m m ord m ord m ord m tph kN m m Scrapers Input
3 Hopper 33.14 0.07 9.32 0.00 0.26 2500 1.00 6.00 0.0000
4 Hopper 3.60 0.13 42.46 0.00 0.33 2500 1.20 6.00 0.0000
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Takeup & Drive Traction Calculation Page 3/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Drive Torque Start-up Factor Loaded 140 % Takeup Pulley Belt Tension 39.23 kN
Drive Torque Start-up Factor Empty 140 % Takeup Mass 8000 kg
Running Starting Braking
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Summary Run / Start Page 4/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
2 Hopper 39.82 39.82 39.82 39.82 43.09 51.30 36.86 38.50 36.86 38.50
3 Hopper 43.84 39.88 43.70 43.70 48.08 52.21 40.01 38.46 40.01 38.46
4 Hopper 46.10 40.26 45.96 45.09 56.40 58.06 36.80 38.22 36.80 38.22
5 Int. Pt 47.42 40.32 47.29 46.16 58.37 58.66 37.55 38.22 37.55 38.22
6 Drive 56.45 41.73 56.37 47.57 74.16 65.79 40.46 38.98 40.46 38.98
7 Snub 38.93 38.93 38.93 38.93 39.45 37.06 39.58 39.22 39.58 39.22
8 Bend 38.98 38.98 38.98 38.98 39.78 38.09 39.38 39.16 39.38 39.16
9 Takeup 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23
10 Bend 39.76 39.76 39.76 39.76 40.07 40.86 39.47 39.63 39.47 39.63
11 Int. Pt 39.11 39.11 39.11 39.11 40.64 44.48 37.73 38.49 37.73 38.49
Minimum Ten 38.93 38.93 38.93 38.93 39.23 37.06 36.63 38.05 36.63 38.05
Maximum Ten 56.45 41.73 56.37 47.57 74.16 65.79 40.46 39.63 40.46 39.63
Effective Ten 18.69 3.96 18.57 9.79
Ave. Belt Ten 43.30 39.85 43.24 42.08 48.96 50.95 38.23 38.58 38.23 38.58
Belt Elong. m 0.154 0.033 0.152 0.111 0.352 0.422 -0.023 -0.011 -0.023 -0.011
T/up Travel m 0.077 0.016 0.076 0.056 0.176 0.211 -0.012 -0.006 -0.012 -0.006
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Belt Details Report Page 5/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Summary Belt Sag Page 6/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Summary Belt Sag Page 7/29
Minimum Ten 38.93 38.93 38.93 38.93 39.23 37.06 36.63 38.05 36.63 38.05
Maximum Sag 0.61 0.61 0.61 0.61 0.61 0.63 0.61 0.61 0.61 0.61
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Run Fully Loaded Page 8/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
6 Drive 0.71 0.22 56.45 37.94 0.19 18.50 0.94 0.05 0.016
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Run Empty Page 9/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
6 Drive 0.71 0.22 41.73 37.94 0.16 3.79 0.94 0.05 0.016
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Run Inclines Loaded Page 10/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
6 Drive 0.71 0.22 56.37 37.94 0.14 18.42 0.94 0.05 0.016
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Run Declines Loaded Page 11/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
6 Drive 0.71 0.22 47.57 37.94 0.15 9.63 0.94 0.05 0.016
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Starting and Stopping Page 12/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Idler Details Report Page 13/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Vertical Curve Radius Calculations Page 14/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Vertical Curve Radius Calculations Page 15/29
Belt Width 1200 mm % Belt Mass for Lift-off Calculation 75 %
Belt Mass - New Belt 19.53 kg/m Curve Tension Safety Factor 14
Top Cover Mass - New Belt 8.14 kg/m Average Drive Torque Start-up Factor - Loaded 140 %
Bottom Cover Mass 4.07 kg/m Average Drive Torque Start-up Factor - Empty 140 %
Worn Belt Mass 14.65 kg/m Belt Modulus 4200 kN/m
Reduction of Top Cover Mass 60 % Belt Rated Tension 63 kN/m 75.6 kN
Conveyed Material Mass 136.36 kg/m Allowable Edge Tension - Running: 115 % Starting 200 %
Station / Section Design
Vertical Running Starting Braking Largest
Load Curve Fully Loaded Empty Fully Loaded Empty Fully Loaded Empty Reqd.
Capacity Radius Tension Radius Radius
Curve Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius
Station Type tonnes/hr m kN m kN m kN m kN m kN m kN m m
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Vertical Curve Radius Calculations Page 16/29
Belt Width 1200 mm % Belt Mass for Lift-off Calculation 75 %
Belt Mass - New Belt 19.53 kg/m Curve Tension Safety Factor 14
Top Cover Mass - New Belt 8.14 kg/m Average Drive Torque Start-up Factor - Loaded 140 %
Bottom Cover Mass 4.07 kg/m Average Drive Torque Start-up Factor - Empty 140 %
Worn Belt Mass 14.65 kg/m Belt Modulus 4200 kN/m
Reduction of Top Cover Mass 60 % Belt Rated Tension 63 kN/m 75.6 kN
Conveyed Material Mass 136.36 kg/m Allowable Edge Tension - Running: 115 % Starting 200 %
Station / Section Design
Vertical Running Starting Braking Largest
Load Curve Fully Loaded Empty Fully Loaded Empty Fully Loaded Empty Reqd.
