Aa Spec 373001

AAC_SPEC_37300112.
doc APPROVED 6 J uly 2006 Page 1 of 13

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.

AAC SPECIFICATION 373001
BELT CONVEYOR IDLERS AND ROLLS
ISSUE 12
COPYRIGHT
CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE OPERATING
DIVISION ENGINEERING MANAGER 2
3 DEFINITIONS 2
4 REQUIREMENTS 3
4.1 GENERAL 3
4.2 ROLLS 3
4.3 DESIGN 3
4.4 ROLL MATERIAL 3
4.5 BEARING ASSEMBLY 4
4.6 IDLERS 6
4.7 CORROSION PROTECTION - MOUNTING BRACKETS 9
5 QUALITY ASSURANCE PROVISIONS 9
5.1 QUALITY MANAGEMENT REQUIREMENTS 9
5.2 DRAWINGS 9
5.3 DESIGN CALCULATIONS 9
5.4 SAMPLING FOR INSPECTION AND TEST 9
5.5 GUARANTEE 9
6 TEST AND INSPECTION METHODS 9
7 MARKING AND PACKING 9
7.1 MARKING 9
7.2 PACKING 10
APPENDIX A : RELATED DOCUMENTS 11
APPENDIX B : ISSUE RECORD 12
APPENDIX C : RELATED CALCULATIONS 13

AAC_SPEC_37300112.doc APPROVED 6 J uly 2006 Page 2 of 13

ISSUE 12
COPYRIGHT
1 SCOPE
This specification details the additions and exceptions to requirements for idlers and rolls
complying with SANS for general purpose belt conveyor systems. This specification shall be
read in conjunction with SANS 1313.
New and upgraded installations shall be specified by the operating division in consultation with
the ATD Design Engineer.
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE OPERATING DIVISION
ENGINEERING MANAGER
The following requirements as applicable shall be specified on every invitation to tender,
contract or order:
- Title, reference number, date and issue of this specification
- Nominal width of belt to be carried
- Number and type of idler(s) (see Clause 4.6)
- Troughing angle of rolls (see Clause 4.6.6)
- Drop height of return idler(s) (see Clause 4.6.4)
- Whether tilted outer inclined rolls are required (see Clause 4.6.8)
- AAC stock code where applicable
- The series (see Clause 4.6.3)
- Corrosion protection requirements (Clause 4.7)
- Fire retardant qualities, if any, of rubber disks for impact idlers
3 DEFINITIONS
For the purpose of this specification the definitions contained in SANS and the following shall
apply:
APPROVED : Approved by the Engineer in writing.
ENGINEER : The General Manager Engineering of the AAC operating Division or
a designated representative.
SANS : South African National Standard
The following terms are defined in the General Conditions of Contract:
- AAC Company, Contractor.


ISSUE 12
COPYRIGHT
4 REQUIREMENTS
4.1 GENERAL
Unless otherwise specified the dimensions and construction of idlers and rolls shall be in
accordance with the requirements of SANS 1313.
4.2 ROLLS
Rolls supplied in accordance with this specification shall have shafts with closed ends and
without end caps.
4.2.1 Idlers shall be supplied offset and with closed end shafts.
4.2.2 Where inline idlers are required open-end shafts are considered acceptable to comply with
spacing requirements.
4.3 DESIGN
Component parts of rolls including fabrication, seals, lubrication and assembly shall be
designed for a basic life rating of not less than 40 000 hours.
4.4 ROLL MATERIAL
Rolls shall be manufactured from steel tube complying with the requirements of SANS 657
Part III. The material for non-metallic rolls or roll sleeves shall comply with SANS 1313.
4.4.1 Roll diameter and Shell thickness
The nominal roll diameter shall be selected from the range permitted in SANS 1313, to limit
the roll rotational speed to 750 min
-1
, or as specified by the Engineer. However, preference
should be given to the following range of roll diameters.
Type Nominal roll diameter
Minimum shell
thickness
Thick wall idlers
Troughing/Return
127 mm 3,8 mm 4,5 mm
152 mm 4,0 mm 6 mm
178 mm 6,0 mm
Impact 159 mm See note
Note: Rubber disks in accordance with SANS 1313, DIN 15209 or DIN 15210 form B only
shall be specified.
4.4.2 Shaft material
Shafts shall be manufactured from steel complying with the requirements of BS 970 part 1
Grade 070M20. (EN3A).


