JD-101E Belt Conveyer

TOKYO L JAPANTOYO ENGINEERING CORP.

STANDARD ENGINEERING SPECIFICATION

BELT CONVEYORS FOR BULK MATERIALS

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ISSUED JUL.15,99 PAGE 1 OF 9

FORM A-G30.002 (9303)

NOTE: THIS SPECIFICATION IS VALID FOR ANY SPECIFIC PROJECT ONLY WHENMODIFIED TO COMPLY WITH SPECIFIC JOB REQUIREMENTS ANDACCOMPANIED BY A COVER SHEET, IF ANY. PARAGRAPHS INDICATEDBY MARK (*) ARE SPECIFIC JOB REQUIREMENTS.

C O N T E N T S

PAGE1. GENERAL

1.1 Scope 2

1.2 Codes and Standards 2

1.3 Related Engineering Specifications 2

2. BASIC DESIGN

2.1 General 2

2.2 Steel Structural Parts 3

2.3 Mechanical Parts 5

2.4 Safety Devices 8

2.5 Safety Guards and Safety Cover 9

3. Painting 9

4. Supply Conditions 9

5. Inspection and Test 9

Appendix 1 General Data Sheet of Belt Conveyor




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FORM A-G30.002 (9303)

1. GENERAL

1.1 Scope

This specification covers the general requirements for the design, fabrication, inspection, test and supply of beltconveyors 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 listedhereunder.

(1) Conveyors for packaged materials, such as bags, boxes, cartons etc.

(2) Portable Belt Conveyors

(3) Belt Feeders and Belt Weighers

(4) Belt Conveyors supplied as a part of equipment

(5) Special Belt Conveyors

(6) Structural part of Truss Type ConveyorIf conveyor s of truss construction is specified, this specification shall only cover the mechanical designother 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 followingstandards,

ISO 5048JIS 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. BASIC DESIGN

2.1 General

(1) Unless otherwise specified, calculation of belt width, required power and tensile strength shall generallybe 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 tensileforces.

(2) Unless otherwise specified in the data sheet, the belt speed shall be designed based on manufacturersstandard design practice, but not faster than ;




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FORM A-G30.002 (9303)

u 90 m/min. for the conveyor in the process unitu 150 m/min. for the conveyors in the warehouse and storage facilities of fertilizer and fine material

handling facilities.u m/min. for the conveyors in the coal yard or other coarse material handling facilities

(3) Conveyors shall be designed to start under full-loaded condition with designed capacity.

(4) Appendix 1 General Data Sheet of Belt Conveyor shall be filled up and submitted with quotation.

2.2 Steel Structural Parts

2.2.1 Girder

(1) Conveyor girders shall be designed taking the following load factors into consideration, i.e. the weight ofthe conveyor, conveyed material, wind load, snow load seismic load, tensile strength of the belt etc.

(2) Deflection of girder shall be within 1/500 of the supporting span.

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 whenrequired.

(2) Plate thickness of chutes shall be minimum 4.5 mm for carbon steel and 3.0 mm for stainless steel.

(3) Chutes shall be big enough so that the material scraped off by the belt cleaner can be received.

(4) Chutes shall be provided with inspection and maintenance door(s), which shall be big enough formaintenance and cleaning. If it is practically difficult to access to whole parts of chutes, adequatenumbers of doors shall be provided. Doors shall be of dust tight type and no pocket construction toprevent dust spillage at door open.

(5) Chutes shall be equipped with rubber curtain to reduce the impact force or breakage of product, ifspecified in the data sheet.

(6) Connecting chutes at the transfer point from conveyor to conveyor shall be arranged to minimize the dropheight and to transfer feed conveyed materials onto the center of the belt.

(7) Feed chutes shall be so designed that the direction of feed shall be lined to the running direction ofreceiving conveyor. If conveying direction is changed, an adjustable flap shall be equipped in the chuteto adjust the feed position of conveying material to centralize the feed point or to prevent belt from sway.

(8) Connecting chutes shall be so designed that they shall be declined and centrally directed to the runningdirection of the receiving conveyor to reduce the impact of dropping materials and to prevent build-up ofmaterials in the chute.

(9) Chutes shall be so steep that materials shall flow smoothly. Minimum angle of bottom plate fromhorizontal shall be 45 degrees unless otherwise specified in the data sheet especially for sticky materials.




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FORM A-G30.002 (9303)

2.2.3 Skirt

(1) Skirt of rigid steel plate construction shall be provided at the feed point to prevent spilling of conveyedmaterial.

(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 rubberu 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 ofconveyors.

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 apart of conveyors. Design requirement for walkways in conveyor gallery or conveyors of truss construction arespecified separately.

(1) Walkway shall be installed to the conveyor, when the height from the floor to the carrying side belt ishigher 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 1200 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 shallgenerally be 1 070 mm.

(7) Over bridges (pedestrian cross walks) shall be installed to permit access for maintenance, at intervals of notexceeding 100 m.

(8) There shall generally be a minimum clearance of 2 000 mm measured vertically from the floor or walkingsurface 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 willcover 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 isgradually increased to prevent coarse materials from oversucking.




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FORM A-G30.002 (9303)

2.2.6 Conveyor Cover

(1) Conveyors shall be equipped with conveyor cover if specified in data sheet.

(2) 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 Mechanical Parts

2.3.1 Drivers

(1) Drivers shall be normally provided at the head part for inclined conveyor and the tail part for declinedconveyor. If normal driving position is unreasonable because of accessibility, maintainability, vibrationetc., drivers may be installed at other location. But calculation of belt tension shall be carefully checked.

(2) Single drives system shall be applied normally when motor is LV motor. Tandem drive may be appliedwhen HV or MV motor is required. But calculation of belt tension shall be carefully checked.

(3) Rated power shall be decided under the following conditions.

(4) Conveyors shall be started under full-loaded condition at the design capacity.

(5) The following allowance shall be covered.

u Motors of 15 kW and under margin more than 15 % of BHP (Brake Horse Power)u Motors of 15 kW or over margin more than 10 % of BHP

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

u Motors of 45 kW and under Gear reducer and chain/sprocket system is acceptable.u Motors over 45 kW Direct coupling with gear reducer and driving pulley shall be

applied. Coupling shall be of non-lubricated or non- greasetype.

(7) Motors of 90 kW and over shall be equipped with fluid coupling. Fluid coupling shall be selected tocontrol the starting time of conveyors.

(8) Conveyors with concave arrangement shall be smoothly started up without jumping of belt from carrierrollers under any load conditions. Soft start function may be considered.

(9) Conveyors with backward torque under stop condition shall be equipped with holdback (backstop) deviceat drive pulley.

(10) Stop time of conveyors longer than 10 seconds and downward conveyors shall be equipped with brake atdrive shaft. Stop time shall be adjustable. Brake shall be of fail-safe design.

(11) Calculated life of bearings of gear reducer shall be longer than 30 000 hours for intermittent service and50 000 hours for continuous service based on ISO equation.




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FORM A-G30.002 (9303)

2.3.2 Take-ups

(1) The type of take-up shall be normally decided based on the conveyor length as shown on the followingtable.

Conveyor Length (m) Type

30 and under Screw take-up type

30 over Gravity take-up type

(2) Gravity take-up shall be provided as near as possible to drive pulley. If gravity take-up is installed at themiddle or non-drive end of conveyors, the take-up stroke shall be designed carefully taking elongation ofbelt into consideration, especially return side as well as the distribution of tensile strength.

(3) The stroke of take-up weight shall be decided based on the length of the following lengthu Permanent elongation specified by belt supplieru Periodical elongation at start-up period on full loaded conditionu mm allowance both above highest and below lowest position

(4) 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.

(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.

