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."‘TABLE 3 ‘DIMENSIONS OF IMPACT RING (cause 6) Al divans {tn mtiimatres, a ” oss, 1 32 103 133 De 018, 1143, (120), 127, 183, 130°7 1397, 152-4, es) (937) 08 Ta see 438, (651) (1683) t 1937) = ” 3s o 6 & 0758 Note 1—Dlsmator 0, shall be #0 chosen that the Impact rlag can be socurely fixed on the idler, ‘Note 2— Dimensions 8, and & and profile shown in Fig. 10 are Indicative only, ‘Hote 3—Bractated values are non-proferved, oye ‘85 ‘Cleaning Dise on Return idler —The cleaning disc on return idlers shall be mounted in those ‘eas08 where the material being carrled on the belt conveyor is sticky in nature. The main dimensions of these diec which shall be made of elastic material will be taken from Table 4 read with Fig. 11. ‘The outer cing diameter D, in cage af self cleaning return iar shall be kept same 28 the external diameter D; in Fig. 5 and 8 Diameter D,_of the impact ring shall be so chosen that they can ~be-tecurely mounted on the tube, : ‘TABLE 4 DIMENSIONS OF CLEANING DISCS ON RETURN IDLERS { ; Oe st ass 784 af 1143 133 Px mem meg, RS Rome = = > * ° = ° rs Note t— Dimensions B, and 8, and profile showa In Fig Note 2—Bracketed values are non-preferred, 11 are indicative only. €8 Spindle Ends — Spindle ends of idlers shall be selected from Table 5 for new installations. Bawover, in case of modification of existing conveyor, spindle ends with end cap may also be used aad Tablo 6 shall be used in such a case. ‘TABLE 5 DIMENSIONS OF SPINDLE END (WITHOUT ADDED END CAP) OF IDLERS, TYPE A READ WITH FIG. 6 All dimensions in malin | 4 4 a = a 20 ey “ ‘ * : 2 2 ‘ 2 Fy » 4 ry 3s 2 s 8 ‘ 2 Note —For return Idlers n +10 ix perminsible,. i \9S IPSS : 2.03.006.85, TABLE 6 DIMENSIONS OF SPINDLE END WITH ADDED END CAP FOR IDLER TYPE @ READ WITH FIO. 7 (Chasse 66) Ail dimensions tn milimetres. a a a m ° 3 2» » 4 10 “6 125, (90) x 4 2 Wote #—For return idler n+ 10 is permis Note 2— The values of dimensions b;. m and n may be taken diferent from the ones Indicated in Tables 5 and 6 t existing conveyor, if mutually agreed between the purchaser and the supplier. Dimension dy i Tabies S ‘ndteative oniy. Note 3—Bracketed value is nan-preferved | 7, Mounting of Idler Sets —Carrying and return idlers shall be mounted in conformity with imensions and arrangement shown in Table 7 and Fig. 8. rere ae Eee eee Cee ‘TABLE 7 MOUNTING OF IDLER SET All dimensions in millimetres. et Width, D 4 e > 500 m0 100 ns maz 650 200. 0 us M16 ‘300 1000 1000 118 M16 +000 1240 1290 15 M16 1200 1450 1500 18 M16 +400 1650 +700 nS M6 1 600 1900 1950 Hs M20 Note — i vegiteg, he values of, “and fay be anulacturet, ae CEE eee ee eee 7.4 The vertical clearance between the top of the retum idlers and bottom of the cross member of the conveyor stringer shall not be less than 75 mm. . ered subject to agreement belween the purchaser and the 2.2 Troughed carrying idler in-line shail be mounted with the height of belt line ‘h’ and clearance ‘m’ as given in Table 8, 1.3 Troughing Angle —The values cf the angle of inclination (A) shall be 20° or 30° or 35° (see Fig. 9). Tolerances on 2 shall be according to Table 2 of IS: 2102-1962. 1.4 Angle of Tilt (+) of Side Idlers — The angle of tilt of side Idlers shall be as small as possible commensurate with the application, and shall not be more than 3° in any case ( see Fig, 9). No side tilt shall be given in impact idiers. Note 4 The angle of tit of side ivlers snail be inthe dection o Ithe belt ‘un for the unditectionst conveyors ang it shall be 0° for reversible conveyors Note 2— Nt is not obligatory te provid+ angle of tilt uness sprcifcally desired by the purchaser, Angle of tilt fon the side idlers may be eliminates by using training idlers or gurde Colle. 