ISSUE 12
COPYRIGHT
4.4.3 Shaft tolerances
Shaft ends shall be machined to the tolerances recommended by the bearing manufacturer
and to a surface finish not rougher than 3,2m in accordance with the requirements of the Ra
series of BS 1134.
Centreless grinding is not permitted.
Knurling of shaft bearing journals is not permitted.
All sharp edges shall be dressed to a minimum 0,5mm radius.
4.4.4 Bearing housings
End cap bearing housing shall be manufactured from materials capable of deep drawing.
Commercial quality steel is not permitted.
Bearing housings shall be accurately aligned in relation to each other and the bearing
assembly. Tolerances for fitting the bearing in the housing and on the shaft shall be as
recommended by the bearing manufacturer.
End cap bearing housing shall be manufactured with turned back edges.
4.4.5 Bearing location
The inner race of each bearing shall be positively located on the shaft on at least one side
using either a circlip or a spring clip.
4.5 BEARING ASSEMBLY
4.5.1 Bearing type
Bearings fitted to rolls shall be one of the following types. Note that deep groove ball bearings
of the 62 and 63 series are to be specified with C4 clearance and with non-metallic cages.
Unless otherwise approved only SKF bearings shall be used.
Series Seize resistant Deep groove ball Spherical roller
25 SKF BB1B 420205 6205/6305 -
30 - 6306 21306CC
35 - 6307 21307CC
40 - 6308 21308CC
Spherical roller bearings may be considered for very heavy duty impact rolls, as approved by
the Engineer.
Rolls with nominal |127 mm shells shall be specified as series 25 only.


ISSUE 12
COPYRIGHT
(See SANS 1313/1 table 8b)
4.5.2 Bearing Static Load
The following table indicates the maximum loading on a roll, based on a rotational speed of
750 min
-1
and a basic bearing life of 40 000 hours.
Dia Series Max Load per roll (kg)
420205 62.. or 63.. 213..
127 25 213 234 -
152
25 212 234 -
30 - 470 1442
35 - 555 1747
40 - 686 2263
178
30 - 471 1444
35 - 556 1749
40 - 687 2266
Note that the idler rolls shall be checked to ensure compliance with the deflection limits. See
4.5.4.
4.5.3 Basic Rating Life
The basic rating life (L
10h
) as defined in BS 5512 for each bearing shall not be less than
40 000 hours for a bearing load as specified in Clause 4.5.2.
4.5.4 Misalignment
Misalignment caused by roller shaft deflection shall not exceed the following when calculated
as detailed in Appendix C, C1.1.
Bearing type Clearance Misalignment
Rigid deep groove ball
Standard 0-6'
C4 0-10
(*)

Seize resistant cage Standard 0-14'
Spherical roller Standard 1-30'
(*) DIN 22112 p2 suggests a total misalignment of 0-15 for C4 clearance bearings
The deflection limits shown above do not make allowance for manufacturing tolerances.
Spherical roller bearing deflections shall not exceed the maximum functional requirement of the
idler bearing sealing arrangement.


ISSUE 12
COPYRIGHT
The manufacturing tolerance for bearing misalignment shall be limited to a maximum of 0-6'.
4.5.5 Seals
Bearing seals shall incorporate the following. Alternatives shall be approved.
Inner lip seal: shall prevent contamination from inside the roll and loss of grease from the
bearing.
Bearing outer seal: shall be of the multiple labyrinth type. Minimum length of the effective
sealing passage shall be 18 mm.
Outer cover: shall assist grease retention and prevent ingress of dirt or water.
Positive location of outer seals is preferred.
Flinger rings are to be considered as an optional extra.
4.5.6 Lubrication
The bearings shall be greased for life at assembly, using grease type GPG-2LXEP complying
with the requirements of AAC specification 166014 and in the quantities as recommended by
the bearing manufacturer. Other grades or consistencies of grease may be specified in
consultation with the engineer.
4.6 IDLERS
Idlers supplied in accordance with this specification shall be as follows:
4.6.1 Number of rolls
For belt widths less than 500 mm, consideration should be given to 2-roll vee-form carrying
idlers.
Impact and troughing idlers shall be 3 rolls for belts up to and including 1200 mm wide, and 5
rolls for belts over 1200 wide unless otherwise specified by the Engineer.
4.6.2 Type
Troughing idlers 3 - or 5 - roll Offset
1

Impact idlers 3 - or 5 - roll Offset
1

Return idlers Single roll flat return
2

Fixed form 5 or 10 Vee
3

Notes
1
Consideration may be given to the use of in-line idlers where appropriate, as specified by
the Engineer.


