March 2023

Document No.: P.23002-ZIRA-MEC-CAL-001.REV.00

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 Issued for aprroval 29 March 2023 Loga Ekaprasta

00
© PT. Zekon Inti Rekayasa (2023)

AUTHOR
1. Author : Loga Ekaprasta
Signed :

2. Author : Ahmad Fauji

Signed :

REVIEWER

1. Reviewed by : Anugerah Rakhmatullah

Signed :

2. Reviewed by : Migi Prasetyo

Signed :

APPROVAL
1. Approved by : Seto Wahyudi (Project Manager- ZEKON INTI REKAYASA)

Signed :

2. Approved by : Mochamad Yainul Manaf (Maintenance and Construction Superintendent -

TIA)
Signed :

Document Title: Document Ref. : Page Number :

Calculation Report P.23002-ZIRA-MEC-CAL-001-REV.00 2
 08 Mar 2023 10:12 Conveyor Design Summary Page 1/29
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

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

1 Tail 3.96 -0.05 0.00 0.00 0.00 0 0.70 1 0.0000

2 Hopper 5.32 0.00 4.00 0.00 0.26 2500 1.00 0.0000

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

5 Int. Pt 37.83 5.43 46.06 0.00 0.46 2500 1.20 0.0000

6 Drive 0.71 0.22 83.54 0.00 5.58 0 10.00 2 0.0000

7 Snub 3.20 -0.62 82.79 0.00 5.29 0 3.00 0.0000

8 Bend 2.04 -2.04 79.65 0.00 4.62 0 10.00 1 0.0000

9 Takeup 1.90 1.90 79.22 0.00 2.58 0 10.00 0.0000

10 Bend 33.08 -4.74 78.80 0.00 4.48 0 3.00 0.0000

11 Int. Pt 46.11 -0.31 46.06 0.00 0.00 0 3.00 0.0000

Totals: 170.89 -0.01 0.00 12.00 4

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

Drive Fully Empty Fully Empty Fully Empty

Number Loaded Belt Loaded Belt Loaded Belt
Drive No. 1 Drive
Pulley No. 6 Lagging Type Rubber Rubber Rubber
Wrap Angle º 215.051 215.051 215.051 215.051 215.051 215.051
Co-efficient of Friction 0.25 0.25 0.35 0.35 0.35 0.35
Drive Factor Cw 0.643 0.643 0.368 0.368 0.368 0.368
Calculated Belt Tension T1 kN 56.45 41.73 74.16 65.79 40.46 38.98
Calculated Belt Tension T2 kN 37.94 37.94 38.42 35.94 38.63 38.25
Minimum Required T2 kN 11.9 2.44 13.15 10.98 0.67 0.27
Surplus T2 Tension (T1-T2) kN 26.04 35.5 25.27 24.96 37.96 37.98
Designers Comments

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

Drive Torque Start-up Factor Loaded 140 %

Drive Torque Start-up Factor Empty 140 % Takeup Mass 8000 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 Tail 39.18 39.18 39.18 39.18 42.01 49.11 36.63 38.05 36.63 38.05

