V1.1.

Belt Conveyor System

V1.1.1. General
V1.1.1.1. The scope of work of the Contractor shall include design, engineering, manufacture,
fabrication, assembly, testing and inspection, packing, dispatch, transportation, transit
insurance, delivery for Purchaser’s site, unloading, handling and storage at site,
insurance during storage, erection supervision, testing, inspection, commissioning,
Warranty testing and handing over to the client including all electrics and standard
accessories of the following components for all the conveyors indicated in the enclosed
drawings.
1. Motors
2. Gear boxes
3. Couplings/Magnetic Coupling for High Speed Coupling
4. Pulleys with bearing blocks – head, tail, snub, bend and take-up
5. Idlers – carrying, return, impact pads, self-aligning and transition
6. Idler frames
7. Belt cleaning devices
8. Hold back devices integral with Gear Box.
9. Electro-magnetic brakes
10. Pull-cord switches with cord
11. Belt sway switches
12. Zero-speed switches
13. Take up pulley frame with take up guides
14. Bend pulley frame
15. Head pulley frame
16. Tail pulley frame
17. Drive base frame
18. Guards – tail pulley, bend pulley, coupling
19. Discharge hood
20. Skirt Boards
V1.1.1.2. The scope of the Contractor shall be deemed to include all such items which although
here not specifically mentioned in the specification, but are needed to make the
equipment complete in all respect for its safe, reliable, efficient and trouble free
operation.
V1.1.2. Codes & standards
V1.1.2.1. Structural steel work for the Machines.
IS 800 : 2007
IS 806 : 1968
 IS 816 : 1969
IS 1024 : 1999
IS 875 : 1987
V1.1.2.2. All structural steel shall conform to IS: 226, IS: 961 (HTW) or IS: 2062 or approved
equivalent thereof.
V1.1.2.3. Unless otherwise specified, materials shall be meeting minimum requirements of the
following specifications:

 Cast Iron : IS 210 Grade 20 except counter weight

 Cast for gears : IS 2644, Grade 1
Steel for pressure pin assembly : IS 2644, Grade 4
for general use : IS 1030-1978/2707-1973, Grade 23-45
 Wrought Steel : IS 1570, C40, Cold Drawn specified
 Forged Steel : IS 1875
 Structural Steel : IS 226 (Standard quality),
IS 2062 (Fusion welding quality)
 High tensile steel : IS 961 (Fusion welding quality)
 Case hardened steel : IS 1570, C-14
 Ductile Iron : IS 1865, Grade 1
 Tubes & fittings : IS 1239, IS 1161
 Bronze : Gunmetal IS 306
 G1 Phosphor Bronze : IS 28
 Aluminium Bronze : IS 305 Grade 2
 Stainless Steel : IS 6911

V1.1.2.4. Components
Items required to be manufactured/fabricated for routine maintenance shall preferably
conform to IS Code of Practice. The following is the list of items, which shall be included
but not be limited for such considerations:
1. Gears & Pinions : Metric system
2. Wire Rope : IS 2266
3. Drum : IS 3177
4. Wheels : IS 3177, IS 1136
5. Sheaves : IS 3177
6. Rails : IS 3443
7. Thread: Metric system as per ISO
8. Fasteners and keys : IS 2048
9. Fits and tolerance : IS 919, IS 210, IS 2709
10. Bolts : IS 1367/IS 3138
11. Plain washers : IS 2016
 12. Fittings : IS 4009
13. Clearance Holes : IS 1821
14. Conveyors : IS 11592 and CEMA
V1.1.2.5. Also, the following specifications shall be considered, wherever applicable:
1. AFBMA : Anti-Friction Bearing Manufacturers Association
2. AGMA : American Gear Manufacturers Association
3. AMCA : Air Moving and Contractors Association
4. ANSI : American National Standards Institute
5. ASCMA : American Sprocket Chain Manufacturers Association
6. ASHRAE : American Council of Governmental Industrial Hygienists.
Ventilation Manual, Latest.
7. ASME : American Society of Mechanical Engineers
8. ASTM : American Society for Testing and Materials
9. CEMA : Conveyor Equipment Manufacturers Association
10. FM : Factory Mutual
11. ISO : International Standards Organization
12. JIC : Joint Industry Conference
13. MPTA : Motor Power Transmission Association
14. MSHA : U.S. Department of Labor, Mine Safety and Health
Administration.
15. NFPA : National Fluid Power Association
16. NFPA : National Fire Protection Association
17. RMA : Rubber Manufacturers Association
18. SAE : Society of Automotive Engineers
19. SMACNA : Sheet Metal and A/C Contractor National Association
20. ICBO : International Conference of Building Officials
21. UL : Underwriters Laboratories
22. UMC : Uniform Mechanical Code
23. ANSI-B17.1, B17.2 : Keys and Key seats
24. ANSI M11.1 : Wire Rope-Mining
25. CSA-G : Steel Wire Rope for General Purpose, for Mine Hoisting and
Mine Haulage.
26. ISO R773/4 : Recommendations for Keys and Key Seats.
27. ISO 281-1990 : Rolling Bearings – Dynamic Load Rating and Rating Life (L2a
bearing life).
28. AISC : American Institute of Steel Construction.
29. AISI : American Iron and Steel Institute
30. AWS : American Welding Society
31. ISO : International Standards Organization
32. ICBO : International Conference of Building Official
 33. AISC : Code of Standard Practice for Steel Buildings and Bridges
34. AISC (LRFD) : Load and Resistance Factor Design Manual of Steel
Construction.
35. AISI : Specification for Cold Formed Steel Structural Members
36. ANSI 14.3 : Safety Requirements for Fixed Ladders
37. ASTM A36 : Structural Steel
38. ASTM A325M : High Strength Bolts for Structural Steel Joints
39. ASTM A 759-85 (1992) : Standard Specification for Carbon Steel Crane Rails
40. AWS D1.1 : Structural Welding Code - Steel.
41. UBC 97 : Uniform Building Code
42. ASTM : American Society for Testing and Materials
43. ACI : American Concrete Institute
44. SSPC : Steel Structures Painting Council
45. ISO : International Standards Organization
46. UL : Underwriters Laboratories
47. ASTM E114 : Ultrasonic Pulse Echo Straight Beam Testing by the Contact
Method.
48. ASTM E587 : Ultrasonic Angle Beam Examination by the Contact Method.
49. ASTM E709 : Magnetic Particle Examination.
50. ISO 8402 : Quality Vocabulary.
51. ISO 9001 : Quality Systems – Model for Quality Assurance in Design,
Development, Production, Installation and Servicing.
52. ISO 9002 : Quality Systems – Model for Quality Assurance in Production
and Installation.
53. ISO 9003 : Quality Systems – Model for Quality Assurance in Final
Inspection and Test.
54. NBFU : National Board of Fire Underwriters
55. NSC : National Safety Council
56. OSHA : US Department of Labor. Occupational Safety and Health
Administration
57. UPC : Uniform Plumbing Code
58. AWWA : American Water Works Association.
V1.1.2.6. Materials and components according to F.E.M./BS/JIS/DIN standards or any other
international standard approved by classification society equipment IS standard is also
acceptable.
V1.1.2.7. Apart from IDLR shall also be applicable, wherever required.
V1.1.3. System requirement
V1.1.3.1. The Bulk cargoes shall be unloaded from vessel of capacity ranging from 60,000 to
180,000 DWT by two numbers of ship unloaders. The 2 nos. of ship unloaders shall
dump the cargo to the mobile hoppers (2 Nos.) and from mobile hoppers to jetty
conveyor (C-1) simultaneously. Jetty conveyor shall have the capacity of 5000 TPH will
 run parallel to the rear side of the berth. Conveyor C-1 shall feed the approach conveyor
C-2 of 5000 TPH capacity. Approach conveyor C-2 shall feed the conveyor C-3 of same
capacity. Conveyor C-3 will feed the conveyor C-4 respectively. Conveyor C-4 shall
discharge the coal to Conveyor C-5. From Conveyor C-5 material shall discharge on two
conveyors (C-6 & C-7) either simultaneously or separately. Yard Conveyor C-6 shall
carry the coal to stackyard and discharge it through ScR. Conveyor C-7 shall discharge
the Coal to another yard conveyor C-8 of 5000 TPH capacity. From Conveyor C-8 coal
shall be stacked via another ScR machine.
V1.1.3.2. Two nos of ScR shall be dedicated to stack the cargo on both side of the yard
conveyors. In each side of the yard conveyor, stockpile will be having length of 475 m
(approx.) & 52.5 m width (approx.)
V1.1.3.3. Stacker Cargo shall be reclaimed via same ScR via Bucket wheel arrangement. From
Conveyors C-6 & C-8 reclaim material shall be either discharged to Conveyor C-9 of
2500 TPH capacity or to conveyor C-10 of 2500 TPH capacity. Conveyor C-9 shall
discharge the coal to Conveyor C-11 which will feed the truck loading Silo. Conveyor C-
11 shall discharge the cargo to reversible shuttle conveyor RSC-1 placed at the top of
the truck loading silos. The RSC-1 will feed the material to 3 different silos, having
capacity of 1000 T.
V1.1.3.4. Reclaim Material can also be evacuated via Wagon loading system. From Conveyor C-
10 material shall move to Conveyor C-12 & C-13 of 2500 TPH capacities
simultaneously. Conveyor C-13 shall discharge the Coal to Wagon Loading silo of 4000
T capacity.
V1.1.3.5. The stackyard shall be designed to achieve the required truck and wagon movement
space as per Phase 1 layout (47406300/MN/LA/T-02)
V1.1.3.6. All belt conveyor system shall be integrated and interlocked for auto start and automatic
stop in proper sequence and shall be equipped with all necessary safety devices of
latest technology for smooth & trouble free operation.
V1.1.4. Conveyor Capacity & Speed
The conveyors shall be of following capacity & speed
Sl. Conveyor Conveyor Capacity Belt Speed,
Conveyor Length (Approx.), m
No. No. (Rated), TPH m/s
1. C-1 320 5000 4
2. C-2 2400 5000 4
3. C-3 270 5000 4
4. C-4 435 5000 4
5. C-5 115 5000 4
6. C-6 680 5000 4
7. C-7 135 5000 4
8. C-8 725 5000 4
9. C-9 280 2500 3.2
10. C-10 220 2500 3.2
 Sl. Conveyor Conveyor Capacity Belt Speed,
Conveyor Length (Approx.), m
No. No. (Rated), TPH m/s
11. C-11 280 2500 3.2
12. C-12 545 2500 3.2
13. C-13 375 2500 3.2
14. RSC-1 35 2500 3.2

All the conveyors shall be designed taking 110% of the rated capacity of the conveyor.
V1.1.5. Conveyor Components
V1.1.5.1. Belt
1. Belting shall be designed for heavy duty condition and shall be suitable for 24
effective working hour operations per day and 365 working days per year. It shall be
suitable for installation over conveyor system having 45° troughing angle and shall
be suitable for operation at an ambient temperature as mentioned in basic
engineering design data. It shall have sufficient resistant against exposure to open
sunlight so that its qualities do not deteriorate while working in open sun. It also
may have to work in rain and / or in conditions where relative humidity goes up
100%.
2. The Belt shall be of Steel Cord grade. The belting shall be pre-stretched, straight ply,
skin coated with open ends. It shall have sufficient strength to give required tension
at 10 safety factor, and 80% tension utilization. All belts shall be joined by hot
vulcanized splicing.
3. The belt shall have sufficient lateral flexibility so that it suits the troughing angle
requirements even when it is empty. The belt shall have sufficient longitudinal
flexibility so that it can easily flex around different pulleys of the conveyor system.
The belt shall have sufficient impact resistance to withstand impact at the loading
points. The rubber cover used in the top and bottom cover of the belting shall be of
M-24 grade. The edge shall be of cut edge construction.
4. On the carrying surface, at interval of maximum 12 meters, the belting shall be
marked as follows:
(a). Manufacturer’s name and trade mark, if any.
(b). Steel Cord belt
(c). Belt designation i.e. KN/m
(d). Code of rubber cover i.e. M-24.
(e). Last two digits of year of manufacturing
(f). Top cover:-8 mm
(g). Bottom cover:- 6 mm
(h). No. of Ply:- 4 nos.
5. Belt roll shall be packed in wooden drums. This packing should enable easy
unreeling of the belting. On the body of the wooden drum the direction of belt and
 location of end of the belting should be indicated so that belting can be properly
placed while unreeling. The design, construction, testing and performance of the
belting shall comply with all applicable codes and as per IS and International
Standards. Before dispatch, the finished material shall be subject to inspection by
the Purchaser/Consultant. The inspection shall be carried out in the presence of
Purchaser/Consultant, in terms of up to date engineering practice and relevant IS
and International Standards in this respect, for which all facilities shall be provided
by the Contractor at his cost. This shall internal, include the following:
(a). Full thickness belt test (As per IS-1891),
(i). Breaking load, Kg/sq. cm for wrap and weft.
(ii). Elongation under reference load (%)
(iii). Elongation at break (%)
(b). Rubber cover test (Top/Bottom)
(i). Tensile strength of cover, Kg/sq. cm
(ii). Elongation at break (%)
(iii). Adhesion between ply to ply and between covers and ply.
(iv). Abrasion loss of rubber cover
(c). Physical dimension check
(d). Flexibility Test
6. All relevant type test certificates shall have to be produced during inspection and
along with supply for necessary verification and approval.
V1.1.5.2. Conveyor Pulleys
1. All pulleys shall be of welded steel construction, stress relieved before boring and
machining and statically balanced. Solid end discs shall be designed and provided
to give maximum strength. End disc thickness shall be of 24 mm min. of high
tension pulley. Pulleys shall be designed as per relevant Indian Standard where
applicable. Pulleys shall be connected to the shaft through keyless friction grip
connections (locking assembly) unless otherwise agreed. Shell thickness of the
pulley shall be suitable for taking bending loads on the pulley. This shall not be less
than 16mm for drive pulley and 12 mm for tail and other pulleys. Drive pulleys shall
be covered with minimum 12 mm thick diamond rubber lagging. Tail, bend and
take-up pulleys shall be covered with minimum 12 mm thick rubber lagging. The
depth and width of the grooves in the lagging shall be 6 mm spaced at 30 mm
interval. The eccentricity of pulley shell shall not be more then + 0.5% of the
diameter prior to lagging. Drive pulleys shall be machined at steel faces prior to
lagging. Shore hardness of rubber for drive pulleys shall be 60 ± 5 and for other
pulleys shall be 40 ±5. All pulleys shall be statically balanced to minimize the
vibration during running.
2. Non-magnetic pulley is required, wherever ILMS is mounted for smooth operation.
 3. Rolled steel may be used for pulley shafts of diameter up to 160 mm. Forged steel
shall be used for shafts above 160 mm diameter. The deflection slope of pulley
shaft at hub shall be restricted to 5 min under rated load condition. The shaft
diameter shall be in multiple of tens. Pulley shafts shall be supported on self-
aligning double row spherical roller bearings with adequate sealing and external
lubrication arrangement in Plummer blocks. One bearing for each shaft shall be
fixed to prevent any movement of the shaft assembly and the other bearing shall be
floating to have free axial movement.
4. All lubricating nipples shall be readily accessible without removing the guards. All
Plummer blocks shall also have four mounting bolts. Welding on the pulley shell
shall be tested radio graphically or by ultrasonic method. Pulley shafts shall be
ultrasonically tested. Checking of out of roundness and static balancing tests shall
be carried out before dispatch of the pulleys.
V1.1.5.3. Conveyor Idlers
Idlers shall conform to IS: 8598. All idler shall be made out of ERW tube. Carrying and
return idlers will be life lubricated. Idler bearings shall be Deep groove ball bearing with
minimum life L-10 of 30,000 hours. Deflection for idler spindle shall be less than 5min
under full load condition.
1. Three no. adjustable type transition idlers shall be provided adjacent to terminal
pulleys.
2. At convex curve, spacing shall not exceed 50% of the normal idler spacing.
3. Berth Conveyor C-1 and yard conveyors C-6 & C-8 are with garland idler in carrying
and return side.
4. Garland type carrying idlers shall be 3 rolls, 152.4 mm dia with 45º troughed in line
and interchangeable rolls. Garland Return idlers shall be V type, 139.7 mm dia. Two
rolls, with minimum 15º incline to the horizontal with articulated joints.
5. Other conveyors are with fixed idler in carrying and return side. Fixed carrying idler
shall be with 3 rolls, 152.4 mm dia 450 troughed. Standard fixed frame return idlers
shall be V type mounted on fixed supports. For both types the rolls shall be
identical. (139.7 mm dia, two rolls, 15 degree)
6. Minimum six (6) set of impact idlers shall be provided at each loading point of the
conveyor with maximum spacing of 400 mm.
7. Garland Impact idlers shall be five (5) roll (with rubber block of minimum size 100
mm x 80 mm x 80 mm at pivot points to absorb shock) in line type having freedom
of movement in both vertical & horizontal direction. Rubber ring dia. shall be: 190
mm OD, ERW tube shall be 139.7 mm.
8. Fixed type impact idler shall be 190 mm OD, ERW tube shall be 139.7 mm. Impact
idlers shall be provided with number of tough rubber discs with minimum shore
hardness of 55 to 60 on shore ‘A’ scale.
9. Idler shaft shall be made of class – 4, IS-1875 or EN – 8, BS – 970 or bright bar of
equivalent grade suitable for the duty requirement. Idler frame shall be made of