ISSUE 12
COPYRIGHT
2
Single roll flat return idlers of series 25 shall not be specified for belt widths greater than
1200 mm.
3
Vee return idlers are preferred for belt widths greater than 1200 mm.
4.6.3 Series
Idlers shall be of the following series as specified in SANS 1313 and shall be specified by the
Engineer (see Clause 2.7.1).
Dia Series
127 25
152
25
30
35
40
178
30
35
40
The use of series 25 impact idlers is not preferred. See also 4.5.3.
The use of stepped shafts is not preferred in this specification.
4.6.4 Drop height of flat return idlers
The drop height of flat return idlers shall be 40 mm or 90 mm as specified by the Engineer.
The drop height for vee return idlers shall be 150 mm.
4.6.5 Mounting brackets
Mounting brackets shall be manufactured from steel to SANS 1431 Grade 300WA.
Construction and the design shall be such that belt damage shall be minimal in the event of
rolls becoming detached.
The bracket landing thickness shall be as indicated below:
Belt width
Minimum Landing thickness
Standard Impact
1200 mm 6,0 mm 8,0 mm
1200 mm <1800 mm 8,0 mm 10,0 mm
>1800 10,0 mm 12,0 mm


ISSUE 12
COPYRIGHT
Note that, in the case of tubular construction or 'belt-friendly' impact idler brackets, the design
shall be such that the torsional deflection of the roll supports shall be minimised.
All idler brackets for impacting rolls shall be so designed as to facilitate ease of removal.
The Engineer shall consider the chute design when considering the options for the above.
4.6.6 Troughing angle
The troughing angle shall be one of the standard angles as permitted in SANS 1313, as
appropriate, namely
20
35
45
The troughing angle of transition idlers shall be selected as appropriate for the transition
distances determined by design.
4.6.7 Direction of belt travel
The direction of travel shall be clearly marked on all idlers.

Figure 1 Direction of belt travel
4.6.8 Angle of forward tilt
Generally, the forward tilting of idlers is not preferred. When this is specified by the Engineer,
the outer inclined rolls shall be tilted forward in the direction of the belt travel to assist training
where specified. The angle of tilt of outer inclined wing rolls shall be the minimum
commensurate with the application and shall not exceed 2 for belt widths up to and including
1 050 mm or 1,5 for belt widths above 1 050 mm. The tilting of wing idlers is not applicable to
reversible conveyors.


ISSUE 12
COPYRIGHT
4.7 CORROSION PROTECTION - MOUNTING BRACKETS
Corrosion protection shall comply with the requirements of AAC Specifications 164050 and
CPS 137.
The colour of the final coat shall be in accordance with the suppliers standard colour, unless
otherwise specified by the Engineer (see Clause 2.8).
5 QUALITY ASSURANCE PROVISIONS
5.1 QUALITY MANAGEMENT REQUIREMENTS
AAC QAP 101 shall apply.
5.2 DRAWINGS
When requested by the Engineer, Contractors shall submit certified general arrangement
drawings with sufficient detail to prove compliance with the requirements of this specification.
Drawings shall be approved in principle by the Engineer prior to contract award.
5.3 DESIGN CALCULATIONS
Design calculations shall be supplied with tenders proving that idlers and rolls comply with the
requirements of this specification. (See Appendix C).
5.4 SAMPLING FOR INSPECTION AND TEST
Sampling shall comply with the requirements of SANS 1313. A minimum of 20% sampling
inspection shall be performed per batch in accordance with SANS 1313 and section 6 of this
specification.
5.5 GUARANTEE
The Contractor shall guarantee idlers against all defects attributable to faulty manufacture,
workmanship and quality of materials for a period of 18 months after installation. Idlers that
fail before 18 months normal service shall be replaced free of charge by the Contractor.
6 TEST AND INSPECTION METHODS
Test and Inspection methods shall comply with the requirements of SANS 1313.
In addition to the test methods as specified in SANS 1313, rolls shall be inspected for bearing
misalignment as per the requirements of 4.5.4.
7 MARKING AND PACKING
7.1 MARKING
Marking shall comply with the requirements of SANS 1313.