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

Low BD = 870kg/m3 High BD = 1000kg/m3

Conveyed Material Belt Speed & Capacity
Material Description COAL - 50mm Belt Speed 5.5 m/s
Low Bulk Density 870 kg/m3 Belt Design Capacity Input 2700 tonnes/hr
High Bulk Density 1000 kg/m3 Section Loading Max Capacity 2500 tonnes/hr
Surcharge Angle 20 deg Carry Idler Trough Angle 35 º
Angle of Repose 35 deg Belt Dimensions
Material Lump size 30 mm Top Cover Thickness 6 mm
Belt Make & Class Bottom Cover Thickness 3 mm
Belt Category Fabric Belt Carcass Thickness 5.6 mm
Belt Description BANDO Belt Total Thickness 14.6 mm
Belt Class / Plies 630/4 4 Belt Total Belt Length (L) 176.5 m
Belt Reinforcement Fibre Fabric Time for 1 Revolution 32.1 sec
Belt Width Selected 1200 mm Belt Load Area and Capacity at 870kg/m3
Belt Modulus 4200 kN/m Minimum Rec. Edge Distance 89 mm
Actual Edge Distance Low BD 97 mm
Load Burden Depth 233 mm
Load Burden Width 853 mm
Belt Tensions Belt Load Area at Minimum
Recommended Edge Distance 0.1621 m2
Belt Rated Tension / m width 63 kN/m
Calculated Tension / m width 47 kN/m Belt Load Area Utilised at Low
Belt Rated Tension for width 75.6 kN Bulk Density 0.1567 m2
Calculated Max Run Tension 56.45 kN Belt Actual % Full at Low BD 96.7 %
Minimum Tension Tmin 37.94 kN Belt Load Area and Capacity at 1000kg/m3
Allowable Tension Rise, Starting 200 % Minimum Rec. Edge Distance 89 mm
Allowable Belt Tension, Starting 151.2 kN Actual Edge Distance High BD 127 mm
Actual Belt Tension, Starting 74.16 kN Belt Load Area Utilised at High
Bulk Density 0.1364 m2
Belt and Material Mass Belt Actual % Full at High BD 84.1 %
Belt Top Cover Mass 8.1 kg/m Flooded Belt Capacity at 1000kg/m3
Belt Bottom Cover Mass 4.1 kg/m Flooded Belt Load Area at Zero
Edge Distance 0.2298 m2
Belt Carcass Mass 7.3 kg/m
Belt Mass Wb (per linear m) 19.5 kg/m Flooded Belt Capacity 4549 tonnes/hr
Material Mass Wm 136.4 kg/m Flooded Belt Material Mass 229.8 kg/m
Total Mass (Wb + Wm) 155.9 kg/m
Total Belt Mass (Wb x L) 3447 kg
Designers Comments

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

Allowable Belt Sag % Running 1.5 %

Allowable Belt Sag % Start / Stop 5 % Takeup Mass 8000 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 Tail 39.18 39.18 39.18 39.18 42.01 49.11 36.63 38.05 36.63 38.05
Idler Spacing m 0.70
Belt Sag % 0.04 0.04 0.04 0.04 0.04 0.03 0.05 0.04 0.05 0.04
2 Hopper 39.82 39.82 39.82 39.82 43.09 51.30 36.86 38.50 36.86 38.50
Idler Spacing m 1.00
Belt Sag % 0.45 0.06 0.45 0.45 0.41 0.05 0.48 0.06 0.48 0.06
3 Hopper 43.84 39.88 43.70 43.70 48.08 52.21 40.01 38.46 40.01 38.46
Idler Spacing m 1.00
Belt Sag % 0.41 0.06 0.41 0.05 0.37 0.05 0.45 0.06 0.45 0.06
4 Hopper 46.10 40.26 45.96 45.09 56.40 58.06 36.80 38.22 36.80 38.22
Idler Spacing m 1.20
Belt Sag % 0.47 0.07 0.47 0.06 0.38 0.05 0.58 0.08 0.58 0.08
5 Int. Pt 47.42 40.32 47.29 46.16 58.37 58.66 37.55 38.22 37.55 38.22
Idler Spacing m 1.20
Belt Sag % 0.45 0.07 0.45 0.06 0.37 0.05 0.57 0.08 0.57 0.08
6 Drive 56.45 41.73 56.37 47.57 74.16 65.79 40.46 38.98 40.46 38.98
Idler Spacing m 10.00
Belt Sag % 0.42 0.57 0.42 0.5 0.32 0.36 0.59 0.61 0.59 0.61
7 Snub 38.93 38.93 38.93 38.93 39.45 37.06 39.58 39.22 39.58 39.22
Idler Spacing m 3.00
Belt Sag % 0.18 0.18 0.18 0.18 0.18 0.19 0.18 0.18 0.18 0.18
8 Bend 38.98 38.98 38.98 38.98 39.78 38.09 39.38 39.16 39.38 39.16
Idler Spacing m 10.00
Belt Sag % 0.61 0.61 0.61 0.61 0.6 0.63 0.61 0.61 0.61 0.61
9 Takeup 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23 39.23
Idler Spacing m 10.00
Belt Sag % 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61
10 Bend 39.76 39.76 39.76 39.76 40.07 40.86 39.47 39.63 39.47 39.63
Idler Spacing m 3.00
Belt Sag % 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18

Helix
Ver 6.0.14.0 Licenced to ZIRA Technologies
08 Mar 2023 10:12 Tension Calculations - Summary Belt Sag Page 7/29

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
11 Int. Pt 39.11 39.11 39.11 39.11 40.64 44.48 37.73 38.49 37.73 38.49
Idler Spacing m 3.00
Belt Sag % 0.18 0.18 0.18 0.18 0.18 0.16 0.19 0.19 0.19 0.19

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

Takeup Mass 8000 kg

Tensions CEMA
Section Section Ten Material Skirt Scraper Section
Station / Pulley
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 3.96 -0.05 39.18 39.34 0.16 0.47 0.00 0.016

2 Hopper 5.32 0.00 39.82 39.82 3.82 0.20 0.019

3 Hopper 33.14 0.07 43.84 43.84 1.01 1.25 0.0179

4 Hopper 3.60 0.13 46.10 46.10 1.01 0.32 0.0192

5 Int. Pt 37.83 5.43 47.42 47.42 9.02 0.0171

6 Drive 0.71 0.22 56.45 37.94 0.19 18.50 0.94 0.05 0.016

7 Snub 3.20 -0.62 38.93 39.09 0.16 -0.11 0.015

8 Bend 2.04 -2.04 38.98 39.14 0.16 0.47 -0.38 0.015

9 Takeup 1.90 1.90 39.23 39.39 0.16 0.37 0.015

10 Bend 33.08 -4.74 39.76 39.92 0.16 -0.81 0.015

11 Int. Pt 46.11 -0.31 39.11 39.11 0.07 0.015

Totals: 1.00 18.5 0.00 3.82 2.02 1.88 9.98

Maximum Tension 56.45 kN Total Effective Tension 18.69 kN
Minimum Tension 37.94 kN Total Belt Power (Te x V) 102.8 kW
Average Tension Fully Loaded 43.30 kN Belt Modulus 4200 kN/m
Average Tension Belt Stationary 38.90 kN Total Belt Length 176.50 m
Average Tension Difference 4.4 kN Belt Elastic Elongation 0.154 m
Takeup Movement 0.077 m
Designers Comments

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

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 3.96 -0.05 39.18 39.34 0.16 0.47 0.00 0.016

2 Hopper 5.32 0.00 39.82 39.82 0.06 0.019

3 Hopper 33.14 0.07 39.88 39.88 0.38 0.0179

4 Hopper 3.60 0.13 40.26 40.26 0.06 0.0192

5 Int. Pt 37.83 5.43 40.32 40.32 1.41 0.0171

6 Drive 0.71 0.22 41.73 37.94 0.16 3.79 0.94 0.05 0.016

7 Snub 3.20 -0.62 38.93 39.09 0.16 -0.11 0.015

8 Bend 2.04 -2.04 38.98 39.14 0.16 0.47 -0.38 0.015

9 Takeup 1.90 1.90 39.23 39.39 0.16 0.37 0.015

10 Bend 33.08 -4.74 39.76 39.92 0.16 -0.81 0.015

11 Int. Pt 46.11 -0.31 39.11 39.11 0.07 0.015

Totals: 0.97 3.79 0.00 1.88 1.10

Maximum Tension 41.73 kN Total Effective Tension 3.96 kN
Minimum Tension 37.94 kN Total Belt Power (Te x V) 21.76 kW
Average Tension Fully Loaded 39.85 kN Belt Modulus 4200 kN/m
Average Tension Belt Stationary 38.90 kN Total Belt Length 176.50 m
Average Tension Difference 0.95 kN Belt Elastic Elongation 0.033 m
Takeup Movement 0.016 m

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

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 3.96 -0.05 39.18 39.34 0.16 0.47 0.00 0.016