 rolled/formed steel with provision for securely bolting to the stringers of the
conveyor frame. All fixing bolts shall have spring washers.
10. Clearance, gap etc. for the carrying and return idlers shall conform to the relevant IS
Standard to the extent possible. The fixing arrangement of carrying and return idlers
shall be such as to permit adjustment of idler sets for the purpose of belt training.
Allowance for such adjustment shall be provided on both sides of the conveyor and
the play shall not be less than 10 mm on either side.
11. All idler rollers shall be painted with 2 coats of red oxide primer and 2 coats of
enamel finish paint.
12. Following tests shall be carried at random on the assembled idler roller in the
presence of Purchaser/Consultant.
(a). Friction factor test
(b). Idler running test at high speed.
(c). Test for dust proof
(d). Test for water proof
(e). Quality test.
(f). Alignment and co-axiality test
V1.1.5.4. Belt Cleaners
1. External belt cleaners
(a). External belt cleaners shall be provided at the discharge pulley of the conveyors.
The cleaner shall have sprung metallic blades (in segments) with tungsten
carbide tips.
(b). Polyurethane deflector skirts shall be provided below the tips to prevent materials
build up on the unit. The cleaners shall be mounted on an elasto mount system to
facilitate automatic blade adjustment on wear. The inclination of the blades
should be such as to effect efficient scrapping of the belt. The spring action of the
individual metallic blades should ensure constant contact with belt during
operation and suitable sprung deflection of contact with uneven surface of the
belt. The blades shall be in segments for ease of replacement and mounting on
the head pulley frame. The material scrapped should fall inside the discharge
chute directly.
2. Internal scraper
‘V’ shaped internal scraper shall be provided on the upper side of the return belt
near the tail end, fitted with wear resistant non-metallic scraper blade to remove
spilled materials on the belt. The blade shall be adjustable after the wear.
V1.1.5.5. Belt Take-Up
1. All conveyors shall be provided with automatic take-up of gravity type. Gravity take
up arrangement shall comprise of a structural steel frame sliding up and down on
two vertical steel pipe guides, a take up pulley unit mounted on antifriction bearing
pillow blocks bolted on to the steel frame and threaded counter weight rods secured
 to the lower edge of the steel frame each provided with two nuts and washer at their
lower end for attaching counter weights. The take up movement shall not be less
than the values specified in Table 15.2 of CEMA 6th edition.
2. Suitable guards marked up scale attached to the frame to monitor belt stretch and
access/maintenance platforms with handrails all around etc. shall be provided.
Adequate access from conveyor gallery/transfer house/ground etc., as the case
shall be provided to inspect, repair and maintain the gravity take up arrangement.
Suitable arrangements shall be provided for clearing accumulated coal from various
platforms to ground level. Guides of take up pulley / counter weights shall be
sufficiently strong so that they do not bend during belt snapping.
3. The prime consideration should be to locate the automatic take-ups at a place where
these will work best, in relation to the drive, to keep belt tension at a minimum.
Conveyors will be provided with automatic gravity type take up as per standard /
system requirement. Take up weight material will be RCC blocks. Belt Feeders and
conveyors less than 50 m long will be provided with Screw take-up.
4. Two (2) meter safety fencing along with suitable gate and locking arrangement shall
be provided around gravity take-up at the base level /ground level.
5. Irrespective of take-up location, the travel zone of take-up weight shall start from a
suitable height above ground level. Suitable buffer arrangement shall be provided to
arrest the fall of take-up pulley in order to avoid damage of the pulley assembly in
case of belt snapping. Similar buffer arrangement shall be provided for take-up
weight also, in case of, take-up weight travel zone terminating above a building
floor. Sandpits of approx. 600 mm deep shall be provided at ground below the take-
up weights.
6. Take-up weight shall consist of multi-blocks and not of single block to facilitate
adjustment in weight if required during operation. Single heaviest piece shall be
suitable for easy handling.
7. Take-up weight block shall be provided with edge protection angle to take care of
any damage. Take up weights shall be kept inside a take up weight box and shall
be properly anchored / bolted with the main frame, so that none of the weight shall
be loose / free inside the box. The box shall be painted with counter weight.
Conveyor number shall be marked and shall have good aesthetic look.
V1.1.5.6. Belt Protection Equipment
1. Pull Cord Switches
Pull cord switches shall be provided for emergency stoppage of conveyor. The first
switch shall be about 4000 mm away from the driving pulley and subsequently at
not more than 30 m interval. The pull wires shall run along the entire length of each
conveyor on both sides. Where mobile trippers are used on conveyors, the pull
wires shall run along the hand-railings on conveyor walkways. All pull cord switches
shall have individual local indication lamps to indicate when operated. All Pull Cord
Switches shall be supplied with applicable Hazardous Area Certificates.
2. Belt Sway Switches
 Belt sway switches shall be provided on each conveyor for protection against
excessive sway of the belt. A pair of switch shall be installed near the head end and
a pair near the tail end and a pair of switch shall be installed at 50 m interval
thereafter. A pair of these switches shall also be provided before the belt weighing
scales. All Belt Sway Switches shall be supplied with applicable Hazardous Area
Certificates.
3. Zero Speed Switches/Under speed switches
Zero Speed Switches shall be provided for each conveyor to stop the drive in case
of excessive slippage. Provision shall be made such that preceding conveyor does
not start unless the running conveyor picks up 80% of the rated speed. All Zero
Speed Switches/ Under-speed switches shall be supplied with applicable
Hazardous Area Certificates.
4. Chute Jamming Detectors
Chute jamming detectors shall be provided on all chutes. The detectors shall be so
located or protected that they do not come in contact with regular flow of material.
The detector shall, also, be protected against deposit of the particles causing false
alarm or stoppage of the conveyors. The position of each detector shall be decided
based on the braking time of the delivery conveyor at rated capacity and the holding
capacity of the chute.
5. Belt Rip Switch
Belt rip switch is used for a trouble free and economical operation to prevent larger
belt damages immediately after a smaller damage has occurred. The belt rip switch
or belt tear switch is activated by small belt damages and stop the conveyor belt
immediately to prevent further damages. Generally the belt rip switch is installed
after an idler in the travel direction of the belt. The sensor loop for belt rip detector
shall be vulcanized at an interval of minimum 50 m throughout the conveyor length.
V1.1.5.7. Drive Base Frame
The drive unit consisting of motor, gear-box, coupling and brakes along with protective
guards shall have a common base frame and shall be fabricated form heavy structural
sections and plates. Suitable bracings should be provided wherever necessary on the
drive unit base frame and structure to make it rigid. Proper arrangements shall be
provided with gear-boxes and motors to maintain correct alignment with finish pads for
mounting. The drive base frames shall be bolted to the structural floor beams / civil
foundation of junction houses. Necessary load data and foundation details shall be
furnished by the successful.
V1.1.5.8. Gearbox
1. Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.
The gearboxes shall be designed for 24 hours continuous duty. Gearboxes with
cooling coils are not acceptable. All gear boxes will be of helical / bevel helical type.
2. Mechanical rating of gearbox will be based on a service factor of 1.5 on consumed
power at rated capacity. Gearbox mechanical KW rating should not be less than
motor rating. Thermal rating should not be less than consumed power. Holdbacks
 integral with gearbox will be provided for all inclined conveyors to prevent reverse
rotation of the conveyors after being stopped in loaded conditions due to power
failure or during normal operational delays.
3. Gear box casing should be spilt type made up of cast iron. The gears used shall be
helical conforming to IS: 3681 (latest revision) or spiral bevel speed reduction units
conforming to suitable Indian Standards. The dimensions of the shaft end shall
conform to IS: 3688 or its latest revision. Above 40 kW drive rating, all gearboxes
shall be helical or bevel helical type only. Recommended oil grade shall be
compatible with gear internals like material of bearing, cages. Further, all gearboxes
shall have suitable breather plugs, dipstick, drain plug etc.
4. Additional Cooling shall be provided to the gearbox for better performance wherever
necessary. Type of cooling shall be as per manufacturer recommendation.
Gearboxes shall conform to the standards IS: 4460 & IS: 7504.
V1.1.5.9. Couplings
1. High Speed Coupling
(a). Fluid couplings shall be provided in all the drive machinery for belt conveyor
systems if the actual power requirement at motor output shaft is more than 30
kW and fluid coupling will be selected based on consumed power at design
capacity.
(b). The fluid coupling for LT motors shall be of delayed fill chamber type.
Delayed fill chamber type fluid coupling are selected for motor power above
30 KW up to 160 KW, beyond 160 KW scoop coupling will be selected.
(c). For below 30 KW Motor Pin Bush coupling shall be selected.
(d). Curve of fluid coupling shall be such that slip across the coupling shall not be
more than 3% at consumed power at motor shaft. Rating of fluid coupling
shall not be less than the connected motor kW.
2. Low speed Coupling
The low speed coupling shall be geared Coupling or equivalent, connecting the
reducer shaft directly to the pulley. Service factor shall not be less than 2.0 times of
motor name plate rating.
V1.1.5.10. Chutes, Hood & Hoppers
1. Guided transfer chutes suitably designed with a minimum valley angle of 65° shall be
provided at all transfer points for transfer of cargo from one conveyor to the next in
the direction of belt travel. Chutes shall be made of structural steel as per IS 2062
and shall have minimum thickness of 10mm.
2. Chutes shall be provided with replaceable type liner plates. Such liner plates shall be
of abrasion resistant type or impact resistant type depending on whether the
surface is subjected to friction or impact. Liner shall be fixed by countersunk bolts.
3. Hoods shall be provided over chutes having provision for fixing dust suppression
system as per requirement. For portion of hood below the pulley frame and up to
 500 mm below the floor, the thickness of plate shall be 10 mm. Minimum 10 mm
thick liner plate shall be provided in this portion of hood in the material impact zone.
The liners should be fixed by wedge type arrangement. The hood shall be in
segments bolted to each other for ease of maintenance. The hood shall cover
discharge opening for the chute as well as pulley. Rubber curtain and guard shall
be provided at the entry of belt in the discharge hood. Easily adjustable baffle plates
shall be provided in the hood to control trajectory of materials, if necessary. Chute
liners will be fixed by wedge. Hinged inspection door shall also be provided in the
hood. The door shall preferably be located within a height of 1200 mm from the
floor. Adequate opening shall be provided in the hood for withdrawal and
adjustment of belt scrapers. (Height of the deflector plate from the conveyor to be
specified).
4. Direct impact of material on conveyor belt shall be avoided by providing and inclined
surface at 65 degrees valley angle at the feeding point to guide the material in the
direction of belt travel. Further, chute construction below flap gate shall be such that
there will be any accumulation of coal dust between chute and flap gate in that
zone.
5. In view of increase in speed at Impact zone stone Box type design may be adopted.
Proper trajectory calculation to be furnished with chute G.A. drawings.
6. Hoppers and Chutes shall be made of minimum 10 mm thick MS – plates with
minimum 10 mm thk. Tiscral / Sailhard liners. Adequate stiffeners shall be provided
as per design requirement. Long chutes guiding flow from considerable height shall
be provided with impact plates wherever change in direction of flow takes place.
Hinged inspection doors (generously sized) of leak proof construction shall be
provided for access / maintenance purpose, at approachable heights, of the chutes.
All chutes should have one inspection door at every floor and for the ones in
between the floors, suitable access ladder and platform etc. shall be provided.
Maximum distance between two inspection doors in a chute shall be 2 mtrs. For
sealing at inspection doors labyrinth type arrangement (with rubber inserted in
grooves) to be provided. In addition to mounting bolts, swiveling eccentric handle to
tighten the door further against rubber shall also be provided. Liner plates shall be
fixed by wedge on the chute plates.
7. Bottom side of the chutes on which the coal slides shall be welded to the side plates
to form a trough. Bottom sides along with its adjacent sides shall be flanged and
made from Tiscral / Sailhard material of 10 mm thickness.
8. The non striking surface i.e. the covers of the trough shall be of 10 mm thick mild
steel and bolted to the flange provided on the trough. Inside welding shall be
provided in the corners for permanent sealing. Further, the chute boxes, not more
than 1.5 m in length, shall be joined through bolted flange connection to the chute
legs.
9. Bolted flange joints shall be of dust tight construction and necessary sealing material
shall be provided in all the flange connections for adequate sealing. Complete chute
work in the region of flap gates shall be fabricated from minimum 12 mm thk. Tiscral
/ Sailhard liner. While finalizing the chute work inside the building, arrangement for
 shifting and replacing chute legs, proper handling arrangement / wall openings,
trolleys, hoists shall also be provided.
10. Hoods over the conveyor head pulleys shall be made of minimum 6 mm M.S. Plates
and shall be provided with hinged and gasket inspection doors with suitable access
to them. Further, rubber seal shall also be provided at the inlet of head chute to
minimize dust nuisance.
11. All conveyor discharge chute will be designed in such a way that snub pulley is
covered.

Technical Data Sheet – Chutes & Hoppers

Sl.
Description Data
No.
0
1. Minimum valley angle 65
2. Material of Chute at Sliding zones 10 mm Thk MS for Chute with 10mm Thk
& adjacent sides. SAILHARD/TISCRAL/ Ceramic Liner
At magnetic Zone ( Near ILMS) 10 mm Thk SS-409 for Chute with 10 mm
THK SS-409 Liner
Flap Gate Zone 12 mm Thk MS for Chute with 10mm Thk
SAILHARD/TISCRAL/ Ceramic Liner
Discharge Hood over Head pulley 6mm Thk MS
3. Inspection doors Hinged & leak proof construction
4. Bolt Type & Fixing Arrangement M 16 Countersunk Bolt with plain & spring
washer.

V1.1.5.11. Skirts
1. Skirt boards of minimum 3000 mm length shall be provided at the loading points of all
conveyors, however wherever dust-suppression system with water spraying
arrangement is provided – the length & height of the skirt shall be suitably designed.
Wherever the loading points are nearer to each other, the skirt board shall be made
continuous between them. Minimum length of skirt boards from the beginning of
loading area in the chute shall be 2500 mm in the direction of belt travel. Skirt shall
be totally covered where dust suppression system is envisaged. The thickness of
skirt plate shall be minimum 10 mm. The top cover plate where provided shall be
minimum 6 mm thick. Skirt plates shall be provided with suitable (minimum 10 mm
thick) replaceable liners.
2. The arrangement for fixing rubber curtain and rubber on skirt boards shall be such as
to ensure quick adjustment. The thickness of rubber curtains shall be minimum 10
mm. Skirt rubber shall be in segments and the design shall ensure automatic flexing
of rubber for proper sealing. Shore hardness of skirt rubber shall be min. 55. Skirt
rubber shall be minimum 10 mm thick. Height of Skirt Board shall be compatible
with DSS requirements.
V1.1.5.12. Two Way Diverter
1. The motor operated flap gates shall be provided in transfer chutes as specified
and shall be complete with electrically operated actuators. The gates shall be of
 robust construction and suitable for trouble free operation. The face of the flap
gate shall be made out of 20 mm thick SAILHARD or equivalent material.
2. The equipment shall be capable of being operated for at least 15 switching at
rated load and thrust and shall be suitable for 10 nos. consecutive switching at
rated load and thrust. The equipment shall be shop tested to prove this
requirement. The motor rating for the actuator shall be so selected as to provide
sufficient thrust for operation of the flap gates against the moving weight of coal
and/or flap gate.
3. The flap gate travel shall be in the range of 60 deg to 70 deg. The motor shall be
completely dust tight.
4. Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.
5. The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flap gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust proof. The limit switches shall be capable of adjustments to vary
the total length of travel of the gates.
6. Suitable thrust dependent limit switches shall be provided in the actuators, which
shall trip off the actuator motor in case of excessive thrust due to jamming of gates
during its travel in either direction. The same shall also be integral to the drive unit
and shall be dust proof.
7. Provision for alternate manual operation shall also be made using declutch able
hand wheel. The diameter of hand wheel shall be selected considering convenient
force to be applied by a single operator. However, minimum diameter of hand
wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel
shall be provided. All the two way chutes shall be provided with flange and flap
gate with a provision to mount an actuator in future.
8. Provision must be there to keep the flap gate at middle vertical position, so as to
run both the streams at the time of requirement.
9. Suitable stiffening shall be provided between the two faces of the gate plate. At
the end of the travel the total length of edge of the flap gate shall rest on a suitable
projected surface from chute to prevent leakage of coal dust through the available
clearance between chute and flap gate.
10. Maximum feasible counterweights shall be provided for better utilization of system.
Suitable self aligned double row ball bearings in dust tight housing shall carry the
gate shaft. Suitable provision for regressing shall be provided.
11. For standardization purposes, only one standard type of actuator for flap gates
shall be provided. The standard type actuator shall be selected for maximum
thrust as calculated for various locations. Flap gate actuator as a whole and
individual component wise shall be completely interchangeable for all locations.
12. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall
be suitable for motor stalled condition and associated twisting.
 Approach/maintenance platforms complete with the chequred plate floor, hand
rails, ladders etc shall be provided for all flap gates.
13. Shaft & flap gate shall be tightly fitted to each other. On both faces of flap gate
main plate, 20 mm thick Sailhard liner plate or equivalent material shall be
provided.

