BALDOR•DODGE

Recommended

GLOBAL CONVEYOR PULLEY SPECIFICATION

CLASS I
A. INTENT
A.1 This specification covers conveyor pulley assemblies used in high tension, steel
belt applications where the belt rating exceeds 438 kN/m (2500 PIW). These
pulley assemblies can also be used in strategic applications using lower PIW
rating belts. Conveyor pulleys provided to these specifications shall have a
proven record of reliability and long life.

B. GENERAL
B.1 All conveyor pulleys shall be of Engineered Class, heavy duty and of welded
steel construction. Internal stiffeners shall not be used. They shall be designed
for starting and occasional peak loads 1.5 times the design running loads. They
shall be of a “T” section design.

B.2 All equipment shall comply with the requirements of this specification along with
the engineering practices set forth in Belt Conveyors for Bulk Materials latest
edition, prepared by the Conveyor Equipment Manufacturers Association
(CEMA).

B.3 Appropriate loading information including belt tensions, wrap angles, bearing
centers, and overhung loads shall be provided for design of all pulleys. It is
recommended that the belt tensions be calculated based upon motor
horsepower. All pulleys shall include a two year warranty.

DESIGN LEVELS
B.4 Stresses exceeding yield are not permissible. The maximum Von Mise’s stress
shall not exceed 70 percent of yield.

B.5 The allowable stress range in parent material shall not exceed that defined by
the Modified Goodman Diagram where the endurance strength shall not exceed
40 percent of yield (20 percent for shear).

B.6 The allowable stress range in weld material shall not exceed that defined by
British Standard BS5400 Part 10 (Code of practice for fatigue.) Design life shall
be based on 5 years operation at two sigma reliability.

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C RIM
C.1 The rims shall be straight.

C.2 Face width shall be equal to belt width plus 305 mm (12 in.), unless otherwise
specified.

C.3 Rims shall be produced from steel with minimum yield strength of 207 N/mm^2
(30,000 psi) and a maximum carbon content of 0.26% [ASTM A36 or ISO 630
(Fe 360)]. Steel plate for rims shall be certified that material is lamination free
per ASTM A435 with 100% search.

C.4 The joint preparation for disc to rim butt weld shall be fully machined, including
the rim inner diameter.

C.5 Pulley rims shall be machine turned. Concentricity about shaft centerline after
machining shall be such that total indicator runout (TIR) shall not exceed 0.381
mm (0.015 in.).

D END DISCS
D.1 All pulleys are to be “T” section end discs.

D.2 Discs shall be produced from solid steel with minimum yield strength of 207
N/mm^2 (30,000 psi) and a maximum carbon content of 0.26%. [ASTM A36 or
ISO 630 (Fe 360)] Steel plate for rims shall be certified that material is
lamination free per ASTM A435 with 100% search.

D.3 End disc shall be designed in such a manner as to prevent dirt and water from
entering the interior of the pulley.

D.4 The exposed surfaces of both end discs shall be adequately prepared and
painted with a high-solids, corrosion-resistant paint.

D.5 Dust shields shall be fitted to pulley end discs to protect locking devices from
dust and moisture.

E SHAFTING
E.1 Shafts shall be produced from steel with minimum yield strength of 427 N/mm^2
(62,000 psi) and a minimum carbon content of 0.38% [AISI C4140 or DIN
42CrMo4]. Shafting material shall be hot rolled or forged steel, manufactured to
standard commercial tolerances for diameter and straightness. No surface heat
treatment is allowed.

E.2 Shafting shall be fully machined. In the area of the locking assemblies and
bearing journals the diameter, tolerance and shaft finish shall be as
recommended by the respective manufacturer. Wherever a shaft is reduced in

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 diameter, a minimum fillet radius of the difference in diameters or 25% of the
smaller diameter (whichever is greater) shall be used. Stress concentrations
resulting from the step-down shall be included in the stress calculations.

E.3 Shafts shall be ultrasonically tested before machining and dye penetrant
inspected after machining.

E.4 All pulley shafts shall be of one piece design. Drive shafts shall be furnished
with keyseats and keys to match the drive components if required.

E.5 Shaft stresses shall be calculated per ASME B17C with design factors Kb = 1.5
(Kb = 2.5 for overhung loads) and Kt = 1.0.
Shaft stresses shall not exceed the following:
Combined bending and torsional stress at hub 69 N/mm^2 (10,000 psi)
Combined bending and torsional stress at turndowns 92 N/mm^2 (13,300 psi)

E.6 Shaft deflection at the shaft to hub connection shall not exceed 0.0010 mm/mm
(in./in.) at full design running belt tensions. Pulley rigidity shall not be included in
deflection calculations. Shaft deflection at the bearings shall not exceed the
bearing manufacturer’s recommendations for all load conditions.