2 Hopper 5.32 0.00 39.82 39.82 3.82 0.06 0.016

3 Hopper 33.14 0.07 43.70 43.70 1.01 1.25 0.0179

4 Hopper 3.60 0.13 45.96 45.96 1.01 0.32 0.0204

5 Int. Pt 37.83 5.43 47.29 47.29 9.08 0.0182

6 Drive 0.71 0.22 56.37 37.94 0.14 18.42 0.94 0.05 0.016

7 Snub 3.20 -0.62 38.93 39.09 0.16 -0.11 0.015

8 Bend 2.04 -2.04 38.98 39.14 0.16 0.47 -0.38 0.015

9 Takeup 1.90 1.90 39.23 39.39 0.16 0.37 0.015

10 Bend 33.08 -4.74 39.76 39.92 0.16 -0.81 0.015

11 Int. Pt 46.11 -0.31 39.11 39.11 0.07 0.015

Totals: 1.00 18.50 0.00 3.82 2.02 1.88 9.98

Maximum Tension 56.37 kN Total Effective Tension 18.57 kN
Minimum Tension 37.94 kN Total Belt Power (Te x V) 102.11 kW
Average Tension Inclines Loaded 43.24 kN Belt Modulus 4200 kN/m
Average Tension Belt Stationary 38.90 kN Total Belt Length 176.50 m
Average Tension Difference 4.34 kN Belt Elastic Elongation 0.152 m
Takeup Movement 0.076 m
Designers Comments

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

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 3.96 -0.05 39.18 39.34 0.16 0.47 0.00 0.016

2 Hopper 5.32 0.00 39.82 39.82 3.82 0.06 0.019

3 Hopper 33.14 0.07 43.70 43.70 1.01 0.38 0.0179

4 Hopper 3.60 0.13 45.09 45.09 1.01 0.06 0.0192

5 Int. Pt 37.83 5.43 46.16 46.16 1.41 0.0171

6 Drive 0.71 0.22 47.57 37.94 0.15 9.63 0.94 0.05 0.016

7 Snub 3.20 -0.62 38.93 39.09 0.16 -0.11 0.015

8 Bend 2.04 -2.04 38.98 39.14 0.16 0.47 -0.38 0.015

9 Takeup 1.90 1.90 39.23 39.39 0.16 0.37 0.015

10 Bend 33.08 -4.74 39.76 39.92 0.16 -0.81 0.015

11 Int. Pt 46.11 -0.31 39.11 39.11 0.07 0.015

Totals: 1.00 18.5 0.00 3.82 2.02 1.88 9.98

Maximum Tension 47.57 kN Total Effective Tension 9.79 kN
Minimum Tension 37.94 kN Total Belt Power (Te x V) 53.83 kW
Average Tension Declines Loaded 42.08 kN Belt Modulus 4200 kN/m
Average Tension Belt Stationary 38.90 kN Total Belt Length 176.50 m
Average Tension Difference 3.18 kN Belt Elastic Elongation 0.111 m
Takeup Movement 0.056 m
Designers Comments

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

System Masses Input Data

Mass of Belt 3,447 kg Belt Speed 5.5 m/s
Mass of Material 10,087 kg Belt Rated Tension 63 kN/m
Carry Idler Equivalent Mass 1,920 kg Allow. Belt Start Tension Rise 200 %
Return Idler Equivalent Mass 556 kg Drive Inertia 2.4181 kg-m2
Pulley Equivalent Mass 1,311 kg Total Braking Torque 0 kNm
Drive Equivalent Mass 1,933 kg Start-up Factor - Loaded 140 %
Total System Equivalent Mass 19,254 kg Start-up Factor - Empty 140 %
Installed Power 160 kW
Tensions and Accelerating Forces
Drive Efficiency (Average) 94 %
Effective Tens. Fully Loaded 18.69 kN
Effective Tension Empty 3.96 kN Stopping Times & Deceleration Rates
Total Braking Force 0.00 kN Stopping Time Loaded Braking 5.67 sec
Stopping Time Loaded Coasting 5.67 sec
Tension Available to Accelerate Conveyor
Stopping Time Empty Braking 12.74 sec
Accelerating Tension - Loaded 20.71 kN
Stopping Time Empty Coasting 12.74 sec
Accelerating Tension - Empty 34.56 kN
Deceleration - Loaded Braking -0.97 m/s2
Starting Times & Acceleration Rates
Deceleration - Loaded Coasting -0.97 m/s2
Starting Time - Fully Loaded 5.11 sec
Deceleration - Empty Braking -0.43 m/s2
Starting Time - Empty 1.46 sec
Deceleration - Empty Coasting -0.43 m/s2
Acceleration Rate - Loaded 1.08 m/s2
Accelerating Rate - Empty 3.77 m/s2 Stopping Distances & Discharge Volumes
Stopping Distance Loaded Braking 15.58 m
Belt Tension Rise Starting / Braking
Stopping Distance Loaded Coasting 15.58 m
Max Belt Tension, Start/Brake 74.16 kN
Stopping Distance Empty Braking 35.04 m
Belt Width 1200 mm
Stopping Distance Empty Coasting 35.04 m
Maximum Belt Tension / width 61.8 kN/m
Belt Rated Tension / width 63 kN/m Discharge Mass, Braking 2125 kg
Actual Max Tension, Start/Brake 98.1 % Discharge Mass, Coasting 2125 kg
Discharge Volume, Braking 2.44 m3
Discharge Volume, Coasting 2.44 m3
Designers Comments

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

Carry Side Idlers Return Side Idlers

Idler Category Sandvik Carry Sandvik Flat Return
Idler Description Series 35 3 Roll Carry 139 Plain Series 35 1 Roll Flat Carry
Inline 139 Dia
Idler Design Belt Width 1200 mm 1200 mm
Idler Series 35 35
Drawing Number
Nominal Idler Spacing 1.2 m 3 m
Total Number of Idlers 79 27
Idler Price 0 0
Troughing Angle 35.0 deg 0.0 deg
Idler Shaft Diameter 30.0 mm 36.0 mm
Idler Bearing Diameter 30.0 mm 30.0 mm
Number of Idler Rolls 3 1
Idler Roll Diameter 139 mm 139 mm
Idler Rotation Speed 756 rpm 756 rpm
Roll Face Width 444 mm 1302 mm
Roll Bearing Centres 366.8 mm 1227.4 mm
Shaft Support Centres 467.4 mm 1328 mm
Idler Support Fixing Width 1450 mm 1450 mm
Idlerset Rotating Mass 24.3 kg 20.6 kg
Idlerset Total Mass 58.3 kg 40.5 kg
Idler Vertical Misalignment Allowance 6.0 mm 5.0 mm
Dynamic Load Factor 1.42 1.40
Belt Deviation Load 1,000 N 500 N
Total Load on Centre Roll 2,858 N 1,588 N
Type of Bearing Ball Ball
Bearing Designation 6306 6306
Bearing Dynamic Load Rating C 28,100 N 28,100 N
Bearing L10h Life 167,762 hrs 977,225 hrs
Allowable Shaft Deflection at Bearing 8.00 min 10.00 min
Actual Shaft Deflection at Bearing 5.43 min 4.87 min
Designers Comments

Helix
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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

08 Mar 2023 10:12 Vertical Curve Radius Calculations Page 14/29

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

1 Tail 39.18 39.18 42.01 49.11 36.63 38.05

2 Hopper 2500 39.82 39.82 43.09 51.3 36.86 38.5

3 Hopper 2500 43.84 39.88 48.08 52.21 40.01 38.46

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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

4 Hopper 2500 46.1 40.26 56.4 58.06 36.8 38.22

5 Int. Pt Concave 2500 47.42 40.32 58.37 58.66 37.55 38.22

Belt Tension at Curve kN 47.42 40.32 58.37 58.66 37.55 38.22

Min. Concave Lift Off Radius 4622 3930 5689 5718 3659 3725 5718
Min. Edge Tension Radius 16 19 13 13 21 20
Max. Centre Tension Radius 10 8 13 14 8 8

6 Drive 56.45 41.73 74.16 65.79 40.46 38.98

7 Snub 38.93 38.93 39.45 37.06 39.58 39.22

8 Bend 38.98 38.98 39.78 38.09 39.38 39.16

9 Takeup 39.23 39.23 39.23 39.23 39.23 39.23

10 Bend 39.76 39.76 40.07 40.86 39.47 39.63

11 Int. Pt Concave 39.11 39.11 40.64 44.48 37.73 38.49

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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