Capacity Radius Tension Radius Radius
Curve Tension Radius Tension Radius Tension Radius Tension Radius Tension Radius
Station Type tonnes/hr m kN m kN m kN m kN m kN m kN m m
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Viscoelastic Friction Factor Report Page 17/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
2 5.32 1.00 0.0190 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0160
3 33.14 1.00 0.0179 0.00653 38.4 895 0.00284 16.7 0.00658 38.7 0.00104 6.1 0.0160
4 3.60 1.20 0.0192 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0160
5 37.83 1.20 0.0171 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0160
6 0.71 10.00 0.0160 0.00274 16.1 1230 0.00015 0.9 0.01356 79.5 0.00061 3.6 0.0160
7 3.20 3.00 0.0150 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0150
8 2.04 10.00 0.0150 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0150
9 1.90 10.00 0.0150 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0150
10 33.08 3.00 0.0150 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0150
11 46.11 3.00 0.0150 0.00000 0.0 0 0.00000 0.0 0.00000 0.0 0.00000 0.0 0.0150
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Belt Resonance Report Page 18/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Mode
Belt Belt Wave Frequency Excitation Idler Spacing Spacing within
Station Description
Tension Tension Range Frequency Spacing Start End +/- 10%
kN kN Hz to Hz Hz m m m m
4 Hopper 46.1 56.45 6.7 7.56 12.59 1.2 0.64 0.72 Warning 2
5 Int. Pt 47.42 38.93 6.82 6.04 12.59 1.2 0.65 0.58 Warning 2
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Takeup Travel Report Page 19/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Takeup Travel
Takeup Type Vertical Gravity
Auto Calc Takeup Mass
Takeup Mass step increment 500 kg
Max no. of Calc Increments 100
Takeup Mass kg (Manual 8000 kg
Input)
Takeup Mass Calculated 8000 kg
Takeup Travel Estimate
Safety Margin Top + 0 m
Belt Splice Allowance + 0 m
Dynamic Travel Up + 0 m
Dynamic Travel Down + 0.5 m
Safety Margin Bottom + 0.5 m
Thermal Expansion Distance
Minimum Site Temperature 25 deg
Maximum Site Temperature 72 deg
Belt Expansion co-efficient
1.17E-05
m/m per degree C
Total Belt Length 176.50 m
Thermal Expansion Distance + 0.096 m
Permanent Belt Stretch
Permanent Stretch co-
0.15 %
efficient % of Belt Length
Permanent Belt Stretch 0.261 m
Distance +
Total Takeup Travel Distance 1.36 m
Helix
Technologies
Ver 6.0.14.0 Licenced to ZIRA
08 Mar 2023 10:12 Drive Details Report Page 20/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Drive Motor Details Report Page 21/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Drive Fluid Coupling Details Report Page 22/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Drive Gearbox Details Report Page 23/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Brake Details Report Page 24/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Shaft Coupling Report Page 25/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Pulley Shafts Page 26/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
6 Drive 2480 * 203.0 56.4 37.9 92.4 74.2 164.9 169.5 170 150 2000 442
7 Snub 2140 * 0.0 38.9 39.1 77.9 39.4 147.0 142.6 150 125 1800 297
8 Bend 2170 * 270.0 39.0 39.1 55.1 39.8 134.9 127.1 120 110 1800 193
9 Takeup 2140 * 180.0 39.2 39.4 78.5 39.2 147.3 143.0 150 125 1800 297
10 Bend 2170 * 270.0 39.8 39.9 56.2 40.1 135.5 128.0 120 110 1800 193
Helix
Ver 6.0.14.0 Licenced to ZIRA
Technologies
08 Mar 2023 10:12 Conveyor Pulleys Page 27/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Station / Section
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 Tail 624 * 12 1350 2140 1800 150 125 180.0 162.1 750 17.9
6 Drive 624 * 12 1350 2480 2000 170 150 203.0 162.1 913 27.1
7 Snub 424 * 12 1350 2140 1800 150 125 0.0 234.5 544 8.9
8 Bend 524 * 12 1350 2170 1800 120 110 270.0 191.7 546 17.5
9 Takeup 524 * 12 1350 2140 1800 150 125 180.0 191.7 646 17.9
10 Bend 524 * 12 1350 2170 1800 120 110 270.0 191.7 546 17.5
Helix
Ver 6.0.14.0 Licenced to ZIRA
Technologies
08 Mar 2023 10:12 Conveyor Pulley Dimensions Page 28/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Station / Section
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 Tail 624 12 648 1350 2140 1800 150 125 1200 750 17.9
6 Drive 624 12 648 1350 2480 2000 170 150 1200 913 27.1
7 Snub 424 12 448 1350 2140 1800 150 125 1200 544 8.9
8 Bend 524 12 548 1350 2170 1800 120 110 1200 546 17.5
9 Takeup 524 12 548 1350 2140 1800 150 125 1200 646 17.9
10 Bend 524 12 548 1350 2170 1800 120 110 1200 546 17.5
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Conveyor Pulleys Data Sheet Page 29/29
PT ZIRA
Project BLC Upgrading 2500TPH Client PT TIA
Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023
Station / Section
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 Tail 624 12 1350 1800 180.0 162.1 39.18 39.34 49.11 49.92
Running Full Starting Empty
6 Drive 624 12 1350 2000 160 203.0 162.1 56.45 37.94 74.16 38.42
Running Full Starting Full
7 Snub 424 12 1350 1800 0.0 234.5 38.93 39.09 39.45 39.8
Running Full Starting Full
8 Bend 524 12 1350 1800 270.0 191.7 38.98 39.14 39.78 40.19
Running Full Starting Full
9 Takeup 524 12 1350 1800 180.0 191.7 39.23 39.39 39.23 40.29
Running Full Starting Empty
10 Bend 524 12 1350 1800 270.0 191.7 39.76 39.92 40.86 41.9
Running Full Starting Empty
Designers Comments
Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies