4 a INTERPLANT STANDARD — STEEL INDUSTRY 0. Foreword 0.4 Interplant standardization activity in steel industry is bei wader the aegis Indian Standards Institution (1S!) and the Stee! Authority of India Limited (SAIL). This Interplant Standard prepared by the Standards Committee on Conveyors, IPSS 2:3, with the active partici~ pation of the representatives of the steel plants, established manufacturers of idlers and idler Sets and reputed consulting organizations, was adopted by the Approval Committee on Design parameters, IPSS 2, on 11 April 1985. eres 0.2 The Interplant Standard on design parameters for idlers and idler sets used in steel plants is intended to provide guidance to the steel plant engineors, consultants and manufacturers In th ign activity. 0.3 This standard is one in the series of standards in the area of conveyors. The other standards are: ') IPSS :2-03-001-81 Design parameters for galleries and tunnels for belt conveyors in steet plants, ii) IPSS : 2-03-002-84 General design features for junction houses for belt conveyors, lil) IPSS + 2-03-003-85 Design considerations for provision of safety in belt conveyor system, iv) IPSS : 2-03-005-84 Design considerations for lighting of junction houses, conveyor galleries and tunnels, ¥) Specification for rubber conveyor belting, general purpose (under preparation), vi) Design specifications for pulleys for belt conveyors in steel plants (under preparation ), and vii) Overall (design and fabrication) parameters for technological structures for belt conveyors (under preparation ). 0.4 Assistance has been derived from the following Indian Standards in the preparation of this Interplant Standard: 'S:2102-1969 Allowable deviations for dimensions without specified tolerances (first revision) < 1S 2102 (Part 1)-1980 General tolerances for dimensions and form and position: Part 1 General tolerances for linear and angular dimensions (second revision) 18 : 4240-1967 Glossary of conveyor terms and definitions 1S : 4776 Specification for troughed belt conveyors: 'S:4776 (Part 1)-1977 Troughed belt conveyors for surface installati 1S: 4776 (Part 2)-1977 Troughed belt conveyors for underground installation IS : 8597-1977 Specification for flat belt conveyors 1S: 8598-1977 Specification for idlers and idler sets for belt conveyors 1. Scope — This interplant Standard covers the design parameters of Idlers and idicr sets. It also provides a procedure for determination of toad rating of the idlers and idler bearings and other details, such as mounting arrangements and lubrication, Tesued_(1o be fled up By the aver deparkent Date of teeue a] Date of tesveSadion fotos given wiSeanastaors ener 2) idler —It 1s a bott supporting roller. ') Carrying (ter — is an idler upon which the load carrying portion.of belting is supported, © Kim'he edges ofthe el upwards fo arm the bat intcta mov usages 82 Tanond a fo 4) Flat Belt Idler —It is an idler consisting of onie or more rollers supporting the belt in a flat Fosition. ) Return Idler —It is the Idler supporting the return run of the belt. 1) Impact Idler — It is @ belt Idler having the rollers fitted with rings of resilient material to absorb the shock of loading material at the loading. point into the conveyor belt to prevent damage to belt and idlers. 9) Belt Training Idler —it is an idler which by means of a belt actuated swivel mechanism controls the side run-out of the belt within Jimitz and aligns the oelt properly. i, the following definitions shall apply, in Jb) -Guide tater — tt is a Zoller free to rotate and Is used to limit or guide the belt within the limits of a defined path of the belt conveyor. i) Troughing Angle —it is the angle of inclination of the axis of the side Idlers from the horl- zontal plane. k) Bulk Materials — Bulk materials includes various lumpy, granular and powdery materials like Fe, coal, coke, sand, etc. 3. Types of Idlers — The two basic types of belt conveyor idlers shall be (i) carrying idlers and (ii) return Tiers subdivided Into the following (see Fig. 1). a) Troughing Carrying Idlers — tt shall consist of three rolls of equal length and may be either in-line or off-set type (see also Fig. 12). cae Bee " b) Flat Carrying Idlers —The horizontal carrying idler for supporting flat loaded belt shall consist of one oF more horizontal rollers. a ©) Impact Idlers ( or Cushion Idlers) — The rollers shall be fitted with rings of resilient material to take care of the impact of the falling