Technical Data Sheet – Two Way Diverter

Sl.
Description Data
No.
1. Type Linear actuator operated, 2-Position
2. Location TT-5, TT-6 & TT-8
3. Required numbers 3 Nos.
4. Capacity 5000 TPH/ 2500 TPH
5. Coal size handled (-) 150 mm
6. Chute valley angle 0
Maximum 65
and gate position
7. Hours of operation / day Continuous/Day
8. No of switching per 15/hr and 10 no’s consecutive switching at rated
hour load and thrust.
9. Travel As required
10. Actuator type Electric
11. Speed of travel 50 mm/sec (min)
12. Minimum thrust 500 Kg
13. Minimum Stroke Length As Required.
14. Material of Construction
(a). Gate Sailhard /Tiscral 20 mm thick, welded construction
(b). Shaft EN-8
(c). Shaft size 100 mm dia. Min
15. Provision for alternative
Hand lever with Ratchet and Pawl
manual operation
16. Motor Three phase, 415 V, 50 Hz
17. Bearing
(a). Type Dust proof, self-aligning anti friction ball or roller
(b). Type of sealing Double labyrinth (min)
(c). Method of
Single shot, pressure lubrication
lubrication
18. Type of Limit Switches Heavy duty IP65 Limit Switch
19. Overload protection
As required. To be provided.
switch

V1.1.5.13. Belt Weigher

The electronic belt weigher for measurement of coal flow rate and quantity will be
provided at shore unloader itself. System shall be complete with flow rate indicator,
totalizer, control panel etc. The electronic belt weigher shall be designed for continuous
 automatic weighing, metering and printing of coal flow. Belt weigher shall be designed
for a range of 20% to 120% of rated capacity with an accuracy of at least (+/-) 0.5
percent throughout its range.
Provisions for local and remote measurement of instantaneous throughput and to falling
shall be made. Signals for remote indication and overload alarm shall be provided.
Local control panel including rate indicator and totaliser shall be provided. The load cells
shall be completely sealed, water and dust proof, and maintenance free.
Codes & Standard as per IS: 11547 Electronic Weighing & Motion system shall also be
followed for the same.
Table—3.6 Technical Data Sheet – Belt Weigher
Sl.
Description Data
No.
1. Type of Belt Weigher Electronic load cell type, Microprocessor based,
fully automatic
2. No of floating idlers 3 Roll, 45 Degree, troughing idlers
3. Type of load cell Strain gauge type hermatically sealed
4. Location Conveyor C-2,C-7,C-9 & C-10
5. Minimum no of Load Cell 4 (min)
6. Weighing Range 30% to 110% Design TPH
7. Overload Protection 110% rated Belt Scale Capacity
8. Structural Capacity 250% of rated belt capacity
9. Accuracy over full weighing
+/-0.5% for inventory control
range
10. Flow Totaliser 8 digit display with reset facility
11. Flow rate indicator Electronic Digital Display of min 4 digits
12. Calibration
(a). Automatic Zero & span Calibration
(b). Manual With test load chain
i) Total load chain
Two idler spaces more than weighing lengths
length
ii) Chain reel equipment Complete with weight adding facility

V1.1.5.14. Inline Magnetic separator

1. Inline Magnetic separator shall be electromagnetic type, oil cooled design, with local
panel.
2. Operating height shall be 500 mm.
3. The oil used for cooling the ILMS shall be transformer oil.
4. Flux density shall be minimum 1000 gauss at operating height. Force index shall be
100,000 (gauss X gauss/inch).
 5. Magnet core material shall be pure annealed iron/equivalent as per IS 4491. Coils shall
be copper wounded with class “H” insulation.
6. Belt for ILMS shall be N/N type with M-24 grade.
7. ILMS shall be suitable for lift
(a). MS cube of 20 mm size
(b). 250 mmX250mmX50 kg M.S. plate
(c). MS round bar of 50 kg with L/D ratio of 5 (min)
(d). MS bolt of M12, M16, minimum length equal to 5 times the size
(e). Shovel teeth & spikes.

Technical Data Sheet – Inline Magnetic Separator

Sl.
Description Data
No.
1. Type Inline electromagnetic type. Oil cooled type
electromagnet with self- cleaning arrangement
complete with local panel.
2. Location Conveyor C-1, C-6 & C-8
3. Operating height 500 mm
4. Flux Density (Minimum) 1000
5. Force Index 100,000
6. Pure annealed iron or equivalent having high
Magnetic core material
magnetic permeability, IS4491
7. Coils Aluminum wounded coil switch class “H” insulation
8. 3 phase full wave bridge using Silicon Diodes
Rectifier
forming rectifier set
9. Suitable tramp metal chute (6 mm thk. SS) with
Tramp Metal Chute
mobile trolley shall be provided for each separator.
10. Non –Magnetic
Conveyor C-1 & Conveyor C-6 discharge pulley
Discharge Pulley
11. Separator Belt N/N type with M-24 grade.

V1.1.5.15. Metal Detector

1. The design, manufacture, inspection and testing of Metal Detectors shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Metal Detectors shall conform to the
latest edition of standards/codes, which ensure equal or higher performance than
those specified, shall also be accepted. Nothing in this specification shall be
construed to relieve the contractor of the required statutory responsibility.
2. Metal detector shall be suitable to detect ferrous metal piece of 40 mm cube and
nonferrous metallic piece of 60 mm cube. Each unit shall be complete with search
coil, electronic cabinet, signal lamp, signal horn and sand bag marker. Annunciation
/Hooter shall be provided with an audible range of 300 m.

Technical Data Sheet – Metal Detector

 Sl.
Description Data
No.
1. Type Ferrous & non-ferrous detector. Coil type suitable to
detect 40 mm diameter of ferrous metal & 60 mm
diameter of non-ferrous metal. Each unit shall be
complete with search coil, electronic cabinet, signal
lamp, signal horn, sand bag marker and provision for
testing the unit
2. Annunciator/Hooter Yes
3. Audible range 300 m
4. Indication type Audio & Visual
5. Power Supply 415 V, 50 Hz +/- 2%, three phase, AC supply
6. Location Conveyor C-2, C-9,C-10
7. Non –Magnetic
Conveyor C-1 & Conveyor C-9 & C-10 discharge pulley
Discharge Pulley
8. Separator Belt N/N type with M-24 grade.