Belt Tension at Curve kN 39.11 39.11 40.64 44.48 37.73 38.49

Min. Concave Lift Off Radius 3812 3812 3961 4335 3677 3752 4335
Min. Edge Tension Radius 20 20 19 17 20 20
Max. Centre Tension Radius

Designers Comments

Helix
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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

Viscoelastic Calculations Input Data

Belt Rubber Description Rubber description ... Carry Idler Centre Roll Dia 102 mm
Top Cover Dynamic Modulus E' 6 N/mm2 Carry Idler Centre Roll Drag 2 N
Top Cover Dynamic Loss Factor Tan(delta) 0.13 Carry Idler Wing Roll Dia 152 mm
Belt Top Cover Temperature 30 deg C Carry Idler Wing Roll Drag 2 N
Rolling Resistance Factor RRF Top 0.072 RRF Bot. 0.072 Return Idler Centre Roll Dia 152 mm
Bottom Cover Dynamic Modulus E' 6 N/mm2 Return Idler Centre Roll Drag 2 N
Bot Cover Dynamic Loss Factor Tan(delta) 0.13 Return Idler Wing Roll Dia 152 mm
Belt Bottom Cover Temperature 30 deg C Return Idler Wing Roll Drag 2 N
Belt & Material Flexure Adjustment factor 1 Idlerset Skew Angle 0.1 deg
Belt has Turnover on Return Run Idlerset Forward Tilt angle 0.1 deg

Station / Section friction factor f (loaded) Empty

Total Indentation Matl.& Belt Idler Drag Idler Skew & Tilt
Loaded Indent Indent Freq Flexure Flexure Drag Drag Tilt Tilt Empty
Section Idler Friction factor factor uency friction friction factor factor friction friction Friction
No Length Spacing factor f fi % rad/s fm % fr % ft % factor f
1 3.96 0.70 0.0160 0.00387 6.9 2092 0.00036 0.6 0.05085 90.2 0.00131 2.3 0.0160

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

Totals: 170.89 -0.01 0.00 12.00 4

Designers Comments

Helix
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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

Carry Roll Diameter 139 mm Belt Speed 5.5 m/s

Return Roll Diameter 139 mm Takeup Mass 8000 kg
Belt Resonance +/- Tolerance 10 %
Station / Section Running Fully Loaded Belt Resonance
Critical Critical Idler
Start End Belt Transverse Idler Roll Section Idler Idler Spacing

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

1 Tail 39.34 43.84 31.58 33.39 12.59 0.7 1.76 1.86 OK

2 Hopper 39.82 46.1 7.35 8.04 12.59 1 0.58 0.64 OK

3 Hopper 43.84 47.42 7.8 8.18 12.59 1 0.62 0.65 OK

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

6 Drive 37.94 38.98 2.17 2.2 12.59 10 1.72 1.75 OK

7 Snub 39.09 39.23 7.34 7.36 12.59 3 1.75 1.75 OK

8 Bend 39.14 39.76 2.2 2.22 12.59 10 1.75 1.76 OK

9 Takeup 39.39 39.11 2.21 2.2 12.59 10 1.76 1.75 OK

10 Bend 39.92 39.18 7.42 7.35 12.59 3 1.77 1.75 OK

11 Int. Pt 39.11 39.18 7.35 7.35 12.59 3 1.75 1.75 OK

Designers Comments

Helix
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 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
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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 No. 1 Drive Pulley No. 6