materials on the belt. Load rating of impact idlers shall not be higher than those of the standard idlers, Transition Idlers— Transition type troughing idler shall be used adjacent to the head and tail pulley and adjacent to plough on troughed belt for wide, high tension low stretch belts. This will prevent excessive stretch of the belt edges. The side idlers in each transition idler set shall preferably be of adjustabte type. However, the supplier shall indicate the recommended spacing of the transition ider set and angle of 1 of side idler in each transition idler ©) Training Idlers (or Aligning Idlers) — These idlers shall be used to trainjalign the belt both gn carrying ae well 8 on return sidq.to a central position in the event of conveyor belt geting dis This is achieved by mounting the perticular idler set on a central pivot. Small vertical guide rolls are attached zt either end of these idler set for limiting the transverse movement of the belt. Fixed vertical guide rollers at both sides of the conveyor belt may also be used in exceptional cases but this arrangement accelerates the belt wear and reduces the useful life of the belt. Proper selection of guide rollers and arrangement ‘of mounting of the training idlers shall be decided by supplier and details of the same shall be intimated to the purchaser. ) Return Idlers — These may consist of a single idler or a set of idlers. In caso of a set of idlers, the idlers are of equal length and are placed inclined to the horizontal to form a ‘V'. The arigle of inclination of the idler is kept at 10° to the horizontal in this case. The latter arrangement is applicable to belt conveyors with belts at least 800 mm wide. 9) Self Cleaning Return Idlers — These idlers are used to clean the belt carrying sticky materials, whose abrasive action wear the shell of the return idler roll. A large build up of the sticky materials may cause misalignment of the return run of the belt. Metal cage, rubber disc and helical rolls used for this purpose present very narrow surfaces for adhosion. g 4. Construction — The carrying and return idlers shall consist of cylindrical shells mounted in auch 2 way 23 to rotate about their longitudinal axis with diametrical run out not more than 0°8 mm. The idlers hall be properly designed for strength, rigidity and accuracy for the load and duty conditions to which these shall be subjected to end to keep the out of balance forces to a minimum value (see 10). 5 Ma ~The idler shall be manufactured from electric resistance welded (ERW) or seamioss steal tubes conforming to 1S: 9295-1983 ‘Specification for steel tubes for idlers for troughed belt conveyors (first revision).. iY IPSS : 2.03-006-85 Y . |S. The rubber used for the impact idlers shall have a Shore A hardness of 65-70 and tensile strength of 100 to 125 kgf/mm. 6. Dimensions 6.1 External Diameter of Idler — The external diameter ‘ch’ in mm of carrying and return idlers shalt ‘be selected from the following read with Fig. 2, 5 and 6: 101°6, 108, 114°3, (120), 127, 133 139°7, 152-4, 159, (1651), (168-3), (193.7) ‘Note — Bracketed values ate non-preterted. | 6.2 Lengths of Carrying Idlers—Lenath of individual carrying idlers for (2) troughing and (b) flat Idlers shall be selected from Table 1 read with Fig. 2,3 and 4. ‘TABLE 1 LENGTHS OF CARRYING IDLERS All dimensions In atimetres. Bett width, © Length J, of Camying Idler For Troughed Belt Conveyor, Having "Thtee Idlers of Equal Length 500 200 00 60 250 750 wo 318 950 fe. 1.000 300 1180 1200 s 1400 |; 1490 530 1600 1600 0 1600 Note —Length “' of Idler ather than those indicated in Table 2 may be used in case of existing belt conveyor, mutually epteed upon between the purchaser and tho supplier. 6.3 Length of Return Idiers —The lengths of the return idlers single and in a set of two shall be selected from Table 2 read with Fig. 5 and 8. ‘TABLE 2 LENGTHS OF RETURN IDLERS All dimensions in millimet Belt Width, 6 One tae 500 00 - 650 750 = m0 950 46s 1060 1150 0 1200 1400 100 1400 1600 00 160 1600 00 6.4 Impact Idlers — These shall consist of impact rings of elastic material mounted on steel tube. The main dimensions of the impact rings for carrying idlers shall be taken from Table 3 read with Fig. 10. The outer ring diameter D, in case of impact troughing idlers shall be kept same as the ‘external diameter d; shown in Fig. 2 and 8. Dimension Di of the impact ring shail be so chosen that they cen be securely mounted on the tube."