TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 1 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

NOTE:

THIS SPECIFICATION IS VALID FOR ANY SPECIFIC PROJECT ONLY WHEN MODIFIED TO COMPLY WITH SPECIFIC JOB REQUIREMENTS AND ACCOMPANIED BY A COVER SHEET, IF ANY. PARAGRAPHS INDICATED BY MARK (*) ARE SPECIFIC JOB REQUIREMENTS. CONTENTS PAGE

1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 2.4 2.5 3. 4. 5.

GENERAL Scope Codes and Standards Related Engineering Specifications BASIC DESIGN General Steel Structural Parts Mechanical Parts Safety Devices Safety Guards and Safety Cover Painting Supply Conditions Inspection and Test General Data Sheet of Belt Conveyor

2 2 2

2 3 5 8 9 9 9 9

Appendix 1

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 2 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

1. 1.1

GENERAL Scope This specification covers the general requirements for the design, fabrication, inspection, test and supply of belt conveyors and their components, which are supplied to the plant constructed by Toyo Engineering Corp. (hereinafter referred to as TEC). This specification shall not be applicable to the belt conveyors listed hereunder. (1) (2) (3) (4) (5) (6) Conveyors for packaged materials, such as bags, boxes, cartons etc. Portable Belt Conveyors Belt Feeders and Belt Weighers Belt Conveyors supplied as a part of equipment Special Belt Conveyors Structural part of Truss Type Conveyor If conveyor s of truss construction is specified, this specification shall only cover the mechanical design other than structural parts. Design requirements for truss parts are separately specified.

1.2

Codes and Standards Unless otherwise specified, design of conveyors shall be in accordance with the requirements of the following standards, ISO 5048 JIS B8805 (Similar to ISO 5048)

1.3

Related Engineering Specifications The related Engineering Specifications to supplement this specification are as follows: (1) J-100 General Design Basis for Package Unit

2. 2.1

BASIC DESIGN General (1) Unless otherwise specified, calculation of belt width, required power and tensile strength shall generally be in accordance with ; ISO 5048 Continuous mechanical handling equipment Belt conveyors with carrying idlers Calculation of operating power and tensile strength

Or JIS B8805 Rubber belt conveyors with carrying Idlers - Calculation of operating power and tensile forces.

(2)

Unless otherwise specified in the data sheet, the belt speed shall be designed based on manufacturers standard design practice, but not faster than ;

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 3 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

u u

90 m/min. for the conveyor in the process unit 150 m/min. for the conveyors in the warehouse and storage facilities of fertilizer and fine material handling facilities. m/min. for the conveyors in the coal yard or other coarse material handling facilities

(3) (4)

Conveyors shall be designed to start under full-loaded condition with designed capacity. Appendix 1 General Data Sheet of Belt Conveyor shall be filled up and submitted with quotation.

2.2 2.2.1

Steel Structural Parts Girder (1) Conveyor girders shall be designed taking the following load factors into consideration, i.e. the weight of the conveyor, conveyed material, wind load, snow load seismic load, tensile strength of the belt etc. Deflection of girder shall be within 1/500 of the supporting span.

(2) 2.2.2

Chutes (1) Chutes shall be of welded construction and shall be provided to prevent spillage of conveyed material. Chutes shall not interfere daily maintenance work and shall have construction of disassembling when required. Plate thickness of chutes shall be minimum 4.5 mm for carbon steel and 3.0 mm for stainless steel. Chutes shall be big enough so that the material scraped off by the belt cleaner can be received. Chutes shall be provided with inspection and maintenance door(s), which shall be big enough for maintenance and cleaning. If it is practically difficult to access to whole parts of chutes, adequate numbers of doors shall be provided. Doors shall be of dust tight type and no pocket construction to prevent dust spillage at door open. Chutes shall be equipped with rubber curtain to reduce the impact force or breakage of product, if specified in the data sheet. Connecting chutes at the transfer point from conveyor to conveyor shall be arranged to minimize the drop height and to transfer feed conveyed materials onto the center of the belt. Feed chutes shall be so designed that the direction of feed shall be lined to the running direction of receiving conveyor. If conveying direction is changed, an adjustable flap shall be equipped in the chute to adjust the feed position of conveying material to centralize the feed point or to prevent belt from sway. Connecting chutes shall be so designed that they shall be declined and centrally directed to the running direction of the receiving conveyor to reduce the impact of dropping materials and to prevent build-up of materials in the chute. Chutes shall be so steep that materials shall flow smoothly. Minimum angle of bottom plate from horizontal shall be 45 degrees unless otherwise specified in the data sheet especially for sticky materials.

(2) (3) (4)

(5)

(6)

(7)

(8)

(9)

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 4 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

2.2.3

Skirt (1) Skirt of rigid steel plate construction shall be provided at the feed point to prevent spilling of conveyed material. (2) The length of skirt shall be minimum three times of belt width, but not less than 1.5 meters. (3) Skirt shall consist of the following three parts ; u Steel parts to hold skirt rubber u Skirt rubber, which is supported from outside of the skirt boards by wedges or bolts. The height of skirt rubber shall be of adjustable. u Rubber curtain of soft rubber to seal the clearance between the bottom of the skirt and belt shall be provided, if needed especially for fine materials. (4) Plate thickness of skirts shall be minimum 4.5 mm for carbon steel and 3.0 mm for stainless steel. (5) Skirt rubber shall be provided at the tail of skirt board to prevent materials from spillage to tail of conveyors.

2.2.4

Walkways of the Conveyor This part is applicable to the walkway (platform) that is directly connected to the conveyors and supplied as a part of conveyors. Design requirement for walkways in conveyor gallery or conveyors of truss construction are specified separately. (1) Walkway shall be installed to the conveyor, when the height from the floor to the carrying side belt is higher than 2.0 m. (2) The top of walkways shall be 600 - 900 mm lower than the carrying side belt. (3) Walkway of the conveyor shall be installed on one side of belt conveyor of which belt width are less than 1 200 mm and on both side of belt conveyors of which belt width are 1 000 mm and wider. (4) The width of walkway shall generally be more than 600 mm, unless otherwise specified. (5) Toe Plate with minimum 50 mm of height shall be installed on walkways along the outside edge. (6) Handrail shall be installed on walkways along the outside edge. The height of the handrail shall generally be 1 070 mm. (7) Over bridges (pedestrian cross walks) shall be installed to permit access for maintenance, at intervals of not exceeding 100 m. (8) There shall generally be a minimum clearance of 2 000 mm measured vertically from the floor or walking surface for headroom.

2.2.5

Dedusting Nozzle (1) Dedusting nozzles shall be generally provided at the top of skirt board of each feed point. If skirt board will cover numbers of feed points, dedusting nozzle shall be provided at the downstream of the last feed nozzle. (2) Dedusting nozzles at the top of discharge chute may be provided, if specified in data sheet. (3) Dedusting nozzle shall be equipped with conical hood at its suction points so that dedusting air velocity is gradually increased to prevent coarse materials from oversucking.

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 5 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

2.2.6

Conveyor Cover (1) (2) Conveyors shall be equipped with conveyor cover if specified in data sheet. Conveyor cover shall be of half pipe shaped and cover upper part of conveyor above stringer. Covers shall be of segment construction for easy removable during inspection or maintenance.

2.3 2.3.1

Mechanical Parts Drivers (1) Drivers shall be normally provided at the head part for inclined conveyor and the tail part for declined conveyor. If normal driving position is unreasonable because of accessibility, maintainability, vibration etc., drivers may be installed at other location. But calculation of belt tension shall be carefully checked. Single drives system shall be applied normally when motor is LV motor. Tandem drive may be applied when HV or MV motor is required. But calculation of belt tension shall be carefully checked. Rated power shall be decided under the following conditions. Conveyors shall be started under full-loaded condition at the design capacity. The following allowance shall be covered.
u u

(2)

(3) (4) (5)

Motors of 15 kW and under Motors of 15 kW or over

margin more than 15 % of BHP (Brake Horse Power) margin more than 10 % of BHP

(6)

Transmission of power to drive pulley shall be composed of the following system.

u u

Motors of 45 kW and under Motors over 45 kW

Gear reducer and chain/sprocket system is acceptable. Direct coupling with gear reducer and driving pulley shall be applied. Coupling shall be of non-lubricated or non- grease type.

(7)

Motors of 90 kW and over shall be equipped with fluid coupling. Fluid coupling shall be selected to control the starting time of conveyors. Conveyors with concave arrangement shall be smoothly started up without jumping of belt from carrier rollers under any load conditions. Soft start function may be considered. Conveyors with backward torque under stop condition shall be equipped with holdback (backstop) device at drive pulley. Stop time of conveyors longer than 10 seconds and downward conveyors shall be equipped with brake at drive shaft. Stop time shall be adjustable. Brake shall be of fail-safe design. Calculated life of bearings of gear reducer shall be longer than 30 000 hours for intermittent service and 50 000 hours for continuous service based on ISO equation.