ISSUE 12
COPYRIGHT
7.2 PACKING
Idlers and rolls shall be packed in such a manner as to prevent damage during transit and
storage.


ISSUE 12
COPYRIGHT
APPENDIX A : RELATED DOCUMENTS
The latest issues of the following documents shall be deemed to form part of this specification:
AAC 164050 : Corrosion protection of steelwork with coatings.
AAC 166014 : Lubricants - specific requirements for general purposes greases.
AAC CPS 137 : Three coat high build epoxy system.
AAC QAP 101 : Quality requirements for minor products.
BS 970 PART I : Wrought steels for mechanical and allied engineering purposes.
BS 5512 : Specification for roller bearings. Dynamic load ratings and rating life.
ISO 15 : Roller bearings - Radial bearings - Boundary dimensions.
SANS 657 PART III : Steel tubes for rolls for conveyor belt idlers.
SANS 723 : Wash primer (metal etch primer).
SANS 1274 : Coatings applied by the powder coating process.
SANS 1313 : Dimensions and construction of conveyor belt idlers and rolls.
SIS 05 5900 : Pictorial surface preparation standards for painting steel surfaces.


ISSUE 12
COPYRIGHT
APPENDIX B : ISSUE RECORD
Issue 03 : Clause 2.8 added
Clause 4.4.3 amended
Clause 5.3 amended
Appendix B changed to C
Appendix B added.
Issue 04 : Clause 4.4.3 and 4.4.5 amended.
Issue 05 : Clause 4.2.3 changed from 3 mm to 1 mm radius
Clause 4.4.1 changed to 1200 belts from 900 belts
Division sign inserted in equation (2) in Appendix C.
Issue 06 : Corrosion control requirements (Clause 4.5) amended
Interchangeability added to scope
Clause 4.2.7 amended
Clause 4.3.5 amended for approved alternatives.
Issue 07 : Clauses 4.2.3 and 4.2.8 amended.
Issue 08 : Second paragraph of Clause 1.0 deleted (ref to Garland idlers).
Issue 09 : Clauses 5.1, 5.5 and 5.6 replaced by QAP 101
Issue 10 : Clauses 4.3.6 and 4.5 amended (A.J . Rawnsley 1996-10-28)
Issue 11 : General Review (G. Shortt 2004-01-29)
Issue 12 : Specification reviewed and updated (April/May 2005 working group
GD / PN)


ISSUE 12
COPYRIGHT
APPENDIX C : RELATED CALCULATIONS
Calculations for the design of AAC conveyor idler rolls.
Misalignment
The maximum static load S per roll is given in Clause 4.5.2.
( )
I t

=
E 4
180 A 2 G A W
Q .........................(1)
Where
Q = Misalignment in degrees
A = Distance from centre of bearing to centre of nearest roll support
(mm)
E = Modulus of Elasticity = 210 000 N/mm
I = Moment of Inertia =
64
d
4
t

d = Shaft diameter at the bearing (mm)
G = Gauge length (mm) See SANS 1313
W = 2S x 9,81 (N) as a maximum
From (1)
( )
4
d
A 2 G A W 0014 , 0
Q

= .....................(2)
Design Life
Select bearings using bearing calculations as published by bearing manufacturers to allow for the
following :
W (N) as previously calculated x 0,5
Q (degrees) as previously calculated
L 10 life rating = 40 000 hours
Rotational speed = 750 r/min.

Aa Spec 373001

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Aa Spec 373001

Hochgeladen von

Copyright:

Verfügbare Formate

AAC_SPEC_37300112.

doc APPROVED 6 J uly 2006 Page 1 of 13

Das könnte Ihnen auch gefallen