V1.1.5.16. Electric & Manual Hoist

1. Suitable handling arrangements shall be provided for all equipment’s to transfer the
equipment to maintenance area within the building and / or to transfer the
equipment outside the building upto ground level for further transportation. For this
purpose Bidder shall provide monorails and hoist blocks with cross travel facility.
2. For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift,
motor operated hoist blocks for both long travel and lift shall be provided. Other
hoist blocks shall be of hand operated type for both travel and lift. However, all
monorails coming out of the building shall be provided with electric hoist blocks,
irrespective of load and lift. Adequate length of Cantilever shall be provided in
monorails to lower the equipment to ground level clearing the building sidewalls.
The center line of monorail shall not deviate by more than 500 mm from the center
of gravity of any equipment that is to be lifted. Bidder shall take clear note of the fact
that the number and monorail hoisting system shall also be decided considering the
movement of the equipment being lifted over/by the side other equipment’s without
removing the later. The necessary levels of floors in various buildings shall be
decided considering the above requirement.
3. Monorails shall be extended outside the building to handle the equipment to ground
level. Suitable machinery well / hatch and removable hand railing / grating shall be
provided on various floors of buildings, as necessary.
4. Electrically operated mono girder type hoists shall consist of following major
components.
(a). Electrically operated trolley complete with drive motor (Trolley travel speed
maximum 15 m/min).
 (b). Hoist cable, hoisting block and hooks complete with drive motor (Hoisting
speed maximum 6 m/min).
(c). Limit switch to prevent over hoisting, over lowering and over travel.
(d). Festoon arrangement of feeding power to trolley assembly.
(e). Erection hardware.
(f). Pendent control station suspended from hoist.
5. The hoist shall be designed and constructed in accordance with the latest revision of
IS:3938 and shall be suitable for duty class 2. Trolley movement and hoisting shall
be effected by using two separate motors.
6. However the motors shall be suitable for 150 starts per hour at 40% CDF. Trolley
shall be designed to accommodate a wide range of beams and shall be capable of
traveling on straight as well as curved monorails with the design being such to
maintain uniform distribution of pressure on the flanges.
7. Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which
shall be driven through motor.
8. Wire rope shall be of pre-formed type, hemp cored, regular lay 6/37 construction with
a breaking strength of 160-175 kgf/mm². Reverse bend of ropes is not acceptable.
9. Minimum number of falls of rope shall be four (4).
10. All electromechanical brake shall provide restraining torque. Brake lining shall be of
asbestos.
11. Cast iron parts, wherever used, shall be of minimum grade 30, IS:210. All hand
operated chain pulley blocks shall be designed to IS:3832, the operating hand chain
shall conform to IS:2429 (1) grade 30 pitched and polished and the load Chain to
IS:3109 grade 40. The chain pulley block shall be suitable for duty class 2. Hooks
shall be of high tensile steel and heat treated as Clause 7.1 (b) IS:3815.
12. All hoists/chain pulley blocks shall be selected to have minimum headroom and shall
be selected to lift heaviest piece of equipment. Further it shall be possible to handle
any equipment without disturbing equipment. The hand chain wheels shall be of
cast steel, the wheels shall be with flanges and designed to ensure effective
operation of hand chain. Further, suitable local brake shall be provided as per
IS:3832 to arrest and sustain loads in all working positions. The velocity rates, effort
on chain required to raise the safe working load and travel and speed shall be
within the limit specified in IS:3832. Proof load test shall be carried out as per
IS:3832.
13. The hoist mechanism shall consist of a grooved rope drum driven by electric motor
through gears, Each end of the rope shall be anchored to the drum in such a way
as the anchorage is readily available for maintenance. Each rope shall have not
more than two (2) full turns of the drum when the hook is at its lowest position and
one (1) spare groove when the hook is at its highest position. The leading rope
taken by the drum should not slope sideways when slack and it should not be
 caught between the gear wheel. Rope drum, gear box, block etc. should be
fabricated out of weld able quality steel.
14. Trolley load hook shall be swiveling type forged circular shank section: and shall
confirm to IS: 3815.
15. All gears and bearings shall be lubricated by grease. All lubricating points shall be
grouped together in easily accessible position.
16. The bottom block shall be of enclosed type and shall have guard against rope
jamming in normal use. It shall have standard forged swivel shank fitted on
antifriction thrust bearing. Lock to prevent hook from rotation and locking
arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom
block shall be provided with antifriction bearings.
17. All parts requiring replacement / inscription / lubrication shall be accessible without
need for dismantling of other parts / structures.
18. All components of hoists of identical capacity and duty shall be interchangeable.
19. Hoists shall have permanent inscription on each side readily recognizable from floor
level stating safe working load.
20. Pendant shall be provided with up/down/forward/reverse travel push buttons and
indicating lamps. Its power supply shall be limited to 24 V AC.
21. The control panel shall be wall mounted type & easily approachable from the floor by
a standing man.
22. For Inspection / maintenance of hoist components a fixed platform with ladder shall
be provided of each hoist.

Technical Data Sheet – Electrically/Mechanically operated Hoist

Sl.
Description Data
No.
1. Type Electrically operated hoist & trolley. And
Manually operated hoist & trolley as
required.
2. Location Top floor of each Transfer Tower (TT-1,
TT-2, TT-3,TT-4,TT-5,TT-6,TT-7,TT-8,TT-
9, TT-10,TLS ,WLS & Pump house.
3. Speed control of hoist As required
4. Monorail track Straight/Curved
5. Gear (a). Type Helical
(b). Material Forged/cast steel
6. Brake (a). Type Electro-magnetic or equivalent.
(b). Brake to be provided for Hoist & trolley
(c). Holding torque 150% of the load torque for hoisting &
125% for trolley.
(d). Method of actuation Automatic / Manual.
7. Bearing (a). Type Ball/Roller
 Technical Data Sheet – Electrically/Mechanically operated Hoist
Sl.
Description Data
No.
(b). Life (Hrs) 30,000 working hours
(c). Lubrication Oil/grease
(d). Shaft Steel-En8/Equivalent
8. Class of Hoist Class – 2 for Electrical Hoist
Class – 1 for manual Hoist
9. Hook (a). Material As per IS-3815
(b). Design As per IS:8610
10. Wire (a). Factor of safety Six (6)
Rope Construction 6 x 37/6x36 as per IS-3938,
(b). Construction regular lay with a minimum strength of
160-175 Kgf/Sq.mm.
11. Other requirements As per IS:3938 & IS:2266
12. Hoist (a). Material MS/Cast Steel as per IS-3933
Drum & (b). Other requirements As per IS:3938
Sheave
(c). Hoist drum surface Hard faced.
13. Catalogue / Leaflet provided Required
14. Inching operation of hoist motor Required

V1.1.5.17. Deck Plates

Deck plates of minimum 3.15 mm thickness shall be provided for throughout the length
of the conveyor. Suitable seal plates of 5 mm thk. Shall also be provided at Gallery
bottom chord wherever Gallery is crossing Rail Track and Road.
V1.1.5.18. Conveyor Frames
Conveyor frames shall be made of beams and /or channels suitably stiffened and
braced. The spacing of supports shall not exceed 3000 mm. Frames shall be connected
to floor beams/civil foundation of junction house by bolting. Conveyor Frames cover
Head Pulley Frame, Tail Pulley Frame, Bend Pulley Frames.
V1.1.5.19. Guards
Guards on the conveyor shall comply with relevant IS Standard. The guards shall be of
expanded metal conforming to IS: 412 (current).
Safety guards shall be provided for all couplings, brakes etc. of the conveyor drive and
screwed on the above base frame.