(8)

(9)

(10)

(11)

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 6 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

2.3.2

Take-ups (1) The type of take-up shall be normally decided based on the conveyor length as shown on the following table. Conveyor Length (m) 30 and under 30 over (2) Type Screw take-up type Gravity take-up type

Gravity take-up shall be provided as near as possible to drive pulley. If gravity take-up is installed at the middle or non-drive end of conveyors, the take-up stroke shall be designed carefully taking elongation of belt into consideration, especially return side as well as the distribution of tensile strength. The stroke of take-up weight shall be decided based on the length of the following length u Permanent elongation specified by belt supplier u Periodical elongation at start-up period on full loaded condition u mm allowance both above highest and below lowest position Initial belt elongation of longer conveyors, 100 m and more, shall be cut after no load operation for specified period. Vendor in the erection instruction shall designate initial take-up weight position.

(3)

(4)

(5)

Safety wire shall be equipped to prevent take-up weight from falling down when take-up wire will break. Two and more lines shall be provided. Take-up weight shall be installed in take-up tower, which shall be equipped with safety cage, ladder and platform. Take-up tower shall be also equipped with scale for checking of movement for take-up weight. Take-up carriage shall be equipped with end stoppers at both ends. Take-up carriage and weight shall move smoothly. Guide wheels shall be equipped on take-up weight.

(6)

(7) 2.3.3

Idlers (1) (2) In case of carrying bulk material, idlers shall be generally of 3-roller 30-troughed type. Minimum one belt trailing device shall be provided at both carrying and return side for conveyor s more than 15 m to prevent belt from swaying. For conveyors of more 30 m lengths, belt trailing devices shall be equipped according to the following conditions.
u

For Carrier Idler Belt training idlers shall be provided at intervals of 15 meters. Self aligning type or forward tilted carrying idlers shall be provided.

For Return Idler Belt training idlers of self aligning type at intervals of 30 meters shall be provided.

(3) (4) (5)

Idlers shall be equipped with grease-filled ball bearings. Seal of the idler bearings shall be of dust proof type. Idlers shall be properly lagged with rubber, PVC etc. for corrosive material application, if specified in data sheet.

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 7 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

2.3.4

Pulleys (1) (2) (3) Pulleys shall generally be of welded construction. Drive pulleys shall generally be crown types with double helical grooved rubber lining. Tail pulleys shall be designed to prevent material from sticking on the surface. Cage type may be selected unless otherwise specified. Type of bearing shall be pillow block or plummer block. Calculated L10h operating hours of bearings at drive, head, tail, snub and take-up pulleys shall be longer than 30000 hours for intermittent service and 50000 hours for continuous service based on ISO equation. Seal of pulley bearings shall be of dust proof type. Drive pulleys shall be equipped with snub pulleys to get enough wrap angles. Pulleys shall be strong enough taking starting torque into consideration. In the calculation of belt tension, the friction factor and wrap angle of belt between drive pulley and belt shall be selected taking into consideration the installed place and the construction of the conveyor mentioned on the data sheet. The diameter of pulleys shall be sized with minimum 20 % larger than the minimum diameter specified by belt manufacturers based on the material and construction of belt. The position of head, tail and drive pulleys shall be adjustable both horizontally and vertically for adjustment of belt swaying at job site.

(4)

(5) (6) (7) (8)

(9)

(10)

2.3.5

Impact Roller (1) (2) Impact rollers shall be equipped at the feed points. Interval of impact rollers shall be less than 1.5 times of idler diameter. Impact idlers shall be equipped for the length of [length of loading chute] plus belt width. Deck plate shall be provided at loading points beneath the impact rollers to prevent spilled material from accumulating on the return belt, if specified in data sheet.

(3)

2.3.6

Lubrication (1) When lubrication points are inaccessible or are in hazardous locations, fittings (grease nipples) and the lubricant pipes shall be located at accessible point. Return idlers, especially equipped below walkway, shall be lubricated from walkway. Lubrication shall be enable from one side especially when greased type idlers are applied.

(2) (3) 2.3.7

Belts (1) Construction and material of belts shall be selected according to the characteristic of the handled materials (such as temperature, water content and property) and the construction of belt conveyor. The carcasses of belts shall be minimum 2 plies. Mono ply belt is only acceptable under special design requirement in data sheet or Contractor acceptance.

(2)

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 8 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

(3) (4)

Splicing of the belt shall be vulcanized or adhered. Width of belts shall be selected in the following table unless otherwise specified. Standard belt width (mm) 400 (750) 1200 2000 500 800 1400 2200 (600) (900) 1600 2400 650 1000 1800 2600 ) can be used subject to

But 500 mm shall be normally the minimum width. Contractors approval. (5)

Belt width in blanket (

Safety factor of tensile strength against the maximum tension, which may be at start-up period, shall be as follows. Construction of Belt Fabric-reinforced Belt Steel-cable Belt Safety Factor Minimum 10 Minimum 10

(6)

The top rubber of carrying side shall have a thickness of minimum 3.0 mm and bottom side shall have minimum 1.5 mm. Splicing material (glue) shall be separately shipped from mechanical parts taking effective period of glue into consideration.