E.7 All exposed areas of the shaft shall be coated with a thick coating of non-water
soluble rust inhibitor.

F LOCKING ASSEMBLIES
F.1 B-Loc, Ringfeder or approved equal locking assemblies shall be used to secure
the pulley shaft to the end disc. Equal size units shall be used for both sides.
Only a single locking assembly per hub is permissible.

F.2 The locking assemblies shall be sized to transmit the motor breakdown torque.

F.3 When a single drive, brake or holdback is used, the locking assembly closest to
the drive shall be capable of transmitting the maximum torque requirement.

F.4 For pulleys having a drive on each end of the shaft, each locking assembly shall
be capable of transmitting torque of the drive closest to it.

F.5 The locking device shall be sized such that the transmitted rotating bending
moment does not exceed 35 percent of the torsional capacity or the maximum
permissible bending moment specified by the locking device manufacturer,
whichever is the most stringent.

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G WELDING
G.1 All welds shall be of the submerged arc process. All welds shall be full
penetration butt welds in accordance with Section Nine of AWS D1.1. Weld
backing plates are not permitted.

G.2 All welding shall be performed by operators qualified per AWS D1.1, latest
edition. All qualifications shall be current.

G.3 All welds are to be 100% ultrasonically inspected and magnetic particle
inspected over their entire length in accordance with AWS D1.1, Section Six.
Acceptance criteria shall be per AWS D1.1, Section Nine.

G.4 The manufacturer shall submit certification of all testing results, upon request.

G.5 Pulleys shall be thermally stress relieved after welding but before machining.

G.6 All circumferential welds, including internal surface welds, shall be finished
smooth.

G.7 Weld filler materials shall be low hydrogen and shall be used with material
control.

H LAGGING
H.1 All pulleys shall have lagging hot vulcanized to the pulley face.

H.2 Lagging for drive and other high tension pulleys shall be a minimum of 25 mm (1
in.) thick and 60 durometer Shore A with a diamond grooving pattern. Lagging
for all other pulleys shall be a minimum of 13 mm (0.5 in.) thick and 60
durometer Shore A. Lagging shall be Dodge D-Lag for high abrasion resistance
or neoprene rubber for underground applications and fire and oil resistance.

H.3 When specified, REMA adhesive bonded lagging material may be used.

H.4 Lagging shall be machined with pulley mounted on the final shaft such that
concentricity about shaft centerline is a maximum of 0.762 mm (0.030 in.) TIR.
When specified, for pulleys used on multiple drive systems, the finished outside
diameter shall be matched within a tolerance of +/-0.381 mm (0.015 in.). When
specified, drive pulley diameters shall be adjusted for mechanical load sharing.

H.5 Pulley direction of rotation shall be clearly marked.

H.6 Lagging shall be fitted with a heavy duty protective cover before shipment.

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J BALANCE
J.1 All pulleys shall be statically balanced in accordance with ISO Standard 1940/1-
1986 (Grade G40).

J.2 If balance weights are required, there shall be only one weight per end disc.
Weights shall be securely welded and shall not project beyond the face of the
pulley.

K ASSEMBLY
K.1 Pulley vendor shall assemble the shaft and applicable bearings, backstops and
low speed couplings. Keys for all keyseats shall be securely taped to the shaft,
when required.

K.2 Metallic identification tags shall be permanently attached to the pulley end disc.
Tags shall include the name of the manufacturer, date of manufacture and a
discrete identification number. The end of the shaft shall also include the
discrete identification number.

K.3 All exposed, machined areas of the assembly shall be coated with a thick
coating of waterproof rust inhibitor. Pulley assembly shall be mounted on a skid
to prevent damage during transport and to facilitate handling.

L DESIGN INFORMATION
L.1 Before construction, the manufacturer shall furnish a shaft and assembly
approval drawing. This drawing shall indicate all machining and assembly
dimensions. After the approval process is completed, a revised, certified,
reproducible copy of the drawing shall also be furnished.

L.2 Upon request, the following information shall be provided with the certified shaft
drawings:
a. Minimum rim thickness after turning
b. End disc thickness
c. Locking Assembly type and size
d. Locking Assembly bolt torque
e. Calculated shaft deflection
f. Maximum running load
g. Maximum starting load