Drive Description Head Pulley Condition Moist
Load Share on Drive Pulley 100 % Pulley Lagging Type Rubber
Starting Torque Factor, Fully Loaded 140 % Belt Wrap Angle 215.05 º
Starting Torque Factor, Empty 140 % Coefficient of Friction, Running 0.25
Number of Motors on Drive Pulley 1 Drive Factor Cw, Running 0.64
Motor Description Electric Motor Coefficient of Friction, Starting 0.35
Motor Power Rating 160 kW Drive Factor Cw, Starting 0.37
Motor Voltage 380 Volts Pulley and Shaft Dimensions
Gearbox Description Flender Helical Bevel Gear Pulley Shell Diameter 624 mm
Drive Efficiency 94 % Pulley Lagging Thickness 12 mm
Fluid Coupling Pulley Outside Diameter 648 mm
Fluid Coupling VOITH TSS Pulley Shaft Diameter at Hub 170 mm
Fluid Coupling Size 562 Pulley Shaft Diameter at Brg 150 mm
High Speed Coupling Pulley and Belt Speed
Motor Full Load Speed 1485 rpm
Required Gearbox Ratio 8.886 :1
Low Speed Coupling Selected Gearbox Ratio 9 :1
LS Coupling Make Falk Required Pulley Speed 167.12 rpm
LS Coupling Model 1080/525 MCFAS Calculated Pulley Speed for Reducer 160.05 rpm
Brake Required Belt Speed 5.5 m/s
Brake Location None Calculated Belt Speed 5.43 m/s
Low Speed Brake Torque Input 0 kNm Drive Inertia
Equiv HS Brake Torque 0 Nm Motor Inertia 2.76 kg-m2
Holdback High Speed Coupling Inertia 0 kg-m2
Static Analysis Runback Force Fv 7527 N High Speed Brake Disc Inertia 0 kg-m2
Static Analysis Horizontal Force Fh 11163 N Flywheel Inertia 0 kg-m2
Calculated Holdback Torque 630 Nm Gearbox Inertia (HSS) 0.0786 kg-m2
Holdback Required (Yes / No) Yes Fv>Fh/2 Total Drive Inertia 2.4181 kg-m2
Holdback Torque 3 x Motor FLT 28278 Nm Total Drive Equivalent Mass 1933 kg
Holdback Make Not Installed
Holdback Model
Designers Comments

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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 No. 1 Drive Pulley No.

6
Drive Description Head Total Motor Power on Drive 160 kW
Number of Motors on Drive Pulley 1 Absorbed Power at Pulley 102.8 kW
Motor Category Metric Motor Drive Efficiency 94 %
Motor Description Electric Motor Absorbed Power at Motor 109.36 kW
Motor Power Rating 160 kW Motor Full Load Speed 1485 rpm
Motor Voltage 380 Volts Motor Full Load Torque 1029 Nm
Number of poles 4 Motor Full Load Current 292 Amps
Motor Frame Size D315M Motor Efficiency @ Duty Point 93.7 %
Motor Shaft Diameter 85 mm Motor Power Factor @ Duty Pt 0.84
Motor Shaft Height 315 mm Mass of Motor 1250 kg
Motor Inertia 2.76 kg-m2
Designers Comments

Helix
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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 No. 1 Drive Pulley No. 6

Drive Description Head Coupling Size 562
Number of Motors on Drive Pulley 1 Motor Power Rating 160 kW
Selection Mode Auto Motor Full Load Speed 1485 rpm
Coupling Category Voith Coupling Rated Slip 3 %
Coupling Description VOITH TSS Peak Torque % 140 % FLT
Coupling Power Rating 275 kW Run-up Torque % (2 sec) 75 % FLT
Min. Required Ramping Time sec Coupling Output Speed 1440 rpm
Max Starting Time 30 sec Mass of Coupling 136 kg

Designers Comments

Helix
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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 No. 1 Drive Pulley No. 6

Drive Description Head Motor Power Rating 160 kW
Number of Motors on Drive Pulley 1 Motor Full Load Speed 1485 rpm
Selection Mode Auto Motor Torque @ FL Speed 1029 Nm
Gearbox Category Flender Motor Torque at Pulley Speed 9143 Nm
Gearbox Description Flender Helical Bevel Gear Gearbox Rated Torque 16000 Nm
Type Helical Bevel Gear Service Factor Required 1.5
Size 7 Service Factor Calculated 1.75
Code B2SH7
Plus Speed Selection Tolerance 5 %
Ratio 9
Minus Speed Selection Tolerance 5 %
Number of Stages B2SH7
Fluid Coupling Slip 3 %
Design Efficiency (Input) 94 % Required Gearbox Ratio 8.886 :1
Gearbox Actual Efficiency 94 % Selected Gearbox Ratio 9 :1
Maximum Input Shaft Speed 1500 rpm Required Pulley Speed 167.12 rpm
Minimum Input Shaft Speed 700 rpm Calculated Pulley Speed for Reducer 160.05 rpm
Input Shaft Diameter 70 mm Required Belt Speed 5.5 m/s
Output Shaft Diameter 105 mm Calculated Belt Speed 5.43 m/s
Gearbox Inertia 0.07862 kg-m2 Mass of Gearbox 615 kg