(6) 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.

(7) Take-up carriage and weight shall move smoothly. Guide wheels shall be equipped on take-up weight.

2.3.3 Idlers

(1) In case of carrying bulk material, idlers shall be generally of 3-roller 30-troughed type.

(2) 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 tiltedcarrying idlers shall be provided.

u For Return Idler

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

(3) Idlers shall be equipped with grease-filled ball bearings.

(4) Seal of the idler bearings shall be of dust proof type.

(5) Idlers shall be properly lagged with rubber, PVC etc. for corrosive material application, if specified in data sheet.




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FORM A-G30.002 (9303)

2.3.4 Pulleys

(1) Pulleys shall generally be of welded construction.

(2) Drive pulleys shall generally be crown types with double helical grooved rubber lining.

(3) Tail pulleys shall be designed to prevent material from sticking on the surface. Cage type may be selected unless otherwise specified.

(4) 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.

(5) Seal of pulley bearings shall be of dust proof type.

(6) Drive pulleys shall be equipped with snub pulleys to get enough wrap angles.

(7) Pulleys shall be strong enough taking starting torque into consideration.

(8) 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.

(9) The diameter of pulleys shall be sized with minimum 20 % larger than the minimum diameter specifiedby belt manufacturers based on the material and construction of belt.

(10) The position of head, tail and drive pulleys shall be adjustable both horizontally and vertically foradjustment of belt swaying at job site.

2.3.5 Impact Roller

(1) Impact rollers shall be equipped at the feed points.

(2) Interval of impact rollers shall be less than 1.5 times of idler diameter. Impact idlers shall be equipped forthe length of [length of loading chute] plus belt width.

(3) Deck plate shall be provided at loading points beneath the impact rollers to prevent spilled material fromaccumulating on the return belt, if specified in data sheet.

2.3.6 Lubrication

(1) When lubrication points are inaccessible or are in hazardous locations, fittings (grease nipples) and thelubricant pipes shall be located at accessible point.

(2) Return idlers, especially equipped below walkway, shall be lubricated from walkway.

(3) Lubrication shall be enable from one side especially when greased type idlers are applied.

2.3.7 Belts

(1) Construction and material of belts shall be selected according to the characteristic of the handledmaterials (such as temperature, water content and property) and the construction of belt conveyor.

(2) The carcasses of belts shall be minimum 2 plies. Mono ply belt is only acceptable under special designrequirement in data sheet or Contractor acceptance.




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FORM A-G30.002 (9303)

(3) Splicing of the belt shall be vulcanized or adhered.

(4) Width of belts shall be selected in the following table unless otherwise specified.

Standard belt width (mm)400 500 (600) 650(750) 800 (900) 10001200 1400 1600 18002000 2200 2400 2600

But 500 mm shall be normally the minimum width. Belt width in blanket ( ) can be used subject toContractors approval.

(5) Safety factor of tensile strength against the maximum tension, which may be at start-up period, shall beas follows.

Construction of Belt Safety Factor

Fabric-reinforced Belt Minimum 10

Steel-cable Belt Minimum 10

(6) The top rubber of carrying side shall have a thickness of minimum 3.0 mm and bottom side shall haveminimum 1.5 mm.

(7) Splicing material (glue) shall be separately shipped from mechanical parts taking effective period of glueinto consideration.

2.3.8 Belt Cleaners

(1) Belt cleaners shall be equipped both at head pulley (in discharge chute) and at tail (near to tail pulley).

(2) 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.

(3) Belt cleaner at tail part shall be of V- type and clean up remaining material on the reverse side. Scrapedmaterial shall be discharged to both sides of conveyor.

2.4 Safety Devices

(1) Slip Detector (Zero Speed Switch) shall be equipped. If actuating slip detector, conveyors shall stop.