17.8 Arrangement of In-Line and Staggered Carrying Idler Sets 7.8.1 Troughing carrying idler sets built up from three idlers may be arranged with the idlers in line or staggered in the plan view as shows in Fig. 12. 7.5.1.1 When staggered the displacement of the axis of the contre idler from the adjacent axis of the side idlers shall not exceed the diameter of the idiers.} * sgpe of service, operating condition, | cess tappredaniapingttidtos acts shall bo arrangdttwithradjacent-onto-of tietside:t entre idlers overlapping by a minimum of 10 mm when measured as indicated inig. 13. 37.5.3 Tho gap botwoen the adjacent ends of the centre and side idler of an in-line 3 idler sebahall : ‘ot be greater than 10 mm when measured as indicated in Fig. 13. Mote — tt may be necassary in certain cases to_adopt, minor modifications in design auch a8 rounding or cham= fetiog of spinaie ends orto reduce dimension a" (Roter Fig. 6 and'?). The valvo of "0" shall not be less than 4m iany casa, 8. Idler Bearings — The minimum rated life for the idler bearing shall be 30.000 hours. ‘The bearings shall be provided according to the recommendations of the reputed bearing manu- facturers for the specific load capacity and application of the bearing. set shall be considered For the purpose of bearing selection, two-thirds of the unit load per idl d ‘as acting vertically upon the middle idler of a 3-idier set. Due regard shall be given to any ax: foad which may be imposed. Only ball or roller bearings shall be provided. 2. Bearing Lubrication —Bearings lubricated for life together with appropriate sealing shall be provided, to prevent ingress of dust and other extraneous matt. 10. Eccontricity of Idlers — For belt conveyors the diametral run out (eccentricity) of idler shall not exceed 0° mm at any point along the shell (roll) of the idler. 11, Design/Selection of Idlers — The design of the belt conveyors starts with the finalization of basic parameters like capacity of the conveyor, belt width, belt speed, troughing angle of the idlers and service conditions. These parameters are made use of in selection of idler and idlers set. 14.1 Selection of proper idlers plays an important role in satisfactory performance of the belt conveyor. The selection of the proper roller diameter size of bearing and roller shaft is based on load carried and the belt speed. 41.2 The severity of the operating conditions under which the idlers are to be used greatly influences the selection of idlers. The operating conditions include the hours of ope per day, the overall life expectancy of the conveyor system and the environment in which the idler is to operate. 31.3 The characteristics of the material to be handled have a direct bearing on the idler selection. ‘The weight of the material governs the idler load and spacing, and lump size modifies the effect of any avial load which may be imposed. Bearing selected on th above basis for central idler of 3 idler set may be equally applied to side idlers having due regard to axial load imposed. lm 3 (Wm+Wb) x Si Load on idier wher "I = Load on central idler roller in N Wm = Weight of material in N/M Wb = Weight of bolt in N/M ‘Si = Idler pitch in metres [to be selected from IS : 4776 ( Parts 1 