Designers Comments

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Project No. 102 Prepared By LEK
Conveyor No. CV_5A_2500_BW1200 Design Date 02 March 2023

Drive / Brake No. 1 Drive Pulley No. 6

Description Head Brake Location None
Load Share on Drive Pulley 100 % Disc Material Mild Steel
Brake Category - Disc Diameter 0 mm
Brake Description No Brake on Drive Disc Thickness 0 mm
Caliper Co-eff of Friction (Pad-Disc) 0.4
Number of Motors on Drive Pulley 1
Caliper Clamping Force Minimum 0 N
Brake Selection Input Data Caliper Clamping Force Maximum 0 N
Low Speed Brake Torque Input 0 kNm Pad offset Width W 0 mm
Equiv HS Brake Torque 0 Nm Maximum Air Gap 0 mm
Design Braking Torque Input 0 Nm Recommended working airgap is 1mm
Selected Brake's Torque Rating 0 Nm Disc Initial Speed 0 rpm
Design Stopping Time 10.0 sec Disc Moment of Inertia 0.0 kg-m2
Consecutive No of Stops 3 Required Gearbox Ratio 8.886 :1
Average No of Stops 6 Drive Efficiency 94 %
Ambient Temperature 40 deg C Mass of Caliper 0 kg
Disc Temperature after stops 0 deg C Brake Caliper Price $0.00

Designers Comments

Helix
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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 No. 1 Drive Pulley No. 6

Drive Description Head Motor Power Rating 160 kW
Load Share on Drive Pulley 100 % Motor Full Load Speed 1485 rpm
Starting Torque Factor, Fully Loaded 140 % Motor Torque @ FL Speed 1029 Nm
Starting Torque Factor, Empty 140 % Motor Torque at Pulley Speed 9143 Nm
Number of Motors on Drive Pulley 1 Pulley Shaft Diameter at Brg 150 mm
Drive Efficiency 94 %
High Speed Coupling Low Speed Coupling
HS Coupling Category Falk SteelFlex Grid LS Coupling Category Falk Rigid
HS Coupling Make Falk LS Coupling Make Falk
HS Coupling Model 1090T LS Coupling Model 1080/525 MCFAS
Coupling Type Grid Coupling Type Rigid Flanged
Coupling Torque Rating 3730 Nm Coupling Torque Rating 455000 Nm
Service Factor Required 1.5 Service Factor Required 1.5
Service Factor Calculated 3.63 Service Factor Calculated 48.27
Maximum Shaft Bore 95 mm Maximum Shaft Bore 300 mm
Minimum Shaft Bore 0 mm Minimum Shaft Bore 0 mm
Maximum Rotation Speed 3600 rpm Maximum Rotation Speed 120 rpm
High Speed Coupling Inertia 0.079 kg-m2 Low Speed Coupling Inertia 59.4 kg-m2
Drawing Number Drawing Number
High Speed Coupling Mass 25.4 kg Low Speed Coupling Mass 1066 kg
High Speed Coupling Price 0 Low Speed Coupling Price 0
Fluid Coupling
Direct Drive
Fluid Coupling VOITH TSS
Fluid Coupling Size 562

Designers Comments

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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 Resul- Calculated Selected

T1 T2 tant T1
Shaft Wrap Run Run Start Defl. Dt. Shaft Brg Brg Shaft
Length Angle Force Dia Dia Dia Dia Ctrs Mass
Station Description mm deg kN kN kN kN mm mm mm mm mm kg
1 Tail 2140 * 180.0 39.2 39.3 78.4 42.0 147.3 142.9 150 125 1800 297

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

Designers Comments * Denotes manual pulley shaft dimensions entered

Helix
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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

Designers Comments * Denotes manual pulley dimensions entered

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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
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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
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