Technical Data Sheet – Belt Conveyor System

Sl.
Description Data
No.
1. Warranted Capacity Rated 5,000 TPH for unloading & stacking/reclaiming
conveyors and 2,500 TPH for power plant dispatch
conveyors & truck loading station conveyors.
2. Design Capacity 110% of the rated capacity
 Technical Data Sheet – Belt Conveyor System
Sl.
Description Data
No.
3. Belt Speed (Max.) As per Specification.
4. Design Code Belt conveyors for bulk materials published by Conveyor
Equipment Manufacturers Association (CEMA) and IS –
11592
5. Brakes To be provided to adjust the coasting time and prevent
spillage of material
5. Hold Back Devices Shall be Integrated.
Roller type to be provided, if required to prevent run
back of conveyors on stoppage
6. Conveyor Belt (a). Sag Max. 2%
(b). Working tension at design capacity less than 80%
of max. allowable working tension
(c). Minimum factor of safety of 10 between the tensile
strength of belt and max. allowable working tension
7. Drive Equipment (a). Rated for 110% requirement of driven equipment at
design capacity (as per elect portion)
(b). Capable of starting fully loaded conveyors from a
tripped condition
(c). Minimum wrap angle 210°
8. Conveyor Profile (a). Min. concave radius – 250 M
(b). Min. convex Radius – 50 M
(c). Max. slope – 14°
(d). Carrying belt line height – 1000 mm above floor
level
9. Belting
(a). Type Steel cord
(b). Cover Grade Fire resistant conforming to CSA-M422-M87
(c). Cover thickness
 Minimum top 8
cover (mm)
 Minimum bottom 6
cover (mm)
(d). Minimum no. of 149
strands
(e). Edge construction Cut edge
(f). Pre-stretched Yes
(Yes/No)
(g). type of belt joint Spliced & Vulcanised
10. Idlers
(a). type Life lubricated, heavy duty, service factor of > 2
(b). Shell IS 8598 with double labyrinth dust seal
 Min. diameter (mm) 152 for carrying and 139.4 for return
 Technical Data Sheet – Belt Conveyor System
Sl.
Description Data
No.
 Min. Thickness (mm) 4
(c). Material ERW
(d). Shaft C-45 or equivalent
(e). Bearings Heavy duty ball bearing with 30,000 hrs. life with life seal
 Size/Type 35 mm for carrying side and 30 mm for return side/deep
groove ball bearing
 Sealing Water, dust and weather proof, with double labyrinth
Arrangements dust seal. Life 30000 hrs.
(f). Supporting Bracket Fabricated steel (Heavy Duty)
(g). Deck Plate 3.15 mm thick throughout the conveyor length
(h). Carrying  Type Three equal roll with 45° troughing (garland & fixed type)
Idlers  Spacing 1100 normal, 550 at convex radius and loading travel
(m) zone 400 for impact. 15 m for self-aligning carrying
idlers.
(i). Self-  Type Direct acting type, complete with actuating rollers fitted
Aligning with ball bearings with the idler frame supported from a
Return pivot bearing
 Spacing 30 m provided only with flat idler return roller conveyors
(m)
(j). Impact Idlers Three equal roll 45°troughing (garland & fixed type)
 Type Rubber cushioned
 Spacing (m) Min. 6 nos. at each loading point with 400 mm spacing
(k). Transition Idlers
 Type Three roll carrying with varying (15, 30°) angle, garland
type
 No. of transition Head end 2, tail end 2
 Spacing (m) As per requirement
11. Belt cleaner
(a). External Double bladed, counter weighted spring loading rubber
scraper type
(b). Internal V-Plough type
12. Belt Take Up
(a). Type Automatic gravity type
Screw type for smaller conveyors (less than 50 m
length)
(b). Access Maintenance platforms to be provided to cover total take
up travel
(c). Travel Minimum 1% of conveyor length
(d). Highest Position To allow minimum two (2) vulcanising joint length
margins
(e). Take Up Holding Chain pulley block
 Technical Data Sheet – Belt Conveyor System
Sl.
Description Data
No.
(f). Fencing 2 m high
13. Pulleys
(a). Min. Pulley Width Belt width + 200 mm
(b). Min. Shell Thickness 16 for drive and high tension pulleys an less for other
(Mm) pulleys
(c). Lagging Hot lagged with natural vulcanised rubber 12 mm thick.
Plain for non-drive pulleys and grooved in diamond
pattern for drive pulleys
(d). Shell Material MS except for pulley below magnetic separators where
non-magnetic stainless steel shall be used, if
recommended by magnet supplier
(e). End Disk 24 mm min. for drive and high tension pulleys and less
for other pulleys
(f). Shaft Material EN8 or equivalent
(g). Shell-Shaft Keyed
Connection
(h). Shaft Deflection Max. 5 minutes at hub
(i). Bearing  Type Heavy duty/spherical roller type
 Sealing Dust tight with double labyrinth seal
 Life 60,000 hrs.
 Lubrication Greasing arrangement with conical head shape nipples
 Plummer Horizontally split type of construction with minimum (4)
Block nos. bolts holding the two split halves with min. (4) nos.
foundation bolts
(j). Standardization Pulleys of same diameter shall be interchangeable in
totality and component-wise. For this purpose drive and
non-drive pulleys need to be categorized separately.
14. Belt Protection
(a). Emergency Stop Switch
 Type Pull chord type (manually reset)
 Location On both sides of each conveyor where walk way is
provided
 Spacing (M) 30 m
(b). Belt Sway Switches
 Type Limit switches snap action (manual reset)
 Location On both sides of each conveyor
 Spacing (M) Every 50 metres
(c). Zero Speed Switches
 Type Electronic type (self-reset)
 Location Away from dusty areas
 Nos. One for each conveyor
 Technical Data Sheet – Belt Conveyor System
Sl.
Description Data
No.
 Speed Sensor Hard rubber faced wheels driven by return belt
(d). Chute Block Switches
 Type Capacitance type
 Location Away from dusty areas.