Roller Supported Chain (RSC) cable carrier with TRAXLINE drag chain cables

Cable carrier and cables from one source: TSUBAKI KABELSCHLEPP implements cable carrier system with 260 meters travel length

A robust cable carrier including a cable package and with a particularly long travel length for a new crane system in the company's own port: this has been the tender from the Indonesian fertilizer manufacturer Pupuk Kaltim. TSUBAKI KABELSCHLEPP has been able to win the bid and to successfully implement the project with an international team. The basis for this RSC system is a MC1300 cable carrier equipped with TRAXLINE drag chain cables. 

Pupuk Kaltim is a subsidiary of the PT Pupuk Indonesia Holding Company with a current production capacity of 2.98 million tons of urea, 1.85 million tons of ammonia and 350,000 tons of NPK fertilizer per year. Pupuk Kaltim also produces organic fertilizers with a capacity of 45,000 tons per year. The company was founded in 1977 and is headquartered in the city of Bontang in the Indonesian part of the island of Borneo.

Since commissioning in September 2015, the system has been running successfully at the Pupuk Kaltim port on the island of Borneo

An international team consisting of TSUBAKI KABELSCHLEPP Germany, TSUBAKI Singapore and the local partner ATI was able to implement the project successfully and cost-efficiently

In early 2013, Pupuk Kaltim launched a tender for a new crane in the company-owned port, which was to be equipped with a cable carrier including special cables across the 260 meters travel length. The installation is used for loading ships. After a face-to-face meeting with the customer and submitting a detailed quotation, Pupuk Kaltim chose to cooperate with TSUBAKI KABELSCHLEPP in summer 2013. 

Cable carrier and cables from one source
“One of the decisive aspects for the customer has been that TSUBAKI KABELSCHLEPP is able to supply cable carrier and cables from one source,” explains 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 10,000 Volt drag chain cables, which are designed especially for long travel lengths. Weight and capacity of the cables are optimized: compared to 1,000-Volt-cables, the active power cable is only a few millimeters thicker at the same weight, but it can transmit up to 10-fold of electric power. This is achieved by a special design, particularly high quality components and materials and a special semiconductor layer. 

TSUBAKI KABELSCHLEPP implemented a cable carrier system including cables with a travel length of 260 meters for an Indonesian fertilizer manufacturer

Low weight and high capacity in a compact design – these cable properties provide an economic benefit for the overall system design: the lighter the electric cables, the less drive power is eventually required. The special single cores applied also make it possible to reduce the cable carrier radius and thus to keep the height of the overall cable carrier system low. These special cables significantly contribute to the performance of the entire system: the main components – cable carrier and cables – are perfectly matched, allowing TSUBAKI KABELSCHLEPP to supply the customer with a ready-to-install “black box”. The principle “everything from one source” also implies for the customer “everything from one responsibility”: the customer has only one contact for cable carrier and cables, who can respond quickly to maintenance tasks and hence ensures the highest possible operating reliability over a long time. Especially in the highly competitive field of container logistics this is a great advantage. It is important to ensure functional reliability of individual components at any time and thereby to ensure the planned availability of the entire cable carrier system.

At the company's own outdoor test facility, TSUBAKI KABELSCHLEPP can run fully automated simulations of travel lengths of more than 100 meters and travel speeds of up to 5 m/s

Decision for rolling chain application
TSUBAKI KABELSCHLEPP has quickly found the right cable carrier for the high performance cable package: “Based on the required travel length in conjunction with the associated cable package, we have immediately decided to use a rolling chain application,” explains Thorsten Serapinas, Manager Project Engineering at TSUBAKI KABELSCHLEPP GmbH. “Our innovative RSC system and the long-term tests of our TRAXLINE cables at the company’s outdoor testing facility convinced Pupuk Kaltim. The project was ready to go ahead.” In the following months detailed technical coordination with both the customer in Indonesia and the manufacturer of the crane system in Sweden took place, to define the position of the complete cable carrier system and the design and connection of the driver.

Roller supported chains are an ideal solution for higher 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 bolt/hole connections of the cable carrier is reduced to a minimum. This virtually 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.  All RSC systems are based on a combination of a proven standard cable carriers from TSUBAKI KABELSCHLEPP and TRAXLINE E-cables, in this case a MC1300 – a multi-variable cable carrier designed especially for crane applications, featuring e.g. seawater resistant aluminum stays for extremely high stability.

Roller supported chains from TSUBAKI KABELSCHLEPP are an ideal solution for high additional loads and long travel lengths

Implemented an international project team

TSUBAKI KABELSCHLEPP set up an international team for implementing the project: the project has been planned and managed from the headquarters in Germany while the TSUBAKI team in Singapore has supported the coordination. For reasons of cost efficiency and sustainability, all steel and sheet metal components were manufactured locally. TSUBAKI KABELSCHLEPP has provided all necessary drawings and quality assurance documents – so that components could have been manufactured in Indonesia in accordance with the defined quality standards. Only the TRAXLINE cable package and the cable carrier itself have been supplied from Germany in individual parts (in pre-assembled roller segments or reeled). The Indonesian project partner ATI was responsible for installation of the system. “This was indispensable for the success and the cost efficiency of the project,” Serapinas stresses. “The travel time from Germany to the site is approx. 30 hours. Without our local partners it would have been impossible to manage this task within budget.”

Final commissioning and successful acceptance of the system through TSUBAKI KABELSCHLEPP took place in September 2015. Since then, the RSC system has been operating successfully in the Pupuk Kaltim port. “260 meters is one of the longer travel lengths we have ever implemented with a rolling system and TRAXLINE electric cables,” concludes Thorsten Serapinas. “One of the reasons why this project is outstanding is that we have been able to implement it successfully and cost-efficiently with an international team cooperating across great distance.”

One of the decisive aspects for Pupuk Kaltim was that TSUBAKI KABELSCHLEPP was able to supply cable carrier and cables from one source, using medium voltage cables from the TRAXLINE range

Peter Sebastian Pütz Key Account Manager Business Development, TSUBAKI KABELSCHLEPP GmbH

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