(2) Sway Detector of 2-stage type shall be equipped at each 100 m interval. Actuating at 1st stage shallmake alarm and 2nd stage shall make emergency stop of conveyors. Actuating position shall be ofadjustable.

u 1st StageAlarmu 2nd stageEmergency Stop

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




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FORM A-G30.002 (9303)

(4) The contact of emergency switch shall be directly connected to MCC, not via control logic, i.e. PLC onthe safety point of view.

(5) An audible or visual warning device for conveyor starting, in case of remotely and automaticallycontrolled conveyors system.

2.5 Safety Guards and Safety Cover

(1) The moving and rotating parts shall be provided with safety guard or safety cover.

(2) 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 General DesignBasis for Package Unit unless otherwise specified.

4. Supply Conditions

(1) Belt conveyors shall be reasonably pre-assembled to minimize installation work at job site. Detailedassembly plan shall be decided at detailed engineering stage.

(2) Mechanical parts and electrical parts or devices shall be packed according to the following procedure.

w Motor and driving parts sealed by plastic sheet and boxedw Pulleys and rollers sealed by plastic sheet and boxedw Other mechanical parts sealed by plastic sheet and boxedw Local Panel sealed by plastic sheet and boxed

Detailed packing and shipping procedure shall conform to separate engineering specification for Packingand Shipping.

(3) Belts shall be shipped as rolled form and deformation shall be prohibited. Detailed procedure given bybelt 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 isattached to the requisition, and manufacturers standard approved by TEC.

Appendix 1 General Data Sheet of Belt Conveyor Page 1 of 2

Material Handled

CodeNameSizeBulk DensityTemperatureAngle of ReposeOther Properties

Serv

ice

Norm

al

Desi

gn

Carr

ier

Retu

rn

Length

Heig

ht

Requir

ed

Inst

alle

d

Dri

ve

Dri

ven

Model

Manufa

cture

Red

uct

ion

Reti

o

Model

Manufa

cture

Model

Manufa

cture

Loca

tion

Type

Model

Manufa

cture

Loca

tion

Type

Loca

tion

Weig

ht

Str

oke

Shape

Dia

mete

r

Linin

g

Shaft

Beari

ng

Fric

tion

Fact

or

Wra

p A

ngle

Shape

Dia

mete

r

Linin

g

Shaft

Beari

ng

Code T/H mm m m m/min. kw kw No. of Teeth kg m mm mm mm mm

JD-101 1 100 120 9003 x 301 xFlat

100 20 120 66 75 1 1500- - MH Sumitomo

Drive Pulley

A B C D

Back StopFluid

CouplingIdlers

Formation

Item

No.

No.

Req

'd

Bel

t Wid

th

Capacity

Mat

eria

l Han

dled

Dimension Power Driving MechanismSprocket

Bel

t Sp

eed

No. of

Moto

rs

Moto

r Lo

tati

on

Gear Reducer Brake Take-up Snub Pulley

Appendix 1 General Data Sheet of Belt Conveyor Page 2 of 2

Serv

ice

JD-101 1

Item

No.

No.

Req

'd

Shape

Dia

mete

r

Linin

g

Shaft

Beari

ng

Shape

Dia

mete

r

Linin

g

Shaft

Beari

ng

Shape

Dia

mete

r

Linin

g

Shaft

Beari

ng

Dia

mete

r

Sets

Beari

ng

Dia

mete

r

Sets

Beari

ng

Type

Inte

rval

No.

Rubber

Carc

ass

Plie

s

Top

Reve

rse

Sta

rt-u

p

Norm

al

Type

No.

Loca

tion

Type

No.

Loca

tion

No.

Inte

rval

mm mm mm mm mm mm mm mm mm mm kg/cm kg/cm

Head Pulley Tail Pulley Carrier Idler

Type

MaterialReturn Idlers Trailing Idlers Belt Tension

Thickness

Conveyor BeltTake-up Pulley Sway Switch Zero Speed Switch

Pull CordSwitch

Str

ength

2: 151:

JD-101E Belt Conveyer

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