and 2)-1977) ‘The load on each bearing of the central idler roller shall be F2<1/2 (FI+WR) in N, where WR-sWeight of the rotating parts of the idler roller (Refer ‘Table 19 for tentative value). Actual weight is to be taken from supplier's catalogue, = TABLE 49 TENTATIVE WEIGHT OF ROTATING PARTS OF EACH ROLLER (ACTUAL WEIGHT SHALL BE FURNISHED BY SUPPLIER) (Clause 128.1) ee eee ee eee ee St Bolt Width External Diameter Weight of Rotating Parts In Newtor = a . roughed Idler 3 Roll Troughed Ialor9 Roll Flat Ke Satcwoighuiot) ‘Sot Welghtfaeny ’ 500 10s 2 0 7 103 = 33 0 sro “ ° 8 2 «0 ors 2 “4 4 143 6 3 110 ° © tot 2 800 163 76 a 481 wre " 103 162 is07 6 its we 1824 1 ‘8 194 ‘ 1000 163 a so 1a 1210 102 108 192 1997 14 18 tor 524 12 ‘20 a2 5 1200 143 6 100 213 were 123 128 29 sa07 132 137 ae se ut ur 266 ‘ 1400 307 10 160 380 ase 159 06 as 7 1600 ast 158 138 me 1826 10 216 Msa PALI Ze IPSS : 2-03-004-85 ‘The equivalent load on each bearing of the idler is gi Feq =F, x KainN where Ka is the application factor for the idlers and is given by Yam Ky x Ky X Ky X Ki are to be selected from Tables 9 to 12. 43.4.2 Flat carrying idlers — Load on roller(s) shall be taken as -qual to Si x (Wm-+Wb) in this ‘case. Other calculations shall be same as in 13.1.1. 43.1.8 Return idlers — In this case only Wb shall be taken as acting uniformly on the return idler. Hence F/ = Wb x Si for single return idler = 4 (Wo x Si) for each of two return idlers in a set. Other cafculations shall be same as in 13.1.1. 13.2 The C/P ratio (that is the ratio of basic dynamic load rating for bearing and equival ‘on each bearing of the idler rol facturer's catalogue shall be sui in this regard: force } required for selection of bearing according to bearing manu- bly calculated. However the following formula may also,bewused where C= Basic dynamic load rating for bearing, N P — Feq = Environment force on each bearing of the idfer, roller, in N (for Feg refer 13.1.4) LH = Required bearing lite=30 000 hours vx 60 n= RPM of roller = L*% where V = Belt speed, m/s D-= Roller diameter, m > ae Basic dynamic load rating ‘C’ can be worked out as under c C= req x & nation — An idler shall be designated by its external diameter, length, type and size of Example — An idler of external diameter 133 mm having a length of 1150mm and spindle end of type A of d, ~ 20 mm shall be designated as: der 133 x 1 150A x 20seeks was 203-0065, fo + FIG.) TYPES OF CONVEYOR IDLERS ANYESYKA (WES FIG.1A PLAIN TROUGHING IDLERS FIG.1E ADJUSTABLE TRANSITION IDLERS = FIG. 1F PLAIN RETURN IOLERS aa FIG, 1B TRAINING TROUGHING IDLERS &, 1? FIG.1G SELF CLEANING RUBBER DISC RETURN IDLERS FIG.1C IMPACT TROUGHING IDLERS 1H TRAINING RETURN IDLERS FIG, 10 SELF CLEANING HELICAL RETURN 1OLERS. FIG. 14. VEE RETURN LOLERScat IPSS : 2-03-0045 FIG, 2 TROUGHED CARRYING IDLERS FIG, 2 FLAT CARRYING IDLERS FIG, 4 TROUGHED CARRYING IDLERS (OFF-SET) FIG. & TWO IDLERS IN “V" FORM,. y a ¢ FIG, 6 SPINDLE END WITHOUT ENO CAP, TYPE A, Ons FIG, 7 SPINDLE END WITH ADDED. END CAP, TYPE B FIG. @ MOUNTING OF IOLER SETswe WLER FIG, 9 ANGLE OF INCLINATIONS AND TILT FOR SIDE IDLERS FIG, 10 IMPACT RINGS FOR CARRYING IDLERS FIG. 14 a DISC FOR RETURN IDLERS.bres FZUS-E8> TiS OMENSION SHALL NOT JEXCEED THE IDLER DIAMETER FIG, 12 PLAN VIEWS OF IN-LINE AND STAGGERED CARRYING IOLER SETS INTERSECTION OF BELT . INTERSECTION OF BELT SIDE IOLER INLINE IDLERS. STAGGERED IDLERS FIG, 18 ARRANGEMENT OF IOLER SETS VIEWED IN VERTICAL PLANE Gulab Printgre, how Delhi, In Inte