(7)

2.3.8

Belt Cleaners

(1) (2)

Belt cleaners shall be equipped both at head pulley (in discharge chute) and at tail (near to tail pulley). Belt cleaner at head part shall be of tip type and clean up remaining material on the carrying side. Scraped material shall be dropped in discharge chute. Belt cleaner at tail part shall be of V- type and clean up remaining material on the reverse side. Scraped material shall be discharged to both sides of conveyor.

(3)

2.4

Safety Devices

(1) (2)

Slip Detector (Zero Speed Switch) shall be equipped. If actuating slip detector, conveyors shall stop. Sway Detector of 2-stage type shall be equipped at each 100 m interval. Actuating at 1st stage shall make alarm and 2nd stage shall make emergency stop of conveyors. Actuating position shall be of adjustable.
u u

1st Stage Alarm 2nd stageEmergency Stop

(3)

A safety pull-cord switch shall be equipped at each 30 m interval. Safety rope shall be provided along with full length of conveyor at walkway side(s). Actuating these switches will make emergency stop of conveyors.

FORM A-G30.002 (9303)

TOKYO

JAPAN

STANDARD ENGINEERING SPECIFICATION BELT CONVEYORS FOR BULK MATERIALS

PAGE

TES
JD-101 E 9 OF 9

TOYO ENGINEERING CORP. ISSUED JUL.15,99

(4)

The contact of emergency switch shall be directly connected to MCC, not via control logic, i.e. PLC on the safety point of view. An audible or visual warning device for conveyor starting, in case of remotely and automatically controlled conveyors system.

(5)

2.5

Safety Guards and Safety Cover (1) (2) The moving and rotating parts shall be provided with safety guard or safety cover. Construction of safety guard and safety cover shall be removable.

3.

Painting (1) Painting system shall conform to the specification in Engineering Specification J-100 Basis for Package Unit unless otherwise specified. General Design

4.

Supply Conditions (1) Belt conveyors shall be reasonably pre-assembled to minimize installation work at job site. Detailed assembly plan shall be decided at detailed engineering stage. Mechanical parts and electrical parts or devices shall be packed according to the following procedure. w w w w Motor and driving parts Pulleys and rollers Other mechanical parts Local Panel sealed by plastic sheet and boxed sealed by plastic sheet and boxed sealed by plastic sheet and boxed sealed by plastic sheet and boxed

(2)

Detailed packing and shipping procedure shall conform to separate engineering specification for Packing and Shipping. (3) Belts shall be shipped as rolled form and deformation shall be prohibited. Detailed procedure given by belt supplier shall be strictly followed.

5.

Inspection and Test (1) Conveyors shall be inspected and tested in accordance with Inspection and Test Procedure (ITP), which is attached to the requisition, and manufacturers standard approved by TEC.

FORM A-G30.002 (9303)

Appendix 1

General Data Sheet of Belt Conveyor

Material Handled
Code Name Size Bulk Density Temperature Angle of Repose Other Properties A B C D

Page 1 of 2

Capacity Material Handled

Idlers Formation

Dimension

Power

Driving Mechanism
Sprocket

Gear Reducer

Fluid Coupling Manufacture

Back Stop

Brake

Take-up

Drive Pulley Friction Factor

Snub Pulley

Motor Lotation

No. of Motors

Manufacture

Manufacture

Manufacture

Wrap Angle

Belt Width

Belt Speed

No. Req'd

Reduction Retio

Item No.

Diameter

Diameter

Required

Location

Location

Location

Installed

Service

Bearing

Code

T/H

mm

m m/min.

kw

kw

No. of Teeth

kg

mm

mm

mm

mm

JD-101

100

120

900 3 x 30 1 x Flat

100

20

120

66

75

1 1500 -

MH

Sumit omo

Bearing

Normal

Weight

Carrier

Design

Length

Return

Driven

Height

Lining

Lining

Model

Model

Model

Model

Stroke

Shape

Shape

Drive

Shaft

Shaft

Type

Type

JD-101 Item No. Service No. Req'd 1 Shape Diameter Head Pulley Lining Shaft Bearing Shape Diameter
mm mm mm mm mm mm mm mm kg/cm kg/cm mm mm

Appendix 1

Tail Pulley

Lining Shaft Bearing Shape Diameter Lining Shaft Bearing Diameter Sets Bearing Diameter Sets Bearing Type Interval No. Type Rubber

General Data Sheet of Belt Conveyor

Take-up Pulley Carrier Idler Return Idlers Trailing Idlers

Material

Carcass Plies Top Reverse Strength Start-up Normal Type No. Location Type No. Location No. Interval

Conveyor Belt
Thickness

Belt Tension Sway Switch Zero Speed Switch Pull Cord Switch

Page 2 of 2

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