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Published: 18 May 2016      

Successful Kabelschlepp project in Indonesia

Tsubaki Kabelschlepp roller supported chains
Tsubaki Kabelschlepp has implemented a roller supported chain (RSC) system with a travel length of 260m

A tender from Indonesian fertiliser manufacturer Pupuk Kaltim for its own port required a robust cable carrier including a cable package and with a particularly long travel length for a new crane system.

Kabelschlepp won the bid and to successfully implemented the project with an international team. The basis for this RSC system is a MC1300 cable carrier equipped with TRAXLINE drag chain cables.

“One of the decisive aspects for the customer has been that Tsubaki Kabelschlepp is able to supply cable carrier and cables from one source,” explained Dipl.-Ing. Winfried Sambale, product specialist for cables at Kabelschlepp. “Only few suppliers are able to offer this, particularly as this project required the use of special medium voltage cables.”

These are continuous bending hi-flex 10,000V drag chain cables, which are especially designed for long travel lengths. Weight and capacity of the cables are optimised – compared to 1,000V cables, the active power cable is only a few mm thicker at the same weight, but it can transmit up to 10 times the electric power.

Tsubaki Kabelschlepp said it quickly found the right cable carrier for the high performance cable package. “Based on the required travel length in combination with the associated cable package, we have immediately decided to use a rolling chain application,” explained Thorsten Serapinas, manager project engineering at Tsubaki Kabelschlepp GmbH. “260m is one of the longer travel lengths we have ever implemented with a rolling system.”

Tsubaki Kabelschlepp added that one of the reasons why this project is “outstanding” is that it was able to implement it successfully and cost-efficiently with an international team cooperating across great distance. The project was planned and managed from the headquarters in Germany while the Tsubaki team in Singapore supported the coordination.

For cost reasons, all steel components were manufactured locally in compliance with defined quality standards. Only the cable carrier itself was supplied from Germany in separate parts and in pre-assembled roller segments. Indonesian project partner ATI installed the system, which was then accepted and released by Tsubaki Kabelschlepp.

The RSC system is installed on the transverse axis of a new crane system used for loading and unloading ships. Serapinas explained: “Based on the required travel length in conjunction with the associated cable package we have immediately decided in favour of a rolling chain application.”

The firm said roller supported chains are an ideal solution for high additional loads and long travel lengths. In contrast to the combined gliding/rolling systems already available in the market, the upper run of the Tsubaki Kabelschlepp RSC system never touches the lower run. The upper run of the cable carrier runs on a guide profile with maintenance-free ball bearing rollers. As this requires only low pull/push forces, wear within the connections of the cable carrier is reduced to a minimum. This excludes unwanted lengthening of the overall system and additional load on the guided cables is avoided. Due to the low pull/push forces the required driving force is reduced and thereby the power of the drives is scaled down as well.

The company added that all its RSC systems are based on its proven standard cable carriers, in this case a MC1300 – a multi-variable cable carrier designed especially for crane applications. One of its main features is the extremely high stability created by seawater resistant aluminium stays.

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